Combined Rolling-Extrusion Die and Roll Layout for Stable Billet Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing extrusions and wire rods from aluminum and aluminum alloys face challenges such as poor deformation treatment, temperature instability, high friction forces, tool wear, and internal defects, leading to non-uniform mechanical properties and reduced efficiency.
Innovation Solution
A combined rolling and extruding device with a rotary mould, grooved and finned rolls, and a temperature control system, featuring labyrinth coupling and controlled gaps to reduce friction and wear, along with a die design that stabilizes temperature and prevents metal loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If combined rolling and extruding is implemented, then deformation treatment quality and product uniformity improve, but device complexity increases
Solution Approach 1:
The patent combines rolling and extruding operations into a single integrated device where rolls and a die work together in one working gauge. This merging of operations allows simultaneous deformation treatment while maintaining product quality uniformity, resolving the contradiction between improved manufacturing precision and increased device complexity.
Solution Approach 2:
The rolls in the device serve multiple functions: they provide support, apply deformation, and work in conjunction with the die for extrusion. This multi-functionality allows the device to achieve high deformation treatment quality without requiring separate dedicated components for each operation, thereby managing device complexity.
2Temperature
If temperature control is added, then product temperature stability improves, but device complexity increases
Solution Approach 1:
The patent applies temperature control locally at specific points in the process where temperature stability is most critical, rather than throughout the entire system. This localized approach improves product temperature stability while minimizing the addition of complex temperature control equipment.
3Duration of action of stationary object
If labyrinth coupling with gaps is used, then friction and wear reduce, but manufacturing precision of the coupling increases
Solution Approach 1:
The patent introduces a cladding layer as an intermediary between the rolls and the product. This cladding layer reduces direct friction and wear between steel surfaces while the labyrinth coupling with controlled gaps provides the necessary precision alignment. The gaps allow for thermal expansion and positioning tolerance without compromising overall manufacturing precision.
4Loss of energy
If casting rate is reduced, then temperature losses reduce, but productivity decreases
Solution Approach 1:
The patent maintains continuous operation of the combined rolling and extruding process, allowing the system to operate efficiently at higher casting rates. The integrated design ensures that temperature control and deformation treatment occur continuously without interruption, reducing temperature losses while maintaining high productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enhances the quality and uniformity of extruded products, reduces energy consumption, extends tool life, and improves mechanical properties by ensuring stable temperature control and minimizing internal defects.
Implementation Method 1
a temperature control device 5 for the cast billet
Implementation Method 2
the temperature of the cast billet is adjusted by additional heating or cooling
Implementation Method 3
metal rolling in the rolls... due to the active friction forces in the deformation zone
Implementation Method 4
labyrinth coupling of the said rolls with each other... between the surfaces of the rolls and the die in the working gauge, there are gaps
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A device for combined rolling and extruding of cast billet including a grooved roll and a finned roll forming a working gauge, at the outlet of which a die installed in the groove of the die holder is placed, is proposed. The upper part of the fin of the finned roll has a T-shaped surface. The grooved roll is provided with fins and the finned roll includes grooves, which are located relative to each other, so that fins and grooves form a labyrinth coupling of the said rolls with each other. The die is made with the possibility of fixing its position relative to the die holder by means of mating grooves and fins made in the die and the die holder. There are gaps provided between the surfaces of the rolls and the die in the working gauge. Besides, the device includes the device installed upstream of the rolls to control the temperature of the fed cast billet. When implementing the method for combined rolling and extruding of metals or alloys, a cast billet with a predetermined temperature is fed to the working gauge, in which it is rolled and then to the die, through which the cast billet is extruded. When the cast billet is fed into the working gauge, a cladding layer of metal or alloy is created on the surfaces of the rolls by extruding the cast billet through the gaps formed between the surfaces of the rolls and the die. This invention makes it possible to improve the quality of the resulting products, as well as to increase the efficiency of the process as a whole.