Rolling Gap Lubrication With Pre-Applied Additive Lubricant
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Solution Overview
Problem
Existing rolling methods face challenges in effectively reducing rolling gap friction and extending the product range of rollable materials, particularly when dealing with higher strength materials, due to inadequate lubrication and increased energy consumption.
Innovation Solution
A method that introduces a cooling lubricant and an additive lubricant, where the additive lubricant is applied ahead of the rolling gap based on determined process parameters such as rollable material speed and compressive strength, to enhance lubrication and reduce friction, allowing for the rolling of higher strength materials with reduced energy output and improved cleanliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cooling lubricant is applied to the contact zone, then friction and temperature are reduced, but the lubrication effectiveness is insufficient for higher strength materials
Solution Approach 1:
The lubrication system is segmented into two distinct components: a cooling lubricant applied during rolling and an additive lubricant applied beforehand. Each component performs a specific function - the cooling lubricant manages heat and baseline friction, while the additive lubricant provides enhanced lubrication for high-strength materials, resolving the insufficiency of single-system lubrication
Solution Approach 2:
The additive lubricant is applied to the contact surface of the rollable material before it enters the rolling gap. This preliminary application ensures that the lubricant is already in position to reduce friction effectively when the high-strength material contacts the rollers, addressing the inadequate lubrication for stronger materials
2Object-affected harmful factors
If more lubricant is applied to reduce friction, then rolling gap friction decreases, but energy consumption increases
Solution Approach 1:
The additive lubricant is applied locally and selectively to the contact surface of the rollable material only when rolling high-strength materials. This targeted approach ensures friction reduction is achieved precisely where needed, without unnecessarily increasing energy consumption during rolling of materials that don't require enhanced lubrication
3Reliability
If additive lubricant is applied ahead of the rolling gap, then lubrication effectiveness improves, but device complexity increases
Solution Approach 1:
The additive lubricant application system is designed to work universally with existing rolling mill equipment. It can be integrated into various rolling configurations and works alongside different cooling lubricant systems, providing enhanced lubrication functionality without requiring complete system replacement or excessive complexity
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
This approach reduces rolling gap friction, enables the production of higher strength materials with increased throughput, and extends the product range by optimizing lubrication based on process parameters, while minimizing energy consumption and maintaining cleanliness.
Implementation Method 1
Lubricating a contact zone in which the rollable material is in contact with a working roller reduces friction between the rollable material and the working roller. In order for the temperature and the wear on the working rollers to reduce, the working rollers are typically cooled.
Implementation Method 2
an additive lubricant is applied to the contact surface of the rollable material ahead of the rolling gap at a predefined application spacing from the rolling gap, when the cooling lubricant quantity currently introduced into the contact zone does not cover the lubrication requirement
Data Source
AI summary
A method for rolling a product to be rolled (3), wherein the product (3) is fed through a rolling gap (11) between two working rollers (9, 10) of a roll stand (1) and a cooling lubricant is introduced into a contact zone (15, 16), in which a contact surface (17, 18) of the product to be rolled (3) lies against a working roller (9, 10), in order to lubricate the contact zone (15, 16). Furthermore, a lubrication demand of the contact zone (15, 16) is determined in accordance with at least one process parameter of the rolling process and an additional lubricant is applied to the contact surface (17, 18) of the product to be rolled (3) before the rolling gap (11) at a specified application distance (D) if a cooling lubricant amount (C) presently introduced into the contact zone (15, 16) does not cover the lubrication demand. The application distance (D) is sized such that adhesion of the additional lubricant to the contact surface (17, 18) is increased and the lubricating effect in the contact zone (15, 16) is improved in comparison with application immediately before the rolling gap (11). In addition, the lubricant amount (C) introduced into the contact zone (15, 16) is reduced if additional lubricant is applied to the contact surface (17, 18).