Rolling Method for Boards with Variable Longitudinal Thickness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The current rolling technology for manufacturing boards with varying longitudinal thicknesses, known as flexible rolling, requires subsequent process steps like straightening and cutting, which are inefficient and wasteful, especially during the developmental stage where only a few pieces are needed for testing.
Innovation Solution
A method for rolling boards with various longitudinal thicknesses using a single rolling mill, where the process involves setting uniform-thickness segments and transitional segments, calculating rolling force, roll gap, and rolling time, and optimizing these parameters to produce a single board with specific thickness profiles without the need for rolling in the form of a roll.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If VRBs are produced in the form of rolls to ensure production efficiency, then productivity is improved, but subsequent process steps of straightening and cutting are added, increasing loss of time and complexity
Solution Approach 1:
The patent extracts and eliminates the unnecessary subsequent processes of straightening and cutting by directly producing boards in the final required shape during the rolling process itself, rather than producing rolls that require further processing
Solution Approach 2:
The patent applies preliminary action by pre-calculating and pre-setting the rolling parameters (rolling force, roll gap, rolling period) for each segment before the rolling process begins, allowing the board to be produced in its final shape directly without requiring subsequent straightening and cutting operations
2Productivity
If VRBs are produced in the form of rolls, then production efficiency is improved, but material is wasted and device complexity increases
Solution Approach 1:
The patent extracts and eliminates material waste by producing boards in their final required shapes and sizes directly during rolling, rather than producing excess material in roll form that requires subsequent cutting and trimming
Solution Approach 2:
The patent calculates and determines the exact raw material length needed (L0+L) before rolling begins, based on the desired board segments and transitional segments, ensuring no excess material is processed or wasted
3Manufacturing precision
If flexible rolling technology is used to manufacture VRBs, then manufacturing precision of thickness variation is improved, but device complexity and process complexity increase
Solution Approach 1:
The patent segments the board into N uniform-thickness segments with N-1 transitional segments between them, allowing precise control of thickness variation through discrete, manageable segments rather than continuous complex control
Solution Approach 2:
The patent achieves precise thickness control by changing rolling parameters (rolling force Pi, roll gap Gi, rolling period ti) for each segment according to pre-calculated values, rather than requiring complex real-time control systems
4Productivity
If rolls are produced for testing purposes, then production efficiency is improved, but ease of manufacture deteriorates due to additional straightening and cutting steps
Solution Approach 1:
The patent removes the cumbersome subsequent processes of straightening and cutting by producing boards in their final required shapes directly during rolling, making the manufacturing process simpler and more direct
Solution Approach 2:
The patent pre-calculates all rolling parameters and raw material dimensions before rolling begins, allowing the board to be produced in its final shape directly without requiring subsequent straightening and cutting operations
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 method allows for the rapid and economical production of test materials with optimized rolling parameters, saving material and time, and is suitable for early product development stages, particularly applicable to magnesium alloy boards with controlled reduction percentages.
Implementation Method 1
calculation of the rolling force Pi=f(H, hi, b, R, μ, tf, tb, T, {dot over (ε)}, σs0)
Data Source
AI summary
Disclosed is a rolling method for a board having various longitudinal thicknesses, comprising the following steps: 1) setting a number N of uniform-thickness segments of a sample, thicknesses h1, h2, . . . , hN of the uniform-thickness segments, lengths L1, L2, . . . , LN of the uniform-thickness segments, and lengths T1, T2, . . . , TN−1 of transitional segments between the uniform-thickness segments, the N uniform-thickness segments having N−1 transitional segments therebetween, and both the thickness and length having a unit of mm; 2) selecting a raw material; 3) setting a rolling force, a roll gap and a rolling period of time for each segment; 4) preparing rolling; 5) conducting rolling; 6) optimizing rolling parameters, measuring thicknesses and lengths of the uniform-thickness segments and lengths of the transitional segments after the rolling member is rolled; comparing the measured thicknesses of the uniform-thickness segments with the set thicknesses for the sample, so as to correct the rolling force Pi and roll gap Gi set for each segment in step 3); comparing the measured lengths with the positions marked in step 4), so as to correct the rolling period of time set for each segment in step 3); repeating steps 4) and 5) using raw materials of the same size, and making correction again, wherein a rolled member meeting the requirements of the sample can be made after 2-3 times of trial rolling. This method avoids preparation of a raw material in the form of a roll, avoids study on a complex controlling method for various-thickness rolling of the roll, and saves the raw material and test time.