Radial-Axial Rolling Mill for Annular Elements with Protruding Portions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rolling machines for annular elements, such as bearings and rims, face challenges in efficiently shaping annular elements with protruding and recess portions due to high shear forces, leading to production inefficiencies and interruptions, and lack versatility in material conveyance.
Innovation Solution
A radial-axial rolling mill with a mandrel, support table, and frustoconical rollers that allow for precise shaping and material conveyance, featuring movable and rotatable components with synchronized actuation to manage shear forces and achieve desired shapes without impairing production efficacy or quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional rolling machines are used to shape annular elements with protruding portions, then the basic rolling function is performed, but high shear forces cause blockage zones and process interruptions
Solution Approach 1:
The rolling machine employs movable and rotatable components including frustoconical rollers that can dynamically adjust their position and orientation. The support table is movable and the mandrel can rotate, allowing the system to adapt dynamically to the varying geometry of annular elements with protruding portions, preventing material blockage and maintaining continuous production
Solution Approach 2:
The rolling process is divided into distinct zones with specialized components: a mandrel for internal support, a movable support table for bottom support, frustoconical rollers for shaping, and a bucking component for lateral support. This segmentation allows each component to handle specific portions of the annular element independently, preventing blockage at protruding portions
2Adaptability or versatility
If conventional rolling machines are used, then simple annular shapes can be produced, but versatility in shaping complex geometries with recess and protruding portions is insufficient
Solution Approach 1:
The rolling machine is designed as a multi-functional system where the combination of mandrel, movable support table, frustoconical rollers, and bucking component can handle various annular element geometries including those with protruding portions, recess portions, and undercut portions. The frustoconical rollers can be adjusted to accommodate different shapes, making the machine universal for complex shaping operations
Solution Approach 2:
The machine employs dynamically adjustable components including movable support tables and rotatable mandrels that can adapt their position and orientation during the rolling process. This dynamic capability allows the machine to handle complex geometries without requiring multiple specialized machines, resolving the contradiction between versatility and complexity
3Manufacturing precision
If high shear forces are applied to protruding portions during rolling, then material deformation occurs, but blockage zones form and interrupt the process
Solution Approach 1:
The rolling machine applies localized control over force distribution through its multiple components. The frustoconical rollers apply shaping forces while the mandrel, support table, and bucking component provide distributed support at different locations. This local quality control prevents excessive shear forces at protruding portions that would cause blockage, while maintaining sufficient force for accurate shaping
Solution Approach 2:
The mandrel acts as an intermediary element between the rolling rollers and the annular element. It provides internal support and distributes the deformation forces, preventing concentration of shear forces at protruding portions that would lead to blockage zones. The movable support table also serves as an intermediary, distributing support forces to prevent material blockage during rolling
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
Enables efficient and effective shaping of annular elements with protruding and undercut portions, ensuring uniform force distribution and preventing blockages, thus enhancing production efficiency and product quality.
Implementation Method 1
a pair of frustoconical rollers (6a, 6b) which are intended each to abut against a portion of a respective side (AE4, AE3) of the annular element (AE)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a machine for shaping at least one annular element (AE), which comprises a support frame (2), a shaft or mandrel (3), a support plate or table (4) of at least one annular element (AE), a bucking component (5), a first (6a) and a second (6b) roller element, actuation means (7) intended to move the first (6a) and the second (6b) roller element, and displacement means for displacing said support plate or table (4). The invention also relates to a method for shaping at least one annular element.