Multi-functional Rolling Stand for Large Ingots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Forging presses have limitations in working large-size ingots or blooms, requiring long processing times, careful control, and re-heating, which hampers productivity and efficiency.
Innovation Solution
A multi-functional rolling stand with large rolls and high compression forces, capable of working ingots and plates up to 1500mm in width and 500mm in thickness, featuring adjustable positioning bolts, channels for sidewise or edgewise rolling, and a reversing design to eliminate internal porosities and achieve efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If forging presses are used to work large-size ingots or blooms, then the products can be forged, but the processing time becomes long and productivity decreases
Solution Approach 1:
The patent replaces the traditional forging press mechanical system with a rolling stand system that uses rolling mills to deform and shape large-size ingots and blooms. This substitution enables continuous rolling operations at high speeds, eliminating the intermittent forging process and significantly reducing processing time while maintaining the ability to work large cross-sections up to 1500mm.
Solution Approach 2:
The invention changes the operational parameters by using multiple rolling stands arranged in sequence, each performing specific reduction tasks. The system achieves high-speed continuous processing by maintaining optimal rolling parameters across multiple stands, with the ability to process ingots at speeds unattainable by single-stage forging presses.
2Ease of operation
If forging presses are used for large-size products, then forging can be performed, but careful control is required in every working step increasing operational complexity
Solution Approach 1:
The patent divides the forging process into multiple sequential rolling stages, each performed by a dedicated rolling stand with specific function (roughing, intermediate, finishing). This segmentation allows each stand to operate within optimized parameter ranges, simplifying control requirements for each individual unit while achieving complex overall transformation through the sequence.
Solution Approach 2:
The rolling stand system is designed to perform multiple functions including roughing, intermediate rolling, and finishing operations within a unified continuous process. The universal rolling mechanism can handle various product shapes and sizes, reducing the need for specialized equipment and complex procedural controls required by traditional forging presses.
3Productivity
If forging presses are used for large-size ingots, then forging can continue, but re-heating is sometimes required reducing productivity
Solution Approach 1:
The patent implements a continuous rolling process where the ingot passes through multiple rolling stands in sequence without interruption. The continuous motion and deformation process maintains favorable temperature and stress conditions throughout, eliminating the need for stopping and re-heating operations that are sometimes required in batch forging processes.
Solution Approach 2:
The rolling process applies progressive deformation through pre-planned reduction schedules across multiple stands, preparing the material in advance for final shaping. This preliminary progressive action prevents material hardening and cracking that would require re-heating, allowing continuous processing without interruptions.
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 rapid processing of large-size products with high compression forces, reducing internal porosities and eliminating the need for re-heating, thereby enhancing productivity and product quality.
Implementation Method 1
The high compression force, in particular in the case of ingots, also causes the elimination or great reduction of the internal porosities that are typically present in the ingots.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3c
AI summary
Multifunctional rolling stand (10) and relative method of use, suitable for rolling /forging large plates, large blooms, large round pieces and other large-size semi-worked products, for example ingots or similar products. The compression force can reach up to about 6000 tonnes in the case of ingots, depending on the type of product being worked and on the reduction ratio to be obtained. Thanks to these high forces in play, which allow to obtain compressions comprised between 100 and 150 mm, the rolling stand (10) according to the present invention is similar to a forge so that the internal porosities of the product are eliminated.