Segmented Main Roll Assembly for Flexible Seamless Ring Rolling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The high cost and complexity of producing large seamless rings due to the use of full-height monolithic main rolls and the inefficiencies in existing ring rolling methods, which result in high material intensity and tooling costs, especially for large-size elements in industries like aerospace and automotive.

Innovation Solution

A segmented main roll design with a base roll segment and an exchangeable roll segment connected by a regular polygon shape, allowing for efficient shaping and rolling of rings with varying profiles, where the exchangeable segment can be easily replaced, reducing tooling costs and improving process efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a full-height monolithic main roll is used for ring rolling, then the structural strength and stability are improved, but the manufacturing cost and device complexity increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoiddevice complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The main roll is divided into a base roll segment and an exchangeable roll segment. The base roll segment provides structural support and is permanently mounted on the drive shaft, while the exchangeable roll segment can be removed and replaced to accommodate different ring profiles. This segmentation reduces the complexity of manufacturing and storing multiple monolithic rolls while maintaining the necessary structural strength during the rolling process.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If a monolithic main roll is used for each ring profile, then the manufacturing precision for specific profiles is improved, but the adaptability and productivity decrease due to frequent tooling changes

Engineering Contradiction:

Improveprofile precisionVSAvoidprofile adaptability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The base roll segment serves as a universal foundation that can support multiple different exchangeable roll segments. Each exchangeable segment is designed for a specific ring profile, but all segments share the same mounting interface and work with the same base structure, drive system, and control mechanism. This multi-functionality allows the rolling mill to produce various ring profiles using a single universal base roll segment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If a monolithic main roll is used, then the structural integrity is improved, but the tooling costs and production time increase due to inability to exchange segments

Engineering Contradiction:

Improvestructural integrityVSAvoidtooling change time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple exchangeable roll segments can be pre-manufactured for different ring profiles and stored ready for use. When a profile change is needed, the appropriate exchangeable segment is already prepared and can be quickly installed on the base roll segment, minimizing downtime. The segmentation design allows for preliminary preparation of tooling without requiring complete roll replacement.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If full-height monolithic main rolls are used for all ring sizes, then the universality of the equipment is improved, but the material intensity and cost increase

Engineering Contradiction:

Improveequipment universalityVSAvoidmaterial waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of changing the entire main roll for different ring profiles, only the exchangeable segment is changed while the base segment remains constant. This parameter change approach allows the equipment to adapt to different production requirements by modifying only the necessary portion (the exchangeable segment) rather than replacing the entire roll, thereby reducing material consumption and manufacturing costs.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3885059B1Method of and assembly for forming seamless rings by process of ring rolling

Publication Date: 2022.06.29 ZARMEN FPA SP ZOO

Figure 1

AI summary

The subject of the invention is a method of forming of seamless rings by process of ring rolling and an assembly for forming of seamless rings by process of hot rolling. The main roll is a shaping tool with a segmented construction, which is composed of a base roll segment (1), placed on the mill's drive shaft (3), where the transmission of the torque from the drive shaft (3) to the base roll segment (1) occurs through the use of rectangular keys (8), and of an exchangeable roll segment (2), the bottom part of which is set coaxially and centred on the surface of the base roll segment (1), whereas the upper part of which is connected with the centre part of the base roll (1) segment by mutually shaped surfaces of both roll segments: the base segment (1) and the exchangeable segment (2), in the form of a regular polygon (12), moreover on the base roll segment (1) and the frontal upper part of the exchangeable roll segment (2) a full ring (9) is placed axially, whereas in the base roll segment a split ring (10) is placed axially with a clamping ring (13) for removing and exchanging the exchangeable roll segment (2).