Sequential Roll Stamping for Distortion-Free Variable Cross Sections
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Solution Overview
Problem
Roll stamping methods face issues with undesirable shapes due to residual stress and unbalance of force between cross-section changing portions, leading to distortion in high-strength steel materials.
Innovation Solution
A roll stamping apparatus with sets of rollers having molding portions on their outer surfaces, where the rollers are arranged to sequentially change the material's cross-section, with over-molding rollers having longer circumferential lengths to reduce residual stress and unbalance, and escape portions to optimize material flow and molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If roll stamping method is used to produce variable cross-section molded articles, then productivity and adaptability are improved, but residual stress and unbalance of force cause distortion and manufacturing precision deteriorates
Solution Approach 1:
The roll stamping process is divided into multiple sequential stages with different molding portions. Each stage applies a specific cross-sectional shape to the material in sequence, allowing progressive deformation that reduces residual stress and prevents distortion while maintaining high productivity.
Solution Approach 2:
The molding portions are designed to preliminarily shape the material cross-section before final forming. By pre-applied cross-sectional shapes in sequential stages, the material is prepared for subsequent deformation, reducing unbalance of force and preventing distortion in the final product.
2Adaptability or versatility
If multiple molding portions are used to change cross-section sequentially, then adaptability for variable cross-section articles is improved, but device complexity increases
Solution Approach 1:
Multiple molding portions with different cross-sectional shapes are combined on a single rotating roll. This integration allows the roll to sequentially apply various cross-sectional shapes to the material during one continuous rotation, achieving variable cross-section forming without requiring multiple separate apparatuses.
Solution Approach 2:
The rotating roll is designed with multi-functional molding portions that can perform different cross-sectional shaping operations in sequence. This universal design allows a single apparatus to handle various cross-section variations, reducing device complexity while maintaining high adaptability.
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
The solution effectively reduces residual stress and unbalance, preventing distortion and ensuring accurate shaping of high-strength steel materials by sequentially changing the material's cross-section and using longer over-molding rollers and escape portions.
Implementation Method 1
molding portions having a stamping structure applied to outer surfaces of the sets of rollers so as to mold the material, wherein a plurality of sets of rollers are disposed in a movement direction of the material, the respective molding portions of the sets of rollers are formed to sequentially change a cross section of the material
Implementation Method 2
sets of rollers rotating while facing each other so as to press opposite surfaces of a material which is continuously supplied to move between the rollers
Data Source
AI summary
A roll stamping apparatus includes sets of rollers rotating while facing each other so as to press opposite surfaces of a material which is continuously supplied to move between the rollers; and molding portions having a stamping structure applied to outer surfaces of the sets of rollers so as to mold the material, wherein a plurality of sets of rollers are disposed in a movement direction of the material, the molding portions of the sets of rollers are formed to sequentially change a cross section of the material in the movement direction of the material, wherein at least one of the sets of rollers before a final set of rollers through which the material finally passes is a set of over-molding rollers having molding portions of which a length in a circumferential direction is longer than a length of the molding portions of the final set of rollers.