Steel Sheet Pile Bending with Single-Drive Roll and Warpage Control
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Solution Overview
Problem
Existing methods for producing steel sheet piles, such as hat-shaped piles, require a large number of calibers and result in shape variations and defective products due to insufficient caliber numbers in traditional rolling mills. Additionally, the need for a drive unit to power both upper and lower rolls in bending machines increases facility and remodeling costs.
Innovation Solution
A bending device that performs bending on a material rolled after hot rolling, using only one roll out of the upper and lower rolls, allowing for bending in the direction of increasing cross-sectional height without causing warpage. This configuration reduces the need for a dual-drive system, simplifying the drive unit and minimizing remodeling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dual-drive system is used to power both upper and lower rolls in the bending machine, then the bending performance is improved, but the facility cost and remodeling cost increase
Solution Approach 1:
The patent extracts and removes the unnecessary drive unit from the bending machine, keeping only the lower roll driven while the upper roll remains passive. This eliminates the complexity of the dual-drive system while maintaining sufficient bending capability through the passive upper roll's geometric constraint function.
Solution Approach 2:
The patent adopts a simplified single-drive configuration instead of the expensive dual-drive system, reducing facility investment and remodeling costs. The passive upper roll serves as a simple geometric constraint rather than an active driving element, significantly lowering system cost and complexity.
2Manufacturing precision
If a large number of calibers are used in the rolling mill, then the shape accuracy is improved, but the facility size and cost increase
Solution Approach 1:
The patent changes the material's physical state by performing bending while the material is still hot (at high temperature). This thermal parameter change allows for more effective shaping with fewer calibers, as the hot material is more formable and requires less incremental shaping steps compared to cold working.
Solution Approach 2:
The patent performs preliminary heating of the material to a high temperature before the bending operation. This preliminary thermal preparation enables the material to be more easily shaped in the subsequent bending process, reducing the number of calibers needed compared to cold rolling operations.
3Productivity
If bending is performed after finish rolling, then the productivity is improved, but the material may warp during bending
Solution Approach 1:
The patent utilizes the high temperature parameter of the material immediately after hot rolling to perform the bending operation. The elevated temperature maintains material ductility and reduces warping tendency during bending, allowing the operation to be performed right after finish rolling without compromising dimensional accuracy.
Solution Approach 2:
The patent performs the bending operation continuously immediately after finish rolling while the material is still hot, without interruption or cooling in between. This continuous process maintains the material in its most formable state, preventing warpage and maximizing production efficiency in one uninterrupted operation.
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 reduces facility and remodeling costs while achieving high dimensional accuracy in steel sheet pile production by preventing warpage during bending. It allows for efficient production with a downsized drive unit and minimal facility modifications.
Implementation Method 1
performing bending on a material to be rolled after being subjected to hot rolling
Data Source
AI summary
A facility cost and a remodeling cost can be reduced, and further, a steel sheet pile product with high dimensional accuracy is produced by suppressing occurrence of warpage of a material to be rolled during bending. There is provided a bending device which produces a steel sheet pile by performing bending on a material to be rolled after being subjected to rough rolling, intermediate rolling, and finish rolling in a hot state, in a direction of increasing a cross sectional height of the material to be rolled, the bending device including: a forming stand including a forming caliber configured by an upper caliber roll and a lower caliber roll; and a drive unit driving either the upper caliber roll or the lower caliber roll.