Sinusoidal Roll Gap Setting for Composite Plate Thickness Control
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Solution Overview
Problem
Conventional flat-roll composite rolling technologies face challenges such as low bonding interface strength, poor plate shape, and large residual stress, and the calculation of rolling force is slow and complex, making it difficult to accurately adjust the roll gap for thickness accuracy and shape quality in metal composite plates.
Innovation Solution
A method for setting the roll gap of sinusoidal corrugated rolling, which involves determining entrance and exit thicknesses, roll speed, and friction factors of metal slabs, calculating the rolling force through functional minimization of total power in the deformation zone, and configuring the roll gap based on real-time rolling parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If finite element method is used to calculate rolling force, then calculation accuracy is improved, but calculation time increases and calculation speed decreases
Solution Approach 1:
The patent replaces the finite element method (a complex numerical simulation approach) with a simplified analytical model based on power minimization principles. This substitution transforms the calculation from a time-consuming iterative numerical process into a more efficient analytical solution that still provides accurate rolling force predictions for corrugated rolling processes.
Solution Approach 2:
The patent changes the calculation approach by introducing specific parameters for corrugated rolling (amplitude A, wavelength λ, corrugation depth d) into the power minimization framework. This parameter transformation allows the model to capture the essential mechanics of corrugated rolling without requiring full finite element analysis, achieving a balance between accuracy and computational efficiency.
2Ease of manufacture
If conventional flat-roll composite rolling technology is used, then manufacturing simplicity is maintained, but bonding interface strength is low and plate shape quality is poor
Solution Approach 1:
The patent applies sinusoidal corrugation (curved surface geometry) to the rolling process instead of conventional flat rolling. The curved contact surface created by sinusoidal corrugating rolls improves material flow and bonding at the interface, enhancing bonding strength while maintaining manufacturing feasibility through standardized rolling equipment.
Solution Approach 2:
The patent specifically addresses composite plate rolling by combining different metal slabs with distinct deformation characteristics. The sinusoidal corrugated rolling process creates intimate contact and mechanical interlocking between dissimilar materials, significantly improving bonding interface strength compared to conventional flat rolling of composite structures.
3Strength
If sinusoidal corrugating roll is used, then bonding strength is improved, but device complexity increases
Solution Approach 1:
The patent employs sinusoidal corrugation patterns on the rolling surfaces, which create periodic deformation zones during the rolling process. This periodic action promotes uniform material flow and consistent bonding along the contact length, achieving improved bonding strength while using relatively simple sinusoidal profile geometry that can be manufactured using standard techniques.
Data Source
AI summary
A method for setting a roll gap of sinusoidal corrugated rolling for a metal composite plate includes steps of: determining entrance thicknesses, exit thicknesses, a width, and a rolling temperature of a difficult-to-deform metal slab and an easy-to-deform metal slab; detecting a roll speed and an entrance speed of a metal composite slab, obtaining a roll radius and friction factors; determining parameters of a sinusoidal corrugating roll and a quantity of complete sinusoidal corrugations on the sinusoidal corrugating roll; then calculating a time required for a complete corrugated rolling; calculating a rolling force at any time during the sinusoidal corrugated rolling of the metal composite plate; and calculating the roll gap S of the corrugated rolling at any time according to the rolling force F, and configuring a rolling mill to have the roll gap S according to an actual rolling schedule before normal production.