Skew Rolling Mill Layout for Small-Diameter Precision Reduction
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Solution Overview
Problem
Existing technologies for outer diameter reducing rolling of pipe or bar materials face challenges in achieving high dimensional accuracy, particularly when reducing the diameter of materials, as they often result in uneven thickness and interference between rolling rolls.
Innovation Solution
A skew rolling mill configuration using three or more rolling rolls, where at least one rolling roll has a roll diameter equal to or less than 90% of another rolling roll's diameter, is employed to expand the range of rollable minimum outer diameters while maintaining high dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If three or more rolling rolls of the same diameter are arranged along the circumferential direction to perform diameter reducing rolling, then the outer diameter dimensional accuracy is improved, but the range of rollable minimum outer diameters is restricted due to interference between adjacent rolling rolls
Solution Approach 1:
The patent applies asymmetry by configuring rolling rolls with different diameters instead of using identical rolls. Specifically, at least one rolling roll has a diameter that is 90% or less of another rolling roll's diameter, creating an asymmetric arrangement that eliminates interference between adjacent rolls while maintaining dimensional accuracy through the skewed rotation configuration
2Adaptability or versatility
If the outer diameters of all rolling rolls are reduced to roll a small diameter material, then the minimum rollable outer diameter is reduced, but the roll shaft deflects under rolling load which reduces outer diameter dimensional accuracy
Solution Approach 1:
The patent resolves this contradiction by using asymmetric roll diameters where not all rolls are reduced to the same small size. At least one rolling roll maintains a larger diameter (90% or more of another roll's diameter) to provide structural rigidity and prevent shaft deflection under load, while the overall configuration still enables rolling of small diameter materials
Solution Approach 2:
Different rolling rolls are assigned different diameters based on their specific functional requirements. Some rolls have larger diameters to maintain rigidity and prevent deflection, while the asymmetric configuration as a whole enables processing of small diameter materials, creating local quality variations optimized for different operational demands
3Adaptability or versatility
If three or more rolling rolls are arranged to narrow the roll interval to achieve small diameter rolling, then the minimum rollable outer diameter is reduced, but interference between rolling rolls occurs which limits further reduction
Solution Approach 1:
The patent eliminates interference between rolling rolls by configuring them with different diameters. The asymmetric arrangement ensures that the rotation paths and contact zones of adjacent rolls do not overlap or interfere with each other, even when the roll interval is narrowed to enable small diameter material processing
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
This configuration allows for diameter reducing rolling with excellent outer diameter dimensional accuracy, expanding the control range of outer diameters and reducing the risk of roll shaft deflection and interference between rolling rolls.
Implementation Method 1
the material to be rolled made of a pipe or bar material is fed between the rolls being rotated, and pulled in and caused to pass through between the rolls while being rotated by the rotation of the rolls
Implementation Method 2
the material to be rolled is caused to pass through between rolls smaller than the outer diameter of the material to be rolled, thereby performing diameter reducing rolling for reducing the outer diameter of the material to be rolled
Data Source
AI summary
A rolling mill includes three or more rolling rolls aligned along a circumferential direction and arranged so each rotary shaft is skewed with respect to a pass line of a material to be rolled, wherein the material to be rolled made of a pipe or bar material passes between the rolling rolls while being rotated to undergo diameter reducing rolling. At least one rolling roll selected from the three or more rolling rolls is smaller in roll diameter than at least one other rolling roll. When at least one rolling roll having a relatively maximum roll diameter defined as a maximum diameter rolling roll and at least one rolling roll smaller in roll diameter than the maximum is defined as a small diameter rolling roll, the small diameter rolling roll has a roll diameter equal to or less than 90% of the roll diameter of the maximum diameter rolling roll.