Steel Plate Texturing Roll With Laser-Formed Raised Points
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Solution Overview
Problem
Existing roll texturing techniques for steel plates suffer from low topography copying ratio, environmental risks, and limited control over surface waviness and microscopic structure, leading to suboptimal steel plate coating effects.
Innovation Solution
A roll with circular or approximately circular textured points of 50-150µm diameter and 2-12µm height, low overlap, and controlled density, manufactured using ultrashort pulse laser ablation to achieve refined surface topography and improved copying ratio with reduced waviness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional texturing methods (shot blast, electro-discharge, laser, electron beam) are used, then surface roughness can be adjusted, but the topography copying ratio is low and pits are easily filled with metal powder
Solution Approach 1:
Instead of forming pits through traditional texturing methods, the invention inverts the approach by creating convex textured points on the roll surface. This inversion resolves the problem of low topography copying ratio and pit filling, as the convex structures maintain their shape better during rolling and are less prone to being filled with metal powder
Solution Approach 2:
The invention changes the fundamental parameter of surface morphology from concave pits to convex textured points. By controlling the height (2-12μm) and diameter (50-150μm) of these convex points, the topography copying ratio is significantly improved while reducing roughness attenuation during the rolling process
2Manufacturing precision
If chromium electroplating texturing technique is used, then topography copying ratio is improved and oil storage effect is enhanced, but environmental protection is at great risk
Solution Approach 1:
The invention replaces the chemical chromium electroplating process with a physical ultrashort pulse laser processing method. The laser directly modifies the roll surface to create convex textured points without requiring harmful chemical plating processes, thus eliminating environmental risks while achieving the desired surface topography
Solution Approach 2:
The invention converts the potentially harmful chromium electroplating process into a beneficial environmental solution by using laser technology. The laser processing not only eliminates environmental pollution but also provides additional benefits such as precise control over textured point parameters and improved topography copying ratio
3Manufacturing precision
If traditional texturing methods are used, then surface roughness can be adjusted, but surface waviness cannot be subjected to refined designing and controlling
Solution Approach 1:
The invention applies local quality by creating textured points with specific local characteristics (height 2-12μm, diameter 50-150μm) that can be precisely controlled. This allows refined designing and controlling of surface waviness at the local level while maintaining overall surface roughness control
Solution Approach 2:
The invention introduces dynamics by making the textured point parameters adjustable and controllable during the laser processing. The ultrashort pulse laser can dynamically adjust the height, diameter, and distribution of textured points, enabling refined control over surface waviness without increasing process complexity
4Manufacturing precision
If textured points with large diameter are used, then topography copying ratio is improved, but overlap among adjacent textured points increases
Solution Approach 1:
The invention optimizes the parameter of textured point diameter to a specific range (50-150μm) that balances topography copying ratio with minimal overlap. This parameter optimization ensures that adjacent textured points maintain appropriate spacing while still providing sufficient surface coverage for effective topography copying
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 enables enhanced topography copying ratio and low waviness, improving steel plate coating effects while avoiding environmental risks and allowing precise control over surface morphology.
Implementation Method 1
performing a layer-by-layer ablation on a surface material of the roll to form the textured points
Data Source
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AI summary
A roll for rolling surface topography of a steel plate is disclosed. A plurality of raised textured points are arranged on a roll surface. The shape formed by a joint between each single textured point and the roll surface is circular or approximately circular. The circular shape has a diameter of 50∼150µm. Each single textured point has a raised height of 2∼12µm, and the overlap among adjacent textured points is lower than 10%. The quantity variance of the textured points per square millimeter of the roll surface is lower than 20%, and the coverage area ratio of the textured points in each square millimeter is 30∼90%. The method comprises performing surface treatment on a feed roll to control the surface roughness Ra of the roll to be smaller than 0.5µm; and performing layer-by-layer ablation on a surface material of the roll to form the textured points.