Thin Metal Strip Cooling Roll Suction Belt Microcrack Prevention
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Solution Overview
Problem
Conventional rapid cooling processes for manufacturing thin metal strips often result in microcracks at the edge portions, particularly in wider strips, which can lead to breakage and reduce productivity, as existing solutions either cause breakage or fail to address microcracks effectively.
Innovation Solution
Adjusting the nearest approaching distance between the cooling roll and the suction type belt conveyor, and optimizing the suction width ratio of the suction box to the thin metal strip width, to minimize microcrack generation during the rapid cooling and winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the speed of the permeable belt of the suction type conveyor is made faster than the strip forming speed to generate friction force, then the thin metal strip can be transported and wound, but the tension applied to the thin metal strip becomes too large and breakage is easily caused
Solution Approach 1:
A fluorine resin coating is introduced as an intermediary layer between the permeable belt and the thin metal strip. This coating layer reduces the friction coefficient between the belt and the strip, thereby reducing the tension applied to the strip during transport and winding, while still maintaining sufficient friction for effective transport and coil formation.
2Strength
If a stainless mesh belt is used to replace the permeable belt to avoid deposition, then friction is reduced and tension is decreased, but flaws are apt to be easily caused in the thin metal strip due to friction
Solution Approach 1:
The invention uses a composite structure consisting of a permeable belt base material combined with a fluorine resin coating layer. This composite material combines the advantages of both components: the permeable belt provides sufficient friction for transport while the fluorine resin coating reduces excessive tension and prevents strip breakage, avoiding the flaw generation associated with stainless mesh belts.
3Shape
If the thin metal strip is transported while applying tension to wind in form of a coil, then the coil can be formed, but microcracks are generated in the edge portions of the thin metal strip
Solution Approach 1:
The invention changes the friction parameter by applying a fluorine resin coating with specific friction characteristics. This parameter change allows for optimized tension control during coil winding, reducing the tension enough to prevent microcrack generation in the edge portions while still maintaining sufficient tension to form the coil structure.
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
Significantly reduces microcrack formation in the edge portions of thin metal strips, enhancing their stability and productivity by controlling the nearest approaching distance and suction width ratio within specific ranges.
Implementation Method 1
rapidly solidifying molten metal with a cooling roll rotating at a high speed
Implementation Method 2
rapidly cooled, so that the temperature of the belt inevitably rises up to about 100° C.
Implementation Method 3
the thin metal strip is transported while applying tension by making the speed of the permeable belt of the suction type conveyor faster than the speed of the thin metal strip just after the separating out from the cooling roll or the strip forming speed to generate friction force between the belt and the thin metal strip
Implementation Method 4
the separated thin metal strip is adsorbed with a permeable belt of a suction type conveyor
Data Source
AI summary
A method for manufacturing a thin metal strip by pouring and rapidly solidifying molten metal onto a cooling roll rotating at a high speed to form a thin metal strip having a width of 50˜350 mm, blowing compression gas from substantially a tangential direction of the cooling roll toward the thin metal strip to separate the thin metal strip from the cooling roll, adsorbing the separated thin metal strip with a permeable belt of a suction type belt conveyor, and transporting to a take-up reel to wind in form of a coil, the thin metal strip is adsorbed by the belt under conditions that a nearest approaching distance L between the cooling roll and the suction type belt conveyor is 2˜50 mm and a suction width S of a suction box arranged in the suction type belt conveyor is 1.2˜2.5 times of a width W of the thin metal strip.