Strip Roll-Embossing Control Roll Entry Angle
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Solution Overview
Problem
Existing roll-embossing methods face challenges in consistently controlling the surface structure of strips on both sides during rolling, due to wear and material pickup by work rolls, and variations in strip dimensions, leading to non-uniform rolling patterns and increased friction.
Innovation Solution
A method involving a control roll positioned before the rolling gap, allowing for adjustment of the entry angle β relative to the pass line, which influences the surface structure by altering the contact angle and lubricant distribution, enabling uniform surface roughness on both sides without changing the roll stand or work rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If work rolls are used for roll-embossing, then surface structure is impressed on the strip, but the work rolls are subject to wear and material pickup leading to non-uniform rolling patterns
Solution Approach 1:
The invention changes the entry angle parameter of the strip relative to the pass line. By adjusting this geometric parameter, the rolling pattern on both sides of the strip can be controlled and equalized, compensating for wear and material pickup on the work rolls. This allows maintaining uniform surface structure despite roll degradation.
2Manufacturing precision
If different work rolls with different surface topographies are used for upper and underside, then uniform surface structure on both sides is achieved, but device complexity increases
Solution Approach 1:
The invention introduces asymmetry in the rolling process by creating a non-zero entry angle between the strip and the pass line. This asymmetric geometric configuration allows identical work rolls to produce uniform surface structures on both sides of the strip, eliminating the need for differentially configured work rolls.
3Adaptability or versatility
If strip dimensions and properties vary, then production flexibility is maintained, but rolling pattern uniformity deteriorates
Solution Approach 1:
The invention implements a feedback mechanism where the entry angle is continuously adjusted based on measurements of the rolling pattern and strip properties. This closed-loop control compensates for variations in strip dimensions, thickness, width, curvature, profile, and strength, maintaining uniform rolling patterns despite material fluctuations.
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 approach allows for precise control of the rolling pattern on both sides of the strip, reducing friction and maintaining uniformity even with worn work rolls, and can be implemented using simple work rolls without bending apparatuses, enhancing process reliability and reducing maintenance costs.
Implementation Method 1
the surface structure of the strip is controlled through the selection of the entry angle β depending on the positioning of the control roll relative to the pass line
Implementation Method 2
The surface structure is preferably designed such that the sheet can be wetted more effectively with lubricants during forming. This further reduces the frictional forces during forming
Data Source
AI summary
Provided is a method for rolling a strip with a roll stand with at least two work rolls. A rolling gap with a pass line is defined between the work rolls. A control roll is arranged before the rolling gap of the work rolls in the rolling direction, the strip is guided into the rolling gap of the roll stand via the control roll at an entry angle relative to the pass line and the surface structure of the strip is controlled through the selection of the entry angle depending on the positioning of the control roll relative to the pass line. Also provided is an apparatus for rolling a strip with a roll stand having at least two work rolls. A rolling gap with a pass line is defined between the work rolls.