Thickness-Profiled Metal Strip via Roller Penetration
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Solution Overview
Problem
Existing methods for producing thickness-profiled metal strips face challenges in achieving homogeneous thickness transitions and reproducibility, often resulting in uneven material flow and strip waves due to the use of flat rolls or multiple profiled rolls, which increase design and control complexity and sensitivity to geometric irregularities.
Innovation Solution
Creating through holes in the metal strip as recesses to allow rollers to penetrate and produce thickness profiles, reducing longitudinal material flow and preventing strip waves, while allowing for increased tolerance to parameter fluctuations and improved reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single flat roll is used to penetrate the metal strip, then the thickness profiling is simplified, but uneven material flow occurs leading to strip waviness
Solution Approach 1:
The invention divides the rolling process into multiple passes, where each pass uses a flat roll to create a localized thickness reduction. By segmenting the deformation into sequential steps rather than a single complex operation, the process achieves precise thickness control while maintaining equipment simplicity.
Solution Approach 2:
The invention performs preliminary thickness reductions in earlier rolling passes before final profiling. This preliminary action prepares the material by gradually reducing thickness and controlling material flow, preventing waviness in subsequent passes while keeping each individual rolling operation simple.
2Manufacturing precision
If multiple profile rollers are used to penetrate the metal strip, then strip waviness is avoided, but design and control effort increases
Solution Approach 1:
The invention segments the thickness profiling into multiple sequential passes using simple flat rolls rather than one or few complex profiled rolls. Each pass handles a specific portion of the thickness reduction, achieving precise control through process segmentation rather than geometric complexity.
Solution Approach 2:
The invention employs continuous rolling passes with flat rolls that maintain consistent contact and pressure across the strip width. This continuous action ensures uniform material flow and thickness control without requiring complex intermittent profiling mechanisms.
3Manufacturing precision
If multiple profile rollers are used to penetrate the metal strip, then strip waviness is avoided, but control complexity increases
Solution Approach 1:
The control process is segmented into discrete rolling passes, each with simple and well-defined parameters. This segmentation makes each control step independent and manageable, avoiding the complex coordinated control required by multiple profiled rolls while maintaining precise thickness uniformity.
Solution Approach 2:
The invention controls thickness profiling by changing rolling parameters (pressure, pass sequence, roll position) rather than relying on complex roller geometries. This approach simplifies control systems by using adjustable process parameters instead of fixed complex tooling, making the process easier to operate and adapt.
4Productivity
If a wide rolling area is used with a single flat roll, then productivity is improved, but uneven material flow increases causing strip waves
Solution Approach 1:
The invention segments the wide rolling operation into multiple narrower passes, each maintaining uniform material flow. By dividing the total thickness reduction across several passes rather than one wide pass, productivity is preserved through efficient sequencing while avoiding the material flow non-uniformity that causes strip waves.
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 method significantly enhances reproducibility and prevents strip waves by controlling material flow, allowing for continuous longitudinal rolling and increased forming capability, even with wide rolling areas, and facilitates easy joining of the metal strip.
Implementation Method 1
the metal strip is rolled longitudinally with at least one roller penetrating the metal strip across its width in certain areas, thereby producing at least a thickness profiling
Implementation Method 2
This special material recess in the metal strip can reduce or even interrupt the longitudinal material flow in the rolling area, counteracting uneven longitudinal expansion and thus preventing strip waviness
Data Source
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AI summary
The invention relates to a method for producing a thickness-profiled metal strip (2), wherein at least one cut-out (9) is formed in the metal strip (2) and, in a subsequent step, the metal strip (2) is longitudinally rolled by means of at least one roller (4), which plunges into the metal strip (2) in some regions over the strip width (8) of the metal strip, and thus a thickness profile is produced at least in the width direction (3) of the metal strips (2). In order to improve the reproducibility of the method, according to the invention at least one hole (11, 12, 13, 14) passing through the metal strip (2) is formed in the metal strip (2) as a cut-out (9), over which hole the roller (4) that plunges into the metal strip (2) longitudinally rolls the metal strip (2) in order to produce the thickness profile in the width direction (3) of the metal strip (2).