Two-Roller Flexible Skew Rolling for Precision Shaft Forming
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Solution Overview
Problem
Current metal plastic forming methods for shaft parts, such as free forging, fast forging, and cross wedge rolling, face limitations in production efficiency, precision, and cost, particularly for small-scale and large-sized shafts, with three-roller skew rolling methods being complex and costly, and lacking flexibility and automation.
Innovation Solution
A two-roller flexible skew rolling device and method that includes a first and second skew roller, guiding plate, guiding cylinders, and axial pushing device, allowing for dynamic motion control and surface features to reduce axial pushing force, enabling flexible and efficient formation of shaft parts with reduced tonnage and equipment complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If three-roller skew rolling forming method is used, then shaft parts can be formed, but device structure becomes complicated and cost increases
Solution Approach 1:
The patent extracts and removes one roller from the traditional three-roller skew rolling system, transforming it into a two-roller system. This extraction simplifies the device structure while maintaining the core skew rolling forming capability through optimized roller arrangement and motion control
Solution Approach 2:
The two-roller system is designed to perform multiple functions: both rollers can rotate independently, one roller can perform axial pushing, and the system can adapt to different shaft part specifications through parameter adjustment, replacing the need for complex dedicated fixtures in traditional three-roller systems
2Manufacturing precision
If cross rolling or extruded cross rolling is used for hollow-shaft type parts, then forming can be achieved, but axial pushing force becomes too large and required tonnage increases
Solution Approach 1:
The patent introduces dynamic motion control where rollers rotate during the forming process rather than remaining stationary. This rotational motion creates a skew rolling effect that reduces friction and axial pushing force requirements while maintaining forming precision
Solution Approach 2:
The system changes the motion parameters of the rollers by introducing rotational speed and tilt angle as controllable variables. By adjusting these parameters, the axial pushing force is significantly reduced compared to traditional cross rolling methods
3Ease of manufacture
If free forging and fast forging are used, then shaft parts can be produced, but production efficiency becomes low
Solution Approach 1:
The skew rolling process enables continuous forming operation where the blank is progressively deformed through the rotating rollers without interruption. This continuous action eliminates the repeated heating and forging cycles required in traditional forging methods, significantly improving production efficiency
4Manufacturing precision
If finish forging is used, then forming quality can be improved, but device structure becomes complicated and investment cost increases
Solution Approach 1:
The patent uses numerically controlled roller motions to replicate complex shaft part geometries without requiring complex physical tooling or fixtures. The forming shape is defined by control parameters rather than complex device structures, reducing both complexity and investment cost
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 two-roller system simplifies equipment design, reduces axial pushing force, allows for flexible production, and minimizes core defects, resulting in a more efficient and cost-effective process for forming shaft parts with improved precision and adaptability for various dimensions and specifications.
Implementation Method 1
rotating the first skew roller and the second skew roller in horizontal arrangement in the same direction at n0 and pressing down them to each other at the speed of v0; and rotating the blank around the axis of the blank under the action of the friction force of the rollers/blank
Data Source
AI summary
The technical field of metal plastic forming processes and equipment, and provides a device and method for forming shaft part by two-roller flexible skew rolling. The device comprises two skew rollers, a guiding plate, two guiding cylinders and an axial pushing device; the skew rollers can do same-direction rotation motion, radial feeding motion and tilt angle adjustment motion; the guiding plate is arranged between the two skew rollers and is used for limiting the radial movement of a blank; the two guiding cylinders are arranged on the two sides of the two skew rollers to limit swing of the blank; and the axial pushing device is arranged at one end of the blank and is used for applying axial pushing force to the blank, and the blank is rolled into a shaft part in a space defined by the skew rollers and the guiding plate. The method of the invention includes a radial compression forming process, a roller tilting forming process, a skew rolling diameter reduction forming process and a roller leveling forming process. The device and method for forming shaft part by two-roller flexible skew rolling have the advantages that forming equipment is simple, the tonnage is small, flexible production can be achieved, and core loose defects can be reduced and even avoided.