Horizontally Vibrating Rollers for Stronger Metal Clad Bonding
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Solution Overview
Problem
The existing sandwich rolling method for bimetallic clad plates results in low bonding strength and performance fluctuations due to low dislocation rates and critical deformation forces of metal surfaces and oxide layers during the rolling process.
Innovation Solution
A rolling device with horizontally vibrating rollers, driven by exciting hydraulic cylinders and dampers, is used to promote dislocation and improve bonding by applying high-frequency micro-stroke horizontal reciprocating movement, aided by spherical pads and dovetail guide blocks for stability and hydraulic systems for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sandwich rolling method is used, then production efficiency is high and process is simple, but bonding strength is low and performance fluctuates widely
Solution Approach 1:
The patent applies horizontal vibration to the rollers during the rolling process. The vibration device generates high-frequency micro-vibrations that increase the dislocation rate of metal surfaces and oxide layers, promoting better metallurgical bonding between the clad plates while maintaining the simplicity of the rolling process.
Solution Approach 2:
The patent changes the rolling parameters by introducing horizontal vibration frequency and amplitude as new control variables. By adjusting vibration parameters alongside rolling pressure and speed, the process achieves both high productivity and consistent high bonding strength through optimized deformation conditions.
2Strength
If rolling pressure is increased to improve bonding, then deformation force increases, but oxide layers may not reach critical deformation force for proper bonding
Solution Approach 1:
The horizontal vibration applied to the rollers creates additional dynamic deformation that helps break through oxide layers more effectively. The vibrational energy supplements the static rolling pressure, enabling oxide layer removal and metal surface bonding at lower overall deformation forces while achieving superior bonding strength.
3Strength
If horizontal vibration is applied to improve bonding, then bonding strength increases, but device complexity increases
Solution Approach 1:
The vibration device is integrated into the existing roller structure, using hydraulic or electromagnetic actuators mounted directly on the roller supports. This approach adds minimal structural complexity while delivering the required horizontal vibration to significantly improve bonding strength.
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 enhances the bonding strength of the clad plates by forming a 'rolling area' at the interface, reducing the required deformation force and accelerating atomic diffusion, resulting in a clad plate with improved physical bonding and high cladding strength.
Implementation Method 1
four horizontal vibration apparatuses which are provided outside the four bearing seats respectively for driving the upper roller and the lower roller to horizontally vibrate
Implementation Method 2
each of the four horizontal vibration apparatuses comprises an exciting hydraulic cylinder and a damper
Implementation Method 3
two dovetail guide blocks are fixed on two of the bearing seats which are fixed with two ends of the upper roller through screws respectively, two second spherical pads are sleeved outside the two dovetail guide blocks respectively
Implementation Method 4
cracking the surfaces of the metals and exposing fresh metals from cracks by plastically deforming the metals under the strong pressure of the rolling mill
Implementation Method 5
meshing the metals with each other, thereby achieving metallurgically bonding
Implementation Method 6
four hydraulic systems for the four horizontal vibration apparatuses respectively
Data Source
AI summary
A rolling device capable of applying horizontal vibration for metal clad plates includes two symmetrically arranged support frames, an upper roller and a lower roller both of which are provided between the two support frames and parallel to each other, four bearing seats which are fixed with two ends of the upper roller and two ends of the lower roller respectively, and four horizontal vibration apparatuses which are provided outside the four bearing seats respectively for driving the upper roller and the lower roller to horizontally vibrate. Every horizontal vibration apparatus includes an exciting hydraulic cylinder and a damper. One end of the exciting hydraulic cylinder and one end of the damper are fixedly connected with two sides of one of the four bearing seats respectively. Every horizontal vibration apparatus is provided outside one of the four bearing seats.