Work Roll Deep Rolling for Uniform Hardness and Internal Stress
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Solution Overview
Problem
Rollers used in metal forming processes face challenges with surface hardness and internal tension variations, leading to rolling errors and the need for frequent reconditioning and reclassification, especially when dealing with new or reground work rolls.
Innovation Solution
A method involving a deep rolling process using a printing tool with a pressure element to adjust surface hardness and internal stress of rollers, ensuring a uniform and reproducible surface condition, which can be integrated with existing surface treatment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rollers are used repeatedly for metal forming, then productivity is maintained, but surface hardness and internal tension vary leading to rolling errors
Solution Approach 1:
The patent applies deep rolling treatment to change the physical parameters of the roller surface, specifically increasing surface hardness and modifying internal tension distribution. This treatment transforms the roller's mechanical properties to maintain consistent rolling quality over extended usage periods, resolving the contradiction between continuous productivity and quality reliability.
2Manufacturing precision
If rollers are reground to restore surface quality, then surface hardness is improved, but internal tension changes causing new variations
Solution Approach 1:
The patent applies deep rolling treatment as a preliminary action before the roller enters service or after minimal grinding. This pre-treatment establishes optimal surface hardness and internal tension distribution in advance, preventing the need for frequent regrounding and avoiding the internal tension variations that would result from repeated grinding operations.
3Reliability
If deep rolling treatment is applied to adjust surface properties, then surface hardness and internal stress are improved, but additional processing time is required
Solution Approach 1:
The deep rolling treatment device is designed to perform multiple functions: it conditions new rollers, restores used rollers, and can be integrated with existing grinding equipment. This multi-functionality consolidates multiple processing steps into one operation, reducing total processing time while maintaining reliable roller performance across different stages of the roller lifecycle.
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 effectively adjusts surface hardness and internal stress, reducing rolling errors and extending the lifespan of rollers by making them suitable for various rolling passes with consistent quality.
Implementation Method 1
the roller is subjected to pressure locally via the at least one pressure element by means of the at least one printing tool... so that a deep rolling process is carried out... not only the surface hardness can be adjusted by work hardening the surface layers
Data Source
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AI summary
The task of specifying a method for conditioning a work roll, with which the material properties of a work roll can be adjusted reliably and uniformly, is solved by a method in which a roll and at least one pressure tool are rotated relative to each other, in which the roll is locally subjected to pressure via the at least one pressure element by means of the at least one pressure tool, which has at least one pressure element, and in which a rolling process is carried out.