Patent Grant
7406853
The invention relates to a process for forming a workpiece and to a rolling machine which is suitable for carrying out the process.
To form workpieces from an initial shape into a desired intermediate shape (semifinished product, performing) or final shape (finished product, finish-forming), in addition to many other processes also rolling processes are known which are considered compression forming processes. During rolling the workpiece (rolling stock) is located between two rotating rollers and its shape is changed by application of a forming pressure by the rotating rollers. In a profile rolling process tool profiles are located on the periphery of the rollers, which enable production of the corresponding profiles in the workpiece. In flat rolling the cylindrical or conical outside surfaces of the rollers act directly on the workpiece.
With respect to the relative motion of the tools or rollers on the one hand and of the workpiece on the other, rolling processes are divided into longitudinal rolling, transverse rolling and oblique rolling. In longitudinal rolling the workpiece is moved perpendicular to the axes of rotation of the rollers in translational motion and generally without rotation through the intermediate space between the rollers (roll gap). In transverse rolling the workpiece does not move translationally with respect to the rollers or their axes of rotation, but turns only around its own axis which is conventionally the principal axis of inertia, especially the axis of symmetry for a rotationally-symmetrical workpiece. In a combination of the two types of motion in longitudinal rolling and in transverse rolling the result is oblique rolling. The rollers are generally slanted to one another and to the workpiece which is moved translationally and rotationally.
Profile transverse rolling machines in which two rollers rotate in the same direction with wedge-shaped profile tools located on the outside periphery around axes of rotation which are parallel to one another are called among others transverse wedge rollers. The tools have a wedge-shaped geometry or a geometry which is triangular in cross section and can increase in their radial dimension along the periphery and/or can run obliquely to the axis of rotation of the rollers.
These transverse wedge rollers or profile transverse rollers allow diverse forming of workpieces with high precision or dimensional accuracy. As a result of the compressive force which is applied to the workpiece by the wedge-shaped tools the distribution of material in the workpiece during rotation of the rollers is changed by a flow process in the workpiece. The wedge-shaped tools can produce peripheral grooves and other constrictions in the rotating workpiece. For example, structures and constrictions in the workpiece which change axially to the axis of rotation can be produced by the axial offset in the peripheral direction or by the oblique arrangement of the tool wedges relative to the axis of rotation. By increasing or decreasing the outside diameter of the tool wedges when running around the axis of rotation, in combination with the oblique arrangement axially running bevels and continuous transitions between two constrictions of different diameters in the workpiece can be produced. The wedge shape of the tools allows production of fine structures by the outside edges or outside surfaces of the wedges. Transverse wedge rollers are especially well suited to production of elongated, rotationally-symmetrical workpieces with constrictions or elevations such as cams or ribs.
The compressive forming force and the forming temperature are dependent on the material comprising the workpiece and on the requirements for dimensional accuracy and surface quality after forming. Especially for iron and steel tools, forming is conventionally carried out in rolling at high temperatures in order to attain the formability or flowability of the material which is necessary for forming. These temperatures which occur especially in forging can be in the range of room temperature for so-called cold forming, for semicold forming between 550° C. and 750° C. and for so-called hot forming above 900° C. The forming or forging temperature is ordinarily also placed in a temperature range in which recovery and recrystallization processes take place in the material and also undesirable phase transformations are prevented.
Transverse wedge rolling machines (or profile transverse rolling machines) are known in which the workpieces at the start of the rolling process are positioned by a positioning means which comprises two positioning carriers (so-called guiding side guards) into an initial position between the two rollers which corresponds ordinarily to the geometrical center or the center of the roll gap. At this point the positioning carriers of the positioning means are pulled back so that the workpiece turns freely between the rollers and is squeezed into the desired shape between the tools. After this rolling or squeezing process and the corresponding completion of the workpiece the workpiece is acquired via a recess in the rotating rolling tool and ejected.
DE 1477 088 C discloses a transverse wedge rolling machine for transverse rolling of bodies of revolution or flat workpieces with two working rollers which rotate in the same direction of rotation and with wedge tools which are interchangeably located on their rolling surfaces. The wedge tools each have reduction strips which are roughened by knurling or in some other way, which rise from the roller shell to a vertical end point matched to the workpiece to be manufactured, and which run in the shape of a wedge or a triangle, and smooth forming surfaces with a calibration effect which run at the same distance to the roller jacket. The wedge tools are made as deformation segments and run only over the partial periphery of the pertinent roller surface. On the workpiece the surfaces and tools of the two working rollers, which surfaces and tools face one another, move in opposite directions to one another.
EP 1 256 399 A1 discloses a transverse rolling machine with two modules which are operated in parallel, that is, modules of two rollers at a time which rotate in the same direction of rotation, and which have tools which are made in the shape of half shells with radially projecting tool wedges on their peripheral surface, the forming of a workpiece requiring only rotation around half the periphery of a roller pair. All four rollers are driven by only one drive motor via one gear train unit and drive shaft connected in between.
DE 195 26 071 A1 discloses a device for rolling profiles into a workpiece, especially transverse rolling, longitudinal rolling and oblique rolling of threads, knurling, tooth rolling profiles or the like, with two forming rollers which are rotated in the same direction around axes of rotations which are parallel to one another and are driven each by the pertinent drive with a drive motor, a braking means being assigned to each drive.
DE 21 31 300 B discloses a transverse rolling machine with two profile rollers which are located axially parallel horizontally over one another for forming and cutting to length rotationally symmetrical workpieces in which the profile rollers touch the workpieces at peripheral points which are diametrically opposite one another and the lower profile roller has a recess for routing the rolled and cut workpieces out of the roll gap.
The object of the invention is to devise a new process for forming of workpieces and a new rolling machine with which the process can be carried out.
This object is achieved with respect to the process as claimed in the invention with the features of claim 1.
The process for forming the workpiece comprises the following process steps:
The term “forming” is defined here as any conversion of the shape of a workpiece into other shape, as was also described above, including performing and finish-forming.
The object is achieved with respect to the rolling machine as claimed in the invention.
The rolling machine as claimed is suited and also intended for carrying out a process as claimed in one of the preceding claims and comprises at least one permanent magnet motor, especially a torque motor, for driving the rollers.
The rolling machine as claimed is suited and also intended for carrying out a process as claimed in one of the preceding claims and comprises for each of the rollers the pertinent drive, the drives being independent of one another.
An advantageous embodiment and development of the process and of the rolling machine follow from the claims which are dependent on claim 1.
In the first embodiment, the dependency of the rotational speed of the rollers on the rotary position of the roller(s) is or has been chosen depending on the machined workpiece. To do this, the optimum characteristic of the rotational speed which is matched to the workpiece is determined beforehand and then set when the workpiece is formed.
The process generally comprises at least three process steps or process phases. In the first process phase the workpiece is positioned between the rollers. In the second process phase the workpiece is formed between the rotating tools of the rollers. In a third process phase the workpiece is removed or ejected again from the intermediate space between the rollers. Over the duration of these three process phases of course the angle of rotation or the angular position of the rollers also changes continuously.
The rotational speed can now be varied in different process phases and/or also within one process phase.
In one version of the process the rotational speed of the rollers in the first process phase is chosen at least on average to be lower than during the second process phase.
In one alternative or additional version the rotational speed of the rollers during the second process phase is chosen at least on average to be greater than during the third process phase. Preferably the workpiece is automatically positioned between the rollers during the first process phase by a positioning means.
At the start of the second process phase the workpiece is acquired preferably by a recess in the tools of at least one roller and then during the second process phase is rolled between the tools of the two rollers. The rotational speed is increased in one advantageous embodiment after acquisition of the workpiece by the recess in the tools of the roller(s).
Preferably at the start of the third process phase the workpiece is further acquired by a recess in the tools of at least one roller and is ejected from the intermediate space between the rollers. Before acquisition of the workpiece by the third recess in the roller(s) the rotational speed of the rollers is preferably reduced.
The rotational speeds when the workpiece is acquired at the start of the second process phase and when the tool is acquired at the end of the second process phase are especially roughly the same.
In one preferred embodiment the rotational speed during the second process phase is kept at least partially constant.
The rotational speed of the roller(s) can however also be changed in the second process phase, especially when several tools on the roller work in succession machine the workpiece in different partial process phases of the second process phase. For example the rotational speed at the start of the partial process phase can be reduced.
The rotational speed can also be kept at least partially constant during the first process phase and the positioning of the workpiece.
The rotational speed and/or the direction of rotation of the rollers is or are set, preferably for the most part, essentially equal to one another at least in angle intervals or time intervals, but can also be set to be different from one another at least in sections.
The current rotary position of the roller(s) can be determined by computation from the initial position or reference position of the roller(s) and the characteristic of the rotational speed. Preferably however the rotary position of the roller(s) is determined by at least one position detection means. The position detection means comprises preferably at least one angular position incremental transducer or an absolute value detector and/or an optical, magnetic, inductive or ultrasonic angular position transducer.
In one especially advantageous embodiment the rolling machine is a profile transverse rolling machine or a transverse wedge rolling machine. As a result of the rpm-controllable and reversible drive the rolling machine or the transverse wedge rolling machine can also be used as a stretch rolling machine or, in short, a stretch roller.
The permanent magnet motor accelerates preferably to the rated rpm for operating the rollers within an angle of rotation of a maximum 3°, 2.2°, 1° or 0.5°. Furthermore the permanent magnet motor preferably has a rated torque between roughly 5000 Nm and roughly 80,000, especially between roughly 35,000 Nm and roughly 60,000 Nm and/or a rated rpm between roughly 20 rpm and 800 rpm, especially roughly 30 rpm or 500 rpm.
In one development of the rolling machine the drive encompasses, besides at least one permanent magnet motor, at least one gear train for transfer of the torque or the rotary motion of the permanent magnet motor to at least two rollers. The gear train encompasses especially at least one central driving gear which is coupled to the driven shaft of the permanent magnet motor and two roller gears which are coupled to one of the rollers at a time and which are engaged or can be caused to engage the driving gear. The transmission ratio of the gear train from the drive motor to each of the rollers is then generally the same and is chosen to be preferably in the range between 1:1 and 1:1.5. This drive is therefore especially mechanically synchronized via the gear train.
In addition to drives with PM motors, roller drives can also be hydraulic drives and/or electric drives with other motors, especially with synchronous or asynchronous motors and/or induction motors. In independent drives for the rollers conversely the rollers are electronically synchronized or controlled, especially via converters which for example convert a line voltage of 400 V and 50 Hz into an AC voltage or an alternating current of suitable amplitude and frequency. Here it is especially advantageous that for transverse wedge rollers the force load on the two motors due to the symmetrical structure of the tools/rollers and/or of the symmetrical forming process is comparatively low and thus synchronization of the drives is promoted.
The invention is further explained below using embodiments. Reference is made to the following schematics.
Parts and quantities corresponding to one another are provided with the same reference numbers in
The embodiment of a rolling machine 1 which is made as a transverse wedge roller or a transverse wedge rolling machine shown in
Tools 20 and 21 and 30 and 31 which are each wedge-shaped in cross section are attached, especially braced to the outside surface or the shell surface of the working rollers 2 and 3. In the embodiment shown the tools 20 and 21 of the first working roller 2 and the tools 30 and 31 of the second working roller 3 are each located obliquely and at an angle to the respective axis A and B of rotation, the tools 20 and 21 of the working roller 2 being located axially in essentially the same positions with respect to the center axis M which defines the geometric center and which runs between the two rollers parallel to the axes of rotation. The tools 20 and 21 and 30 and 31 increase in their cross section viewed in the peripheral direction, the increase of the cross section for the tools 20 and 21 being in the same direction of rotation or orientation and for the tools 30 and 31 of the second working roller 3 oppositely or in the opposite direction to that for the tools 20 and 21 of the first working roller 2.
Each working roller 2 and 3 is detachably held in a holding means consisting of two parts and can be removed from the holding means in its unlocked state for replacement of the tools 20 and 21 and 30 and 31 or of the working rollers 2 and 3 in their entirety with the tools 20 and 21 and 30 and 31. The holding means for the working roller 2 is labelled 12 and the holding means for the working roller 3 is labelled 13. The first part 12A of the holding means 12 located on the left in
The receiver 14 continues as a hollow shaft axially to the axis A of rotation and in its end area facing away from the working roller 2 have a toothed gear 18 which in the same manner as the corresponding toothed gear 19 which is assigned to the second working roller 3 engages a control gear (pinion gear, driving gear) 5. The toothed gear 18 which is used to drive the first working roller 2 via the holding means 12 fits from overhead into the control gear 5 and the toothed gear 19 which is coupled to the second working roller 3 via the holding means 13 fits from underneath into the control gear 5.
The control gear 5 is now coupled via driven shaft 45 to a drive motor 4. The control gear 5, the driven shaft 45 and the rotor of the drive motor 4, which rotor is not shown, are rotating or can be rotated around a common axis R of rotation. The drive which is composed of the drive motor 4, the driven shaft 45 and the control gear 5 for the toothed gears (roller gears) 18 and 19 and thus the working rollers 2 and 3 which turn synchronously with the toothed gears 18 and 19 is thus a direct drive.
The mechanical output provided by the drive motor 4 corresponds to the product of the torque and angular velocity or angular frequency ω, the angular frequency ω being equal to the product of 2π and the rpm n. The drive motor 4 is preferably a torque motor and has a high torque even at a comparatively low rpm n of the drive motor 4 for producing the required drive output for the drive rollers 2 and 3.
The transmission ratio from the control gear 5 to the toothed gears 18 and 19 can thus be selected to be in the range around 1, especially between roughly 1:1 and roughly 1:2. At a transmission ratio of 2 the drive rollers 2 and 3 turn twice as fast as the control gear 5 and the drive motor 4, at a transmission ratio of 1:1 exactly as fast. Typical rpm of the working rollers 2 and 3 are between roughly 10 revolutions per minute (rpm) and roughly 40 rpm, typically 15 rpm.
With such a low speed drive motor 4 or one which turns with low rpm at this point, very dynamic matching or control of the rpm of the working rollers 2 and 3 can be accomplished.
One preferred embodiment of the drive motor 4 is a permanent magnet motor in which there are permanent magnets, generally on the rotor, which produce a magnetic flux which turns in the induction field of the stator which has been generated by electromagnets or windings, by the interaction of the magnetic flux of the permanent magnets and the induction field rotation of the rotor arising based on the induction principle or electromotive principle. Generally a torque motor is a synchronous motor, i.e. the rotor turns synchronously with the rotating magnetic flux. The induction windings of the stator are generally associated with the phases of a three-phase connection and are located offset by 120° to one another. Preferably permanent magnets with an energy product as high as possible are used, for example rare earth-cobalt magnets. The stator for this purpose generally has an iron core with a three-phase winding packet, while the rotor has a cylindrical iron core with permanent magnets. Such a torque motor can have a torque of up to 80,000 Nm. The high torque also causes very rapid rotary acceleration. In particular the permanent magnet motor or torque motor can accelerate the rollers within a rotary angle of only 10, preferably even only 0.5°, to the nominal rpm, for example 30 rpm. This high dynamics or rotary acceleration of the torque motor allows very dynamic control of the rpm.
The control of the rpm n of the working rollers 2 and 3 which rotate synchronously to one another as claimed in the invention is now matched to the rolling process with a special control process. To do this, the rpm n or the angular velocity ω of the working rollers 3 and 3 are matched to the respective rotary position or angular position φ of the working rollers 2 and 3 and controlled depending on this rotary position φ. Thus, depending on the respective process, the respective rolling machine and mainly depending on the workpiece to be machined, the forming by the working rollers 2 and 3 can be optimized by controlling the rpm n or the angular velocity ω=dφ/dt.
The workpiece 10 is moved by means of two guiding side guards of a positioning means which is not detailed into a position between the working rollers 2 and 3 in which it is acquired by the recess 23 in the tool 20 of the first working roller 2. This process phase with the tool 10 inserted in the initial position is shown by
As the working rollers 2 and 3 continue to turn to one another the workpiece 10 is moved between the tools 20 and 30, and under the pressure of the tools 20 and 30 which have a shorter distance w to one another than the original diameter of the workpiece 10, is taken into a smaller diameter. The reduced diameter (pass) of the workpiece 10 which has arisen after forming at the point shown in cross section corresponds largely to the minimum distance w between the tools 20 and 30 of the working rollers 2 and 3.
Therefore, in the rolling process, basically three process phases can be distinguished, specifically a first process phase for preparation of the rolling process and positioning of the workpiece in the initial position, therefore the process phase which is shown in
The angular position φ3 is the angular position of the first rotary roller 2 in which the workpiece 10 is fixed in the recess 23 and the rolling process can begin. Let it be noted here that the angular position or rotary position of the second working roller 3 is directly correlated with the angular position of the working roller 2 and changes synchronously, but in the opposite direction with the angular position of the first working roller, the rotation of the working rollers 2 and 3 taking place in the same direction to one other. Therefore it is sufficient to examine the rotary position of the first working roller 2. Of course the angular position of the second working roller 3 could be taken in exactly the same way as a variable or parameter on which the rpm n is made dependent. In any case it is sufficient to provide on one of the two working rollers 2 or 3 a position detection means for determining the rotary angle φ relative to the reference or zero position φ0 which is chosen and drawn in
When the angular position φ3 is reached and the workpiece 10 locks into the recess 23, the rpm n between the angular position φ3 and the following angular position φ4 is quickly increased in the curve section K3 with a correspondingly high rotary acceleration or rise of the characteristic line K. At the angular position φ4 then a high rpm n2 is reached at which the rpm n is kept during the component curve K4 up to a new angular position φ6. This component curve K4 between the angular positions φ4 and φ6 marks the actual rolling process.
Shortly before the recess 33 of the tool 30 of the second working roller 3 reaches the workpiece 10, at an angle φ6 of the first working roller 2, which angle is in front of the pertinent angular position φ7 of the first working roller 2, the rpm n is again reduced during the component curve K5, preferably again with a high braking acceleration, and then further reduced with lower braking acceleration according to the flatter rise in the component curve K6 between the angular positions φ7 and φ8. Therefore the workpiece is ejected at lower rpm n and lower rotary acceleration in order to eject the workpiece carefully. The ejection of the workpiece is ended at the end of the component curve K6 at the angular position φ8 of the first working roller 2 and the rpm is returned again to rpm n=0 when the process of machining this workpiece 10 between the rotary angles φ8 and φ9 is ended according to the component curve K7. One working cycle or one forming process is thus ended.
Of course other angular position-dependent profiles of the rpm n can also be traversed. Thus it is also possible to turn the two working rollers 2 and 3 during the component phases of the process with different rpm or even a different direction of rotation from one another. Furthermore, the profile n (φ) can be controlled depending on the number and arrangement of tools on the working rollers.
As shown by the profiles shown in
To set or correct the tooth play or tooth engagement between the roller gears 18 and 19 and the central control gear 5 there can furthermore be an adjustment drive which is not shown and which can move the rotary drive with the permanent magnet motor 4 and the gear train with the driven shaft 45 and the control gear 5 relative to the two roller gears 18 and 19. In this way asymmetrical engagement or tooth profile play can be corrected. Furthermore it is also possible to provide separate drives for adjusting the rollers 2 and 3 with their roller gears 18 and 19 so that the tooth engagement of the rollers gears 18 and 19 to the central control gear 5 can be set independently of one another.
The holding means 12 and 13 of the two working rollers 2 and 3 are carried by a carrier means 6 and supported or anchored in it. The carrier means 6 comprises four column-like carrier elements 6A to 6D which are arranged in a rectangular arrangement and are mounted or attached to a common bottom plate 6E which is supported on the bottom 50. In each of the carrier elements 6A to 6D there is a pertinent tie rod 7A to 7B arranged vertically in the lengthwise direction of the respective carrier element which is attached underneath to the carrier plate 6E and is pretensioned above by means of a pertinent lock nut, preferably a hydraulically actuated lock nut (9B, 9C in
Each of the permanent magnet motors 44 and 45 is triggered electronically, especially via a converter. In this way the working rollers 2 and 3 can be driven either electronically synchronously or also synchronously.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
In the foregoing, all temperatures are set forth uncorrected in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.
The entire disclosures of all applications, patents and publications, cited herein and of corresponding German application No. 10309536.5, filed Mar. 4, 2003, and German application No. 10319258.1, filed Apr. 28, 2003 are incorporated by reference herein.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 103 09 536 | Mar 2003 | DE | national |
| 103 19 258 | Apr 2003 | DE | national |
This application is a divisional of application Ser. No. 10/792,388 filed Mar. 4, 2004, now U.S. Pat. No. 7,225,656.
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| Number | Date | Country | |
|---|---|---|---|
| 20070044533 A1 | Mar 2007 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10792388 | Mar 2004 | US |
| Child | 11463113 | US |
