Rolling method and apparatus using planetary cross-rolls

Abstract: A rolling method and apparatus permits a long metal blank to be rolled across its width at high rolling speed. A sun roller 2, is mounted on a machine stand 1, and a plurality of planetary rollers 9, is mounted for rolling movement around the sun roller 2. The long metal blank 14 is rolled by feeding it between the sun roller 2, and the set of planetary rollers 9, in the axial direction of the rollers. In another embodiment, a backing-up housing 28 is mounted on the machine stand 1 around a set of planetary rollers 29. The long metal blank 14 is rolled by feeding it between the set of planetary rollers 29 and the backing-up housing 28 in the axial direction of the rollers.

Description: The present invention relates generally to the roll working field, and more particularly to providing a high-speed rolling method that consists of causing a plurality of cross-rolls to roll a long metal blank across the width thereof, i.e., perpendicularly to the direction in which the metal blank is being fed through the rolls. The present invention relates also to providing a high-speed rolling apparatus that includes a plularity of rolls that are driven to roll a long metal blank across the width thereof, i.e., perpendicularly to the direction in which the metal blank is being fed through the rolls. One similar prior art method and apparatus employs the process of rolling a long metal blank by moving the rolls across the width of the metal blank as it is being fed through the rolls. This is disclosed by the same inventor as the current applicant in the Japanese patent publication JP-B-59-46683, which document discloses the features of the pre-characterising parts of claims 1 and 4. Another prior art method and apparatus employs a different rolling process that uses a pair of planetary rolls or a combination of a planetary roller and an anvil in order to roll a long metal blank as it is being fed through the rolls. This process is different from the first mentioned process in that the metal blank is rolled so that it can be elongated in its longitudinal direction. The first prior art method or apparatus, wherein the long metal blank may be rolled across its width while being fed through the rolls, has been used in the roll working industry with a great success, but it is difficult to provide the high-speed rolling process because the rolls must have the reciprocating motion across the width of the metal blank being rolled while being fed forward. The mass production cannot be achieved with high efficiency. It is also observed that when the rolls are reciprocated across the width of the metal blank, the metal blank may be placed under the alternating rolling stress, also the metal blank may be elongated irregularly across the width. So that the finished product may contain defects, such as irregularities (wavy formations) along the longitudinal edges on the opposite sides. Furthermore, the metal blank may have the greater rolling pressure on the center than along the longitudinal edges on the opposite sides, and may have the greater elongation on each of the opposite edges than on the center as the reduction becomes the greater. The finished product that results from the rolling process may contain wavy formations or cracks along each of the opposite edges, which will degrade the quality of the finished product. As another disadvantage of the rolling process, the metal blank will become hardened in the central area during the rolling process, and the central area will have greater resistance to deformation than on each of the opposite edges. In the second prior art method or apparatus, the rolling process uses the set of planetary rollers that is specifically provided for rolling a long metal blank in the direction of the length thereof (that is, in the direction in which the metal blank is being fed forward), and cannot be used for rolling the metal blank across the width thereof. This process has the disadvantage in that it cannot provide the great rolling pressure because the backing-up pressures are not sufficient. In the rolling process that uses the set of planetary rollers and an anvil for rolling a long metal blank therebetween in the direction in which it is being fed forward, the set of planetary rollers and the anvil are arranged to permit the metal blank to be placed therebetween. This arrangement has the problem in that the set of planetary rollers cannot be mounted rigidly, and the metal blank cannot be rolled across the width thereof. The rolling across the width may be performed by placing a short metal blank between the set of planetary rollers and the anvil at a certain angle with regard to the direction in which it is being fed. In this case, however, the problem is that the set of planetary rollers cannot provide the sufficient backing-up pressure. For the practical purposes, this rolling process cannot be used to roll a long metal blank across the width thereof. In order to solve the problems of the prior art rolling processes, one object of the present invention is to provide the combination of a single sun roller and a set of a number of planetary rollers wherein a long metal blank may be rolled across the width thereof as it is being fed stepwise between the sun roller and the set of planetary rollers. Another object of the present invention is to provide a single sun roller, a set of a number of planetary rollers, and a backing-up housing that are arranged such that the set of planetary rollers is mounted for rolling around the sun roller, and the backing-up housing is mounted around the set of planetary rollers, whereby a long metal blank can be rolled across the width thereof at high speeds between said set of planetary rollers and said backing-up housing. The first method of the present invention, as defined in claim 1, features the planetary cross-rolling process that can roll a long metal blank across the width thereof, by feeding it stepwise between the sun roller and the set of planetary rollers, specifically by feeding the long metal blank in the direction parallel with the center line axes through the sun roller and the set of planetary rollers. During the process, the metal blank may be rolled step by step while it is fed under the tensile stress. The metal blank may be advanced by a predetermined length thereof immediately after one planetary roller finishes rolling. And the metal blank may be advanced by said predetermined length thereof at every interval between the two adjacent rollers (at the every interval from the time at which one roller finishes rolling to the time at which the adjacent roller that follows begins rolling). The first apparatus of the present invention includes a machine stand, a sun roller rigidly mounted to the stand, an anvil mounted to any appropriate part of the outer wall of the sun roller, a set of a number of planetary rollers mounted around the sun roller so that the individual planetary rollers can engage with the sun roller and can be rolling around the sun roller, a backing-up wheel mounted around set of planetary rollers, and feeding meens for feeding a long metal blank being rolled in the direction parallel with the center axial lines through the set of planetary rollers. The apparatus provides the planetary cross-rolling capabilities. The sun roller may have a groove formed on its outer wall which extends longitudinally in parallel with the center axis through the sun roller. This groove is adapted to accept the anvil that moves into and out of the groove. A wedge-like member may be provided between the inner bottom of the groove and the inner wall of the anvil for controlling the movement of the anvil into and out of the groove. Preferably, a pair of pinch rollers is provided on the entry side of the rolling arrangement, and a pair of pinch rollers is provided on the exit side of the rolling arrangement. These pairs of pinch rollers work together so that a long metal blank can be fed stepwise into the rolling arrangement. In the first apparatus described above, the anvil may be mounted either on the upper side wall or lower side wall of the sun roller. In its variation two anvils may be provided, one being mounted on the upper side wall and the other being on the lower side wall of the sun roller. In either case, each individual planetary roller of the set of a plurality of planetary rollers may be arranged in the equally-spaced relationship inside the backing-up wheel. Also the set of a plurality of planetary rollers may include a predetermined number of sets, each set including a plurality of planetary rollers, and each set may also be arranged in the equally-spaced relationship. Several units of the apparatus as described above may be configured into the tandem arrangement in which those units are in series. The rolling arrangement described above has two possible alternatives. One is the arrangement in which the upper face of the anvil is maintained in parallel with the surface of each individual planetary roller, and the other is the arrangement in which the former is maintained at a certain angle with regard to the latter. In the first alternative arrangement, a long metal blank must be fed through every step by the length equal to the entire length of the planetary roller, so totally the amount of the metal blank that can be rolled simultaneouly can be increased. Thus, the high rolling speed can be achieved, and any elongation along the length of the metal blank can be eliminated. In the second alternative arrangement, a long metal blank may be fed through every step by a certain length (which may be equal to several tenths of the entire length of the planetary roller), and may have the same area thereof rolled several times. Those two alternatives have the tradeoff relationships, and each has merits and demerits. It is difficult to determine which is the better of the two, but the choice between the two alternatives may be made, depending upon the type of the material of a long metal blank to be rolled, the number of the individual rolling arrangements to be included in the tandem configuration, the amount of reductions that may occur when the particular metal blank passes through each individual rolling arrangement, and other factors. The number of planetary rollers in each individual rolling arrangement should preferably be three rollers. If more than three planetary rollers are used, the width of a long metal blank being rolled must be restricted. Therefore, the number of planetary rollers may be chosen by considering the required width of the metal blank to be rolled. If less than three planetary rollers, or two planetary rollers, are used, they cannot be mounted with stability. If the interval between the adjacent planetary rollers is smaller than the width of the metal blank being rolled, at least one of the planetary rollers always engages with the metal blank. This makes it difficult to feed the metal blank through the rolling arrangement. It may be understood from the above that the number of planetary rollers is restricted by the particular width of a long metal blank being rolled. According to the first method and apparatus of the present invention, a long metal blank may be fed between the sun roller and the set of planetary rollers which is supported by the backing-up wheel (housing), and may be advanced through every step of the rolling process. Thus, the rolling steps can proceed with every part of the hardware retaining its mechanical strength and rigidity. As each set of the planetary rollers preferably includes three or more planetary rollers, it ensures that the rolling process can occur with high stability. The interval between the two adjacent rollers (the interval from the time at which one roller finishes rolling to the time at which the adjacent roller that follows begins rolling) may be determined according to the specific number of rollers, the specific width of a long metal blank being rolled, and so on. According to the present invention, a long metal blank may be fed into the apparatus and may be advanced under the tensile stress. This forward movement of the metal blank may be aided by the pairs of pinch rollers on the entry and exit sides of the apparatus. Thus the metal blank may be advanced by a predetermined length thereof immediately after one planetary roller finishes rolling. And the metal blank may be advanced by said predetermined length thereof at every interval between the two adjacent rollers (at the every interval from the time at which one roller finishes rolling to the time at which the adjacent roller that follows begins rolling). The spacing between the surface of the anvil and the outer wall formed by the set of the planetary rollers may be adjusted by using a wedge-like member and moving it by means of a screw as it is known to the prior art. The apparatus according to the present invention may include a single unit of the rolling arrangement or several units of the rolling arrangement connected in series in a tandem. The number of rolling arrangements in the tandem configuration, the number of sets of planetary rollers or number of planetary rollers in each set in each rolling arrangement, etc. may be determined by the particular type of material of a long metal blank being rolled, the desired width of the metal blank, and other factors. Objects that may be processed according to the present invention include long metal blanks of round, angular, square, rectangular, or any other cross section, which can be rolled into a strip shape. Using the method and apparatus of the invention, a long metal blank can be rolled across the width thereof, and the elongation in the direction of the width can be obtained through a single rolling arrangement, without producing any cracks or waves along the longitudinal edges of the rolled product. Every lot of long metal blanks can be rolled one after another on the continuous production basis and with the high speed, and the high productivity can be achieved. Each one of the long metal blank lots can also be rolled across the width thereof successively through the rolling arrangements, and no elongation will occur along the length of the metal blank. Thus, the high rolling speed can be achieved. If the prior art rolling process is applied to the long metal blank product which has been rolled by the present method and apparatus, in this case, the direction in which the long metal blank product has been rolled can be crossed. The product that has gone through the rolling processes of the present invention and the prior art has the bidirectional properties nearly equal to the isotropy, so that it can be pressed or bended without any further works to select the part of the products which has the excellent mechanical properties. As the long metal blank can always be rolled in the one and same direction across the width, it can have the constant directional property in the metal fiber structure which reduces the magnetic resistance. Thus, the product may be used as an electromagnetic material which produces little heat. Those and other objects, features, and advantages of the present invention will become apparent from the following detailed description of preferred embodiments that are shown in the accompanying drawings, in which: Fig. 1 is a fragmentary sectional view illustrating the apparatus according to a typical preferred embodiment of the present invention that may be used to implement the steps of the method of the invention; Fig. 2 is a front view of the apparatus of Fig. 1, with some non-essential parts thereof not shown; Fig. 3 is a perspective view of the apparatus of Fig. 1, with some essential parts thereof shown on an enlarged scale; Fig. 4 (a) is a perspective view of a first variation of the apparatus in Fig. 1 that includes an even number of planetary rollers in a set, with some essential parts thereof shown on an enlarged scale; Fig. 4 (b) is a perspective view of a second variation of the apparatus in Fig. 1 that includes an odd number of planetary rollers in a set, with some parts thereof shown on an enlarged scale; Fig. 5 is a perspective view of the apparatus according another preferred embodiment of the invention, with some parts thereof shown on an enlarged scale; Fig. 6 (a) is a perspective view of a long metal blank being rolled between the set of planetary rollers and the sun roller; Fig. 6 (b) is a front view illustrating the position of the long metal blank relative to the particular planetary roller and the sun roller; Fig. 7 is a schematic diagram showing a series of rolling units configured into a tandem according to a further embodiment of the invention; Fig. 8 is a front view of the apparatus according to another embodiment of the invention, with some parts thereof not shown; A first method according to the present invention is described by referring to Figs. 1 and 2. The apparatus that may be used in conjunction with the first method includes a sun roller 2 that has an external diameter of 400 mm, a set of eight planetary rollers 9, 9 rollingly mounted around the sun roller 2 in the equally-spaced relationship, each roller having a diameter of 120 mm and a length of 200 mm (see Figs. 1 and 2), and a backing-up housing 11 mounted around the set of planetary rollers 9, 9. In operation, the backing-up housing 11 rotates at 500 r.p.m., and then a strip of stainless steel 14 having a thickness of 1 mm and a width of 40 mm is fed between the anvil 6 on the sun roller 2 and the set of planetary rollers 9. The stainless steel strip 14 that has completely passed through one rolling arrangement has been rolled into a thickness of 0.5 mm and a width of 80 mm. The stainless steel strip may be fed at the rate of 3 m/min., and it has then been observed that it has been elongated by 5% along the length thereof. The rolling process for individual stainless steel strips can occur in the continuous manner, and the rolling process for each can be completed within a very short time. Each individual stainless steel strip through the rolling process can be easily deformed plastically, and its metal structure exhibits the improved mechanical properties. Furthermore, the rolling process can occur in one direction, which can eliminate any possible waves that might otherwise be formed along the longitudinal edges on the opposite sides. It can thus yield the high-quality products on the mass production basis. A first apparatus of the present invention is described, and the preferred embodiment of the apparatus is shown in Figs. 1, 2, and 3. The apparatus, generally designated as "A", includes a machine stand 1 that supports a sun roller 2 mounted to a horizontal shaft 3. The sun roller 2 has a groove 4 formed on the upper side wall thereof and extending in parallel with the center axis through the sun roller 2. The groove 4 can accept a member 5 formed like a wedge and an anvil 6 therein which are placed one on the other. An adjusting screw 7 is rigidly connected to the outer end of the wedge-like member 5 so that it can be controlled to move forward or backward. The adjusting screw 7 extends through a support plate 8 fixed to the sun roller 2, and engages the support plate 8 internally so that the adjusting screw 7 can advance or retract through the support plate 8 by rotating it in the appropriate direction. A set of three or more planetary rollers 9, 9 is mounted between annular rack 10, 10 so that set of planetary rollers 9, 9 can orbit around the outer circumference of the sun roller 2, each individual planetary roller 9 being rotatably supported by its respective shaft in parallel with the shaft 3. A backing-up wheel 11 is mounted around the set of planetary rollers 9, 9. The backing-up wheel 11 is driven by a drive motor (not shown) by means of a belt 13 which threads across the backing-up wheel 11 and motor pulley 12. In this embodiment, the motor (not shown) is started up, and a metal blank 14 being rolled, for example, a stainless steel strip, is caused to advance with its head being guided onto the anvil 6. Then, the belt 13 travels in the direction of an arrow 15, causing the backing-up wheel 11 to rotate in the direction of an arrow 16. Thus, the individual planetary rollers can rotate on their respective shafts and orbit around the sun roller 2 in the direction of an arrow 16. That is to say the planetary rollers rotate both axially and orbitally. The metal blank 14 advances further between the anvil 6 and the set of planetary rollers 9, 9 and is being rolled therebetween. When the metal blank 14 has completely passed through the rolling process, it will have been rolled into a product 14a whose original width W₀ has been elongated to a width W₁, as shown in Fig. 6 (a). The symbols used in Figs. 6 (a) and (b) have the following meaning: a = the amount of advance (the amount of elongation of the metal blank in the direction opposite to the forward direction of the planetary rollers) b = the amount of retract (the amount of elongation of the metal blank in the direction identical to the forward direction of the planetary rollers) c = W₀ = the original width of the metal blank before being rolled h₁ = the thickness of the metal blank after being rolled h₀ = the original thickness of the metal blank before being rolled l₁ = the interval between the two given working points l₂ = the interval between a given working point and the neutral point l₃ = the interval between the center line and the neutral point. After the metal blank has completely passed through the rolling process, its width, W₁, may be expressed as follows: W₁ = a + b + c (= W₀) In the embodiment shown in Figs. 1, 2 and 3, the anvil 6 is mounted above the sun roller 2 with its face being directed upwardly. In the alternative form, the anvil 6 may be mounted with its face being directed downwardly as shown in Fig. 5. In a further variation as shown in Fig. 4, two anvils may be mounted symmetrically with respect to a single sun roller, one with its face being directed upwardly and the other with its face directed downwardly. This arrangement provides double the efficiency. In this case, an even number of planetary rollers (as shown in Fig. 4 (a)) may roll the metal blank at two locations at the same time, whereas an odd number of planetary rollers (as shown in Fig. 4 (b)) may not roll the metal blank at two locations at the same time (because the anvils are provided symmetrically with resepct to the single sun roller) According to the embodiment, two pairs of pinch rollers are provided as shown in Fig. 1, one pair 17 being on the entry side of the machine and the other pair 18 being on the exit side. Those pairs of pinch rollers place the metal blank under the applied tensile stress, under which it can be fed forward. When a particular metal blank 14, such as a stainless steel strip, is being fed into the machine, at which time the metal blank 14 does not engage any one in the planetary roller set, the pairs of pinch rollers 17, 18 are driven for rotation in the direction of respective arrows 19, 20, causing the metal blank 14 to advance in the direction of an arrow 21. The wedge-like member 5 may be advanced or retracted as indicated by an arrow 22 or 23 by turning the adjusting screw 7 in the appropriate direction. Depending upon the movement of the wedge-like member 5 forward or backward, the anvil 6 may be raised or lowered as indicated by an arrow 24 or 25. In this way, the gap between the upper surface of the anvil 6 and the planetary roller set 9 can be adjusted. This gap may be chosen, depending upon the desired reduction in the thickness of a metal blank being rolled. In Fig. 1, reference numeral 26 refers to a screw that secures the sun roller 2 in position. The rolling arrangement A as described above may be used as a single unit, namely, as a stand-alone unit, but several rolling units as shown by A₁, A₂, A₃, A₄ in Fig. 7 may be configured into a tandem, in which those rolling units are in series, one being followed by another, followed by another, and so on. In the tandem configuration, a single metal blank may pass through each of the rolling units A₁ to A₄ until it has been rolled into a final product. For example, a particular metal blank that has the original thickness of 1.0 mm and width of 10 mm may, be rolled into the thickness of 0.2 mm and width of 50 mm, respectively. The number of rolling units that may be included in the tandem configuration may depend upon the particular requirements for a metal blank being rolled. If the number of planetary rollers in each individual rolling unit is increased, the interval between the adjacent rollers will be the smaller, which can limit the elongation in the width of a metal blank that can be obtained. As shown in Fig. 8, however, this limitation may be removed by providing a set of two planetary rollers that are close to each other and by providing those sets B₁, B₂, B₃, B₄ which should be located away from each other at the possible greatest interval. Although the present invention has fully been described with reference to preferred embodiments thereof, it should be understood that various changes and modifications may be made without departing from the scope of the invention as defined in the appended claims.

Claims: A cross-rolling method that consists of rolling a long metal blank (14) across the width thereof, characterised by the method comprising: providing a sun roller (2) and a set of planetary rollers (9), each of said planetary rollers (9) being mounted for rolling around said sun roller (2); and feeding the long metal blank (14) between said sun roller (2) and said set of planetary rollers (9) in the axial direction of said sun roller (2) and said planetary rollers (9), thereby rolling the long metal blank (14) into the required thickness and width. The method as defined in claim 1, characterised in that said step of feeding the long metal blank (14) between said sun roller (2) and said set of planetary rollers (9) comprises feeding the long metal blank (14) under applied tensile stress, and then advancing the long metal blank (14) by a predetermined length thereof for each interval between each pair of adjacent rollers (9), thereby rolling the long metal blank (14) successively as it advances stepwise. The method as defined in claim 1, characterised in that said step of feeding the long metal blank (14) between said sun roller (2) and said set of planetary rollers (9) comprises feeding the long metal blank by a predetermined length thereof immediately after one planetary roller (9) finishes rolling, and advancing it by said predetermined length thereof at each interval between each adjacent pair of rollers (9). A planetary cross-rolling apparatus which comprises a machine stand (1); characterised in that it further includes: a sun roller (2) mounted on said machine stand (1); an anvil (6) mounted in part of the outer wall of said sun roller (2); a set of planetary rollers (9) mounted to roll around said sun roller (2); a backing-up wheel (11) mounted outside said set of planetary rollers (9); and feeding means (18, 19) for feeding a long metal blank (14) to be rolled between said anvil (6) and said set of planetary rollers (9) in the axial direction of said planetary rollers (9). The apparatus as defined in claim 4, characterised in that said sun roller (2) includes a groove (4) formed on part of the outer wall of said sun roller (2) and extending longitudinally in parallel with the center axis through said sun roller (2), said groove (4) being adapted to accept said anvil (6), and said anvil (6) being movable into and out of said groove (4), and wherein the apparatus further includes: a wedge-like member (5) mounted between the bottom of said groove (4) and the radially inner wall of said anvil (6) for controlling the movement of said anvil (6) into and out of said groove (4). The apparatus as defined in claim 4 or 5, wherein said feeding means (18, 19) includes pairs of pinch rollers, one pair (19) being on the entry side of said apparatus and the other pair (18) being on the exit side of said apparatus. The apparatus as defined in claim 4, 5 or 6, characterised in that the anvil (6) is mounted on a vertically upper side or on a vertically lower side of said sun roller (2) (Figs. 3 and 5). The apparatus as defined in claim 4, 5 or 6, characterized by two anvils (6) one of which is mounted on the upper side of said sun roller (2) and the other of which is mounted on the lower side of said sun roller (2) (Figs. 4a, 4b). The apparatus as defined in any one of claims 4 to 8, wherein said set of a plurality of planetary rollers includes a predetermined number of planetary rollers mounted circumferentially along an inside of said backing-up wheel in equally-spaced relationship. The apparatus as defined in any one of claims 4 to 9, wherein said set of a plurality of planetary rollers (9) includes a predetermined number of groups (B₁, B₂, B₃, B₄), each group (B₁, B₂, B₃, B₄), including a plurality of planetary rollers (9) and said groups (B₁, B₂, B₃, B₄), being mounted circumferentially along an inside of said backing-up wheel (11) in equally-spaced relationship. Planetary cross-rolling apparatus comprising: a plurality of apparatus (A₁, A₂, A₃, A₄) as defined in any one of claims 4 to 9, configured into a tandem arrangement (Fig. 7).

Inventors: YOSHIDA KEIICHIRO, YOSHIDA, KEIICHIRO
Applicants: YOSHIDA KEIICHIRO, YOSHIDA, KEIICHIRO
Application year: 1992
Main classification: B21B1
IPC codes: B21B13, B21B1