Main Sector of relevance\IRC classification 8. Industrial Manufacturing, Material and Transport Technologies

8.24 Transverse wedge-type rolling (TWR) technology and design of new processes, equipment and tools for their implementation

Developers’ contact information

State Scientific Institution “The Physical-Engineering Institute of the National Academy of Sciences of Belarus”, Laboratory for Microcrystalline and Amorphous Materials
10 Academician V.F.Kuprevich Street, Minsk BY-220141

Summary

Transverse wedge-type rolling is a high-performance resource saving technology of under-pressure metal treatment with metal recovery (MR) amounting to 0.8-0.98 designed for manufacturing of axiosymmetrical parts, mostly stepped shaft type.

Description

The purpose of the development is maximum energy and resource saving and production of high-quality die-forged parts. Transverse wedge-type rolling (TWR) is a high-performance resource saving technology of under-pressure metal treatment with metal recovery (MR) amounting to 0.8-0.98. The TWR method is used to manufacture prolonged axis parts rotation body type formed by metal redistribution along the stock axis carried out during axis transversal movement of a flat wedge-type tool. There are a lot of different part configurations: cylinder, cone and spheroidal surfaces with various grooving and overhangs. The resulting parts are characterized by good lasting and durability operating qualities.
An important advantage of flat rolling equipment is that it is easy to produce and the flat wedge-type tool is characterized by high precision and low costs.

Flat wedge-type tool

Low cost is ensured by involving general-purpose milling and grinding machines. Tool design in the developed technologies is optimized both by component amounts and by best design parameters selection. The optimization was carried out on the basis of studies on tension states correlation dependence, stock deformation and deformation region geometry taking into consideration tool stiffness and rolled metal actual mechanical properties.

Technology type

• Process
• Other:
  Equipment.
  Tool.

Technical advantages and economic benefits

Competitive advantages:

• 30–60% reduction of metal consumption;
• productivity gain;
• high-precision and clean product surfaces;
• 20–30% improvement in operating qualities of resulting parts;
• tool durability till its complete failure is 1 mln. products;
• elimination and minimization of need for product final mechanical polishing;
• reduction in energy consumption value for the process.

Technology differentiation and uniqueness

Payoff period is less than one year.

Context in which technology was identified

Hannover industrial fair, Moscow International Salon of Innovations and Investments, “Belpromexpo”, “Vietnam EXPO”, International Indian trade fair.

Technological keywords

Plastic deformation, transverse wedge-type rolling, stamping.

Development Stage

• Currently in use/production

Intellectual property rights

• Patent pending
• Specific Patent Information:
  
  • Patent of the Republic of Belarus 3560, IPC В21 H 1/18. Part making processes with the use of bar stock transverse wedge-type rolling and corresponding process equipment, dated 16.06.1998,
  • Patent of the Republic of Belarus 298, IPC В21 H 1/18. Rolling mill for bar stock reduction, dated 03.11.2000,
  • Positive decision on application No u20080095 as of 12.02.08, IPC В21 H 1/18. Transverse wedge-type rolling tool for on-expander tube stock
  • Useful model application No u20080073 as of 05.02.08, IPC В21 H 1/18. Transverse wedge-type rolling tool

Range of applications

It is applied in manufacturing of parts for motor-vehicle construction, machine-tool building, instrument-making industry, agricultural machine-building, tractor and aircraft, motor and cycle, mining and nuclear power industries. It allows processing of almost any construction steel as well as brass, titanium, zirconium and nickel.

Classifier Used at the EU Innovation Relay Centres

• Industrial Manufacturing, Material and Transport Technologies

Preferable Regions

• North America
• Europe
• Asia
• Australia

Practical experience

State Scientific Institution “Physics and Technology Institute of the Academy of Sciences of Belarus” carries out fundamental research on plasticity and endurance theory, constitutional and structural changes in metals and alloys, impulse and electrophysical metal treatment methods, develops new production and treatment processes for engineering materials and products. Theoretical foundation of the transverse wedge-type rolling method and design of proper tools and equipment is the main activity of the Department for process-oriented deformability. The institute created a school of transverse wedge-type rolling specialist which is recognized as leading all over the world. Innovative cooperation activities engage universities and research institutes in Russia, the USA, China, Poland, Germany, Turkey, Brazil, India, South Korea, Vietnam, Rumania, and Czech Republic.

Environmental impact

Minimal.

Type of collaboration sought

• Other:
  
  • parts supply,
  • technology transfer,
  • production establishment,
  • transfer of drawings for tools and equipment,
  • specialist training,
  • license sale.

Terms and restrictions

—

Available technical assistance

• Documentation
• Personnel