Roller Structure Research Articles

Effect of ultrasonic vibration on the roll bending deformation behavior of ultra-thin-walled corrugated sheets

The ultra-thin-walled corrugated sheet is a crucial component of metal honeycomb structures. Due to the size effect, the traditional roll bend forming process often leads to significant dimensional deviations in ultra-thin-walled corrugated sheets. To address this issue, an ultrasonic vibration-assisted roll bend forming process was proposed. First, an ultrasonic vibration-assisted roll bend forming device was designed, which had a special drive roller structure that can alter the original axial direction of ultrasonic vibration to produce a radial vibration with an amplitude of 0–2 µm. Under the high-frequency impact and acoustic softening effect of ultrasonic vibration, the ultra-thin-walled corrugated sheets formed numerous plastic penetration zones. As a result, the influence of individual grain heterogeneity was weakened and the stress distribution states underwent an interchange. Therefore, the ultra-thin-walled corrugated sheets demonstrated improved edge length uniformity, increased hardness in the deformed areas, reduced surface roughness, and decreased springback angle. However, excessive ultrasonic amplitude resulted in severe thinning or even rupture. Ultimately, high-quality ultra-thin-walled corrugated sheets were successfully fabricated using pure titanium foil with a t/d of 5.4 and an ultrasonic amplitude of 1.6 μm.

Performance enhancement of a rotary magnetorheological damper induced by needle roller structure

In order to improve the mechanical performances of magnetorheological (MR) damper, a rotary MR damper with needle rollers was proposed based on squeeze mode. The MR fluid was induced to work in a special mode by inserting the needle roller structure, thus the output damping torque of the damper was significantly improved. The experimental results show that the damping torque shows a trend from stable to increased when the angular velocity of the damper is low, and the maximum damping torque increases with the increase of the excitation current due to the insertion of the needle roller structure, which is exactly consistent with “Stribeck effect”. Finally, this interesting phenomenon was analyzed and summarized.

Research on the influencing factors of hysteresis heat of rubber roller in battery pole piece calendering

AbstractThe calendering process of pole piece is a key step affecting the performance of the power battery. In the calendaring process, rubber roller materials will produce hysteresis heat, resulting in rolling resistance, which will lead to energy loss. The thermo‐mechanical coupling model for calendering rubber roller has been established and the effects of materials, calendering speeds, and roller structure shape on the viscoelastic temperature rise of rubber roller were analyzed. Solution‐polymerized styrene–butadiene rubber (SSBR) materials with different fillers have the greatest impact on temperature rise, followed by the roller shape, and calendering speed is smaller. The loss modulus of SSBR filled with white carbon black studied was smaller, and the temperature rise at high speed was 14.5°C higher than that at low speed. The optimized roller shape has a temperature rise of 10.4°C lower than the original shape. The research results could provide reference for the calendering rubber roller design of pole piece and similar processing.Highlights A thermo‐mechanical coupling model of calendering rubber roller was established. The rubber roller made of SSBR‐VN3 has a lower temperature rise. Optimized structure reduced contact pressure by 28.1% and temperature rise by 10.4°C.

Numerical Simulation of Heat Transfer of Roller Slag in Centrifugal Preparation of Inorganic Fiber

The synergistic preparation of aluminum silicate ceramic fibers from dust removal ash and fly ash is a newly developed process that achieves green and high added value treatment of solid waste. In this process, the centrifugal fiber forming method is used to treat molten slag to obtain aluminum silicate ceramic fibers. During the production process, the centrifugal roller, as a key component in fiber forming, is in long-term contact with high-temperature slag. The heat transfer between the two causes a huge temperature gradient inside the roller material, causing significant thermal stress inside the material, which has a significant impact on the stability of the centrifugal roller structure and its working condition. This article mainly conducts numerical simulation research on the heat transfer between the roller and the slag during the centrifugal fiber forming process, providing theoretical support for ensuring the structural stability of the roller and improving its service life. The research was carried out using the FLUENT module of the ANSYS software (V2021R1), and the heat transfer model of the slag and roller was established. The effects of the internal circulating water, different slag temperatures, different slag film widths, and different boundary layer thicknesses on the heat transfer of the roller were analyzed. The results show that the water temperature at the outlet is about 6 °C higher than that at the inlet on average; when the temperature of the slag increases by 1 °C, the temperature of the roller surface in contact with the slag increases by 0.91 °C; when the width of the slag on the roll surface is 11–17 mm and the slag thickness (boundary layer thickness) is less than 1 mm, it is beneficial for fiber production.

Study on the Position Deviation between the Iron Roughneck’s Spin-Rollers and the Drilling Tool

The spinner mechanism is one of the main working mechanisms of the iron roughneck, which is used to realize the rapid screwing-in or screwing-out of the drill pipe thread. The main problems of the spinner mechanism and the existing solutions are analyzed in this paper, and the spinner mechanism driven by a single hydraulic cylinder and transmitted by a wedge plate is designed. The upper and lower drilling tools are not concentric and affect the spin effect when the spinner mechanism works, and to address this problem, the influence of deviation in different directions is analyzed, and it is proposed that the lateral position deviation of drilling tools is the key factor affecting the spin performance. The relationship between the position deviation of the spin-roller and the position deviation of the drilling tool is established and solved. A method to reduce the lateral position deviation of drilling tools is proposed, and the effectiveness of this method is verified by experiments. The analysis shows that a spinner mechanism with a single follow-up roller easily causes the lateral position deviation of the drilling tool; the deviation of the spin-roller increases with the increase of the lateral deviation of the drilling tool, and the increase of the longitudinal deviation is more obvious; and with the increase of the drilling tool’s diameter, the deviation increases further. The symmetrical double follow-up roller structure can effectively reduce the lateral deviation of drilling tools and spin-rollers and ensures centering performance and the realization of reliable spin.

Establishment of millet threshing and separating model and optimization of harvester parameters

Aiming at the problems of low threshing rate and high loss rate in threshing and separating device of millet combine harvester, an axial-flow threshing and separating device with front-end rasp bar and rear-end nail tooth structure was designed. The difference of threshing performance and separating performance between rasp bar and the nail tooth was obtained, based on the mathematical model of threshing and separating performance. The threshing and separating performance of the rotary roller of full stripe bar, full nail tooth, and combined-stripe bar and nail tooth were compared by model analysis. The earhead model was established by using Hertz-Mindlin with bonding model. The Discrete Element Method (DEM) simulation test was carried out, and its results combined with that of model analysis to optimize the rotary roller structure parameters. The simulation single factor tests were carried out to obtain the influence rules of rotary roller speed, threshing clearance and concave grid spacing on the operation performance. Finally, a three-factor five-level quadratic orthogonal rotation combination test was carried out. Using the method of variance analysis and multi-objective optimization, it was calculated the best operating parameters and optimal performance indicators of the device. The verification test of the optimization results shows that they are basically consistent with the optimization results, which shows that the rasp bar and nail tooth rotary roller can meet the requirements of millet threshing and separation operations. Mathematical model analysis and DEM can provide reference for the optimization design of millet threshing and separation device.

3D Printed Double Roller-Based Triboelectric Nanogenerator for Blue Energy Harvesting.

The ocean covers 70% of the earth’s surface and is one of the largest uncultivated resources still available for harvesting energy. The triboelectric energy harvesting technology has the potential to effectively convert the ocean’s “blue energy” into electricity. A half-cylinder structure including rollers floating on the water has already been used, in which the pendulum motion of the rollers is driven by the waveform. For the stable motion of the rollers, the printed surface of the device was treated with acetone for attaining hydrophilicity. The electrical outputs with the proposed device were enhanced by increasing the contact surface area by simply implementing the double roller structure with double side-covered electrodes. With the optimized structure, the maximum power density reached a value of 69.34 µW m−2 at a load resistance of 200 MΩ with the device’s high output durability. Finally, the fabricated device was also applied to the artificial water waves to demonstrate the possibility of using this device in the ocean. By simply modifying the electrode structure and adding a roller, this device demonstrated the ability to generate over 160% of electrical output with the same covered area of the ocean by the triboelectric nanogenerators (TENGs) and potential ocean application.

Effect of polishing roller structure on pressure distribution during the linear hydrodynamic polishing

The effect of roller structural parameters on polishing flow field pressure during linear hydrodynamic polishing (LHP) was optimized by applying orthogonal test design. We used CFD simulation results to analyze the effect of structural parameters on the magnitude and uniformity of hydrodynamic pressure. By using the nlinfit fitting method, multiple nonlinear regression equations for the hydrodynamic pressure mean and mean square deviation of the structural parameters were obtained. A genetic algorithm that could globally search for the optimal solution in the independent variable range was used to obtain optimal structure parameters. We found that the magnitude and uniformity of dynamic pressure on the polished surface were improved. Experimental results showed that surface scratches on the polished surface were significantly reduced, and the excellent surface roughness could be obtained under different polishing processing conditions.

Design and wear resistance analysis of bionic roller for folding of automobile body cover parts based on pearl shell surface texture

In order to improve the forming quality of automobile body cover parts, the trundle attrition between the roller and panel in a roll-wrap robot has been investigated to minimize the frictional losses. This paper presents a design scheme of bionic roller structure based on the surface texture of pearl shell. The microstructure of pearl shell surface is analyzed and the mapping model of pearl shell surface structure is established. Meanwhile, the best texture type is determined by simulation analysis and theoretical formula. Based on the optimal texture type, the optimized roller structure is simulated and analyzed by utilizing the golden section method to determine the best depth-to-width ratio. The roller model is made by 3D laser marking mechanism. The validty of the theory and design method is verified by the correspoding experiments. By comparing the simulation and experimental analysis data, it can be seen that the vertical stripe bionic roller achieves the optimal performance when the depth-to-width ratio is 0.382. Compared with the ordinary roller, the maximum principal stress at the node is reduced by 2038.5 N, the frictional loss energy during movement is reduced by 8.43 × 108J, the wear mass is reduced by 285.63%, the wear depth is reduced by 47.4%.

Analyses on the roller structure of equivalent honeycombs for forest harvester under impact loading

The roller honeycomb feeding roller (RHFR) of forest harvester in logging was raised for reducing damage to logs. The equivalent relationship of roller double V-wings honeycomb (RDWH) were proposed and analytically derived in the mass, platform stress and elastic modulus. The finite element models of RDWH with various cell densities under the equivalent relation were established. The mechanical properties, energy absorption characteristics, impact response, structural stability, structure efficiency and improvement performance efficiency of RDWH under compression impact were investigated in comparison with roller hexagonal honeycomb (RHH). The RDWHs with equivalent relationship had approximate mechanical properties under unit compression displacement. The RDWH, benefiting from the NPR enhancement phenomenon in deformation, possessed about multiple times of mechanical properties and energy absorption efficiency than RHH. The performance efficiency of RDWH related to cell densities and cell layers in “PVP” and “Bunching Phase” trend. The RHFR exceeded that of the steel feeding roller (SFR) with about 2 times in maximum contact area under the corresponding contact force. The phenomenon of “sequential increment” and “uprush stage” appeared in contact area of RHFR for Gi groups were recorded with relating of cell densities and cell layers, which provided significance on reducing damage to logs.

Neck-spinning quality analysis and optimization of process parameters for plunger components: Simulation and experimental study

The plunger component is a key part of the plunger pump in the aircraft hydraulic system. Neck-spinning process is commonly used to fabricate plunger components, of which the quality of the spinning process significantly affects the performance of plunger pumps. One of the bottlenecks faced by the industry in the spinning process is to choose a suitable neck-spinning process so as to ensure the quality of plunger components. It is necessary to propose a reliable method to optimize the process parameters which affect the neck-spinning quality of plunger components. In this study, a calculable finite element analysis (FEA) model is established to simulate the three-roller neck-spinning process of the plunger component, which includes six typical slipper structures, two roller structures, and two spinning parameters. The FEA model is then validated by comparing the simulated spinning forces with the corresponding experimental results. The influence of the process conditions on the neck-spinning quality is investigated. And the orthogonal simulation results are analyzed by a combination of range method and fuzzy mathematical analysis method to recommend a reasonable slipper structure, roller structure and neck-spinning parameters. This study provides a promising method to improve the manufacturing quality of the typical plunger components.

Design and Optimization of Feeding Device for Sterile Seed Long Fiber Extractor

The feeding status of feeding device is an important factor that affects the performance of the main machine and even the process line. Taking the assembly layout of the feeding device and the structure of key parts as the research object, we conducted research design and analysis of the feed roller and cotton-feeding roller structure and their configurations. The results show that vertical feeding is conducive to the continuous and uniform feeding of materials; the combined use of cotton-plucking feed roller with roller is superior to the combination of multiple rollers; the progressive differential feeding mode makes for gradually thinning the material bed, improving the long fiber extraction rate, reducing the impurity rate, reducing the unattached fiber and greatly improving the machine performance; Φ58×1200mm cotton-feeding roller with a hexagonal spindle structure has higher deformation resistance than simple hollow structure. The research can be a reference for the optimization and design of sterile cottonseed extraction machine and equipment.

Study on Rotary Bending Forming Process of Torsional Damper Shell Pulley

To study the integral forming process of torsion damper shell pulley with characteristic structure is of great significance for producing and developing of the rotational part such as shell pulley. A processing way was proposed by combining plate bending forming and roller structure design, to integral forming torsion damper shell pulley. A model for two-step bending forming was establishedvia finite element method. Under the radial feeding of roller, the outer edge of plate was subjected to compress thickening and secondary thickened after bending, and effective stress and metal flow in the deformation zone were analyzed by using marking point. Combining with the structural characteristics of shell pulley, a design criterion "rotating thickening, gathering thickening" of roller was proposed. The metal flow in deformation zone was effectively controlled through the characteristic structure of roller, thereby the specific region to forming multi-wedge toothwas obtained. The quantitative analysis of the instantaneous part section in the forming process, combining with the design criteria of roller structure and material flow rate, radius and arc angle of roller were determined. With the objective forming parameters, the comparison between the simulation results and the experimental are basically coincided, the ribs were fully formed and the specific regions was thickened to minimum value, which verified the feasibility of sheet-bulk metal rotary bending forming theory and the design criterion of roller structure.

Global Overview of Research and Development of Crop Residue Management Machinery

Abstract. Crop residue retention has been recognized worldwide to improve soil structure and fertility, reduce pollution and erosion, and enhance soil water retention/conservation. However, some factors limit the widespread adoption of on-farm machinery that can appropriately manage in-field residue. Two key factors are the quality of residue chopping and spreading uniformity. This article initially summarized the research on blade design, blade arrangement and power consumption. The article classified residue management machinery into three types: single function, multiple function and harvester powered straw chopper/spreader. Single function straw chopper/spreader was further subdivided into four types, according to installation and movement modes of the chopping blade; multiple function straw chopper/spreader was subdivided into six types, according to function and location; harvester powered straw chopper/spreader was subdivided into three types, according to mounting position. To improve the chopped straw spreading uniformity, adding a blower fan and improving blade roller structure were proposed to increase the air velocity. Finally, the article proposed future directions for straw chopper/spreader development, including awareness raising of straw chopping and spreading mechanism, analysis of flow characteristics in the machine, development of straw chopping and spreading regulating device. Keywords: Chopping quality, Crop straw, Spreading uniformity, Straw chopper/spreader.

An optimum design on rollers containing the groove with changeable inner diameter based on response surface methodology

In order to realize the precision plastic forming of the revolving body component with changeable wall thickness, a kind of roller containing grooves with changeable inner diameter is put forward, as the forming mould of the technology of rolling-extrusion. Specifically, first, the arc length of the groove in the roller is designed according to the prediction on the forward slip value during the process of forming, to make accurate control of the actual length of the forming segments; then, to obtain better parameters of the roller structure, a second-order response surface model combining finite element numerical simulation and response surface methodology was put forward, taking the factor of forming uniformity as evaluation index. The result of the experiment shows that, for the formed component, not only the size can meet the needs but also each mechanical property index can be greatly improved, which verify the rationality of the forward slip model and the structural parameter of the optimum model based on the response surface methodology.

원통형 중공롤러의 응력 및 변형거동에 관한 유한요소해석

본 연구에서는 원통형 중공롤러의 응력과 변형거동 안전성을 FEM으로 해석하고, 그 계산결과를 기초로 과도 설계 여부를 고찰하였다. 중공롤러의 강도에 관련된 응력해석 결과에 따르면, 중공롤러를 지지하는 베어링을 설치한 인근에서 발생한 최대응력 39.8MPa은 구조용 강재의 항복강도인 250MPa 대비 15.9% 수준으로 과도한 설계로 평가될 수 있다. 또한, 원통형 중공롤러의 전체 길이 대비 중간 스팬부에서 발생한 최대 변위량 0.032mm는 중공롤러의 전체 길이와 두께에 견주어 볼 때 충분히 안전하다할 수 있다. 결국, 강도와 변형거동에 대한 FEM 해석결과에 의하면, 현재의 원통형 중공롤러 FEM 해석모델은 과도하게 설계되었다고 분석된다. The stress and deformation behavior safeties of cylindrical hollow rollers have been analyzed by the finite element method, and investigated for over design capability based on the computed results. According to the stress analysis result which is related to the strength of a hollow roller, the maximum stress of 39.8MPa in which is operated near the bearing for supporting a hollow roller structure is overestimated design as 15.9% level compared with a yield strength, 250MPa of a steel material. And the maximum deformation of 0.032mm in which is operated at the middle span of a total length of cylindrical hollow rollers is very small and sufficiently safe compared with a total length and a thickness of a hollow roller. Thus, the FEM computed results for a stress and deformation indicate that a current FEM analysis model of cylindrical hollow rollers is over designed.

Research on Flange State during Spinning of AZ31 Magnesium Alloy Rotators

The stress-strain condition and flange state during spinning of magnesium alloy rotators was researched. The preliminary conclusion is obtained: There are three states during spinning of rotators, which appropriate "forward" and "straight" is conducive to forming, but the "backward" should be avoided. Based on ABAQUS/Explicit platform to analyze flange state and forming quality of these rotators under various load conditions. FE analysis shows: blank diameter, roller structure and feed ratio are key factors of formability. Most favorable process parameters are blank diameter 160mm, feed ratio 0.8r/mm, while using combination roller. Finally, the role of the main process parameters on flange state was verified by experiment method.

와이어 소 머신용 중공롤러의 변위량과 응력해석에 관한 연구

본 연구에서는 원통형 중공롤러를 갖는 와이어 소 머신에 대한 변위와 응력강도 안전성 해석결과를 제시하고 있다. 유한요소법을 사용하여 세 개의 튜브 사이에 Y형상의 편위형 컬럼과 수직형 컬럼을 설치한 중공롤러에서 변형거동과 응력강도 안전성을 높인 중공롤러를 개발하고자 한다. 동일한 직경과 길이를 갖지만, 중량을 달리하는 중공롤러 모델에서 Y 형상의 편위형 및 수직형 중공롤러에 작용하는 변위거동 안전성은 중공롤러의 전체길이에 의해 더 많은 영향을 받는 것으로 나타는데, 이것은 중공롤러의 굽힘 모멘트와 밀접한 관련이 있다. 그러나, 중공롤러의 응력강도는 중량 차이가 크지 않을 경우 절단면의 형상에 의해 더 큰 영향을 받는 것으로 나타났다. 따라서, 중공롤러의 강도안전성을 높이고, 총중량을 낮추기 위해서는 Y형상을 갖는 중공롤러를 사용하는 것이 바람직함을 알 수 있다. In this paper, the displacement and stress strength safeties have been presented for cylindrical hollow rollers of a wire saw machine. Using the finite element method, the hollow roller with Y-shaped shift and vertical columns between three tubes has been developed to analyze the displacement behavior and stress strength safeties. For the same diameter and length of hollow roller models with a different weight, the displacement behavior safety of Y-shaped shift column and vertical column models is heavily depending on the total length of a hollow roller, which is closely related to the bending moment of a hollow roller structure. But, the stress strength of a hollow roller is more influenced by the cross sectional area of a hollow roller for the similar weight. Thus, this paper recommends Y-shaped hollow roller for increasing the roller strength safety and decreasing a total roller weight.

Multi-Objective Optimal Design Roller of Y-Type Mill Using Ga Combined with FEM

Y-Type rolling mill with three roller is a new kind of wire mill. Because of its unique advantage, It is very important to optimize structure. Roller is important part of the rolling mill, whose size effects the strength, stiffness, as well as the rolling piece quality and service life of the rolling mill. Therefore, It is important to optimize the roller structure dimension of Y-type mill.A new structure optimizing method is set up combined the modified genetic algorithms with finite element method.This method can solve multi-objective problems with more complex constraints in the engineering. Compared with the zero order method and first order method companied with ANSYS, the result of this optimizing method is better. This method can solve multi-objective problems with more complex constraints in the engineering, providing a new and effective means for the engineering problems.

Surface Heating Fuser with Roller Structure

The surface heating fuser structure has low energy consumption and high heating speed due to its low heat capacity and simple structure. The authors have introduced a surface heating fuser system in NIP 29. The heating material is composed of carbon nano tube and silicon rubber composite, and fabricated with thin film layer structure in order to minimize the heat capacity. A nip supporting member is applied to the heating tube inside slide along the surface of heating tube. But the high friction between the nip support member and the heating tube caused to the limitation of fusing speed and failure of electrical supply unit due to leaked lubricant. In this study, the roller type surface heating fuser structure is proposed. The fusing performance has been predicted by numerical simulation and verified by fabricated proto sample. The high fusing speed and durability of structure is confirmed through the evaluation of fusing system.