The design of a flexible model ring rolling machine

Interest in the development of flexible forming technologies is growing yet the process of ring rolling has remained largely unchanged for over a century. In previous work, we have explored the possibility of an ‘incremental ring rolling’ process in which a mandrel having reduced contact with the roll moves both radially and axially to produce ring cross-sections of arbitrary profile. Extending this concept led to a structured search for possible innovations in ring rolling process design, which has been presented as a ‘periodic table’ of candidate machines. In order to examine the value of these new designs, an innovative model flexible ring rolling machine has been designed. The machine is modular, comprising one, two or three elemental machines which can be positioned at various circumferential locations. Increasing the number of elemental machines gives the possibility of increasing the flexibility of the process and increasing its production rate. The machine will be used to examine the possibility of deforming pre-formed rings with rectangular cross-section into any ring shape with a flat outer face. The model machine has been designed to have extensive flexibility, which is likely to be beyond the requirements of a machine used in production. However, lessons learnt from its use will allow development of industrial machines able to respond more rapidly to changing market needs.