Introduction
This report explores the design and craft parameters for wedge-rolling ladders, axes and dies. The scope of the report is limited to broader concepts relating to the mechanics behind the wedge-rolling process performed with ladders, axes and dies. It does not address the finer detail associated with specifics of components nor the specific use of instrumentation.
Wedge-rolling
Wedge-rolling is a cold forming process in which a component is formed between a pair of wedge-shaped tools and progressively compressed. This process is most commonly used to form flat-bottomed grooves in shafts, pipes or components as well as to lead and cone rolls. The wedge-rolling process requires relatively low forces and generates very little residual stress in the interior of the component, allowing it to achieve an accurate form with a smooth surface finish.
Wedge-rolling ladders, axes and dies
In order to perform wedge-rolling, ladders, axes and dies are required. Ladders are the basic components of the process and consist of a pair of wedge-shaped tools arranged in a distinctive ladder configuration that allows for large variations in stock size. Axes are large-scale versions of ladder tools and require a larger-scale press to perform wedge-rolling. Dies are used to form small components and are usually made out of tool steel.
Design and craft parameters
There are several parameters that need to be considered when designing ladders, axes and dies for the wedge-rolling process. These parameters include the material hardness of the tools, the geometrical shape of the tools, the stock size, and the effective length of the tools.
Material hardness: The material hardness of the tools must be carefully chosen to ensure that they are able to withstand the forces involved in wedge-rolling without sustaining damage. The hardness should not be too soft, as this will result in excessive wear and tear on the tools, but it also should not be too hard, as this can result in weaker tools that are prone to fracture.
Geometrical shape: The geometrical shape of the tools is critical to the success of the process. The tools should be designed with a uniform wedge-angle, as this will ensure a smooth surface finish on the component being formed. The wedge-angle should be as close to 90 degrees as possible, as this will ensure an even pressure distribution across the forming area.
Stock size: The size of the stock material being used should be carefully considered when designing the tools. The stock material should be sized so that it can easily fit between the tools, while still allowing sufficient clearance between the tools to form a smooth surface finish on the component.
Effective length: The effective length of the tools is also a critical consideration when designing wedge-rolling tools. The effective length should be set to slightly exceed the length of the stock material so that the tools can reach the underside of the component without requiring additional force.
Conclusion
This report has outlined the design and craft parameters for wedge-rolling ladders, axes and dies. The material hardness, geometrical shape, stock size and effective length of the tools should all be carefully considered when designing wedge-rolling tools. The design of the tools is critical to ensuring a successful wedge-rolling process and a high-quality finished product.
