Roller Swaging for Precision Lug Manufacturing
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Summary
Problems
Existing methods for producing lugs with multiple diameters result in material waste, high cycle times, and tool wear due to heat generation and friction, leading to inefficiencies and increased costs.
Innovation solutions
The use of roller swage apparatuses and attachments that shape metal by swaging a cylinder to form a lug body with a barrel and tongue portion, reducing material waste and cycle times while minimizing heat-affected stresses and spindle loads through controlled swaging processes.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If turning and drilling operations are used to create lugs with multiple diameters, then the required material waste is excessive, but the manufacturing precision can be maintained
Why choose this principle:
The patent applies parameter changes by transitioning from subtractive manufacturing (turning and drilling) to a formative process (swaging) that changes the physical state and flow characteristics of the conductive material. The swaging process uses controlled plastic deformation to reshape the material into the desired lug geometry with multiple diameters, eliminating material waste while maintaining precision through controlled forming parameters
Principle concept:
If turning and drilling operations are used to create lugs with multiple diameters, then the required material waste is excessive, but the manufacturing precision can be maintained
Why choose this principle:
The patent replaces the traditional mechanical turning and drilling operations with a swaging process that uses controlled plastic deformation and material flow. This substitution eliminates the need for material removal while achieving the same geometric transformations, thereby reducing material waste without sacrificing manufacturing precision
Application Domain
Data Source
AI summary:
The use of roller swage apparatuses and attachments that shape metal by swaging a cylinder to form a lug body with a barrel and tongue portion, reducing material waste and cycle times while minimizing heat-affected stresses and spindle loads through controlled swaging processes.
Abstract
The present subject matter relates to roller swage apparatuses, roller swage attachments and related methods. For example, in some embodiments, a roller swage apparatus for swaging a portion of a cylinder of material can be provided. The roller swage apparatus can comprise a spindle for holding and rotating a cylinder of material and a tool post that is movable into and out of alignment with the spindle as well as a controller for operating the spindle and the movement of the tool post. The roller swage apparatus can comprise a roller swage attachment secured to the tool post for engaging the cylinder of material to shape the cylinder of material into a desired shape.