Angled Knife Bolster Forging via Oblique Bead Alignment
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Solution Overview
Problem
Existing methods for forging a knife with an angled bolster from a single piece of flat steel material face challenges in achieving optimal material distribution and mold filling, leading to inefficient processes and increased scrap rates due to high deformation work and material stress.
Innovation Solution
Aligning the longitudinal axis of the bolster obliquely to the knife's longitudinal axis, with angles between 5 to 60 degrees, allows for better pre-distribution of material, reducing deformation work and stress during forging, and enabling more design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the bolster is forged at an angle to the longitudinal axis of the knife from flat material with a centrally aligned bead, then the bolster can be formed, but high deformation work is required leading to insufficient mold filling and increased scrap
Solution Approach 1:
The bead is pre-formed with its longitudinal axis aligned obliquely to the longitudinal axis of the flat material at an angle of 5 to 60 degrees before forging. This preliminary alignment of the bead axis prepares the material distribution in advance, reducing the deformation work required during subsequent forging and enabling complete mold filling for angled bolster geometries.
Solution Approach 2:
The bead is formed with asymmetric orientation relative to the flat material, where the longitudinal axis of the bead is deliberately aligned obliquely rather than parallel or perpendicular to the longitudinal axis of the flat material. This asymmetric pre-alignment optimizes material flow during forging of angled bolsters.
2Shape
If high forming is carried out during forging to create an angled bolster, then the desired geometry is achieved, but large amounts of material must be driven into the blade causing insufficient mold filling
Solution Approach 1:
The oblique alignment of the bead's longitudinal axis is performed as a preliminary action before forging. This pre-positioning of material reduces the complexity and force requirements of the subsequent forging operation, enabling more efficient production of angled bolsters with complete mold filling.
3Strength
If the bead is formed with oblique alignment to the flat material axis, then deformation work and material stress are reduced, but additional processing steps are required for bead formation
Solution Approach 1:
The oblique bead alignment is performed as a preliminary forming step using compression or rolling processes before the main forging operation. While this adds an initial preparation step, it significantly reduces the deformation work and material stress during the critical forging phase, improving overall process reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in reduced production costs, shorter times, fewer rejects, and improved material distribution, leading to a more stable and efficient forging process with enhanced design options for bolster and blade geometries.
Implementation Method 1
a knife (1) with a blade (2), bolster (3) and tang (4) ... forged from a single piece of flat steel material (5)
Data Source
Figure 1~3
Figure 3
AI summary
The invention relates to a method for producing a knife (1) with a blade (2), a bolster (3) and a handle, in particular a tang (4), forged from a single piece of flat steel material (5), wherein, before forging, the flat material (5) is upset in the region between the blade (2) and the handle or tang (4) to form a bead (6), the longitudinal axis (LW) of which is arranged transversely in relation to the longitudinal axis (LM) of the knife, and is then formed by forging to form a bolster (3), which has at least one side edge (K2) positioned obliquely in relation to the longitudinal axis (LM) of the knife, wherein the longitudinal axis (LW) of the bead (6), which later forms the bolster, is oriented obliquely in relation to the longitudinal axis (LM) of the knife (1).