Angled Ring Deep-Drawing and Upset Sealing
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Solution Overview
Problem
Existing methods for producing angle rings from sheet metal, such as turning and forging, result in material waste, high energy consumption, and undesirable rebate joints, while machining processes are costly and prone to thermal distortion.
Innovation Solution
A method involving deep-drawing a cup from sheet metal to form a radial disc section and axially extending peripheral wall, where the radial edge is folded over and back-upset to create a thickened hub section, allowing for efficient, precise, and energy-saving production without cutting, and sealing the joint with oil to prevent corrosion and fluid penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sheet metal is turned up axially and compressed back to create a rebate joint, then the bearing disk can be produced, but an undesirable rebate joint is created in the corner area which is unsuitable for certain types of loads
Solution Approach 1:
The manufacturing process is segmented into distinct operations: deep-drawing the cup shape first, then separately folding and upsetting the edge. This separation allows each operation to be optimized independently, avoiding the creation of weak rebate joints while achieving the desired geometric complexity.
Solution Approach 2:
The cup shape is preliminarily formed through deep-drawing before the edge is folded and upset. This preliminary action creates a pre-formed geometry that receives the upset material, ensuring proper material flow and eliminating rebate joint formation while maintaining structural integrity.
2Ease of manufacture
If angle rings are produced by turning disc-shaped blanks, then the angle rings can be manufactured, but material waste is high and production costs are increased due to clamping movements and tool wear
Solution Approach 1:
The manufacturing approach changes from subtractive turning to formative deep-drawing and upsetting operations. This parameter change in the manufacturing process enables near-net-shape production from sheet metal, dramatically reducing material waste while maintaining production efficiency.
3Productivity
If angle rings are produced by forging or casting processes, then large quantities can be produced, but energy consumption is high due to material heating and thermal distortion occurs during cooling requiring post-processing
Solution Approach 1:
The thermal forging or casting processes are replaced with cold-forming operations (deep-drawing and upsetting). This substitution eliminates the need for material heating while maintaining high productivity through efficient press operations, significantly reducing energy consumption without compromising production volume.
4Strength
If the radial edge is folded over and back-upset to create the hub section, then a compact high-strength angle ring is produced without cutting, but the joint area requires sealing to prevent corrosion and fluid penetration
Solution Approach 1:
An intermediary sealing substance (oil or other sealant) is introduced into the joint area created by folding and upsetting the edge. This intermediary prevents direct contact between corrosive environments and the metal joint, protecting the high-strength connection from corrosion while allowing the compact geometric design to be maintained.
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 method enables the production of compact, high-strength angle rings with reduced material waste and energy consumption, providing a fluid-tight seal that prevents corrosion and allows for surface treatment without oil leakage, while accommodating various shapes and sizes.
Implementation Method 1
the sheet metal is formed into a cup, which has a radial inner edge, a radial outer edge and an axially extending peripheral wall lying in between, which merges into the inner edge or the outer edge with a drawing radius
Implementation Method 2
the radial inner edge or the radial outer edge is folded over axially and being applied to the axially peripheral wall
Implementation Method 3
the free end of the folded edge is axially back-upset, whereby a clearance at at least one drawing radius of the peripheral wall is filled
Implementation Method 4
a joint between the axial peripheral wall and the applied edge is closed in a fluid-tight manner during axial compression
Data Source
Figure 1
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Figure 3
AI summary
The method involves forming bowl (20) having a radial inner edge (22), a radial outer edge (26) and an intermediate axially extending peripheral wall (28) by sheet metal. A drawing radius (34a) of inner edge and outer edge is changed and edges are merged by peripheral wall. A thickened hub portion (14) of edges is formed in axially folded state and is applied to axial peripheral wall. A free end (30) of folded edges is protruded to peripheral wall. The free end of folded edge is axially compressed back, and a clearance gap (36) is filled to draw radius of peripheral wall. An independent claim is included for a metallic angular ring.