Annular Component Fabrication via Press Forming Undercut
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Solution Overview
Problem
The existing methods for fabricating annular component parts, such as stop collars for engine starters, are inefficient due to increased processing time, equipment costs, and energy consumption, particularly in forming undercuts which require cold forging, annealing, and lubrication treatments, leading to productivity and energy-saving challenges.
Innovation Solution
A method using press forming of plate-like metallic raw materials to create annular components with tapered profiles, eliminating the need for cold forging and subsequent treatments by expanding and chamfering the inner diameters to form undercuts without cutting operations, thereby reducing equipment costs and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cold forging is used to form the workpiece, then the structural integrity is improved, but the processing time and energy consumption increase due to required annealing and lubrication treatments
Solution Approach 1:
The patent changes the material state from solid bar steel to plate-like metallic raw material, enabling press forming instead of cold forging. This parameter change eliminates the need for annealing and lubrication treatments while maintaining structural integrity, directly resolving the contradiction between strength and processing time
Solution Approach 2:
The patent extracts and eliminates the cold forging process and its associated treatments (annealing, lubrication) from the manufacturing sequence. By using press forming of plate material directly, the problematic steps are removed while still achieving the required structural integrity
2Reliability
If cold forging and multiple treatment steps are used, then the component quality is improved, but the equipment cost and requisite space increase
Solution Approach 1:
The patent merges multiple separate processes (cutting, forging, annealing, grinding, lubrication) into a single press forming operation. This consolidation reduces equipment requirements and space while maintaining component quality, directly addressing the contradiction between reliability and device complexity
Solution Approach 2:
The press forming process serves multiple functions simultaneously: it forms the annular body, creates the tapered cylindrical wall, and produces the undercut structure in one operation. This multi-functionality eliminates the need for specialized equipment for each step, reducing overall equipment cost
3Manufacturing precision
If cutting operations are used to form the inner diametric concave portion, then the precision is improved, but the productivity decreases and delivery schedule extends
Solution Approach 1:
The patent performs preliminary action by forming the tapered profile and undercut structure directly during the press forming process before any subsequent operations. This eliminates the need for separate cutting operations while maintaining precision, directly resolving the contradiction between manufacturing precision and productivity
Solution Approach 2:
Instead of forming the undercut by removing material through cutting operations, the patent inverts the approach by forming the undercut through plastic deformation of the plate material during press forming. This adds material in the required shape rather than subtracting it, eliminating cutting steps
4Ease of manufacture
If softening and annealing steps are conducted, then the material workability is improved, but the energy consumption increases significantly
Solution Approach 1:
The patent changes the material form from bar steel requiring thermal softening to plate-like metallic raw material that can be directly pressed. This parameter change eliminates the need for thermal processes while maintaining adequate workability, directly resolving the contradiction between ease of manufacture and energy consumption
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 significantly shortens processing time, reduces equipment costs, and enhances productivity while achieving energy savings by eliminating the need for cold forging and associated treatments, allowing for precise formation of undercuts in annular components.
Implementation Method 1
expanding the inner circumferential periphery of the cylindrical wall to an inner diameter corresponding to the inner diametric concave portion upon forcing a punch into the inner circumferential periphery of the cylindrical wall
Implementation Method 2
squeezing the cylindrical wall in a tapered profile such that the inner diameter of the cylindrical wall gradually decreases from the root portion to the distal end of the cylindrical wall
Data Source
AI summary
A method of fabricating an annular component part is disclosed wherein press forming is carried out to prepare an annular body having a cylindrical wall, having a root portion and a distal end, and an annular flange portion. The fabricating method comprises expanding an inner circumferential periphery of the cylindrical wall to an inner diameter corresponding to an inner diametric concave portion formed on the inner circumferential periphery and squeezing the cylindrical wall in a tapered profile such that the inner diameter of the cylindrical wall gradually decreases. During inner diametric expanding operation, an annular shoulder is formed on the inner circumferential periphery of the cylindrical wall and plays a role as an undercut of the annular component.