Annular Object Forming Assembly for Precision Stress Control
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Solution Overview
Problem
Current methods for forming annular objects, such as inlet lips for aircraft propulsion systems, face inefficiencies and defects due to limitations in clamping and shaping processes, particularly in achieving precise geometries and reducing material stress.
Innovation Solution
A method involving a die clamp angle less than the preform angle, with a frustoconical preform clamped between an inner and outer clamp member, and an actuation system to translate components, allowing for precise shaping and annealing of the annular object, reducing defects like cracks and wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional clamping and shaping processes are used for forming annular objects, then the formation process can be completed, but geometric precision and material stress control are insufficient leading to defects
Solution Approach 1:
The patent applies parameter changes by optimizing the die clamp angle to be less than the preform angle, and by controlling the relative co-axial movement parameters between the punch and preform. This allows precise control over the forming process, achieving the desired geometric precision while managing material stress to prevent defects like cracks and wrinkles.
Solution Approach 2:
The invention employs dynamic control of the forming process through relative co-axial movement between the punch and preform. The actuation means enables controlled translation and rotation, allowing the process to adapt to material flow requirements during forming, thereby improving both geometric precision and reducing defects.
2Manufacturing precision
If a die clamp angle less than the preform angle is used, then geometric precision is improved, but the process complexity increases
Solution Approach 1:
The forming process is segmented into distinct functional components: the punch for internal shaping, the die clamp for external constraint, and the actuation means for controlled movement. This segmentation allows each component to be optimized independently, achieving geometric precision through the die clamp angle configuration while managing overall process complexity through modular design.
3Reliability
If relative co-axial movement between punch and preform is controlled, then material stress is reduced, but the forming time increases
Solution Approach 1:
The actuation means implements periodic or controlled intermittent movement between the punch and preform, allowing material to gradually adapt to the forming forces. This controlled progression reduces material stress and prevents defects while managing the overall forming time through optimized movement cycles.
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 enhances the formation of annular objects by improving geometric precision and reducing material stress, leading to higher quality and defect-free annular structures, such as inlet lips for aircraft propulsion systems.
Implementation Method 1
The method may also include a step of annealing the externally drawn body following the translating of the die assembly
Data Source
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AI summary
A method is provided for forming an annular object. This method includes: providing a frustoconical preform (104) extending axially along an axis (28), wherein a sidewall of the frustoconical preform (104) is angularly offset from the axis (28) by a preform angle (120); externally drawing the frustoconical preform (104) over an outer surface (34) of a punch (22) and an outer surface (80) of a die clamp (72) to provide an externally drawn body (122), wherein the outer surface (80) of the die clamp (72) is angularly offset from the axis (28) by a die clamp angle (82) that is different than the preform angle (120); mating a die (74) with the die clamp (72) to provide a die assembly (26), wherein the externally drawn body (122) is clamped radially between the die (74) and the die clamp (72); and translating the die assembly (26) axially along the axis (28) and into a bore (38) of the punch (22) to at least partially internally draw the externally drawn body (122) against an inner surface (36) of the punch (22).