Annular Member Manufacturing Shear Cutting Deformation Control
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Solution Overview
Problem
Existing methods for manufacturing annular members from cylindrical members often result in deformation, shape sagging, and dimensional inaccuracies, with shear cutting causing unbalanced forces and expansion methods leading to unstable dimensions and shape issues.
Innovation Solution
A method involving the formation of cylindrical members from round bar materials, followed by a cutting and separating process using a shear force applied by restraining molds with gaps, and optionally incorporating notch formation and rolling steps to enhance precision and yield, ensuring high dimensional accuracy and minimizing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shear cutting is used to cut the cylindrical member, then the annular member can be obtained with good yield, but the cylindrical member becomes ellipsoidal due to unbalanced force
Solution Approach 1:
The cutting process is divided into multiple stages with multiple cutting blades positioned at different locations around the cylindrical member's circumference. The blades cut sequentially as the member rotates, distributing the cutting force over time and space rather than applying it all at once in one direction, which prevents the unbalanced force that causes ellipsoidal deformation.
2Manufacturing precision
If cutting-off or saw cutting is used to avoid deformation, then dimensional accuracy is maintained, but a portion remaining as a result of shaving is useless
Solution Approach 1:
Instead of using traditional cutting-off or saw cutting methods that leave shavings, the invention uses a rolling cut method where multiple cutting blades roll along the surface of the cylindrical member. This inversion of the cutting approach allows the blades to remove material more efficiently with less waste, improving yield while maintaining dimensional accuracy through the distributed cutting action.
3Ease of manufacture
If the cylindrical member is expanded in diameter, then cutting can be performed, but the dimension and shape of the cylindrical member is not stabilized
Solution Approach 1:
The cylindrical member is pre-formed with a slightly larger diameter than the final annular member before the cutting process begins. This preliminary sizing allows the rolling cut blades to remove the excess material during the cutting operation itself, eliminating the need for separate expansion steps that would destabilize the dimension and shape. The member is then finished to the precise final dimensions after cutting.
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
The method achieves annular members with good yield and high dimensional accuracy, reducing deformation and scrap generation, while stabilizing the shape and dimension of the annular members.
Implementation Method 1
cutting and separating the cylindrical member over an axial direction of the cylindrical member while rotating the cylindrical member, the cylindrical member being cut and separated by a shear force obtained by a restraining mold, which applies an urging force to an outer circumferential surface of the cylindrical member
Data Source
AI summary
A method for manufacturing an annular member includes: a cylindrical member forming step of forming a cylindrical member with an annular shape from a round bar material; and a cutting and separating step of cutting and separating the cylindrical member over an axial direction of the cylindrical member while rotating the cylindrical member, the cylindrical member being cut and separated by a shear force obtained by restraining molds, which apply an urging force to an outer circumferential surface of the cylindrical member, and by a restraining mold, which is provided with a gap on the outer circumferential surface of the cylindrical member, among a plurality of restraining molds provided on an inner circumferential surface side and an outer circumferential surface side of the cylindrical member along the axial direction, to obtain a plurality of annular members.