Annular Ring Forming with Stepless Cup Wall Material Flow
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Solution Overview
Problem
Existing methods for producing rolling bearing rings result in a thicker cup base due to restricted material flow during cup extrusion, leading to increased material waste and inefficiencies in the forming process.
Innovation Solution
A method involving cup extrusion into a cup with a stepless cup wall, allowing unhindered material flow and subsequent separation of annular sections to form thinner annular moldings, reducing material waste and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stepped forming punch and stepped forming die are used to produce annular sections, then the annular sections can be formed in a single step, but the material flow is restricted and the cup base cannot be formed as thin as desired
Solution Approach 1:
The forming process is divided into two separate steps: first forming the cup base with a plain punch, then forming the annular sections with a stepped punch. This segmentation allows each step to be optimized independently, enabling thin cup base formation without material flow restriction.
Solution Approach 2:
The cup base is formed in advance as a preliminary action before forming the annular sections. By pre-forming the cup base with a plain punch, the subsequent stepped punch can focus on forming the annular sections without restricting material flow to the already-formed base area.
2Shape
If a stepped profile of the forming die and forming punch is used, then annular sections can be formed, but the cup base thickness is increased leading to material waste
Solution Approach 1:
The forming operations are segmented into two distinct phases: cup base formation using a plain punch, and annular section formation using a stepped punch. This eliminates the need for a stepped profile during cup base formation, allowing minimal material to be used for the base.
Solution Approach 2:
The cup base is formed as a preliminary structure before the annular sections are formed. The plain punch creates the base geometry first, then the stepped punch adds the annular sections, ensuring the base thickness is determined solely by base formation requirements rather than annular section formation constraints.
3Shape
If cup extrusion is performed with a stepped forming punch, then annular sections are formed, but material cannot be displaced freely increasing energy consumption
Solution Approach 1:
The forming process is segmented into two steps: first step uses a plain punch for cup base formation where material can flow freely, and the second step uses a stepped punch for annular section formation. This segmentation reduces the total energy required compared to using a stepped punch for the entire process.
Solution Approach 2:
The cup base is formed in advance with a plain punch, creating a preliminary structure that facilitates subsequent annular section formation. This preliminary action reduces the energy required in the second step because the material has already been partially formed and can be more easily displaced into the annular sections.
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 enables the production of thinner cup bases and reduced material waste, improving the efficiency of the forming process and subsequent processing steps for rolling bearing rings.
Implementation Method 1
a forming punch (2) is pressed against the blank (3), whereby the blank (3) is formed into a formed cup (3'') with a cup wall (31) and a cup base (30)
Data Source
Figure 1~2
Figure 3~8
Figure 9~10
AI summary
The invention relates to a method and a forming device for producing an inner and outer annular molded part from a blank. The method has the steps of extruding the blank in order to form a cup with a formed cup base (30) and a continuous cup wall which adjoins said base; forming the cup wall such that the formed cup wall comprises an inner annular section (32) and an outer annular section (33) which adjoins the inner annular section and is partly offset in the axial direction; separating the outer annular section (33) from the inner annual section (32); and separating the inner annular section (32) from the formed cup base (30), wherein the separated outer annular section forms the outer annular molded part, and the separated inner annular section forms the inner annular molded part.