Arc-Shaped Washer Layout for Higher Material Yield
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Solution Overview
Problem
Conventional methods for manufacturing arc-shaped washers result in low material yield due to clearances between adjacent washers, leading to wasted material and inefficiencies in the manufacturing process.
Innovation Solution
A method involving a preparing step and two cutting-out steps to create washers, where the second washer is cut from a partially overlapping area with the first washer, ensuring the outer peripheral cut-away portions of the second washer contact the inner peripheral face of the first washer, thereby reducing clearance and improving material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If washers are manufactured by stamping material with constant direction movement and clearances between adjacent washers, then the manufacturing process is simple, but material yield is low due to wasted material at clearance portions
Solution Approach 1:
The patent changes the arrangement dimension of washers from linear sequential placement to overlapping placement where the second washer is positioned partially over the first washer's area. This dimensional change in layout allows the outer peripheral cut-away portion of the second washer to contact the inner peripheral face of the first washer, eliminating clearances and improving material yield without complicating the stamping process
2Loss of substance
If clearances are maintained between adjacent washers during stamping, then the manufacturing process is straightforward, but material is wasted resulting in low material yield
Solution Approach 1:
The patent segments the washer manufacturing into two distinct cutting-out steps: first cutting out the first washer, then cutting out the second washer from the remaining material. This segmentation allows precise control over the positioning and overlap between washers, eliminating material waste at clearance portions while maintaining manufacturing simplicity
3Productivity
If washers are arranged with clearances in the stamping process, then the manufacturing is easy, but productivity is reduced due to low material yield
Solution Approach 1:
The patent applies preliminary action by first cutting out the first washer completely, then using the remaining material to cut out the second washer with overlapping positioning. This preliminary cutting sequence establishes the foundation for subsequent washers to be arranged without clearances, improving material yield and productivity while keeping the process straightforward
Data Source
AI summary
There is provided a method of manufacturing washers with improved material yield. The method includes: a preparing step of preparing a material having a panel shape; a first cutting-out step of cutting out a first thrust washer having a substantially arc shape from the material; and a second cutting-out step of cutting out a second thrust washer from a portion of the material in contact with a portion from which the first thrust washer is cut out.