Axial Forming Tool Oscillating Control for Profile Precision
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Solution Overview
Problem
Existing axial forming processes for producing workpiece profiles on plastically deformable materials, such as cylindrical workpieces, suffer from non-uniform relative movements and fixed oscillating parameters, leading to suboptimal machining results.
Innovation Solution
A programmable numerical control system adjusts the oscillating relative movement of the forming tool and workpiece during the forming process, allowing for empirical determination of control parameters to match the actual geometry with the target geometry, considering factors like workpiece stiffness, material properties, and lubrication, and combining oscillating and unidirectional movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed oscillating parameters are used in axial forming, then the process is simple to control, but the machining precision and geometry matching are suboptimal
Solution Approach 1:
The patent implements dynamic adjustment of oscillating parameters (amplitude, frequency, stroke length) during the forming process through a programmable numerical control system. The control system varies these parameters in real-time based on process requirements, transforming the static control into dynamic adaptive control to achieve superior geometry matching precision.
Solution Approach 2:
The patent changes the oscillating parameters (amplitude, frequency, stroke length) during the forming process to optimize the geometry matching. By varying these parameters dynamically rather than keeping them fixed, the system achieves better manufacturing precision while using a programmable control system that manages the complexity.
2Manufacturing precision
If non-uniform relative movement is used in forming, then the process is simpler, but the machining quality and surface finish are suboptimal
Solution Approach 1:
The patent implements dynamic control of the relative movement between the forming tool and workpiece, transitioning from non-uniform simple movement to dynamically adjustable oscillating movement. The numerical control system varies the movement characteristics during forming to optimize profile quality and surface finish.
Solution Approach 2:
The patent employs periodic oscillating movement of the forming tool relative to the workpiece during the forming process. This periodic action with variable amplitude and frequency improves the profile quality and surface finish by preventing material flow irregularities that occur with continuous non-uniform movement.
3Manufacturing precision
If oscillating forming with variable parameters is implemented, then the machining quality improves, but the process control becomes more complex
Solution Approach 1:
The patent implements a programmable numerical control system that automatically manages the variable oscillating parameters based on pre-programmed sequences. The system serves itself by autonomously adjusting amplitude, frequency, and stroke length without requiring complex manual intervention, thereby achieving high geometry accuracy while managing control complexity through automation.
Solution Approach 2:
The patent utilizes programmable parameter changes in the oscillating movement characteristics. The numerical control system stores and executes predefined parameter sequences that automatically adjust the forming process variables, achieving improved profile geometry accuracy while the programmable nature manages the inherent complexity through systematic control.
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 enhances the precision and quality of the workpiece profiles by dynamically adapting the forming process to achieve accurate geometry matching, improving machining results.
Implementation Method 1
a forming tool exerts a compressive force on the workpiece to be formed, which is dimensioned such that the yield strength of the workpiece material is exceeded
Implementation Method 2
an oscillating relative movement of the forming tool profile and the workpiece to be formed is performed, in which a forming stroke and a return stroke directed opposite to the forming stroke are performed alternately
Data Source
Figure 1~2
Figure 3
AI summary
In a process for generating a profile on a plastically deformable, preferably cylindrical, workpiece (2) by axial forming, a relative movement of a forming tool profile provided on a forming tool and the workpiece (2) to be formed is carried out in a forming process to generate a workpiece-side profile with a workpiece-side profile length (L). During the relative movement of the forming tool profile and the workpiece (2), an oscillating relative movement is generated, in which a forming stroke and a return stroke in the opposite direction to the forming stroke are performed alternately. The ongoing forming process is varied with respect to the oscillating relative movement. A machine arrangement (100) is designed for carrying out the above process.