Backward Extrusion Inner Profile Forming
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Solution Overview
Problem
Existing processes for producing inner profiles in tubes or hollow profiles face limitations in profile height, leading to inadequate filling of the forming die and under-filling in the running-in region, resulting in unusable products.
Innovation Solution
The process involves inserting a tube into a supporting sleeve and applying a pressure-loaded annular die at one end, while pressing a forming die from the other end, allowing the annular die to counter-pressure the backward-flowing material to ensure full filling of the die contour, and reducing pressure load as the die returns to maintain constant force conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the profile height is increased to produce deeper inner profiles, then the forming die can accommodate more complex geometries, but the material flow becomes inadequate and under-filling occurs
Solution Approach 1:
The annular die applies preliminary counter-pressure to the backward-flowing material before the forming die completes its pressing action. This counter-pressure prevents material from flowing backward and ensures adequate material supply to fill the forming die contour completely, even for high profile heights.
Solution Approach 2:
The pressure load on the annular die is dynamically adjusted during the return stroke, decreasing as the forming die penetrates deeper. This parameter change maintains optimal pressure conditions throughout the deformation region, ensuring uniform material flow and complete filling regardless of profile height.
2Shape
If the forming die presses deeply into the tube to create high profiles, then the inner profile geometry is improved, but the material flows backward and causes under-filling at the running-in region
Solution Approach 1:
The annular die positioned at the tube end provides preliminary anti-action by applying counter-pressure to the backward-flowing material. This prevents material from receding at the running-in region and ensures complete filling from the start of the inner profile throughout the entire deformation zone.
3Manufacturing precision
If a constant high pressure load is applied by the annular die to prevent under-filling, then the profile filling is improved, but the wall friction between the tube and supporting sleeve increases excessively
Solution Approach 1:
The pressure load on the annular die is made dynamic rather than constant. During the return stroke, as the forming die penetrates deeper and the deformed region lengthens, the pressure load on the annular die is automatically reduced. This dynamic adjustment maintains optimal pressure conditions while compensating for increasing wall friction, ensuring uniform material flow throughout the deformation region.
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 ensures improved filling of the forming die, allowing for higher profile heights and preventing under-filling, thereby producing usable inner profiles with uniform pressure conditions throughout the deformation region.
Implementation Method 1
The supporting sleeve radially supports the tube or hollow profile, thus preventing a radial expansion
Implementation Method 2
A process carried out in this way allows a counter pressure to be built up on the back-flowing, completed tube or hollow profile with an inner profile, which counter pressure forces the material to flow into the full profile cross-section of the forming die
Implementation Method 3
pressing a forming die with an outer profile into the tube or hollow profile from the latter tube end for producing the inner profile
Implementation Method 4
More particularly, the improved inventive process can be carried out as a cold forming process
Data Source
AI summary
A process of producing an inner profile (18)in a tube or hollow profile (11) includes inserting the tube or hollow profile (11) into a supporting sleeve (12), with a first tube end (19) being axially supported; placing a pressure-loaded annular die 16 on to the other tube end (20); pressing a forming die (15) with an outer profile into the tube or hollow profile (11) from the latter tube end (20) for producing the inner profile (18); allowing a return of the annular die (16) under a pressure load in the opposite direction of that of pressing in the forming die (15).