Ball Screw Actuator Shafts Using Multi-Stage Radial Forging
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Solution Overview
Problem
The manufacture of tubular components with complex geometries typically results in significant material waste due to machining, leading to high costs, especially when using high-grade specialist alloys in industries like aerospace.
Innovation Solution
A method involving multiple radial forging operations, where a workpiece is progressively reduced in diameter through a series of forging processes, including heating, axial movement, and the use of mandrels, to shape the component without the need for extensive material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining is used to manufacture tubular components with complex geometries, then manufacturing precision and tolerance can be achieved, but significant material waste occurs
Solution Approach 1:
The patent changes the manufacturing process parameter from subtractive machining to additive/extrusive radial forging. The workpiece is progressively deformed radially outward through controlled plastic deformation stages, building the complex geometry through material redistribution rather than removal, thereby achieving both precision and material efficiency
Solution Approach 2:
The patent performs preliminary forming operations to create a near-net-shape component before final precision operations. The multi-stage radial forging process progressively shapes the workpiece close to the final geometry, minimizing the amount of material that would subsequently need to be removed by machining
2Loss of substance
If radial forging is used to reduce diameter progressively, then material waste is reduced, but process complexity increases
Solution Approach 1:
The patent segments the radial forging process into multiple discrete stages, each reducing the diameter by a controlled amount. This segmentation allows complex geometry changes to be broken down into manageable steps, with each stage addressing a specific portion of the overall shape transformation, making the complex process controllable and repeatable
Solution Approach 2:
The patent employs dynamic control of the forging parameters throughout the process. The ram speed, force, and positioning are adjusted in real-time based on the stage of deformation and material response, allowing the system to adapt to changing geometric conditions and maintain precision throughout the progressive diameter reduction
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 reduces material waste, lowers production costs, and enhances mechanical properties by forming components with a fine-grained structure, while maintaining stringent tolerances.
Implementation Method 1
radially forging at least a portion of a first region proximal to the first end of the workpiece from a first outer diameter to a smaller second outer diameter
Implementation Method 2
The method further includes heating the workpiece between the first radial forging operation and the second radial forging operation, and between the second radial forging operation and the third radial forging operation
Data Source
AI summary
Methods are presented for the manufacture of tubular components having complex geometries. An exemplary method includes performing three radial forging operations on a workpiece that includes a bore along a longitudinal axis extending from a first end to a second end opposite the first end. The first radial forging operation includes holding the workpiece at the second end, and radially forging at least a portion of a first region proximal to the first end of the workpiece. The second radial forging operation includes holding the workpiece at the first end, and radially forging at least a first portion of a second region of the workpiece, the second region extending from the second end to a third region adjoining the first region. The third radial forging operation includes holding the workpiece at the first end, and radially forging at least a second portion of the second region of the workpiece.