Rotating Ball Tool Head for Precision Separation Disc Forming
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Solution Overview
Problem
Existing methods for manufacturing separation discs with integrally formed elevations face issues such as incomplete depression filling, unsatisfactory completion, vibration generation, tool head wear-out, and heat-related breakdowns during flow forming.
Innovation Solution
A tool head comprising a ball element, holding device, and fixating element that allows detachable and rotational arrangement, combined with a machine tool and fluid pressure, to form separation discs on a rotating mandrel, reducing vibrations and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a roller is used to press the workpiece over the mandrel, then the separation disc can be formed, but the depressions are not completely filled and elevations do not reach the required height
Solution Approach 1:
The patent replaces the traditional roller with a ball element that has a spherical contact surface. This spherical geometry allows the ball element to better conform to the mandrel surface and apply pressure more effectively, ensuring complete filling of the depressions and achieving the required elevation height on the separation disc.
Solution Approach 2:
The patent changes the contact geometry parameter from cylindrical (roller) to spherical (ball element). This parameter change improves the pressure distribution and contact area during the flow forming process, enabling complete depression filling and achieving the desired elevation dimensions.
2Productivity
If a roller is used to press the workpiece over the mandrel, then the separation disc can be formed, but vibrations are generated during the process
Solution Approach 1:
The spherical ball element provides smoother contact and rolling motion compared to the cylindrical roller, reducing mechanical vibrations during the flow forming process. The ball's geometry allows for more uniform pressure application and less impact loading on the workpiece and mandrel.
3Productivity
If a roller is used to press the workpiece over the mandrel, then the separation disc can be formed, but the tool head experiences large heat generation and may break down
Solution Approach 1:
The ball element's spherical geometry reduces the contact area and improves heat dissipation compared to the roller. The point contact allows for better heat distribution and reduces concentrated thermal loading on the tool head, preventing breakdown due to excessive heat generation.
4Productivity
If a roller is used to press the workpiece over the mandrel, then the separation disc can be formed, but the complete tool head must be replaced when the roll is worn out
Solution Approach 1:
The patent divides the tool head into separable components: the ball element and the holding device. The ball element can be independently removed and replaced through the opening in the holding device, allowing maintenance of only the wear-prone ball element rather than replacing the entire tool head assembly.
Solution Approach 2:
The ball element is extracted as a separate, replaceable component from the tool head. It can be removed through an opening in the holding device and replaced independently, simplifying maintenance and reducing downtime compared to replacing the complete tool head.
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 tool head effectively completes separation discs with high tolerance and surface finish, reduces vibrations, eliminates the need for complete tool head replacement, and dissipates heat, ensuring efficient manufacturing.
Implementation Method 1
A known method for pressing separation discs with integrally formed elevations involves flow forming of a sheet metal blank or workpiece over a mandrel to produce a separation disc with integrally formed elevations
Implementation Method 2
the tool head further comprises a fixating element for detachably and rotatably arrange the ball element at the holding device
Data Source
AI summary
A tool head for manufacturing a separation disc includes a ball element configured to bear on a work piece to form the separation disc on a rotating mandrel; a holding device for holding the ball element; and a fixating element for detachably and rotatably arranging the ball element at the holding device. A method for manufacturing a separation disc uses a tool head.