One-Piece Bow-Shaped Rake Forging to Prevent Joint Breakage
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Solution Overview
Problem
Existing methods for producing bow-shape rakes with one-piece steel suffer from low production yield, poor standardization, and frequent deformation or breakage due to complex forging processes and inadequate material firmness.
Innovation Solution
A method involving heating a rectangular steel blank to a high temperature, stamping to form rake teeth and handle blanks, bending and forging to create a unified rake body without separate connections, using equipment like steel heating units, stamping devices, and roll forging to reduce bulges and forging times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stamping welding method is used to produce rake head, then production process is simple, but rake tooth deformation and breakage occur at joint between bow-shape handle and rake body
Solution Approach 1:
The patent merges the rake head and handle into a single integrated component forged from one-piece steel. The rake head, rake teeth, and handle are formed as one unified structure through forging, eliminating separate welding joints and improving structural integrity and durability while maintaining manufacturing feasibility.
Solution Approach 2:
The patent uses steel material that is heated to austenite phase and then forged, utilizing the material's phase transformation properties. The steel is heated to high temperature to achieve appropriate plasticity for complex shaping, then cooled and forged to achieve the desired shape with enhanced mechanical properties.
2Reliability
If existing one-piece forging method is used, then structural firmness is improved, but production yield decreases and standardization is poor
Solution Approach 1:
The patent employs preliminary heating of the steel blank to austenite phase before forging. This preliminary thermal preparation ensures the material has optimal plasticity and uniform properties throughout the forging process, enabling consistent production of standardized components with high yield and maintaining structural firmness.
Solution Approach 2:
The patent controls and optimizes forging parameters including heating temperature, forging pressure, and cooling rate. By precisely controlling these parameters, the process achieves both high production yield with good standardization and maintains the structural firmness of the one-piece forged rake.
3Shape
If complex five-times stamping and forging is used, then bow-shape rake is formed, but bulges occur in middle part requiring secondary operations
Solution Approach 1:
The patent incorporates the bow-shape curvature directly into the forging die design. The curved die surface guides the flow of heated steel material to naturally form the desired bow-shape in a single forging operation, eliminating the need for multiple stamping and forging cycles and preventing bulge formation.
Solution Approach 2:
The patent achieves the complete bow-shape formation in one rapid forging operation by using appropriately designed dies and controlling the forging process speed. This single-step approach skips the need for multiple intermediate operations and secondary bulge correction, reducing overall process complexity.
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 method results in a firm, standardized bow-shape rake with reduced production defects and increased yield, avoiding unnecessary operations and bulges during the forging process.
Implementation Method 1
heating a rectangular steel blank to a high temperature
Implementation Method 2
stamping to form rake teeth and handle blanks, bending and forging to create a unified rake body
Data Source
AI summary
This application provides an enhanced method and equipment for forging bow-shape Conjointed rake with one-piece steel. The methods of the present application include: S1: heating the rectangular blank to target temperature; S2: stamping the rectangular blank to mold rake tooth with rake handle blank reserved at both sides, and conduct cutting at the shoulder; S3: horizontally forging and stamping the rake handle blanks at both sides respectively to columnar; S4: heating the rake handle blank locally, stretching the rake handle blank with roll forging machine to mold rake handle, and bending the rake handle back in reverse to the rake tooth; S5: bending the rake handle stretched out from the sides inward and forge the two ends of the rake handle together to form the main body of the bow-shape rake; S6: placing the main body of the bow-shape rake between the convex stamping equipment to stamp the rake tooth.