Cold-Formed Wire Ends for Larger Cross-Sections in Two Steps
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Solution Overview
Problem
Existing machines for forming wire ends with increased diameters and specific shapes, such as hexagonal or star-like forms, require multiple machining passes, leading to material wastage and increased costs due to the need for large initial wire diameters, and cannot efficiently shape both ends simultaneously without forming undercuts.
Innovation Solution
A forming apparatus with two devices, one for cold-deformation of each end, allowing both ends to be shaped in two forming steps without adjusting the wire orientation, using fixed and movable die assemblies to ensure stability and precision, reducing material waste and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple machining passes are used to form wire ends with increased diameters and specific shapes, then the desired mechanical resistance and shape are achieved, but material wastage increases and production costs increase
Solution Approach 1:
The patent combines multiple machining operations into a single integrated device that performs cold-moulding and extrusion simultaneously. The device includes a first forming unit for cold-moulding the wire end to increase diameter and a second forming unit for extruding the wire to create the final shape, both operating on the same wire piece in one setup, thereby reducing material wastage while achieving the desired mechanical properties and shape.
2Shape
If both ends of wire are deformed with upsetting and enlargement to obtain increased diameter, then the necessary diameter is achieved, but undercuts are formed that prevent extraction of the machined piece
Solution Approach 1:
The patent divides the forming process into two distinct functional units: a first forming unit that performs cold-moulding to increase diameter, and a second forming unit that performs extrusion to create the final shape. This segmentation allows each unit to perform its specific function without creating undercuts that would prevent extraction, as the extrusion process in the second unit forms the shape from the enlarged cross-section without interfering with the extraction of the first formed end.
3Strength
If large initial wire diameters are used to obtain desired mechanical resistance, then the mechanical resistance to twisting and bending is achieved, but the cost of the finished product increases
Solution Approach 1:
The patent changes the physical state and properties of the wire through cold-moulding and extrusion processes. By applying cold deformation, the wire material undergoes work hardening which increases its mechanical resistance to twisting and bending. The extrusion process also refines the grain structure, further enhancing mechanical properties. This allows the use of smaller initial wire diameters while achieving the desired strength characteristics, thereby reducing material costs.
4Manufacturing precision
If at least three machining passes are required to form wire ends, then the desired shape and cross-sectional area are obtained, but the productivity decreases and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple machining passes into a single integrated operation. The device simultaneously performs cold-moulding to increase cross-sectional area and extrusion to create the final shape in one continuous process. The wire is fed through both forming units in sequence without requiring intermediate handling or setup changes, effectively combining what would traditionally require three separate machining passes into one unified operation, thereby increasing productivity while maintaining manufacturing precision.
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 apparatus effectively forms wire ends with increased cross-sectional areas using less initial material, achieving high mechanical resistance and reducing production costs by minimizing material usage and machining steps.
Implementation Method 1
a first device for forming the first end of the piece of wire, configured to form the first end by means of cold-deformation, such as to produce a cross-section of the first end greater than the cross-section of the initial piece of wire
Implementation Method 2
a second device for forming the second end of the same piece of wire, configured to form the second end by means of cold-deformation such as to produce a cross-section of the formed second end greater than the cross-section of the initial piece of wire
Data Source
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AI summary
Apparatus for deforming two opposite ends (1a,1b) of a piece of wire (1) extending in a longitudinal direction (X-X), comprising a first device (1000) for forming the first end (1a) of the piece of wire (1), configured to form the first end (1a) by means of cold-deformation, such as to produce a cross-section of the first end with an area greater than the cross-section of the initial piece of wire; and a second device (2000) for forming the second end (1b) of the same piece of wire (1), configured to perform forming of the second end (1b) by means of cold-deformation such as to produce a cross-section of the formed second end greater than the cross-section of the initial piece of wire.