Cold Forming Die Stroke Modulation for Wear Reduction
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Solution Overview
Problem
Existing cold forming devices and methods, such as those used for forming toothings on shafts, face issues with inconsistent tip circle diameters and material flow, leading to dimensional inaccuracies and reduced service life of the forming die due to uniform stroke lengths in forward and reverse movements.
Innovation Solution
Modulating the feed device's stroke travels in cold forming devices by varying the lengths of forward and reverse strokes in successive forming steps, using fuzzy logic to distribute loads chaotically across the forming die, thereby adapting to specific forming conditions and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If uniform forward and reverse stroke lengths are used in forming steps, then the forming process is simple and consistent, but the service life of the forming die is reduced due to continuous loading of the same areas
Solution Approach 1:
The patent applies dynamics by making the stroke lengths variable rather than fixed. The forward stroke length and reverse stroke length are dynamically adjusted in different forming steps according to the formula Lf = k1 * Li and Lr = k2 * Li, where the coefficients k1 and k2 vary between steps. This dynamic variation prevents continuous loading of the same die areas, thereby extending die service life while maintaining process control.
2Duration of action of stationary object
If frequency modulation is applied to vary stroke travels, then the service life of the forming die is improved, but the control system complexity increases
Solution Approach 1:
The patent implements parameter changes by systematically varying the stroke travel parameters (forward stroke length Lf and reverse stroke length Lr) across different forming steps. The variation follows a defined relationship with the basic stroke length Li and coefficients k1, k2 that change between steps. This parameter modulation distributes mechanical loads across different die zones, extending die life while maintaining deterministic control through mathematical relationships rather than random variation.
3Manufacturing precision
If variable stroke travels are used in successive forming steps, then material flow and forming quality are improved, but the consistency of the forming process is reduced
Solution Approach 1:
The patent applies periodic action by implementing a systematic cycle of varying stroke lengths across forming steps. The stroke parameters follow a periodic pattern defined by the relationships Lf = k1 * Li and Lr = k2 * Li, where coefficients k1 and k2 are varied in a controlled manner across different steps within a forming cycle. This periodic variation improves material flow and forming precision while maintaining process stability through repeatable, predetermined patterns rather than random changes.
Data Source
AI summary
The present invention relates to a device for forming, in particular for cold forming, here in particular for cold extruding, a workpiece, which device has a forming die and a feed device by means of which a relative movement can be generated between the workpiece and the forming die, wherein the device has a frequency generating device which interacts with the feed device and by which the relative movement between the workpiece and the forming die, as generated by the feed device, can be modulated in such a way that following a forward stroke in which the workpiece and/or the forming die pass through a first stroke travel in the feeding direction, a movement of the forming die and/or of the workpiece can be effected in a subsequent reverse stroke, over a second stroke travel in a direction opposite to the feeding direction, and to a method for forming a workpiece wherein a relative movement between the workpiece and a forming die is generated by a feed device, which relative movement between the workpiece and the forming die, produced by the feed device, is modulated in such a way that following a forward stroke in which the workpiece and/or the forming die pass through a first stroke travel, a movement of the forming die and/or of the workpiece can be effected in a subsequent reverse stroke, over a second stroke travel in a direction opposite to the feeding direction.