Cold-Forming Profiling with Synchronized Orbiting Tool Motion
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Solution Overview
Problem
Existing cold-forming methods for profiling solid or hollow parts are inflexible, require significant tool changes for different diameters, and often result in surface roughness or limited profiling lengths, especially when producing large reshaping or high-quality profiles near outwardly projecting shoulders.
Innovation Solution
A method utilizing a tool holder with synchronized orbiting and rotation movements, allowing the tool to engage the workpiece in a complex movement that includes periodic orbiting and axial rotation, enabling precise and high-quality profiling up to close to outwardly projecting shoulders with minimal post-machining requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a non-profiled sheet metal part is reshaped by a device with multitude of tools distributed over a circumference, then hollow parts can be provided with profiling in a single step, but the method is not flexible and requires replacement of all tools for profile gap shape changes or diameter adjustments
Solution Approach 1:
The patent applies dynamics by replacing static, fixed tools with a dynamic system where a single profiling tool moves in complex synchronized orbiting and rotation movements. This allows the tool to dynamically engage different circumferential positions and axial depths, achieving multiple profile configurations without tool replacement.
Solution Approach 2:
The invention makes a single profiling tool universal by enabling it to perform multiple functions through synchronized movements. The tool can create different profile gap shapes, accommodate various workpiece diameters, and machine different axial sections, replacing the need for multiple specialized tools.
2Adaptability or versatility
If tools are driven in an orbiting manner for producing profiling, then the method is flexible and permits production of very long profilings with large material reshaping, but a leading of profiling up to close to an outwardly projecting shoulder is not easily possible
Solution Approach 1:
The patent adds another dimension to the tool movement by combining circumferential orbiting motion with axial rotation and feed movements. This multi-dimensional motion allows the tool to reach close to outwardly projecting shoulders while maintaining the flexibility to produce long profilings, overcoming the limitation of pure orbiting motion.
Solution Approach 2:
The synchronized complex movements create a dynamic tool path that can adapt to different workpiece geometries. The tool can dynamically adjust its position in both circumferential and axial directions, enabling it to machine profilings near shoulders while maintaining control for long profiling production.
3Length of moving object
If a profiling tool acts in a hammering manner with radially running linear to and fro movement, then profiling up to close to outwardly projecting shoulder is possible, but the hollow part is only machined in a short axial section with each engagement resulting in slight scaly roughness
Solution Approach 1:
The patent achieves continuous useful action by synchronizing the profiling tool's orbiting movement with its rotation and axial feed. This ensures that the tool continuously machines the workpiece surface along the entire desired profiling length without interruption, eliminating the scaly roughness caused by discrete hammering engagements.
Solution Approach 2:
The synchronized complex movements create a periodic yet continuous machining action. The tool periodically engages and disengages in a controlled manner while maintaining continuous material removal along the profiling length, ensuring high surface quality without the roughness associated with simple reciprocating hammering.
4Length of moving object
If at least one profiling tool is made to strikingly act in a hammering manner upon the hollow part, then profiling up to close to outwardly projecting shoulder is possible, but post-machining is necessary for high surface quality demands
Solution Approach 1:
The synchronized complex movements enable continuous machining action that achieves high surface quality in a single operation. The tool continuously removes material along the entire profiling length while maintaining controlled engagement, eliminating the need for separate post-machining operations to correct surface roughness.
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 enhances flexibility, surface quality, and profiling length, allowing for precise and efficient production of profiles with large material reshaping, particularly in solid materials, while avoiding the limitations of existing methods regarding tool changes and surface finish.
Implementation Method 1
The invention relates to the field of producing profilings, in particular by way of cold forming, for example in rotationally symmetrical solid or hollow parts
Implementation Method 2
the outer surface in the machining region is machined by a tool in a multitude of successively executed reshaping engagements
Data Source
AI summary
A method for profiling a profile body by cold forming a workpiece having a longitudinal axis and a cylindrical outer surface extended along the longitudinal axis. The workpiece carries out a rotation movement about the longitudinal axis and is machined by a tool in a multitude of successively executed reshaping engagements. The tool is held by a tool holder, to be rotatable about a tool axis. The tool holder is mounted in an orbiting body to be rotatable about a rotation axis, is driven into a rotation movement about its rotation axis, and is driven into an orbiting movement by the orbiting body. Rotation movement of the workpiece is synchronised with orbiting movement of the tool holder and rotation movement of the tool holder is synchronised with orbiting movement of the tool holder. The tool axis is different from the rotation axis.