Cold Forming Tool Holder With Synchronized Orbiting and Rotation
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Solution Overview
Problem
Existing cold reshaping methods for producing profilings in solid or hollow parts are inflexible, require significant reconfiguration for changes in profile shape or diameter, and often result in low surface quality due to momentary tool contact and multiple machining steps.
Innovation Solution
A method utilizing a tool holder and tool that perform synchronized orbiting and rotating movements, allowing for a complex movement including rolling and sliding components, enabling continuous machining along the axial profile extension with reduced tool engagements and improved surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a non-profiled sheet-metal part is reshaped by an apparatus with a multitude of tools distributed over a periphery, then a profiling can be produced in a single step, but the apparatus is very inflexible and requires replacement of all tools for profile shape changes
Solution Approach 1:
The tool holder is designed to execute a complex movement combining orbiting motion around the workpiece axis with rotation about its own axis. This dynamic motion pattern allows a single tool to sequentially engage different circumferential positions of the workpiece, effectively replacing the need for multiple stationary tools while maintaining single-step profiling capability.
Solution Approach 2:
The tool holder system serves multiple functions: it positions the tool at various circumferential locations, provides rotational movement for continuous engagement, and enables profiling of different shapes by adjusting motion parameters. This universal tool holder replaces the need for multiple specialized tools, enhancing adaptability while maintaining productivity.
2Adaptability or versatility
If tools are driven to carry out an orbiting movement for periodic hammering, then flexibility is improved, but profiling up to close to an outwardly projecting shoulder is not easily possible
Solution Approach 1:
The tool holder executes a complex dynamic movement that combines orbiting around the workpiece with rotation about its own axis. This dual motion enables the tool to approach and engage the workpiece surface at various positions, including areas near outwardly projecting shoulders, while maintaining periodic hammering action for flexibility in product reconfiguration.
3Productivity
If multiple tool engagements are used to machine the complete axial profile extension, then productivity is reduced, but surface quality can be improved with fewer engagements per section
Solution Approach 1:
The continuous rotation of the tool holder about its own axis during orbiting motion ensures uninterrupted tool engagement with the workpiece surface throughout the entire axial profile extension. This continuous action achieves high surface quality while maintaining high productivity by eliminating the need for multiple discrete tool engagements.
Solution Approach 2:
The tool holder's rotational movement is synchronized with its orbiting motion to pre-position the tool for continuous engagement along the axial profile extension. This preliminary coordination of movements ensures that the tool is always properly oriented for machining, achieving both high surface quality and productivity in a single profiling operation.
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, productivity, and surface quality by allowing profiling up to workpiece projections with fewer tool engagements and synchronized movements that ensure consistent azimuthal alignment, reducing the need for post-machining and enabling efficient reconfiguration for different products.
Implementation Method 1
The invention relates to the field of the production of profilings, in particular by way of cold reshaping (also referred to as cold forming), for example in rotationally symmetrically solid or hollow parts.
Data Source
AI summary
A workpiece executes a rotation movement about a longitudinal axis and is machined by a tool in a multitude of reshaping engagements, in which an active region of the tool comes into contact with the machining region. The tool is held by a tool holder. The tool holder is mounted in an orbiting body so as to be rotatable about a rotation axis and is driven to carry out a rotating movement about the rotation axis, and is driven to carry out an orbiting movement by the orbiting body. Rotation movement of the workpiece is synchronised with the orbiting movement of the tool holder and the rotating movement of the first tool holder is synchronised with the orbiting movement of the tool holder.