Cold-Forming Profile Tool Motion for Shoulder-Close Workpieces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cold forming processes for producing profiles in solid or hollow parts are inflexible, require significant material deformation, have limited profile length, and often result in low surface quality or necessitate post-processing, especially when creating profiles close to workpiece projections or between limiting structures.
Innovation Solution
A method involving a tool holder and tool that perform synchronized revolving and rotational movements, allowing for precise, high-quality profiling with tools that can engage and disengage quickly, enabling profiling close to workpiece projections and between limiting structures, using a drive device with planetary gears for synchronization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-step profiling process with distributed tools is used, then the profiling can be created efficiently, but the process becomes inflexible and requires tool replacement for profile shape changes
Solution Approach 1:
The tool holder is designed to perform both revolving movement around the workpiece and rotational movement around its own axis, with the tool axis oriented at an angle to the revolving axis. This dynamic dual-motion system allows a single tool to dynamically engage and disengage from the workpiece at different angular positions, enabling flexible profile creation without tool replacement
Solution Approach 2:
A single tool mounted on the rotating tool holder can create different profile shapes by adjusting the rotational speed ratio between the tool holder and the workpiece, and by modifying the tool's angular orientation. This universal tool replaces multiple specialized tools, achieving both high productivity and adaptability
2Adaptability or versatility
If rotating tools hammer the workpiece periodically to create profiles, then the process is flexible and can create long profiles, but profiling close to outwardly projecting shoulders becomes difficult
Solution Approach 1:
The tool periodically engages and disengages from the workpiece during its revolving motion, with controlled hammering actions at specific angular positions. This periodic engagement allows the tool to reach close to outwardly projecting shoulders by timing the hammering strokes to occur only when the tool is at the appropriate angular position, avoiding interference with the shoulder
Solution Approach 2:
The tool holder's dual rotation system dynamically controls the tool's path, allowing it to approach the shoulder region closely while maintaining safe clearance through coordinated rotational movements. The system adapts the tool's position and engagement timing to accommodate profiles extending near shoulders
3Length of moving object
If a profiling tool is suddenly hammered onto the hollow part from the outside with oscillation, then profiles can be created close to shoulders, but the surface quality becomes rough and flaky requiring post-processing
Solution Approach 1:
The tool performs high-frequency oscillating movements during engagement with the workpiece, which prevents material buildup and reduces flaky surface roughness. The oscillation combined with the revolving and rotational motions creates a more uniform material deformation pattern, improving surface quality and reducing or eliminating the need for post-processing
Solution Approach 2:
The profiling process maintains continuous material deformation through coordinated revolving, rotational, and oscillating motions, avoiding the intermittent hammering that causes surface defects. The tool continuously engages the workpiece surface with controlled material removal, producing a smoother finish
4Manufacturing precision
If synchronized revolving and rotational movements are used with a planetary gear drive, then precise profiling with high surface quality is achieved, but the device complexity increases
Solution Approach 1:
A planetary gear mechanism serves as an intermediary between the motor drive and the tool holder, automatically generating the required synchronized revolving and rotational movements. The planetary gears provide precise speed ratios and coordination without requiring complex electronic control systems, reducing overall system complexity while maintaining high profiling 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
Enables flexible adaptation to different product specifications, high surface quality, long profile creation, and precise profiling with reduced material deformation, avoiding the need for post-processing.
Implementation Method 1
using a drive device with planetary gears for synchronization
Implementation Method 2
Device and method for the cold-forming profiling of workpieces
Implementation Method 3
which may result in a slight, flaky roughness
Data Source
Figure 1~8
AI summary
The invention relates to a method for producing a profiled body having a profiling by cold-forming a workpiece (1), the workpiece having a longitudinal axis (Z) and an outer surface (11a), for example a cylindrical outer surface, which extends along the longitudinal axis (Z) in a working area (11), and to which the profiling (P) is applied. The workpiece (1) carries out a rotational movement (R1) about the longitudinal axis (Z) and is worked by a tool (2) in multiple forming actions, during each of which the tool (2) comes into contact with the working area (11). The tool (2) is held by a tool holder (5) and is rotatable about a tool axis (Q). The tool holder (5) - is rotatably mounted in a rotating member (8) about an axis of rotation (W) and is driven to perform a rotary movement (R5) about its axis of rotation (W), and - is driven by the rotating member (8) to perform a rotating movement (R8). The rotational movement (R1) of the workpiece (1) is synchronized with the rotating movement (R8) of the tool holder (5), and the rotary movement (R5) of the tool holder (5) is synchronized with the rotating movement (R8) of the tool holder (5). The tool axis (Q) is different from the axis of rotation (W). The invention also relates to a corresponding device.