Cold Upsetting Hollow Members Using Cam-Based Force Multiplier
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Solution Overview
Problem
Conventional hot upsetting methods for hollow metal members require separate heating and cooling cycles, increasing manufacturing time and costs, and altering the material properties of the workpiece, necessitating additional processing steps.
Innovation Solution
A system and method for upsetting hollow metal members that involves inserting a mandrel into the workpiece and using a die to compress the end portion within a clamp, increasing the wall thickness without heating, utilizing a cam-based force multiplier to apply significant force for deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot upsetting is used to increase wall thickness at end portions, then the necessary gauge increase is achieved, but manufacturing time increases due to separate heating and cooling cycles
Solution Approach 1:
The invention extracts the heating process from the upsetting operation, eliminating the need for separate heating and cooling cycles. By performing cold upsetting instead of hot upsetting, the method removes the time-consuming thermal processing steps while achieving the same wall thickness increase through direct mechanical compression at ambient temperature.
Solution Approach 2:
The invention replaces the thermal-mechanical system (heating followed by compression) with a purely mechanical system (cold compression). Instead of using heat to make the material malleable and then compressing it, the method applies sufficient mechanical force directly to the workpiece at ambient temperature, substituting thermal energy with mechanical energy to achieve the same deformation.
2Manufacturing precision
If hot upsetting is used to create localized increased gauge, then the end portions can be affixed by welding, but capital costs increase due to separate upsetting station and heaters
Solution Approach 1:
The invention merges the upsetting operation with the existing press station used for forming the hollow member. Instead of requiring a separate upsetting station with its own heating equipment, the method performs the wall thickening operation at the same location where the member is initially formed, consolidating multiple operations into a single integrated process and eliminating duplicate equipment.
Solution Approach 2:
The invention extracts the heating equipment from the upsetting process, eliminating the need for separate heaters and associated capital investment. By using cold upsetting, the method removes the thermal processing infrastructure while maintaining the ability to achieve the required wall thickness increase through mechanical means alone.
3Manufacturing precision
If hot upsetting is used to increase wall thickness, then localized gauge increase is achieved, but material properties are altered requiring additional hardening treatment
Solution Approach 1:
The invention extracts the heating and cooling cycles from the upsetting process, eliminating the thermal treatment that alters material properties. By performing cold upsetting, the method achieves wall thickness increase without subjecting the material to temperature changes that would require subsequent hardening treatments, thereby removing an entire class of additional processing steps.
4Manufacturing precision
If hot upsetting is used to deform the hollow member, then wall thickness increases, but operating costs increase due to heater operation
Solution Approach 1:
The invention replaces the thermal energy input from heaters with mechanical energy input from the press. Instead of continuously operating heaters to maintain elevated temperatures during the upsetting process, the method uses direct mechanical compression to achieve the deformation, eliminating the ongoing energy consumption associated with thermal processing while maintaining the ability to increase wall thickness.
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 reduces manufacturing time and costs by eliminating the need for separate heating stations and additional processing, while maintaining the material properties of the workpiece, allowing for localized thickening of hollow metal members without altering their properties.
Implementation Method 1
A die is forced against the exposed end of the workpiece to upset the exposed end by compressing the end towards the clamp
Implementation Method 2
driving the die toward the clamp to decrease the length of the end of the workpiece to be upset while increasing the wall thickness of that portion
Data Source
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AI summary
An apparatus and method for upsetting an end of a hollow workpiece to increase the wall thickness of that end is taught. A mandrel is inserted into the workpiece within a clamp which holds the workpiece. A die is urged into contact with the end of the workpiece to compress the end, decreasing its length and increasing the wall thickness of the end while the mandrel and clamp prevent deformation of the workpiece held in the clamp.