Connecting Element Groove Forming With Radial-Axial Shifting
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Solution Overview
Problem
Existing methods for producing rod- or pipe-shaped connecting elements, such as drills or chisel insertion ends for hammer drills, require excessive forming forces, leading to high costs and machine complexity due to the need for substantial compression forces and specialized machinery.
Innovation Solution
Reducing the longitudinal extension of radially movable forming bodies to be smaller than the desired longitudinal groove, allowing for lower radial plunging and axial shifting forces, which simplifies the machine design and reduces die wear, enabling the simultaneous formation of rotary entrainment surfaces and longitudinal grooves with reduced forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If forming bodies with length corresponding to the longitudinal groove length are used, then the longitudinal groove can be formed completely, but enormous compression forces (about 80 tonnes) are required
Solution Approach 1:
The forming process is divided into two independent stages: (1) radial plunging of a forming body with reduced length (1-3 times the groove width) to create the groove cross-section, and (2) axial shifting of the semi-finished product to extend the groove along the longitudinal axis. This segmentation allows each stage to use optimized force levels rather than requiring one forming body to perform both functions simultaneously.
Solution Approach 2:
The invention transitions from a single-dimensional radial forming approach to a two-dimensional process by adding axial movement. The forming body first acts radially to create the groove profile, then the workpiece is shifted axially to complete the groove length, effectively using both radial and axial dimensions to achieve the final groove geometry with reduced forces.
2Manufacturing precision
If machines are designed for enormous forming forces, then the longitudinal groove can be formed, but the machines become expensive and slow
Solution Approach 1:
The machine system is segmented into separate functional units: a radial forming mechanism with a compact forming body, and an axial shifting mechanism for the workpiece. This allows each mechanism to be optimized independently for lower force requirements rather than requiring a single oversized machine capable of delivering 80 tonnes of compression force.
Solution Approach 2:
The invention introduces dynamic movement along the axial direction by shifting the workpiece during the forming process. This dynamic approach allows the forming body to work at a fixed, low-force radial position while the workpiece moves axially to achieve the full groove length, replacing the need for a static, high-force machine design.
3Manufacturing precision
If forming bodies with full groove length are used, then complete groove formation is achieved, but die wear increases and production costs rise
Solution Approach 1:
The forming body is designed with reduced length (only 1-3 times the groove width) rather than matching the full groove length. This segmented approach means the forming body only needs to create the groove cross-section locally, while the axial extension is achieved through workpiece movement. This significantly reduces die wear on the forming body and lowers production costs.
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 significantly lowers the required forces for producing connecting elements, allowing for smaller, simpler machines and lower production costs while improving production speed and reducing die wear.
Implementation Method 1
about 80 tonnes of compression force are necessary in order to press the forming bodies in the drill's semi-finished product
Implementation Method 2
radial plunging of the at least one forming body into the semi-finished connecting element
Implementation Method 3
at least one rotary entrainment surface is formed by forced insertion of the semi-finished connecting element into the die in the direction of a longitudinal axis
Data Source
AI summary
The invention relates to a method for producing a rod- or pipe-shaped connecting element (100, 100′) having an end face (106) from a semi-finished connecting element (102) made of metal, in particular of a drill or chisel insertion end which is secured in an axially movable manner in a chuck of a hammer drill, a semi-finished connecting element (102) is provided, characterized in that at least one radially movable forming body (206) guided in the recesses (204) of a die (202) for forming at least one longitudinal groove (122, 124) closed on both sides in the semi-finished connecting element (102) has a smaller longitudinal extension (LR) than a planned length (L) of the longitudinal groove (122, 124) and that the forming of the at least one longitudinal groove (122, 124) closed on both sides in the semi-finished connecting element (102) is performed by radially applying the at least one forming body (206) and by subsequently axially shifting the semi-finished connecting element (102) in a longitudinal die opening (214) of the die (202).