Connecting Element Forming with Single-Die Locking Groove Embossing
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Solution Overview
Problem
Existing methods for producing rod- or pipe-shaped connecting elements with rotary entrainment surfaces and locking grooves require multiple dies, leading to high production costs and machine downtime due to part twisting during processing, and the production of hollow drill bits is expensive and prone to quality issues like scoring.
Innovation Solution
A method and apparatus that form rotary entrainment surfaces and locking grooves in a single die using radially movable forming bodies, with an interior pin to reduce pipe diameter and enhance torque transmission, and a divided die for reduced ejection forces, allowing for compact apparatus design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple dies are used for forming rotary entrainment surfaces and locking grooves, then the forming process can be completed, but production costs increase and machine downtime occurs due to part twisting
Solution Approach 1:
The patent combines multiple forming operations (rotary entrainment surface formation and locking groove embossing) into a single die. The die includes multiple forming bodies that can simultaneously or sequentially create multiple features on the connecting element without requiring transfer between different dies, thereby eliminating machine downtime and part twisting issues.
Solution Approach 2:
The die is divided into multiple independent forming bodies, each capable of performing a specific forming operation. These forming bodies can be radially movable and can be positioned independently to create different features on the connecting element, allowing complex multi-step forming in a single die.
2Ease of manufacture
If multiple dies are used for forming operations, then various features can be created, but the apparatus becomes narrowly limited regarding lengths and diameters of processable parts
Solution Approach 1:
The single die design with multiple radially movable forming bodies can accommodate different connecting element dimensions (lengths and diameters) by adjusting the position and configuration of the forming bodies. This universal die structure can process various drill and chisel dimensions without requiring dedicated dies for each size.
Solution Approach 2:
The forming bodies are designed to be radially movable, allowing dynamic adjustment of their positions and orientations. This enables the same die to adapt to different part dimensions and forming requirements, providing versatility across a wide range of connecting element sizes.
3Ease of manufacture
If semi-finished connecting element is transported between multiple dies, then forming operations can be performed, but part twisting occurs leading to breakage and tool destruction
Solution Approach 1:
By combining all forming operations into a single die, the patent eliminates the need to transport the semi-finished connecting element between multiple dies. The element remains stationary in one die throughout the entire forming process, preventing twisting and associated failures.
4Ease of manufacture
If hollow drill bits are produced by drilling deep holes, then hollow bore is created, but scoring at bottom of borehole occurs resulting in scrap
Solution Approach 1:
The patent incorporates an interior pin that is inserted into the hollow bore before the forming operations. This pin serves as a support structure during the forming process, preventing the forming bodies from contacting and scoring the bottom of the hollow bore, thereby eliminating a major source of scrap.
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 production costs, minimizes machine downtime, and improves the quality of hollow drill bits by avoiding twisting and scoring issues, enabling the production of a wider range of drill dimensions and reducing the price of hollow drill bits.
Implementation Method 1
the embossing of the at least one or multiple locking depressions in the semi-finished connecting element is performed by radially applying one or multiple forming bodies
Implementation Method 2
the interior pipe diameter is reduced or closed by the prior insertion of an interior pin profiled along its longitudinal axis by changes in its cross-section in the semi-finished connecting element
Implementation Method 3
By means of a locking groove additional torque can be transmitted
Data Source
AI summary
The invention relates to a method and an apparatus for producing a rod- or pipe-shaped intermediate product provided with an end face (106) from a semi-finished connecting element (102) made of metal, in particular an insertion end of a drill or chisel attached in an axially movable manner in the chuck of a hammer drill, the connecting element (100′) having at least one rotary entrainment surface (162, 164) and at least one locking depression (122, 124), the locking depression (122, 124) being preferably embodied as a locking groove, a semi-finished connecting element (102) being provided, the at least one rotary entrainment surface (162, 164) being formed in the semi-finished connecting element (102) by axially forcing the semi-finished connecting element (102) in the direction of the longitudinal axis (136) of the semi-finished connecting element (102) into a longitudinal die opening (204) of a die (202), or being embossed in the semi-finished connecting element (102) by radially applying at least one movable forming body (206), and the at least one locking depression (122, 124) being embossed by radially applying at least one or multiple forming bodies (206) that are movable in the same die (202).