Crankshaft Weight-Reduction Forging With Diagonal Cavity Forming
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Solution Overview
Problem
Current methods for calibrating and lightening crankshaft weight in vehicles face interference issues between moveable bodies during the forging process, particularly when attempting to form cavities in a single blow, which can lead to structural problems and incorrect rotation, and existing solutions struggle with productivity and complexity.
Innovation Solution
The device employs moveable bodies with a lowered portion forming a projecting portion, allowing diagonal movement and rounded edges, with two types of moveable bodies designed for different chamfer geometries, and uses a tooling assembly with springs to facilitate a single-blow process without interference, enabling the formation of cavities without invading oil flow passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If moveable bodies are used to form cavities in crankshaft during forging, then weight is reduced and productivity is improved, but interference between moveable bodies occurs causing structural problems and incorrect rotation
Solution Approach 1:
The moveable bodies are designed to move diagonally rather than linearly, changing their trajectory dynamically to avoid interference with oil flow passages and other moveable bodies during the forging process
Solution Approach 2:
The moveable bodies traverse along the diagonal of the crankshaft module rather than moving perpendicular to the surface, utilizing a different spatial dimension (diagonal path) to achieve cavity formation without interfering with critical areas
2Ease of manufacture
If moveable bodies penetrate perpendicular to the crankshaft surface, then cavity formation is simplified, but interference with oil flow passages and space constraints in tooling occur
Solution Approach 1:
Instead of moving perpendicular to the crankshaft surface, the moveable bodies are configured to move diagonally through the material, utilizing a different spatial trajectory that avoids oil flow passages and reduces tooling space requirements
3Reliability
If multiple blows are used for forging to avoid interference, then structural integrity is maintained, but productivity decreases
Solution Approach 1:
The diagonal movement path of the moveable bodies allows all cavities to be formed simultaneously in a single blow without interference, eliminating the need for multiple forging blows while maintaining structural integrity
Solution Approach 2:
The forging process is completed in a continuous single blow operation rather than multiple discrete blows, maintaining continuous material flow and structural integrity while improving productivity
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 allows for a more productive and simpler weight reduction of crankshafts, ensuring correct rotation and functionality by avoiding interference between moveable bodies, enabling the process to be completed in a single forging blow, thus improving productivity and reducing material loss.
Implementation Method 1
uses a tooling assembly with springs to facilitate a single-blow process without interference
Data Source
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AI summary
The invention relates to a device for lightening the weight of vehicle components, which comprises a tooling (10) provided with a seat (11) wherein the component is formed and a plurality of moveable bodies (1a, 1b), which are moveable between an initial position and a final position, such that in the final position one end of each moveable body (1a, 1b) penetrates the seat (11) of the tooling to form a cavity to lighten the weight of a component of the vehicle (10), wherein at least one of said moveable bodies (1b) can move laterally. Such device allows lightening the weight in a more simple and productive way than in currently known systems. This is achieved because the moveable bodies do not interfere with each other during the movement thereof, such that the lightening process can be done in a single blow during a forging procedure.