Forged Crankshaft Tool Guide Mechanism
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Solution Overview
Problem
Conventional methods for manufacturing forged crankshafts with recessed arms face challenges in ensuring sufficient movable ranges for tools during the coining process, leading to difficulties in shaping and removing the forged blanks due to interference issues and the need for excessive force, which complicates the weight reduction and stiffness enhancement of crankshafts.
Innovation Solution
A forged crankshaft manufacturing apparatus that includes a pair of dies and a first tool with guides on its surface, allowing the tool to move from a retracting to a contacting position without interference, enabling the deformation of excess portions to create recesses in the journal-facing surface of crank arms, thereby reducing weight and ensuring stiffness while allowing easy removal of the processed blank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a tool is used to deform excess portions to create recesses in crank arms, then weight reduction and stiffness enhancement are achieved, but tool interference occurs and sufficient movable range cannot be ensured
Solution Approach 1:
The invention introduces guides on the tool surface to enable movement in an additional dimension, allowing the tool to navigate around interference zones while maintaining contact with the workpiece for effective deformation of excess portions
Solution Approach 2:
The guides act as intermediary elements between the tool and the workpiece, providing a constrained path that ensures sufficient movable range while maintaining proper tool positioning during the deformation process
2Shape
If excessive force is applied to deform excess portions, then recesses can be created in crank arms, but tool durability decreases and manufacturing complexity increases
Solution Approach 1:
The invention changes the geometric parameters of the tool by adding guides, which transforms the force application mechanism from requiring excessive force to using controlled, directed force along the guide paths, thereby simplifying the overall mechanism
3Manufacturing precision
If the tool is designed to contact the journal-facing surface of crank arms, then manufacturing precision is improved, but tool interference with dies and movable range are compromised
Solution Approach 1:
The invention makes the tool dynamically movable along guided paths, allowing it to transition between contacting and retracting positions while maintaining precision contact with the journal-facing surface, thereby resolving the conflict between precision and operability
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
The apparatus ensures a wide movable range for tools, facilitating the creation of recesses in crankshaft arms, resulting in a forged crankshaft with reduced weight and maintained stiffness, improving the manufacturing efficiency and accuracy by preventing tool interference and reducing the need for excessive force.
Implementation Method 1
a pair of upper and lower dies, capable of deforming the first excess portion and thereby thickening the side portion
Data Source
AI summary
An apparatus for manufacturing a forged crankshaft includes a pair of upper and lower dies and a first tool. The pair of dies deforms first excess portions and thereby thickens both side portions of a rough crank arm, in a region near a rough pin adjacent thereto. The first tool is fitted in an open space made in the pair of dies, and is capable of coming into contact with a rough-journal-facing surface of the rough crank arm, except the side portions in the region near the adjacent rough pin. The first pair of dies and the first tool have first guides to guide the first tool from a retracting position to a contacting position. The first guides include a first guide disposed on at least one of an upper surface and a lower surface of the first tool.