Cup Forging Relief Hole Structure to Prevent Flash
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Solution Overview
Problem
The manufacturing of cup structures by forging often results in flash due to material entering clearance between the die and sleeve, and uneven pressure distribution, leading to voids and increased flash occurrence.
Innovation Solution
A method using a die with a relief hole and a pressing member to ensure even pressure distribution, where the material is pressed by both the molding punch and the pressing member, with a part of the material being pushed into the relief hole to form a projection, preventing flash by securing a space below the projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If general pressure is increased to prevent voids in the end surface, then manufacturing precision is improved, but flash occurs more easily
Solution Approach 1:
The patent extracts the harmful factor (excessive material) by providing a relief hole that allows material to be pushed out intentionally. The relief hole is positioned to receive excess material that would otherwise cause flash, thereby separating the harmful effect from the desired forming process
Solution Approach 2:
The relief hole acts as an intermediary channel that mediates between the high pressure forming process and the prevention of flash. It provides a controlled path for material flow, allowing high pressure to be applied without causing uncontrolled material escape into the clearance
2Manufacturing precision
If a closed space is used for forging, then manufacturing precision is improved, but material enters clearance causing flash
Solution Approach 1:
The relief hole extracts the problematic excess material from the closed forging space. By providing an intentional escape route, it prevents material from entering the harmful clearance between die and sleeve, thus eliminating flash while maintaining the benefits of closed-space forging
3Manufacturing precision
If odd-shaped parts are forged, then manufacturing precision is improved, but uneven pressure distribution causes voids
Solution Approach 1:
The patent applies local quality by providing different functions to different parts of the die structure. The relief hole is strategically positioned to receive material from specific areas, allowing localized material flow control that compensates for uneven pressure distribution in odd-shaped parts
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 method prevents flash in the peripheral portion of the cup structure while maintaining flatness of the end surface, even under high pressure, and allows for the removal of the cup structure without significant changes to the existing die.
Implementation Method 1
the material pressed into the die by the punch loses a place for escape in a closed space
Implementation Method 2
a pressing member provided around an outer periphery of the molding punch to press the peripheral portion of the material
Data Source
AI summary
A forging press apparatus includes: a die with a die hole into which a material is to be contained and a relief hole smaller in diameter than the die hole; a molding punch configured to press an inner portion inside a peripheral portion of the material contained in the die hole; and a pressing member provided around an outer periphery of the molding punch to press the peripheral portion. A method includes: loading the material into the die; and forging the cup structure shaped by pressing the inner portion inside the peripheral portion of the material with the molding punch to cause the peripheral portion of the material to be brought into contact with the pressing member, and a part of the material to be pushed out into the relief hole by the molding punch to form a projection while a space is secured below the projection.