Cylindrical Portion Forming by Plastic Flow for High Cylindricity
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Solution Overview
Problem
Existing manufacturing methods for forming cylindrical portions integrally with plate-like portions, such as in metal processing, face challenges in achieving high accuracy for the outer circumferential diameter and cylindricality while maintaining mass production capability, as machining methods are inferior to press-forming in productivity.
Innovation Solution
A manufacturing method using a multi-stage plastic forming process with metal molds, where a first mold forms a protruding portion, a second mold shapes the cylindrical portion by plastic flow against an inner surface, and a third mold ensures precise transfer of the inner surface shape to the outer surface, enhancing accuracy and preventing metal structure shortages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining such as cutting is conducted to achieve high accuracy in outer circumferential diameter and cylindricality, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The forming process is divided into multiple stages: a first plastic forming step to create a protruding portion, and a second plastic forming step to form the final cylindrical portion. This segmentation allows each stage to optimize for its specific function, achieving high precision without sacrificing productivity
Solution Approach 2:
The first plastic forming step performs preliminary action by creating a protruding portion that serves as the basis for the second forming step. This preliminary shaping ensures sufficient metal structure is available before the final precision forming, preventing material shortage and enabling high-accuracy mass production
2Productivity
If press-forming method is used to maintain mass production capability, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The press-forming process is segmented into multiple plastic forming steps, each using specifically designed metal molds. The first step creates a protruding portion, and the second step forms the precise cylindrical shape. This segmentation enables mass production while achieving high precision through controlled plastic flow against precision-machined mold surfaces
Solution Approach 2:
The inner circumferential surface of the first metal mold serves as a precision master copy. During the second plastic forming step, the metal structure flows to replicate this inner surface geometry, transferring the high-precision dimensions of the mold to the workpiece through controlled plastic deformation
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 achieves high accuracy in the outer circumferential diameter and cylindricality of the cylindrical portion, matching the dimensions of the metal molds, while maintaining productivity by ensuring consistent plastic flow and shape transfer, thus overcoming the limitations of traditional machining methods.
Implementation Method 1
a portion of the workpiece undergoes plastic flow toward the inner circumferential surface, whereby the portion that underwent the plastic flow comes into press contact with the inner circumferential surface
Data Source
AI summary
Provided is a manufacturing method for a cylindrical portion in a cylindrical shape protruding in a plate thickness direction of a plate-like portion made of metal, the cylindrical portion being formed integrally with the plate-like portion. The manufacturing method uses a manufacturing device including: a first metal mold provided with an inner circumferential surface that comes in contact with an outer circumferential surface of the cylindrical portion; a second metal mold coming in contact with a protruding tip of the cylindrical portion; and a third metal mold coming into press contact with a workpiece toward a side of the second metal mold. The third metal mold is displaced toward the side of the second metal mold and a portion of the workpiece undergoes plastic flow toward the inner circumferential surface, whereby the portion that underwent the plastic flow comes into press contact with the inner circumferential surface.