Deep Cavity Thin-Walled Metal Forming for Extremely Small Fillets
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Solution Overview
Problem
Existing forming technologies for deep cavity thin-walled metal components with extremely small fillet radii suffer from issues such as uneven wall thickness distribution, local wrinkling, poor part-mould contact gap, and insufficient local fillet dimension accuracy due to irregular geometry and uneven stress, and require high-grade servo presses, limiting their application and efficiency.
Innovation Solution
A forming method involving geometric analysis, process parameter optimization, and multi-stage deep drawing and extrusion using rigid dies to form global cavities and local fillets, reducing the dependence on high-grade devices and improving process coordination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-pass rigid die deep drawing technology is used to manufacture deep cavity thin-walled metal components with extremely small fillet radii, then the component can be formed, but uneven wall thickness distribution, local wrinkling, and poor dimensional stability occur due to asymmetric geometry and uneven stress
Solution Approach 1:
The patent replaces the traditional rigid mechanical deep drawing system with a hybrid system that introduces magnetic field action. Magnetic fields are applied to the blank during forming to control material flow and stress distribution, substituting pure mechanical contact with a combination of magnetic and mechanical forces. This eliminates the asymmetric stress problems caused by rigid die geometry while maintaining forming capability.
Solution Approach 2:
The patent changes the physical state and properties of the blank by applying magnetic fields during the forming process. The magnetic parameters (field strength, direction, distribution) are adjusted to control material flow and stress state, transforming the uniform magnetic field into a controlled non-uniform field that compensates for geometric asymmetry and achieves uniform stress distribution throughout the blank.
2Manufacturing precision
If conventional deep drawing methods are used, then deep cavity components can be formed, but the process requires 6-8 passes with intermediate annealing, resulting in low productivity and high cost
Solution Approach 1:
The patent applies magnetic fields in advance during the forming process to pre-control material flow and stress distribution before the rigid die contact occurs. This preliminary magnetic action prepares the blank for forming, enabling single-pass or reduced-pass deep drawing without the need for multiple intermediate annealing cycles, thereby significantly improving productivity.
Solution Approach 2:
The patent replaces the multi-pass mechanical deep drawing process with a hybrid magnetic-mechanical forming process. The magnetic field substitution eliminates the need for repeated mechanical loading and intermediate heat treatment cycles, reducing the number of passes from 6-8 to 1-2 passes while maintaining or improving forming quality.
3Shape
If rigid die deep drawing is used with asymmetric geometry, then deep cavity components can be formed, but local wrinkling and cracking occur due to unreasonable stress distribution
Solution Approach 1:
The patent changes the stress state parameters by introducing magnetic field action that modifies the stress distribution throughout the blank. The magnetic parameters are adjusted to counterbalance the asymmetric stress caused by the rigid die geometry, transforming the unreasonable stress distribution into a uniform and controlled stress state that prevents wrinkling and cracking while achieving the desired cavity shape.
Solution Approach 2:
The patent introduces the magnetic field as an intermediary between the rigid die and the blank. This magnetic intermediary transmits and distributes forces uniformly throughout the blank, mediating the interaction between the asymmetric rigid die geometry and the material, thereby eliminating the unreasonable stress concentration that causes defects.
4Manufacturing precision
If high-grade servo presses are used to achieve small fillet dimensions, then forming accuracy can be improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces the need for high-grade servo presses with a hybrid magnetic-mechanical system. Instead of relying on sophisticated mechanical control systems to achieve precise fillet dimensions, the invention uses magnetic field control to manage material flow and stress distribution, achieving the same precision with simpler, more cost-effective equipment.
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 method effectively forms deep cavity thin-walled metal components with extremely small fillets, reducing wrinkling and cracking, ensuring accurate fillet dimensions, and enhancing forming efficiency while lowering device requirements.
Implementation Method 1
A forming method of a deep cavity thin-walled metal component with extremely small fillet radius under action of magnetic field is provided
Implementation Method 2
hybrid forming system and process path of rigid die deep drawing under action of magnetic field
Data Source
AI summary
A forming method of a deep cavity thin-walled metal component with extremely small fillet radius is provided. In the forming method of a deep cavity thin-walled metal component with extremely small fillet radius, a global cavity is formed by deep drawing by means of a rigid die, an extremely small fillet is formed by means of aextrusion/pushing die, so that the deep drawing process is independent of the extremely small fillet forming process, and the problems of wrinkling, cracking and the like in the process of forming the two simultaneously are avoided. Thus, the problem that the extremely small fillet is difficult or impossible to form can be solved.