Disk-Shaped Member Flange Forming via Segmented Press and Cut
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Solution Overview
Problem
It is challenging to form a disk-shaped member with a small flange width using press forming, as it is difficult to create a flange with a narrow width due to the limitations of the process.
Innovation Solution
A two-step forming method where a preformed body with a wider protrusion is first created, and then the flange is formed by cutting and removing the outer peripheral surface of the protrusion, allowing for the production of a disk-shaped member with a smaller flange width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If press forming is used to form a flange, then the manufacturing process is simple, but the flange width cannot be reduced to a small size
Solution Approach 1:
The manufacturing process is divided into two distinct stages: first forming a protrusion with press forming, then cutting and removing the outer peripheral surface to create the final flange. This segmentation allows each process to be optimized independently, enabling small flange width while maintaining manufacturing feasibility
Solution Approach 2:
A protrusion with larger width is formed in advance through press forming, creating a preformed body that serves as the basis for subsequent flange formation. This preliminary action enables the final cutting process to achieve small flange width that would be impossible through press forming alone
2Volume of moving object
If the flange width is reduced to minimize external dimensions, then the recliner size and weight are reduced, but the manufacturing difficulty increases
Solution Approach 1:
The manufacturing process is divided into two distinct stages: first forming a protrusion with press forming, then cutting and removing the outer peripheral surface to create the final flange. This segmentation allows each process to be optimized independently, enabling small flange width while maintaining manufacturing feasibility
Solution Approach 2:
A protrusion with larger width is formed in advance through press forming, creating a preformed body that serves as the basis for subsequent flange formation. This preliminary action enables the final cutting process to achieve small flange width that would be impossible through press forming alone
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 enables the production of disk-shaped members with reduced external dimensions and weight, facilitating the integration of the ratchet on the inner peripheral side of the guide member while maintaining structural integrity.
Implementation Method 1
form a preformed body from a plate member by press forming
Implementation Method 2
cutting and removing an outer peripheral surface side of the protrusion
Data Source
AI summary
A forming method of a disk-shaped member in which a plate formed into a disk shape and a protruded flange protruding from an outer periphery of the plate are integrally formed, includes: forming a preformed body from a plate member by a press forming, the preformed body having a protrusion in an outer periphery of the plate, the protrusion having a width larger than a width of the flange; and forming the flange by cutting and removing an outer peripheral surface side of the protrusion to punch the preformed body from the plate member in a state where a mold is in contact with an inner peripheral surface of the protrusion and a portion connected to a root of the protrusion.