Dual-Spindle Flow Forming for Faster Tubular Workpiece Processing
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Solution Overview
Problem
Flow-forming machines for producing tubular workpieces, such as vehicle wheel rims, are associated with high capital expenditure and inefficient processing due to lengthy cycle times, primarily caused by extensive loading and unloading, and ancillary movements.
Innovation Solution
A forming machine design featuring two main spindle units with spinning chucks and axially opposite forming roller units, allowing simultaneous forming and reducing traversing movements, with the forming roller units directed towards the center of the workpiece and capable of axial movement, enabling faster cycle times and high-quality surface formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional forming machines with single spindle units are used, then the machine design is simple, but the cycle time is lengthy due to extensive loading and unloading movements
Solution Approach 1:
The forming machine is divided into two independent main spindle units, each with its own forming roller unit. This segmentation allows simultaneous forming operations on both sides of the workpiece, eliminating the need for sequential operations and reducing cycle time despite increased machine complexity.
Solution Approach 2:
Both main spindle units and forming roller units are merged into a single integrated machine structure, allowing coordinated simultaneous operation. The merging enables both spindles to rotate the workpiece in opposite directions while both forming rollers apply pressure simultaneously, achieving high productivity through unified control.
2Speed
If forming roller units are positioned for simultaneous forming, then the forming speed increases, but the axial and radial strokes increase
Solution Approach 1:
The two main spindle units are positioned asymmetrically with respect to the workpiece center, allowing optimized stroke lengths for each side. The forming roller units are positioned to apply pressure at optimal points, reducing the required axial and radial strokes while maintaining high forming speed through asymmetric force distribution.
Solution Approach 2:
The forming action is extended from single-sided sequential operation to dual-sided simultaneous operation, effectively utilizing the third dimension (axial direction) by positioning forming rollers on opposite sides of the workpiece. This dimensional expansion allows simultaneous forming without increasing individual roller stroke lengths.
3Loss of time
If two main spindle units with forming roller units are used, then loading and unloading movements are minimized, but the device complexity increases
Solution Approach 1:
The workpiece is pre-positioned between the two main spindle units before forming begins. Both spindles are pre-configured with forming roller units at optimal positions, allowing immediate simultaneous forming operation without sequential setup, thereby minimizing loading and unloading time despite increased device complexity.
Solution Approach 2:
The dual spindle configuration enables continuous simultaneous forming action on both sides of the workpiece throughout the entire forming cycle. This continuous useful action eliminates idle time between operations and maintains productive work throughout the cycle, offsetting the complexity through sustained efficiency.
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 design significantly reduces cycle times by minimizing loading and unloading movements and allows for efficient processing of tubular workpieces with reduced axial and radial strokes, enhancing the quality and speed of the forming process.
Implementation Method 1
at least one first forming roller unit which can be positioned for forming the clamped and rotatably driven workpiece, and at least one second forming roller unit which can be positioned for forming the clamped and rotatably driven workpiece
Data Source
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AI summary
The invention relates to a forming machine for forming a tubular workpiece, comprising a machine base body, a first main spindle unit, to which a first spinning mandrel is attached and can be driven to rotate about a main spindle axis, and a second main spindle unit, on which a second spinning mandrel is attached and can be driven to rotate about the main spindle axis, wherein the second main spindle unit is axially opposite the first main spindle unit and the two main spindle units can be axially adjusted between a forming position, in which the workpiece is axially clamped between the first main spindle unit and the second main spindle unit, and a set-up position, in which the first main spindle unit is axially spaced apart from the second main spindle unit for introducing and removing the workpiece. The forming machine further comprises at least one first forming roller unit, which can be moved to the clamped and rotationally driven workpiece to carry out forming, and at least one second forming roller unit, which can be moved to the clamped and rotationally driven workpiece to carry out forming.