Explosion Forming Plug and Die for Tubular Work Pieces
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Solution Overview
Problem
Existing explosive forming methods for tubular work pieces are complex, time-consuming, and costly due to the need for precise pre-equipment of molds, multiple handling steps, and wear-prone sealing elements, which hinder industrial acceptance.
Innovation Solution
A multipart forming die with a plug and collar system that seals and fixes the work piece during explosive forming, integrating multiple functions into a single step to reduce cycle time and costs, and includes features like conical designs for easy plug insertion and removal, and a force coupling mechanism to manage explosion forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If explosive forming without liquid is used, then handling complexity increases, but productivity decreases due to multiple time-intensive working steps
Solution Approach 1:
The patent combines multiple separate operations (sealing the explosion space, positioning the work piece, and fixing it during deformation) into a single integrated plug insertion step. The plug simultaneously performs sealing by engaging with the nozzle arrangement, positions the work piece through deformation, and fixes it during the explosive forming process, thereby reducing handling complexity and cycle time
Solution Approach 2:
The plug serves multiple functions simultaneously: it seals the explosion space by forming a seal with the nozzle arrangement, positions the work piece through deformation and clamping, and acts as a fixing mechanism during deformation. This multi-functionality eliminates the need for separate sealing elements and handling steps
2Reliability
If sealing elements are used in the mold, then sealing is achieved, but reliability decreases due to wear causing additional costs
Solution Approach 1:
The plug is designed as a simple, replaceable component that can be easily inserted and removed. Instead of using durable but complex sealing elements subject to wear, the invention employs a straightforward plug that seals the explosion space through a simple sealing engagement with the nozzle arrangement, reducing reliability concerns related to wear
Solution Approach 2:
The work piece itself contributes to the sealing process by being deformed and clamped between the plug and the forming die. The work piece's own material deformation creates the seal, eliminating the need for separate sealing elements that would be subject to wear
3Manufacturing precision
If precise pre-equipment of molds is performed, then forming precision is improved, but device complexity increases due to multiple components
Solution Approach 1:
The patent merges the functions of multiple mold components (sealing elements, positioning fixtures, and fixing mechanisms) into a single integrated plug and forming die system. The plug combines sealing, positioning, and fixing functions, while the forming die integrates the work piece holding area and forming area, thereby reducing device complexity while maintaining forming precision through the conical design and controlled 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 approach simplifies handling, reduces cycle time, and achieves cost-effective industrial production by sealing and fixing the work piece in a single step, while diverting explosion forces for secure sealing and forming, resulting in high-quality hole edges and reduced machining time.
Implementation Method 1
By introducing the plug, the work piece is preferably plastically deformed and tightened between the plug and the forming die
Implementation Method 2
By introduction of an explosive charge into the water bath and then ignition, the sheet metal plate is forced into the mold and thus acquires its final shape
Implementation Method 3
a collar (11) for enclosing a section of the nozzle arrangement (6) when the forming die (1) is in the closed state
Data Source
AI summary
With the invention, a method and a device for explosive forming of a tubular work piece, which comprises a multipart forming die almost fully enclosing the work piece in the closed state, and in which a plug is provided in the area of at least one end of the forming die, is to be improved, in that forming of a tubular work piece is possible in a simple method that promotes fewer individual work steps and is therefore cost-effective. This task is solved by a method and a device for explosive forming, in which a seal between the forming die and the plug is formed when the plug is inserted, in which the work piece end is mounted between the forming die and deformed.