Cold Extrusion Functional Contour Accuracy
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Solution Overview
Problem
Existing methods for producing functional parts like spur gear wheels and bearing journals through cold extrusion face challenges in achieving a long functional contour with high dimensional accuracy while minimizing production complexity and avoiding costly machining operations.
Innovation Solution
A method involving a punch pressed against the end face of the functional part within a tool cavity, allowing a material flow that extends the axial extent and improves dimensional stability of the functional contour, potentially combined with a calibrating tool to refine the shape and reduce deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cold extrusion is used to produce functional parts like spur gear wheels and bearing journals, then production simplicity is improved, but achieving a long functional contour with high dimensional accuracy deteriorates
Solution Approach 1:
The method performs preliminary forming of the functional contour during the cold extrusion process itself, using specifically designed extrusion tools with calibrated cavities that pre-establish the desired dimensional accuracy. This preliminary action eliminates the need for subsequent precision machining operations, thereby maintaining production simplicity while achieving high dimensional accuracy of the functional contour.
2Length of moving object
If the axial extent of the functional contour is increased, then functional performance is improved, but production complexity increases
Solution Approach 1:
The invention extends the functional contour in the axial direction by utilizing the third dimension (axial extent) during the extrusion process. By designing extrusion tools with appropriate cavity dimensions and material flow characteristics, the method achieves extended axial functional contours without increasing radial or circumferential complexity, thereby improving functional performance while maintaining production simplicity.
3Ease of manufacture
If conventional cold extrusion methods are used, then production simplicity is maintained, but the need for subsequent machining operations increases
Solution Approach 1:
The method merges the forming of the functional contour with the primary cold extrusion process by integrating calibrated cavity designs into the extrusion tools. This combination allows the functional contour to be formed directly during extrusion without requiring separate machining operations, thereby maintaining production simplicity while eliminating additional manufacturing steps and improving overall productivity.
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 enhances the length and stability of the functional contour, reducing deviations and the need for subsequent machining operations, thereby simplifying the production process and improving the functional performance of the parts.
Implementation Method 1
a material flow of material of the functional part is brought about by the tool in this way
Data Source
AI summary
A method for working a functional part, which extends in a longitudinal direction and has a lateral surface that surrounds a longitudinal central axis of the functional part running in the longitudinal direction and has an end face bounding the functional part at a free end in the axial direction, may involve pressing a punch that can be moved in the longitudinal direction of the functional part against the end face of the functional part, while the functional part is initially located in a cavity of a tool, at least over a partial portion of its longitudinal extent that adjoins its free end, which cavity is bounded in the radial direction with respect to the longitudinal central axis by a wall surface surrounding the lateral surface and lying at least partially against the lateral surface, and pulling off the tool from the functional part over the free end of the functional part over a pulling-off travel, while the punch remains pressed against the end face of the functional part, at least over a partial travel of the pulling-off travel of the tool from the functional part. A material flow of material of the functional part is brought about by the tool during the pulling-off of the tool from the functional part.