Eyelet Manufacturing Forge Processing Material Yield
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Solution Overview
Problem
The existing methods for manufacturing eyelets, particularly those used in light emitting devices, suffer from low material yield due to press work, resulting in significant disposal of products, with conventional methods like cutting and press work either being time-consuming or inefficient in terms of material utilization.
Innovation Solution
A method involving forge processing to form the base body of the eyelet in a disk shape, followed by press work to create a through hole, enhancing material yield by reducing waste and processing time, utilizing a single forging machine for both steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If press work is used to manufacture eyelets, then the base body can be formed, but the material yield is low resulting in disposal of 90% or more of products
Solution Approach 1:
The patent changes the manufacturing method from press work to forge processing. This parameter change in the manufacturing process enables the base body to be formed with significantly improved material yield, reducing waste from 90% or more to approximately 10% disposal rate, while maintaining the disk shape and structural integrity of the eyelet base body
2Manufacturing precision
If cutting work and press work are used sequentially, then the through hole can be formed, but the processing time increases
Solution Approach 1:
The patent combines the base body formation and through hole formation into a single forge processing step. The forging die includes a through-hole portion that forms the through hole simultaneously with the base body during forge processing, eliminating the need for separate cutting work or press work steps, thereby reducing total processing time while maintaining manufacturing precision
3Manufacturing precision
If multiple processing steps are used, then the eyelet can be manufactured with required precision, but device complexity increases
Solution Approach 1:
The patent merges multiple processing steps into a single forge processing operation. The forging die is designed with integrated features including the base body shape and through-hole positioning, allowing simultaneous formation of both features in one step, thereby reducing device complexity and number of processing steps while maintaining required manufacturing precision
Solution Approach 2:
The forging die serves multiple functions simultaneously: it forms the base body shape, creates the through hole, and defines the final dimensions all in one operation. This multi-functionality of the forging die reduces the need for multiple specialized tools and processing steps, simplifying the overall manufacturing system
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 significantly improves material yield, reducing disposal to about 10% and matching processing time efficiency with press work methods, while requiring only a single forging machine for both base body formation and through hole creation.
Implementation Method 1
forming a base body of which width is greater than a width of the metal base material by applying forge processing on the metal base material
Implementation Method 2
forming a through hole by press work and cutting work
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A method of manufacturing an eyelet includes forming a metal base material by cutting a metal wire material, flattening a first face and a second face of the metal base material by applying pressure to the metal base material, forming a base body of which width is greater than a width of the metal base material by applying forge processing on the metal base material of which the first face and the second face are flattened, and forming a through hole penetrating through the base body in a thickness direction by punching through the base body.