Flat Link Chain Production via Axial Upsetting
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Solution Overview
Problem
Existing methods for producing flat link chains, particularly for underground mining, face challenges in achieving high strength, abrasive wear resistance, and cost-effectiveness, with known methods requiring electrical heating and resulting in uncontrollable free-form surfaces at transition sections.
Innovation Solution
A method involving axial upsetting of profiled bars to create chain links with enlarged cross-sectional areas at curves and smaller cross-sectional areas at legs, allowing for individual shaping and reduced material usage, using a combined forming and upsetting tool to produce chain links with optimized cross-sectional contours for strength and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical heating and compression is used to enlarge cross section at curves, then the cross-sectional area is increased, but the process requires additional heating equipment and creates uncontrollable free-form surfaces
Solution Approach 1:
The patent replaces the electrical heating and thermal compression process with a purely mechanical cold-forming process. A forming die with predetermined curvature is used to directly shape the profile bar into the curve geometry, eliminating the need for heating equipment and thermal processes while achieving the same cross-sectional enlargement at curve areas.
Solution Approach 2:
The patent changes the forming temperature parameter from hot (electrical heating) to cold (ambient temperature). This parameter change eliminates the need for heating equipment, simplifies the process, and provides better surface control through deterministic cold-forming geometry rather than thermally-induced variable deformation.
2Shape
If material is removed from longitudinal sections to achieve smaller cross-sectional area at legs, then the chain link geometry is achieved, but material usage increases and manufacturing complexity increases
Solution Approach 1:
Instead of starting with a uniform cross-section and removing material to create the desired geometry, the patent inverts the approach by starting with a profile bar that already has the correct variable cross-sectional distribution. The profile bar is cold-formed into the final shape, eliminating material removal operations and reducing waste.
Solution Approach 2:
The patent performs preliminary shaping of the profile bar before the main forming operation. The profile bar is pre-configured with the appropriate cross-sectional area distribution (smaller at legs, larger at curves), so that the subsequent cold-forming operation only requires shaping rather than material removal, thereby reducing material waste and manufacturing steps.
3Ease of manufacture
If conventional forming methods are used, then chain links can be produced, but the freedom of shape and precision of transition sections cannot be controlled
Solution Approach 1:
The patent replaces thermal-mechanical forming with cold mechanical forming using precision dies. The cold-forming process with predetermined die geometry provides deterministic control over transition section surfaces, eliminating the uncontrollable free-form surfaces that result from thermal compression methods.
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
The method enables the production of highly efficient, cost-effective flat link chains with improved freedom of shape and reduced material usage, maintaining full tensile force transmission while minimizing wear and production costs.
Implementation Method 1
axial upsetting with at least lengthwise enlargement of the cross-sectional area, with the cross-sectional area being increased in the area of the subsequent curves
Data Source
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AI summary
A method for producing a link chain, in particular for underground use in mining, wherein the link chain is produced from a steel material and has chain links in the form of horizontal links and vertical links, wherein each horizontal link and each vertical link has limbs which run parallel to each other and are connected to each other on the end sides via rounded portions, wherein each limb has a smaller cross-sectional area than the cross-sectional area of each rounded portion, characterized by the following method steps: – providing a profiled bar, wherein the cross-sectional area of the profiled bar is smaller than the nominal diameter of the chain link to be produced, – inserting the profiled bar into a compression tool and compressing same axially, thereby enlarging the cross-sectional area in terms of length, wherein the cross-sectional area is enlarged in the region of the subsequent rounded portions, – removing the compressed semi-finished chain link product and deforming same to form a chain link, and welding together end-side ends of the deformed chain link.