Flow-Forming Tool Layout for Lower Drive Power and Downtime
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Solution Overview
Problem
Existing flow-forming devices require high drive power and torque, leading to increased costs and reduced service life, especially when changing workpieces, which affects their cost-effectiveness and utilization.
Innovation Solution
A device where the outer forming tool is driven to set the workpiece in rotation, reducing friction losses and allowing for lower drive power requirements, and multiple workpieces can be processed using a common drive unit, enabling alternating operation and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the workpiece is driven directly by a rotary drive acting on the workpiece, then the workpiece can be set in rotation for flow-forming, but high drive power and torque are required leading to increased costs
Solution Approach 1:
The patent introduces an outer forming tool as an intermediary element between the drive and the workpiece. The drive rotates the outer forming tool, which in turn rotates the workpiece through contact during the flow-forming process. This mediator approach reduces the drive power and torque requirements compared to direct driving of the workpiece.
2Adaptability or versatility
If multiple forming devices are arranged independently, then each device can operate autonomously, but the device occupies more space and maintenance requires shutting down all devices
Solution Approach 1:
The patent combines multiple forming devices into a single integrated structure where multiple outer forming tools are mounted on a common rotating carrier. This merging reduces the overall space occupation and allows maintenance to be performed on individual tools without shutting down the entire device, as other tools can continue operating.
3Ease of operation
If multiple outer forming tools are driven by separate drive units, then each tool can be controlled independently, but the device complexity and cost increase
Solution Approach 1:
The patent employs a single drive unit that rotates a common carrier, which in turn presents different outer forming tools to the workpiece at different times during rotation. This universal drive system performs the function of multiple independent drives while reducing overall system complexity and cost.
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
Significantly reduces drive power needs while allowing for efficient processing of multiple workpieces with reduced downtime and increased production capacity, lowering overall costs and improving device utilization.
Implementation Method 1
hollow body-shaped, preferably rotationally symmetrical and/or rotationally symmetrical workpieces are produced by the plastic deformation of preforms or semi-finished products
Implementation Method 2
the temperature during the implementation of the flow-forming process, starting from the feed temperature of the workpieces, increases only as a result of the heating generated by the internal friction of the plastically deformed material during the deformation
Data Source
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AI summary
A device (1) for flow-forming workpieces (2, 2.1, 2.2) has a rotatable first outer forming tool (3, 3.1) for engaging an outer contour of a first hollow-body-shaped workpiece (2). It also has a first inner forming tool (6, 6.1) for attacking an inner contour of the workpiece (2). The first workpiece (2) can be set in rotation about a first workpiece axis (X, X.1) and through a forming zone formed in a between the first forming tools (3, 3.1, 6, 6.1) by one of the first inner forming tool (6 , 6.1) and the pressure applied to the first outer forming tool (3, 3.1) can be plastically deformed by causing the material to flow between the first forming tools (3, 3.1, 6, 6.1). The device (1) has a drive (4) for driving the first outer forming tool (3, 3.1).