Flow-Forming Clamping Rollers With Radial Pre-Positioning
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Solution Overview
Problem
Flow-forming machines face challenges in efficiently clamping workpieces with varying diameters, leading to increased non-productive time and reduced machine utilization due to the need for frequent adjustments of clamping devices, which occupy interior space and require high axial clamping forces.
Innovation Solution
A flow-forming machine with a clamping device featuring a first adjusting device for consistent clamping path and a second adjusting device for radial pre-positioning of clamping elements, actuated by a control device based on workpiece diameter, allowing for automatic adaptation and efficient clamping without occupying interior space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a counterholder is used to clamp the workpiece axially on the spindle, then high axial clamping forces can be applied to hold the workpiece firmly, but the interior space within the drum-shaped workpiece wall is occupied and no longer available as processing space
Solution Approach 1:
The clamping device transitions from axial clamping (along the spindle axis) to radial clamping (perpendicular to the spindle axis). The clamping elements are arranged on the periphery of the spindle and clamp the workpiece from the outer diameter side, completely freeing the interior space while maintaining effective clamping forces through the radial direction.
2Adaptability or versatility
If the clamping device is adjusted for different workpiece diameters, then adaptability to various workpieces is improved, but non-productive time increases due to frequent adjustments
Solution Approach 1:
The control device receives diameter information about the workpiece to be machined and automatically actuates the second actuating device to pre-position the clamping elements radially before the actual clamping operation. This preliminary automatic adjustment eliminates manual intervention and significantly reduces non-productive time while maintaining full adaptability to different workpiece diameters.
Solution Approach 2:
The manual adjustment process is replaced by an automated control system that receives diameter data and automatically actuates the radial positioning mechanism. This substitution of mechanical/manual adjustment with an automated control system eliminates time loss while preserving adaptability to various workpiece dimensions.
3Productivity
If the clamping elements are pre-positioned radially for different workpiece diameters, then setup time is reduced and machine utilization is improved, but the device complexity increases due to the additional second adjusting device
Solution Approach 1:
The clamping device integrates two functions into a single system: the first actuating device provides axial clamping motion, while the second actuating device provides radial pre-positioning. This multi-functional integration allows the same device structure to handle both positioning and clamping operations, improving productivity without requiring separate dedicated mechanisms for each function.
Data Source
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AI summary
The invention relates to a flow-forming machine and to a method for flow forming a substantially rotationally symmetrical workpiece with a drum-shaped circumferential portion, with a spindle which can be driven in rotation about a spindle axis, a clamping device, and a plurality of clamping elements which are adjustable between a clamping position and a release position by means of a first adjustment device, the clamping force for holding the workpiece on the spindle during the reshaping being applicable by the first adjustment position, and a plurality of shaping rollers which can be moved radially and axially relative to the drum-shaped circumferential portion to reshape the circumferential portion of the workpiece. According to the invention, a second adjustment device is provided on the clamping device and by means of this second adjustment device a position of the clamping elements is adjustable in a radial direction in order to adapt to a diameter of the workpiece, and a control device is provided, by means of which the second adjustment device is actuatable depending on the diameter of the workpiece to be reshaped, the clamping elements being pre-positioned radially depending on the diameter of the workpiece.