Forged Component Warm Coining to Reduce Springback Bending
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Solution Overview
Problem
High strength materials used in forged components like connecting rods for vehicles experience increased bending due to spring back after cold coining, and bursts can occur during the process, affecting mechanical properties and coining quality.
Innovation Solution
A method involving hot forging followed by heating to a first set temperature for warm coining, with controlled cooling and high-frequency induction heating, which eliminates the need for stress relief annealing and cold coining, reducing bending and preventing bursts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cold coining is performed on high strength materials, then the connecting rod can be shaped, but bending occurs due to spring back
Solution Approach 1:
The patent changes the temperature parameter from cold conditions to warm conditions (heating to a first set temperature before coining). This parameter change reduces the spring back effect and bending amount while maintaining the shaping capability, directly resolving the contradiction between achieving proper shape and minimizing bending.
2Shape
If cold coining is performed on high strength materials, then the connecting rod can be shaped, but bursts occur during the process
Solution Approach 1:
The patent applies parameter changes by heating the material to a first set temperature before coining and controlling the cooling rate. This thermal parameter modification increases material ductility during forming, preventing bursts while achieving the desired shape, thus resolving the contradiction between shaping and reliability.
3Stress or pressure
If stress relief annealing is performed after cold coining, then residual stress can be removed, but additional process time and cost are required
Solution Approach 1:
The patent extracts and eliminates the separate stress relief annealing process from the manufacturing sequence. By performing warm coining (heating to first set temperature before coining and controlling cooling), the process inherently manages residual stress without requiring additional heat treatment steps, thus resolving the contradiction between stress removal and process efficiency.
4Strength
If high strength materials are used, then mechanical properties improve, but bending amount increases due to spring back
Solution Approach 1:
The patent applies parameter changes by modifying the temperature conditions during coining (heating to first set temperature). This allows high strength materials to be formed with reduced spring back and bending, maintaining their mechanical strength advantages while improving dimensional accuracy, thus resolving the contradiction between strength and manufacturing precision.
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 improves mechanical properties, coining quality, and process quality by reducing bending and residual stress, eliminating bursts, and achieving equivalent durability without additional heat treatments, thereby enhancing the manufacturing process efficiency and reducing costs.
Implementation Method 1
The controlled cooled material may be heated to the first set temperature by performing high-frequency induction heating for 5 to 10 minutes.
Implementation Method 2
The hot forged material may be subjected to controlled cooling to a third set temperature at a predetermined cooling rate.
Data Source
AI summary
A method for manufacturing a forged component includes: performing hot forging on a material; heating the hot forged material to a first set temperature; and performing warm coining to correctly shape the heated material. The material may be heated to a second set temperature before hot forging. The material heated to the second set temperature may be hot forged. The second set temperature may be higher than the first set temperature. The hot forged material may be subjected to controlled cooling to a third set temperature at a predetermined cooling rate. The controlled cooled material may be heated to the first set temperature. The third set temperature may be lower than or equal to the first set temperature.