Forged Hammer Head With Integrated Side Nail Puller
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Solution Overview
Problem
Existing hammers with side nail pullers often suffer from high production costs and material waste due to machining processes like milling, and they may be prone to failure at machined areas.
Innovation Solution
A forged hammer head with a side nail puller formed in a single forging process, where the side nail puller comprises a side wall and a notch, and the tool parting line of the forging process does not intersect the notch, reducing material waste and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If milling process is used to form side nail puller on forged hammer head, then side nail puller can be formed, but material waste increases and production cost increases
Solution Approach 1:
The side nail puller is integrated into the hammer head through a single forging process, combining two previously separate manufacturing operations (hammer head forging and side nail puller machining) into one unified process. This eliminates the need for subsequent milling operations and reduces material waste.
Solution Approach 2:
The side nail puller geometry is pre-formed during the initial forging process before any material removal occurs. The forging dies are designed to create the complete hammer head with integrated side nail puller in one operation, preventing material waste that would occur with post-forging machining.
2Reliability
If milling process is used to form side nail puller, then side nail puller can be formed, but structural integrity decreases due to prone to failure along machined area
Solution Approach 1:
The side nail puller is forged as an integral part of the hammer head, merging the two components into a single monolithic structure. This eliminates the machined interfaces that create stress concentration points and potential failure zones in traditionally manufactured hammers.
Solution Approach 2:
The entire hammer head including the side nail puller is formed from homogeneous forged metal with consistent grain structure throughout. The forging process creates uniform material properties without the heterogeneous zones introduced by machining operations, resulting in improved structural integrity.
3Device complexity
If welding procedure is used to attach side nail puller to forged hammer head, then side nail puller can be attached, but device complexity increases and production cost increases
Solution Approach 1:
The side nail puller and hammer head are combined into a single forged component, eliminating the need for separate attachment operations such as welding. This integration simplifies the manufacturing process by reducing the number of steps and eliminating the complexity of joining different components.
Solution Approach 2:
The forging dies are segmented into multiple sections that work together to form the complex geometry of the hammer head with integrated side nail puller. This die segmentation allows the complex shape to be formed in a single forging operation without requiring complex tooling or multiple assembly steps.
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 forged hammer head with an integrated side nail puller reduces material waste, lowers production costs, and enhances the structural integrity and performance of the hammer, making it more effective for nail removal.
Implementation Method 1
the head of this hammer is formed by a forging procedure/process
Implementation Method 2
The side nail puller is configured to engage and pull a nail from a workpiece
Data Source
AI summary
A forged hammer head formed in a forging process comprises a forged hammer face at one end of the head; a forged hammer claw at an end of the head opposite the face; and a forged side nail puller disposed between the face and the claw. A method for forming a hammer head comprises sequentially placing a blank in a series of cooperating forging dies, and sequentially shaping the blank in the forging dies into a hammer head, a hammer claw, a hammer face and a side nail puller disposed between the face and the claw. The side nail puller is configured to engage and pull a nail from a workpiece. The side nail puller comprises a side wall and a notch formed in the side wall. A tool parting line of the forging process does not intersect the notch.