Forging Large Workpieces via Bending Zone Shear Stress
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Solution Overview
Problem
Existing methods for forging workpieces with larger cross-sectional dimensions struggle to achieve a uniform grain structure due to limited influence from forging parameters, and existing devices are unsuitable for large cross-sections.
Innovation Solution
The workpiece is deformed in a bending zone between two central supports using radially acting forging tools, creating transverse loads that distribute shear stresses across the cross-section, allowing for grain refinement and easy processing of large workpieces in a single pass, with additional cross-sectional reductions and finishing for improved surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forging tools are used on large cross-sectional workpieces, then the workpiece can be processed, but uniform grain refinement cannot be achieved
Solution Approach 1:
The invention introduces a bending zone that displaces the workpiece cross-section perpendicular to the forging axis, adding a dimensional element to the deformation process. This bending displacement creates transverse loads and shear stresses distributed across the cross-section, enabling uniform grain refinement even in large cross-sectional workpieces that cannot be adequately processed by conventional radial forging alone.
2Manufacturing precision
If rolling with deflection channels is used for grain refinement, then grain structure is improved, but the device is suitable only for small workpiece cross-sections
Solution Approach 1:
The invention changes the deformation parameters by introducing bending displacement perpendicular to the forging axis. Instead of relying solely on radial compression and small-radius deflection, the system creates transverse loads through bending zone displacement, distributing shear stresses across the entire cross-section. This parameter change enables the processing of large cross-sectional workpieces while achieving uniform grain refinement.
3Manufacturing precision
If four hammers with 45° lateral movement are used, then some grain refinement is achieved, but the construction effort is high and refinement is limited
Solution Approach 1:
The invention extracts the essential function of creating transverse shear stresses from the complex four-hammer system. By implementing a bending zone with displacement perpendicular to the forging axis, the system achieves the same grain refinement effect through a simpler mechanism that distributes shear stresses across the cross-section without requiring multiple laterally moving hammers with precise angular guidance.
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 method ensures uniform grain refinement over the entire cross-section of large workpieces, enhancing the grain structure and surface quality, while allowing for central support and precise guidance during deformation, making it suitable for larger workpieces.
Implementation Method 1
transverse loads occur both during the bending of the workpiece out of the forging axis and during the bending thereof back into the forging axis, and these transverse loads lead to shear stresses which are distributed over the cross-section and which ensure a notable grain refinement
Implementation Method 2
the workpiece is deformed in the sense of a cross-sectional displacement perpendicular to the forging axis in a bending zone between two central supports by means of the forging tools acting on the workplace radially in relation to the forging axis
Data Source
AI summary
A description is given of a method and a device for forging a rod-shaped workpiece (5) which is deformed with the aid of forging tools (1, 2, 3, 4) in the sense of a cross-sectional displacement perpendicular to the forging axis (a) and is subjected to an axial advancement and possibly a rotation about the forging axis (a) during the pauses in the engagement of the forging tools (1, 2, 3, 4). In order to achieve an advantageous grain refinement, it is proposed that the workpiece (5) is deformed in the sense of the cross-sectional displacement perpendicular to the forging axis (a) in a bending zone (13) between two central supports (11) by means of the forging tools (1, 2, 3, 4) acting on the workpiece (5) radially in relation to the forging axis (a).