Forging Die Vent Cleaning Using Ultrasound and Aqueous Injection
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Solution Overview
Problem
Forging die vents become clogged during production runs, leading to air pocket formation, shape variations in metal parts, and reduced productivity due to manual cleaning at high temperatures, which is hazardous and time-consuming.
Innovation Solution
A cleaning device that injects an aqueous solution and ultrasound into the vent to dislodge residues, using a valve system to control the injection and evacuation of the solution and air, allowing for continuous production without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning of vents is performed during production runs, then blockages are removed, but productivity is reduced and safety hazards occur due to high temperature operations
Solution Approach 1:
The automated cleaning device performs vent cleaning during inter-operational periods (setup time) before production begins, rather than during active production. This preliminary action removes blockages without interrupting the production run, thus maintaining productivity while ensuring vent functionality.
Solution Approach 2:
The patent replaces manual mechanical cleaning (using brushes or wires by hand) with an automated system that uses pressurized fluid injection and ultrasonic vibration. This substitution eliminates safety hazards associated with manual high-temperature operations and maintains consistent cleaning quality.
2Reliability
If vent diameter is increased to prevent clogging, then airflow is improved, but metal part geometry accuracy deteriorates due to protrusion formation
Solution Approach 1:
The patent changes the cleaning parameters (using pressurized fluid and ultrasonic frequency) rather than changing the vent geometry. This allows maintaining the original small vent diameter (which preserves part geometry accuracy) while improving cleaning effectiveness to prevent blockages.
Solution Approach 2:
The automated cleaning system enables the vent to be self-maintained during setup periods without manual intervention. The cleaning device automatically removes blockages, allowing the vent to maintain its original dimensions while staying functional throughout production.
3Productivity
If production runs are extended to improve productivity, then output increases, but vent blockage risk increases due to residue accumulation
Solution Approach 1:
The automated cleaning device enables continuous production by cleaning vents during inter-operational periods without stopping the production flow. The cleaning action is integrated into the continuous process, ensuring vent performance is maintained throughout extended production runs while output increases.
Solution Approach 2:
Cleaning is performed as a preliminary action during setup time between production batches, preventing blockage accumulation before it affects production. This allows extended production runs with maintained vent effectiveness.
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 device effectively cleans the vents during inter-operational periods, maintaining productivity by preventing blockages and ensuring consistent part quality without safety hazards or downtime.
Implementation Method 1
an ultrasonic generator, adapted to generate ultrasonic waves in the vent
Implementation Method 2
an aqueous solution injection pump, adapted to inject aqueous solution into the vent
Data Source
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AI summary
An aspect of the invention relates to a device (100) for cleaning a vent (20) of a first forging die (11), suitable for receiving, between the first die and a second die, a metal blank to be shaped in order to produce a metal part, the cleaning device comprising: - a pump (110) for injecting an aqueous solution, suitable for injecting the aqueous solution into the vent (20), - an ultrasound generator (150), suitable for generating ultrasound waves within the vent (20), - an air intake (140) suitable for ensuring a venting of the vent (20), and - a valve system (130) for alternately controlling at least the injection of aqueous solution and ultrasound and the venting of the vent (20). Another aspect of the invention relates to a method for using the device.