Forging Device with Dual Punches for Cylindrical Shaping
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Solution Overview
Problem
Existing forging devices require multiple processes and complex structures for drawing/ironing processing, leading to long processing times and low material use ratios, while impact processing devices often result in non-uniform sidewall thickness during cylindrical shaping.
Innovation Solution
A forging device with a first and second mold, each with a punch that compresses the raw material, and a drive control system to control the movement and thickness reduction of the punches, allowing material to flow into a gap between the punches and molds to form a bottomed cylindrical shape efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If general drawing ironing processing is used to manufacture bottomed cylindrical bodies from metal plate material, then the processing can be performed with conventional equipment, but multiple processes (5-8 processes) are required resulting in long processing time
Solution Approach 1:
The invention combines drawing and ironing operations into a single integrated forging process. The mold and punch system performs both the drawing function (forming the bottomed cylindrical shape) and the ironing function (controlling wall thickness) simultaneously, eliminating the need for separate drawing and ironing processes that require 5-8 operations in conventional systems.
Solution Approach 2:
The forging process is segmented into controlled deformation zones within the mold cavity. The raw material is divided into regions that will form the bottom, walls, and flange through differential material flow control, allowing complex shaping in a single operation rather than requiring multiple sequential processes.
2Ease of manufacture
If general drawing ironing processing is used, then conventional equipment can be utilized, but the mold and press machine structures become complicated
Solution Approach 1:
The mold and punch assembly is designed as a universal forging tooling system that can accommodate different raw material shapes (plates, slugs, ingots) and produce various bottomed cylindrical configurations. This multi-functional design simplifies the overall equipment requirements compared to specialized drawing and ironing tooling.
Solution Approach 2:
Instead of using complex multi-stage drawing dies with gradual reduction sections, the invention inverts the approach by using a simple mold cavity shape combined with controlled material flow through the punch-mold gap to achieve the desired complex geometry in one step.
3Ease of manufacture
If intermediate trim and finish trim processes are performed after drawing ironing, then edge portions can be removed, but the material use ratio decreases to approximately 50%
Solution Approach 1:
The forging process preliminarily forms the final product geometry including the flange and wall portions with minimal excess material before any trimming operations. By pre-shaping the material to closely match the final product dimensions through controlled plastic flow, the amount of material requiring removal is minimized, improving the material use ratio from 50% to over 90%.
4Productivity
If impact processing with backward extrusion method is used for cylindrical shaping, then shaping can be performed quickly, but the plate thickness of sidewall becomes non-uniform
Solution Approach 1:
The mold gap between the punch and mold wall acts as a feedback-controlled constraint on material flow during extrusion. As material is forced through the gap, the gap dimensions automatically regulate the wall thickness, providing real-time control that prevents the non-uniform thickness problems associated with uncontrolled backward extrusion methods.
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 solution enables accurate and efficient forging of raw materials into bottomed cylindrical shapes in a short time with a high material use ratio, reducing the need for multiple processes and ensuring uniform thickness.
Implementation Method 1
a first mold (an upper mold) and a second mold (a lower mold) that compress the raw material
Implementation Method 2
causing a material to flow into a gap between the first punch and the second hole part
Data Source
AI summary
A forging device that shapes a raw material for forging includes an upper mold and a lower mold that compress a raw material, an upper punch provided to be pierceable through a first hole part formed in the upper mold, a lower punch provided to be pierceable through a second hole part formed in the lower mold, and a drive control part that performs control of driving the upper and lower molds and control of driving the upper punch and/or the lower punch. In accordance with a decreased amount of a thickness of a raw material portion compressed by the upper punch and the lower punch the drive control part performs drive control to move the raw material portion compressed by the upper and lower molds to a side of the upper mold and enlarge a cylindrical part formed by causing a material to flow into a gap between the upper punch and the second hole part.