Forging Flanges via Upset Punch Diameter Expansion
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Solution Overview
Problem
Existing methods for producing spindles, such as those for vehicle wheel assemblies, face inefficiencies in forging processes, particularly in forming flanges, which can lead to material waste and increased tooling setup times, especially when transitioning between different products.
Innovation Solution
A method involving the use of forging die sets to shape metal workpieces into tubular or non-tubular configurations, where a workpiece is heated and then forged into a tube with a flange formed using an upset punch, reducing material removal and optimizing tooling efficiency by forming the flange through diameter increase rather than reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional forging methods are used to form flanges, then the flange can be produced, but material waste increases and tooling setup time increases
Solution Approach 1:
Instead of reducing the diameter of the workpiece to form a flange (traditional method), the patent increases the diameter at the flange location through upset forging. This inverted approach forms the flange by expanding the metal outward rather than removing material, directly reducing material waste while maintaining production efficiency
Solution Approach 2:
The patent changes the fundamental parameter of diameter modification from reduction to increase. By applying upset forging to increase the diameter at the flange location, the process achieves flange formation with minimal material removal, resolving the contradiction between material waste and production efficiency
2Ease of manufacture
If traditional forging methods are used to form flanges, then the flange can be produced, but tooling setup changes increase
Solution Approach 1:
The upset forging die is designed to perform multiple functions: it forms the flange, controls the diameter increase, and defines the flange geometry all in a single operation. This multi-functional tooling reduces the number of setup changes required compared to traditional methods, thereby maintaining high production throughput while improving ease of manufacture
Solution Approach 2:
The patent combines multiple operations (flange formation, diameter control, and geometry definition) into a single upset forging operation. This merging of functions into one process step reduces tooling setup changes and maintains high productivity, resolving the contradiction between ease of manufacture and production throughput
3Shape
If diameter reduction is used to form flanges, then the flange shape can be achieved, but material removal increases
Solution Approach 1:
The patent inverts the traditional approach by increasing the diameter at the flange location rather than reducing it. This allows the flange geometry to be formed through controlled expansion of the metal, achieving the desired shape with minimal material removal instead of significant material removal
Solution Approach 2:
The patent changes the diameter modification parameter from negative (reduction) to positive (increase). By controlling the upset forging process to increase the diameter at the flange location, the desired flange geometry is achieved while minimizing material removal, resolving the contradiction between shape quality and material loss
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 enhances throughput, reduces material waste, and minimizes tooling setup changes, allowing for more efficient production of spindles with improved material utilization and reduced machining operations compared to traditional methods.
Implementation Method 1
An upset punch may be actuated against a second end of the tube that is disposed opposite the first end to forge a flange between the first and second ends
Data Source
AI summary
A system and method of making a forged part. A flange may be forged between first and second ends of the part by actuating an upset punch against a second end of the tube that is disposed opposite the first end. The flange may extend away from an axis along which an upset punch is actuated.