Forging Mold Guide Profile for Longitudinal Billet Flow
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Solution Overview
Problem
Existing forging methods, such as those described in Japanese Unexamined Patent Application Publication No. 2004-122163, fail to efficiently extend rod-shaped billets in the longitudinal direction due to material flow limitations, resulting in inefficient material usage and potential burr formation.
Innovation Solution
A mold and forging method featuring a lower mold with a groove portion and an upper mold with a pressing portion, guide portion, and restricting portion, where the guide portion guides material flow in the longitudinal direction and the restricting portion prevents transverse flow, using curved shapes and support portions with elastic members to enhance material flow control and reduce friction and burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the billet is extended in the longitudinal direction by pre-molding, then the yield is improved, but the material flows in the left-right direction only by a protruding amount and the billet cannot be extended efficiently in the longitudinal direction
Solution Approach 1:
The guide portion is designed with an asymmetric profile where the top portion protrudes more into the groove portion than the end portions. This asymmetric configuration creates a gradient effect that guides material flow preferentially in the longitudinal direction, resolving the contradiction by enabling efficient billet extension while maintaining proper material flow distribution
Solution Approach 2:
The guide portion acts as an intermediary element between the groove portion and the billet. By positioning the guide portion with its top portion protruding more into the groove, it mediates the material flow path, directing the billet material along the longitudinal axis and preventing lateral flow, thus improving both productivity and material utilization
2Manufacturing precision
If material flow is restricted in transverse direction, then burr formation is suppressed, but frictional resistance and internal pressure increase
Solution Approach 1:
The restricting portion is designed with different protruding amounts at different locations - the end portions protrude more than the top portion. This local variation in geometry creates zones of different flow restriction, allowing burr suppression at the edges while maintaining lower internal pressure in the central region through the reduced protrusion at the top
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 method effectively extends billets in the longitudinal direction, reducing frictional resistance and internal pressure, thereby improving material flow efficiency and suppressing burr formation, allowing for more efficient forging of rod-shaped products.
Implementation Method 1
elastic members that expand and contract in the vertical direction of the mold
Data Source
AI summary
A mold of the present disclosure is used when forging a billet having a rod shape, and the mold includes: a lower mold having a groove portion for housing the billet; an upper mold having a pressing portion engaged with the groove portion and that presses the billet; and a guide portion disposed in the groove portion or the pressing portion and that guides a flow of a material of the billet in a longitudinal direction of the billet. In a state in which the groove portion and the pressing portion are engaged, in a direction in which the groove portion extends, a protruding amount of a top portion of the guide portion to an inner side of the groove portion is larger than a protruding amount of end portions on both sides sandwiching the top portion of the guide portion to the inner side of the groove portion.