Forging Punch Recess Locks Component Position
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Solution Overview
Problem
The unpredictability of the forged component's position after the forging process in both manual and automated manufacturing processes due to the component sometimes sticking to the upper press, leading to increased process time and reliability issues in automated systems where precise positioning is required for further processing.
Innovation Solution
Incorporating an extrusion punch with a recessed striking surface that locks the shaped component to the punch, ensuring consistent positioning by preventing attachment to the upper press and allowing easy separation, enabling reliable automated handling and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the upper press is moved away from the lower press after forging, then the forged component can be removed from the die, but the component may stick to the upper press at the interface, causing unpredictable positioning
Solution Approach 1:
A punch with a recessed striking surface is introduced as an intermediary element between the upper press and the billet. The recess captures material during forging, creating a mechanical lock that prevents the forged component from sticking to the upper press interface, thereby ensuring predictable positioning while still allowing easy removal from the die.
2Adaptability or versatility
If manual handling is used to locate and transfer the forged component, then flexibility is maintained, but process time increases and automation cannot be implemented
Solution Approach 1:
The punch with the recessed striking surface enables the forged component to effectively locate itself in a consistent position after forging. This self-positioning capability eliminates the need for manual handling and locating operations, allowing direct integration with automated transfer systems and significantly reducing process time.
3Device complexity
If the striking surface is flat, then the forging process is simple, but the component position becomes unpredictable after extrusion
Solution Approach 1:
Instead of making the entire striking surface complex, only a localized recess is created in the striking surface. This minimal modification to the punch structure is sufficient to capture material and lock the component position, maintaining overall structural simplicity while achieving precise and predictable positioning accuracy.
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 solution ensures consistent and predictable positioning of the forged component, reducing process time and enhancing the reliability of automated manufacturing by allowing robots to accurately locate and transfer the components for further processing.
Implementation Method 1
a ram is used to strike the billet so as to provide a, typically horizontal, force to press the metal billet into a die. In this way, the shape of the billet deforms so as to take on the shape of the die.
Data Source
AI summary
A forging apparatus and method is disclosed in which an extrusion punch is held between an upper press and a lower press and propelled towards a billet by a ram to form an extruded shaped component. The extrusion punch has a striking face in which a recess is formed. During the extrusion process, material from the billet enters the recess so as to lock the extrusion punch and the shaped component together. Accordingly the shaped component is not lifted up with the upper press when it is separated from the lower press and so the position of the shaped component after the forging extrusion operation is known accurately and reliably.