Rear-End Workpiece Fixing in Forging to Cut Tray Plate Width
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Solution Overview
Problem
Conventional forging methods require a wider tray plate to fix the workpiece, leading to increased manufacturing costs and potential shaping failures due to chips or burrs generated during the process, which affects the precision and efficiency of the final product.
Innovation Solution
A forging method and apparatus where only the rear end of the workpiece is fixed to the tray plate, reducing the tray plate's width and minimizing the workpiece size, using a tray plate with a convex bent portion and guide rolls to prevent interference and improve accuracy, and a cutting and pressing assembly to compress-cut the workpiece, thus preventing shaping failures from chips or burrs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the workpiece is fixed to a wide tray plate using conventional methods, then the workpiece can be securely held during forging, but the tray plate width increases leading to higher manufacturing costs and material waste
Solution Approach 1:
The tray plate is segmented into a main body portion and a protruding portion that extends beneath the workpiece. This segmentation allows the fixation area to be concentrated only where needed (under the workpiece) rather than requiring a uniformly wide tray plate, thereby reducing overall tray plate width while maintaining secure workpiece holding during forging operations
Solution Approach 2:
The fixation structure extends in the vertical dimension with the protruding portion going beneath the workpiece, rather than relying solely on horizontal expansion of the tray plate width. This dimensional change allows effective fixation with a narrower tray plate, resolving the contradiction between fixation stability and tray plate width
2Manufacturing precision
If a larger tray plate is used to fix the workpiece, then the workpiece can be properly positioned, but chips or burrs generated during punching affect the shaped part leading to shaping failures
Solution Approach 1:
The harmful punching operation is extracted and relocated to the protruding portion of the tray plate, separate from the workpiece shaping area. This allows chips and burrs generated during punching to be isolated away from the shaped part, preventing shaping failures while maintaining accurate workpiece positioning through the protruding fixation structure
Solution Approach 2:
The protruding portion of the tray plate acts as an intermediary structure that separates the punching operation from the workpiece shaping area. This intermediary allows necessary punching for workpiece fixation while preventing the harmful effects of generated chips and burrs from affecting the final shaped product
3Productivity
If multiple workpieces are arranged closely on the tray plate, then productivity increases, but workpieces interfere with each other during compression shaping reducing accuracy
Solution Approach 1:
Each workpiece is associated with its own protruding portion of the tray plate, creating segmented fixation zones. This segmentation allows multiple workpieces to be processed simultaneously with adequate spatial separation, preventing interference during compression shaping while maintaining high productivity through parallel processing
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 reduces the amount of tray plate used, minimizes defective shaping rates, and enhances working accuracy by preventing interference between workpieces, resulting in a high-precision product with reduced manufacturing costs.
Implementation Method 1
a tray plate with a convex bent portion and guide rolls to prevent interference and improve accuracy
Implementation Method 2
a cutting and pressing assembly to compress-cut the workpiece
Implementation Method 3
forging is a shaping method that presses a workpiece such as iron or non-ferrous metal to cause plastic deformation thereof
Data Source
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AI summary
The present disclosure relates to a forging method and forging apparatus in which only a rear end of a workpiece is fixed to a tray plate that fixes the workpiece to reduce a front-rear direction width of the tray plate and thus to reduce an amount of the tray plate used during the workpiece shaping, and in which a compression shaping of the workpiece is performed while a minimum size workpiece required for a final product is fixed on the tray plate such that an amount of the workpiece as used can be minimized. The forging apparatus includes a press having upper and lower dies; a tray plate supply assembly configured to supply, by one pitch, a tray plate from one side of the press to an opposite side of the press towards a top of the lower die such that the tray plate can ascend and descend each time the upper die is raised; a punching unit disposed on the upper and lower dies at one side thereof to continuously form a workpiece fixing hole in the tray plate; a workpiece plate supply assembly disposed in front of an opposite side of the punching unit for feeding the workpiece plate by one pitch to a position below the workpiece fixing hole defined in the tray plate, wherein the workpiece plate supply assembly forms a through-protrusion to pass through the workpiece fixing hole on a top of a rear end of a portion of the workpiece plate corresponding to the fed one pitch; a cutting and pressing and fixing assembly provided on the upper and lower die at an opposite side of the punching unit for cutting the workpiece plate to be fed to the position below the workpiece fixing hole of the tray plate by one pitch and for pressing and fixing the through-protrusion formed on the rear end of the cut workpiece into the workpiece fixing hole; and a pressing and shaping unit disposed on the upper and lower dies at an opposite side of the cutting and pressing and fixing assembly for compressing and shaping the fed workpiece.