Rear-End Workpiece Fixing in Forging to Cut Tray Plate Usage
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Solution Overview
Problem
Conventional forging methods require a wider tray plate to fix workpieces, leading to increased manufacturing costs and potential shaping failures due to chips or burrs generated during drilling, which can result in defective products and increased material usage.
Innovation Solution
A forging method and apparatus where only the rear end of the workpiece is fixed to the tray plate, allowing for reduced tray plate width and minimizing material usage, while preventing shaping failures by avoiding interference from chips or burrs, and enabling high-precision shaping by spacing workpieces apart in the left-right direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the workpiece is fixed to the tray plate using conventional drilling methods, then the workpiece can be securely held during forging, but the tray plate width must be increased to accommodate drilling operations, leading to increased material usage and manufacturing cost
Solution Approach 1:
The invention extracts the harmful drilling operation from the workpiece fixing process. Instead of drilling holes through the tray plate to fix the workpiece, the method uses a clamp that applies pressure to the rear end of the workpiece without penetrating or drilling the tray plate, thereby eliminating the need for wide tray plates while maintaining secure fixing
Solution Approach 2:
The invention introduces a clamp as an intermediary device between the workpiece and the tray plate. The clamp serves as a mediator that provides secure fixing through clamping force without requiring direct penetration or wide contact area with the tray plate, thus resolving the contradiction between fixing reliability and material usage
2Reliability
If the workpiece is fixed using drilling methods, then the workpiece can be secured to the tray plate, but chips or burrs generated during drilling can cause shaping failures and defective products
Solution Approach 1:
The invention extracts the harmful drilling operation from the workpiece fixing process. Instead of drilling holes through the tray plate to fix the workpiece, the method uses a clamp that applies pressure to the rear end of the workpiece without penetrating or drilling the tray plate, thereby eliminating the need for wide tray plates while maintaining secure fixing
Solution Approach 2:
The invention converts the potential harm of drilling operations into a beneficial non-contact fixing method. By replacing drilling with clamping, the process eliminates chip and burr generation entirely, transforming a harmful process into a clean, safe fixing method that improves product quality
3Productivity
If multiple workpieces are arranged closely on the tray plate, then productivity increases, but lateral expansion during shaping causes interference between adjacent workpieces
Solution Approach 1:
The invention segments the workpiece support function by using individual clamps for each workpiece rather than a continuous fixed tray plate structure. This segmentation allows each workpiece to be independently clamped and positioned, preventing lateral expansion interference while maintaining close spacing for high productivity
Solution Approach 2:
The invention introduces dynamic clamping where the clamp can apply adjustable pressure to restrain lateral expansion during shaping. This dynamic control allows workpieces to be positioned closely for high productivity while actively preventing interference through controlled clamping force during the shaping process
4Reliability
If a wide tray plate is used to fix the entire workpiece, then the workpiece can be securely held, but the amount of tray plate material increases manufacturing cost
Solution Approach 1:
The invention extracts the harmful drilling operation from the workpiece fixing process. Instead of drilling holes through the tray plate to fix the workpiece, the method uses a clamp that applies pressure to the rear end of the workpiece without penetrating or drilling the tray plate, thereby eliminating the need for wide tray plates while maintaining secure fixing
Solution Approach 2:
The invention applies local quality by concentrating the fixing function at the rear end of the workpiece rather than distributing it across the entire workpiece length. The clamp provides localized, high-intensity fixing pressure where needed, eliminating the need for wide tray plates while maintaining secure fixing reliability
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 tray plate usage, minimizes defective shaping rates, and enhances working accuracy to produce high-precision products by fixing only the rear end of the workpiece to the tray plate and spacing workpieces to prevent lateral expansion interference.
Implementation Method 1
forging is a shaping method that presses a workpiece such as iron or non-ferrous metal to cause plastic deformation thereof
Data Source
AI summary
The present invention relates to a forging method and a forging apparatus, capable of: reducing the amount of tray plates used during the forging of materials by reducing the width from front to back of the tray plates by fixing only the rear of the materials to the tray plates for fixing the materials; and minimizing the amount of materials used, by compression-molding products by fixing, to the tray plates, the materials having a minimum size necessary for the fmal products, the present invention comprising: a press having upper and lower molds; a tray plate supply means for supplying, to the top rear of the lower mold, tray plates to be vertically movable from one side to the other side by a pitch and to be spaced from the upside of the lower mold; a punching unit provided at one side of the upper and lower molds so as to continuously punch material fixing hole parts in the tray plates; a material plate supply means provided at the front of the other side of the punching unit so as to supply material plates by a pitch to under the material fixing hole parts of the tray plates and, at the same time, form penetrating protrusion parts, which penetrate into the material fixing hole parts, on the rear top of the material plate in each pitch, which is moved by a pitch; a cutting and compressive fixing unit provided on the upper and lower molds at the other side of the punching unit so as to cut the material plates, which are inserted into the material fixing hole parts of the tray plates, by a pitch and, at the same time, allow the penetrating protrusion parts formed at the rear of the cut materials to penetrate into the material fixing hole parts, thereby compressively fixing same; and a compression molding unit provided on the upper and lower molds at the other side of the cutting and compressive fixing unit so as to compression-mold the materials being transferred.