Forging Apparatus with Receding Pin for Thin Section Precision
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Solution Overview
Problem
Current liquid forging or squeeze casting techniques are unable to produce articles with complex shapes and homogenous structures, particularly failing to achieve tight dimensioning tolerances and forming parts with small through holes of fine tolerances, leading to non-homogenous structures and increased porosity in thinner sections.
Innovation Solution
A forging apparatus comprising a die cavity and a punch that exerts forming pressure, along with a pin that recedes to exert a feature forming pressure, allowing for the formation of articles with through holes and thin sections while maintaining a homogenous structure by controlling the solidification process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional liquid forging or squeeze casting techniques are used to produce articles with complex shapes, then the articles can be formed with high density and porosity-free structure, but the articles exhibit non-homogenous structure and increased porosity in thinner sections
Solution Approach 1:
The die cavity is segmented into multiple zones with different pin configurations. First pins form basic article features while second pins form additional features in thinner sections. This segmentation allows different regions to be optimized independently, enabling complex shapes while maintaining homogeneous structure and tight tolerances in each zone.
Solution Approach 2:
The pins are positioned and configured before the forming process begins. First pins are retracted to allow material flow to thinner sections, and second pins are positioned to form features in those sections. This preliminary positioning ensures that when material flows into thin sections, features are already prepared to be formed, preventing premature solidification and porosity.
2Strength
If high pressure is exerted on at least partially molten metal during solidification to produce fine-grained microstructure, then article strength and toughness are improved, but thinner sections solidify prematurely resulting in greater porosity
Solution Approach 1:
The pin positioning system is dynamic rather than static. First pins can be retracted during the forming process to allow material to flow into thinner sections before features are formed. Second pins are then positioned to form features in those thin sections. This dynamic adjustment prevents premature solidification and porosity while maintaining the high pressure needed for fine-grained microstructure and strength.
Solution Approach 2:
The system changes the spatial parameters of pin positioning during the forming process. Pins are moved from initial positions to final positions at different times, and their retraction distances are adjusted based on the specific section being formed. This parameter control ensures material flows properly into thin sections before solidification, eliminating porosity while maintaining strength through fine-grained structure.
3Manufacturing precision
If excess material is allowed to extend beyond actual article dimensions to compensate for varying volumes of at least partially molten metal, then articles with predetermined dimensions can be obtained, but additional trimming operations are required
Solution Approach 1:
Pin features are formed preliminarily before final solidification completes. By positioning pins to form features in thin sections while material is still plastic, the system eliminates the need for post-forming trimming of those features. This preliminary formation of features in critical sections reduces subsequent machining requirements while maintaining predetermined dimensions.
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
Enables the production of articles with complex shapes and homogenous structures, reducing porosity and grain size, and enhancing the strength and toughness of thin sections, particularly suitable for small products like casings for disk drives.
Implementation Method 1
a hydraulic press on the punch die
Implementation Method 2
exerting a high pressure on at least partially molten metal during solidification
Implementation Method 3
the at least partially molten metal solidifies into an article under external pressure
Implementation Method 4
applying an oscillating squeeze pressure during solidification
Implementation Method 5
double acting pressure to improve article strength and toughness
Implementation Method 6
exert a feature forming pressure when receded and thereby form the article having the article feature
Data Source
AI summary
An apparatus for forming an article by forging. The apparatus has at least one die having a die cavity to receive material, said material being at least partially molten, and at least one punch to slidably engage the die cavity and to exert a forming pressure on material disposed in the cavity. There is also at least one pin for forming an article feature. The pin is to slidably engage the die and to contact the material, the pin being further to recede upon exertion of the forming pressure and to exert a feature forming pressure when receded and thereby form the article having the article feature when the material solidifies under the forming pressure.