High-Velocity Forming Tool Release to Prevent Multiple Strikes
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Solution Overview
Problem
High velocity forming and cutting processes face challenges in controlling energy delivery to work materials, leading to potential tool rebound and impaired product quality, particularly due to the risk of the plunger striking the tool multiple times, which can result in weakening and unevenness of the end product.
Innovation Solution
A method where the tool is operatively disassociated from the drive unit before striking the work material, allowing for controlled kinetic energy transfer by adjusting the tool's velocity and mass, and using a hydraulic system with a braking chamber to decelerate the plunger, thereby reducing the risk of multiple strikes and improving energy control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the plunger is used to drive the tool at high velocity, then high kinetic energy is transferred to the work material, but the plunger may strike the tool multiple times causing product impairment
Solution Approach 1:
The patent extracts the tool from continuous contact with the plunger drive unit, allowing the tool to be propelled forward and then separated before striking the work material. This prevents the plunger from making multiple strikes on the tool, eliminating the source of product impairment while maintaining high kinetic energy transfer during the initial strike.
Solution Approach 2:
The tool is positioned and prepared in advance on the plunger, and the plunger is accelerated to high velocity before the tool strikes the work material. This preliminary acceleration ensures that the tool delivers the required kinetic energy in a single controlled strike, preventing multiple impacts that would compromise product quality.
2Strength
If the tool possesses high stiffness to avoid excessive deformation, then tool durability is improved, but the system capacity and mass increase
Solution Approach 1:
The patent changes the operational parameters by using high velocity (typically at least 1 m/s, preferably at least 3 m/s, preferably at least 5 m/s) to achieve high kinetic energy transfer. This allows the tool to have lower stiffness and mass while still delivering the required forming force, as the kinetic energy (KE = 1/2 mv²) is squared with respect to velocity, making velocity a more efficient parameter for energy delivery than mass.
3Force
If conventional metal forming is used with heavy tools at low velocity, then material forming force is achieved, but production rate and measuring accuracy are limited
Solution Approach 1:
The patent replaces the conventional mechanical system of heavy tools moving at low velocity with a high-velocity kinetic energy-based system. Instead of relying on continuous mechanical pressure, the invention uses a plunger-driven tool that accelerates to high velocity and delivers energy in a single rapid strike, dramatically increasing production rate while maintaining forming capability.
Solution Approach 2:
The patent employs periodic, impulse-based action rather than continuous force application. The plunger accelerates the tool to high velocity and delivers a concentrated energy impulse in a single strike, then the tool is reset for the next cycle. This periodic high-velocity action achieves both high productivity and measuring accuracy.
4Power
If the tool is kept in contact with the plunger during acceleration, then kinetic energy transfer is maximized, but control precision during striking is reduced
Solution Approach 1:
The patent extracts the tool from the plunger drive unit at the optimal moment during acceleration, allowing the tool to coast forward with its acquired velocity. This separation ensures that the tool delivers maximum kinetic energy to the work material while the plunger does not interfere with the precise moment of impact, improving manufacturing precision.
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 enhances the control of kinetic energy delivered to the work material, reduces the risk of tool rebound, and improves the quality of the end product by preventing multiple strikes, allowing for more precise and efficient high velocity forming and cutting processes.
Implementation Method 1
a plunger (1) arranged to be driven by a hydraulic system (16, 17, 18), the hydraulic system comprising a first chamber (17) for biasing the plunger (1) towards the workpiece (W)
Implementation Method 2
allowing, for the deceleration of the plunger (1), a part of the plunger (1) to enter a braking chamber (15), and allowing thereby hydraulic fluid to be trapped in the braking chamber (15), whereby an increased pressure in the trapped fluid decelerates the plunger (1)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention provides a method for material forming and/or cutting, by means of a tool (4) and a drive unit (1), the method comprising moving the drive unit (1) to provide kinetic energy to the tool (4), for the tool (4) to strike a work material (W), so as to form and/or cut the work material (W), wherein the tool (4) is operatively disassociated from the drive unit (1) before the tool (4) strikes the work material (W).