Heated Pressure Forming with Elastic Media for Shape Compliance
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Solution Overview
Problem
Current flexible forming methods face challenges in producing high-quality components from composites or metallic alloys like titanium alloys, which are required for aerospace and automotive industries, as they often result in insufficient shape compliance using 'cold' forming processes.
Innovation Solution
A process and system involving a press with a pressure generator, a forming tool, and an elastically deformable element, where the workpiece and/or forming tool are heated to elevated temperatures, allowing the elastically deformable element to deform and press the workpiece against the forming tool to achieve the desired shape, with pressures ranging from 5 MPa to 200 MPa and temperatures between 200°C and 500°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cold forming is used, then the process is simple and fast, but the shape compliance and quality of the formed component are insufficient
Solution Approach 1:
The patent applies thermal energy to heat the workpiece and/or forming tool to elevated temperatures (typically between ambient temperature and the material's recrystallization temperature), which changes the material properties to enable better plastic deformation and shape compliance during forming, directly resolving the contradiction between simple cold forming and high-quality shape compliance
2Manufacturing precision
If high pressure is applied, then the forming quality improves, but the risk of material damage and tool wear increases
Solution Approach 1:
By heating the workpiece and/or forming tool, the patent changes the material's mechanical properties (reducing flow stress and increasing ductility), which allows high forming pressures to be applied without causing material damage, thus enabling high forming quality while maintaining material integrity
Solution Approach 2:
The patent applies heat treatment before the actual forming process to prepare the material in advance, making it more resistant to damage during the high-pressure forming operation, effectively cushioning against potential material failure
3Manufacturing precision
If elevated temperature forming is used, then shape compliance improves, but the process complexity and energy consumption increase
Solution Approach 1:
The patent combines the heating function and forming function into an integrated process, where the forming tool serves dual purposes as both the shaping element and the heat transfer medium, reducing overall system complexity despite the added thermal processing requirement
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 method enables the formation of high-quality components from composites or metallic alloys, such as titanium alloys, that meet industry standards by facilitating deformation at elevated temperatures, improving shape compliance and quality for aerospace and automotive applications.
Implementation Method 1
The pressurization of at least one of one side of the elastically deformable element opposite to the side of the elastically deformable element facing the workpiece, or the forming tool causes the elastically deformable element to deform
Implementation Method 2
The process comprises heating at least one of the workpiece or the forming tool, and forming the workpiece using the press so as to obtain a formed workpiece. The heating of at least one of the workpiece or the forming tool is such that the temperature of the at least one of the workpiece or the forming tool during the forming of the workpiece
Data Source
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AI summary
A process (100) and a system (20, 40) for forming of a workpiece (10) using a press (20) comprising a pressure generator (21), a forming tool (22), and an at least in part elastically deformable element, are disclosed. At least one of the workpiece (10) or the forming tool (22) is heated, and the workpiece (10) is formed using the press (20) so as to obtain a formed workpiece (60). The heating of at least one of the workpiece (10) or the forming tool (22) is such that the temperature of the at least one of the workpiece (10) or the forming tool (22) during the forming of the workpiece (10) by way of forming pressure generated by the pressure generator (21) is higher than the ambient temperature.