Hexagonal Washer Belt Forging with Positioning Holes
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Solution Overview
Problem
Conventional methods for producing washers with wedge planes, V-shaped grooves, and ridges are overly complex, costly due to unnecessary steps, and result in inaccurate positioning and deformation during fine-tuning, especially when trying to create hexagonal washers.
Innovation Solution
A method involving a belt of material with strategically placed through holes and residual slots, followed by forging wedge planes and V-shaped grooves or ridges, with precise positioning and fine-tuning before separation from the belt to achieve the desired dimensions and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sloped surfaces are forged before fine-tuning for desired precision and dimension, then the process can be completed, but the rings cannot be positioned accurately causing damage during fine-tuning and reducing yield
Solution Approach 1:
The patent applies preliminary action by first forming the hexagonal shape and positioning features (guiding holes and residual slots) before forging the sloped surfaces. This ensures that the ring structure is stable and can be accurately positioned during subsequent fine-tuning operations, preventing damage and improving yield.
2Adaptability or versatility
If the conventional multi-step process is used to produce washers with variable thickness, then variable thickness can be achieved, but the process becomes too complicated and costly
Solution Approach 1:
The patent segments the washer production process into distinct functional zones: guiding holes for positioning, residual slots for material removal and thickness control, and forged regions for structural formation. This segmentation allows variable thickness to be achieved through a simplified process where each zone performs a specific function, reducing overall process complexity.
Solution Approach 2:
The through holes serve multiple functions: they guide the positioning of the ring during forging, define the inner diameter, and serve as reference points for forming the residual slots. This multi-functionality reduces the number of separate operations needed, simplifying the process while maintaining variable thickness capability.
3Ease of operation
If each ring is supported by four legs connected to the smallest thickness locations, then the ring can be supported during processing, but residuals cannot be dispersed easily and accumulated residuals deform the ring
Solution Approach 1:
The patent extracts the problematic support structure (four legs at thin sections) and replaces it with a support system based on residual slots positioned at the hexagonal corners. The residual slots are specifically designed to disperse material accumulation, preventing deformation while providing stable support during processing.
4Productivity
If hexagonal washers with wedge planes, V-shaped grooves, and ridges are produced using conventional circular washer methods, then production can proceed, but the methods are not appropriate for hexagonal geometry
Solution Approach 1:
The patent applies asymmetry by designing the mold cavity and forging process specifically for hexagonal geometry rather than adapting circular washer methods. The six wedge planes are forged around the bottom surface, and V-shaped grooves or ridges are formed on the top surface, with all features positioned according to hexagonal symmetry rather than circular patterns, ensuring geometric accuracy.
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 simplifies the process, reduces mold investment, improves yield by precise positioning, and minimizes deformation by supporting the washer at less prone locations, resulting in accurately formed hexagonal washers with enhanced precision and reduced costs.
Implementation Method 1
at least two through holes are provided in the middle of a belt of material which are also used for positioning and advancing the belt
Implementation Method 2
six wedge planes are forged around the bottom surface of each ring
Implementation Method 3
six wedge planes are forged around the bottom surface of each ring
Implementation Method 4
at least a V-shaped groove or a ridge is forged on the top surface of each ring
Implementation Method 5
at least a V-shaped groove or a ridge is forged on the top surface of each ring
Data Source
AI summary
Hexagonal washers are formed by the following steps: at least two through holes are provided in the middle of a belt of material, which are also used for positioning and advancing the belt; a first residual slot is formed between every two adjacent through holes; a second residual slot and a third residual slot are formed at the two sides of every first residual slot, thereby forming a hexagonal ring around each through hole; six wedge planes are forged around the bottom surface of each ring, and at least a V-shaped groove or a ridge is forged on the top surface of each ring; a larger through hole as the inner hole of a washer is produced at the center of each ring; the major shape of each washers is then formed without separating the washers from the belt; and the washers are fine-tuned to obtain the precise form factor and dimension before they separated from the belt.