M-Type Holder Flange Forming Sagging Suppression
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Solution Overview
Problem
Existing methods for producing M-type holders face challenges such as sagging in bent parts, requiring complex split molds or short-lived elastic bodies with low productivity, and insufficient pressure application in bulge forming.
Innovation Solution
A method involving a receiving member and die setup where the outer peripheral surface of the working target article is restrained, allowing a pressing member to apply outward pressure to form flange portions without thinning, thereby preventing sagging and enhancing strength by increasing the thickness of bent parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the amount of compression by the upper punch is increased to suppress sagging, then sagging is reduced, but the working target article deforms due to insufficient restraint of the smaller-diameter portion
Solution Approach 1:
The mold is divided into multiple segments: a periphery restraining mold for external constraint, and an inner peripheral surface restraining mold that fits inside the smaller-diameter portion for internal constraint. This segmentation allows independent optimization of restraint mechanisms at different locations, preventing both sagging and unwanted deformation simultaneously.
Solution Approach 2:
The inner peripheral surface restraining mold is nested inside the working target article within the smaller-diameter portion, while the periphery restraining mold constrains from the outside. This nested configuration enables dual restraint without requiring the molds to interfere with each other, solving the contradiction between compression force and structural stability.
2Manufacturing precision
If a split mold is used to restrain the inside of the working target article, then sagging is suppressed, but the mold structure becomes more complicated
Solution Approach 1:
The restraining function is segmented between two simple molds: the periphery restraining mold and the inner peripheral surface restraining mold. Each mold has a straightforward structure performing a specific restraint function, avoiding the complexity of a single complex split mold while achieving superior sagging suppression through coordinated action.
3Manufacturing precision
If the working target article is thinned to enhance bending formability, then sagging is prevented, but the strength of the flange portion is reduced
Solution Approach 1:
The inner peripheral surface restraining mold applies preliminary counter-action by fitting inside the smaller-diameter portion and preventing inward collapse during bending. This preliminary support eliminates the need to thin the material for formability, allowing the flange portion to maintain full thickness and strength while still achieving proper bend formation.
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 effectively suppresses sagging in flange portions without using split molds or bulge forming, improving productivity and strength by forming thicker bent parts, suitable for small holders and various press forming applications.
Implementation Method 1
receiving an inner peripheral surface of at least a smaller-diameter portion of a working target article by an outer peripheral surface of a receiving member inserted into the working target article
Implementation Method 2
pressing, in the receiving state, an end portion of the working target article by a pressing member for flange portion formation; and forming the flange portion while a peripheral surface portion of a convex portion formed in the pressing member receives the end portion and applies an outward pressure to the end portion
Data Source
AI summary
A method for producing a holder in which sagging is suppressed in a bent part to be formed into a flange portion, without using bulge forming and a split mold that restrains the inside of a working target article; and a holder. An upper punch presses and bends one end portion of a working target article inward, whereby a flange portion is formed in the one end portion. A smaller-diameter portion of the working target article is restrained from the inside and outside by a lower punch and split mold portions. Then, a peripheral surface portion of a convex portion of the upper punch receives the end portion of the working target article and applies an outward pressure to the end portion. A bent part is pushed toward a larger-diameter portion restraining part of a split die, so that sagging is prevented from occurring in the bent part.