Holding Mandrels for Percussive Forming Without Clamp Ends
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Solution Overview
Problem
Existing methods for forming workpieces in impact forming machines, such as forging hammers or presses, require significant material and energy consumption due to the use of gripping devices like manipulators or industrial robots, which account for up to 10% of the material used and incur high energy costs.
Innovation Solution
A method involving holding mandrels that clamp a workpiece between two mandrels, allowing them to move relative to each other and decouple from impact forces, eliminating the need for clamp ends and reducing material and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gripping devices like manipulators or industrial robots are used to hold workpieces, then the workpiece can be securely controlled and positioned, but material consumption increases by up to 10% and energy consumption increases
Solution Approach 1:
The invention extracts the gripping function from the workpiece material itself by introducing separate holding mandrels. The mandrels are inserted into bearing points on the workpiece, separating the holding function from the workpiece material, thereby eliminating the need for additional clamp ends and reducing material consumption by up to 10%.
Solution Approach 2:
The holding mandrels serve as intermediary elements between the gripping device and the workpiece. These mandrels transmit the holding force while allowing the workpiece to maintain its original material composition, eliminating the need to incorporate gripping features directly into the workpiece design.
2Reliability
If gripping devices are used to hold workpieces during forming, then the workpiece can be securely positioned, but energy consumption increases due to heating and processing of additional material
Solution Approach 1:
The gripping function is extracted from the workpiece material and assigned to separate holding mandrels. This eliminates the need to heat and process additional clamp end material, directly reducing energy consumption associated with material heating and formation.
Solution Approach 2:
The holding mandrels are designed to be inserted into bearing points that are part of the workpiece's original structure. The workpiece's bearing points serve the dual purpose of structural integrity and gripping interface, eliminating the need for additional energy-intensive processing of separate gripping features.
3Manufacturing precision
If holding mandrels are positioned between the die tools, then material utilization is optimized and burrs are minimized, but the mandrels must withstand high impact forces during forming
Solution Approach 1:
The holding mandrels act as intermediary elements positioned between the die tools and the workpiece. This positioning allows precise control of the workpiece during forming, optimizing material utilization and minimizing burrs, while the mandrels themselves are designed to withstand the resulting impact forces.
Solution Approach 2:
The mandrels are designed with sufficient strength and structural characteristics to beforehand withstand the high impact forces that occur during the forming process. This pre-engineering of the mandrels ensures they can handle the forces generated when positioned optimally between the die tools.
4Stability of the object's composition
If the holding mandrels are fixed in position, then the holding device remains spatially fixed, but the mandrels may be destroyed during the forming process due to impact forces
Solution Approach 1:
The holding mandrels are designed with dynamic characteristics that allow them to absorb and withstand impact forces during the forming process. The mandrels can experience controlled movement or deformation to dissipate impact energy while maintaining their holding function, preventing destruction despite fixed spatial positioning of the holding device.
Solution Approach 2:
The mandrels are pre-engineered with sufficient strength and impact resistance to beforehand withstand the high forces generated during forming. This pre-cushioning through proper material selection and structural design ensures the mandrels survive the forming process while maintaining spatial fixation of the holding device.
Data Source
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AI summary
The invention relates to a method for forming a heated workpiece (1) in a percussive forming machine, comprising the following steps: a) picking up and clamping the workpiece (1) between two holding mandrels (3) which are held by at least one handling device (6), b) introducing the workpiece (1) in the held state into a working area of a percussive forming machine between two forming die tools (24, 25) of a die (23), c) maintaining the clamped state during a forming step in which the die tools (24, 25) are moved relative to one another and the workpiece (1) is formed between the die tools (24, 25).