Horizontal Tube Forging to Eliminate Deep Machining
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Solution Overview
Problem
The traditional hot forging process in vertical press using solid steel rods requires time-consuming and costly deep machining operations to produce parts, resulting in inferior quality products.
Innovation Solution
A hot steel forging process in horizontal press using a cylindrical steel tube as raw material, involving partial heating and multiple deformations to achieve the desired geometry, followed by deburring and controlled cooling, significantly reducing subsequent machining needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hot forging in vertical press using solid steel rod is used, then the part can be obtained with traditional process, but deep machining operation is required which is time-consuming and expensive
Solution Approach 1:
The invention changes the raw material form from solid steel rod to hollow steel tube, and changes the forging direction from vertical to horizontal. This parameter change allows the forging process to directly achieve the desired geometry without requiring subsequent deep machining operations, thereby reducing both machining time and cost while maintaining manufacturing precision.
Solution Approach 2:
Instead of using a solid rod and machining away material to achieve the hollow geometry, the invention inverts the approach by starting with a hollow tube and forging it horizontally to achieve the final shape. This inversion eliminates the need for time-consuming deep machining operations while producing the same or better quality parts.
2Ease of manufacture
If hot forging in vertical press using solid steel rod is used, then the part can be obtained, but the process is expensive and produces inferior quality products
Solution Approach 1:
By changing the raw material from solid rod to hollow tube and the forging direction from vertical to horizontal, the process achieves better manufacturing precision directly during forging. The horizontal forging process distributes material more uniformly and maintains structural integrity, eliminating the need for costly machining operations that compromise quality.
Solution Approach 2:
The hollow tube geometry is prepared in advance as the raw material, which is then directly forged into the final shape through horizontal pressing. This preliminary preparation of the hollow structure eliminates the need for subsequent machining operations, reducing both cost and improving quality by avoiding the defects associated with deep machining.
3Loss of substance
If tube is used as raw material with diameter 1.5-2.5 times the final part, then material consumption is reduced, but the process requires horizontal press which is different from traditional vertical press
Solution Approach 1:
The invention changes the press configuration from traditional vertical to horizontal orientation, and changes the raw material from solid rod to hollow tube with optimized diameter ratio. This allows the tube to be cut to the exact length needed and forged horizontally, minimizing material waste while the horizontal press configuration enables direct forming without additional machining.
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 process results in a cost-effective, faster production of high-quality parts with reduced material consumption and equipment requirements, maintaining mechanical properties equivalent to those from solid rods while being lighter in weight.
Implementation Method 1
a first stage, a tube, preferably a cylindrical steel tube, undergoes a partial heating process done in an electric induction oven
Implementation Method 2
it is subjected to three different deformations (stamping)
Implementation Method 3
the part is cooled in a controlled manner in order to impart the required mechanical properties to the final part
Data Source
AI summary
The present disclosure relates to a steel forging process, in particular a hot steel forging process in horizontal press of a metal tube, preferably a cylindrical steel tube.