Multi-Axis Hose Fitting Cold Forging with Part Rotation
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Solution Overview
Problem
Current multi-station cold-forging machines are limited in versatility due to the number of stations, hindering the efficient production of complex metal parts with features on multiple axes, leading to increased material and labor costs, and the need for secondary machining operations.
Innovation Solution
A progressive forming machine with an increased number of stations, including a part rotator and gas spring biased die systems, forms a banjo-style brake hose fitting with features on multiple axes, allowing for secure alignment and reducing secondary machining needs by forming a counterbored connector body with an integral alignment tang.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of stations in a progressive cold-forging machine is increased to produce complex parts with multiple features on different axes, then the versatility and capability to produce complex parts is improved, but the device complexity and machine cost increase
Solution Approach 1:
The complex part formation process is divided into multiple sequential stations, each performing a specific forming operation. The part is progressively shaped through discrete stages including initial forming, intermediate shaping, and final feature creation, allowing complex geometries to be achieved through systematic breakdown of the forming process into manageable segments across multiple stations
Solution Approach 2:
The patent introduces rotational movement between stations to enable feature formation on multiple axes. The part is rotated between forming stations, allowing punches and dies to create features not only on the primary axis but also on perpendicular axes, thereby achieving complex multi-axial geometries that would be impossible with linear single-axis forming
2Productivity
If traditional multi-station machines are used with limited stations, then the device complexity is reduced, but the productivity and capability to produce near-net-shape parts deteriorate
Solution Approach 1:
The machine performs preliminary forming operations at earlier stations that prepare the workpiece for subsequent operations. Intermediate features are pre-formed and positioned before final shaping operations, allowing the part to approach its final near-net-shape geometry through progressive refinement rather than requiring all features to be created in single complex operations
Solution Approach 2:
The progressive forming process maintains continuous useful action by ensuring that each station contributes to the final part geometry without idle transitions. The workpiece moves continuously through the station sequence with each station performing a productive forming operation, minimizing non-value-added time and maximizing material utilization to achieve near-net-shape efficiency
3Adaptability or versatility
If complex parts are formed with features on multiple axes, then the adaptability and part functionality are improved, but the manufacturing precision and alignment of features deteriorate
Solution Approach 1:
The system employs dynamic positioning and rotation mechanisms that adjust the workpiece orientation between stations. The part is rotated to precise angular positions between forming operations, and the machine maintains dynamic control of part orientation to ensure accurate alignment of features formed on different axes, compensating for potential misalignment through active positioning control
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
The solution enables the production of complex metal parts with multiple features on perpendicular axes, reducing material costs and labor, and producing a brake hose fitting ready for assembly with minimal secondary machining, except for drilling a fluid passage.
Implementation Method 1
progressive cold-forming or forging machine
Implementation Method 2
the metal blank is at or near the volume of the finished part, sometimes referred to as net shape or near net shape
Implementation Method 3
gas spring biased die systems
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A machine, tooling and method for cold forming complex metal parts such as a banjo style hose fitting (10) starting with a near net shape volume of wire and continuing with multiple forging blows and an intermediate rotation of the blank to produce a hose coupling shell end (86), a transition neck (87), a large counterbored annular coupling body (88) and a perpendicular alignment tang (68).