Housing Ring Cold Forming Process
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Solution Overview
Problem
Existing methods for producing ring-shaped casings require mechanical processing, which complicates handling and manufacturing, and lack a streamlined, economical approach for producing a housing ring.
Innovation Solution
A method involving cold forming processes such as shearing, flat upsetting, combined cup extrusion, punching, hollow reverse pressing, and forming a circumferential annular groove on a multi-stage transverse transport press, eliminating the need for mechanical processing and utilizing a wire bundle as the starting material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical processing (turning, milling, drilling) is used to produce ring-shaped housings, then manufacturing precision and structural integrity are improved, but device complexity and handling difficulty increase
Solution Approach 1:
The patent changes the fundamental processing parameter from mechanical removal (machining) to plastic deformation (cold forming). The wire bundle is progressively deformed through rolling, forging, and drawing operations to achieve the final housing ring geometry, eliminating the need for complex machining operations while maintaining dimensional accuracy and structural integrity.
Solution Approach 2:
The patent replaces the mechanical cutting and removal system (turning, milling, drilling) with a plastic deformation system. Instead of removing material to create the housing ring shape, the wire bundle is plastically deformed into the desired geometry through controlled forming operations, simplifying the overall manufacturing system.
2Manufacturing precision
If multiple processing steps including mechanical work are used, then housing ring quality is improved, but productivity decreases and production time increases
Solution Approach 1:
The patent combines multiple discrete operations into an integrated cold forming process sequence. The wire bundle undergoes rolling, forging, cutting, and drawing operations in a coordinated manner to produce the finished housing ring in one continuous process flow, eliminating the need for separate machining operations and intermediate handling steps.
Solution Approach 2:
The patent performs preliminary shaping operations on the wire bundle before final cutting. The wire is first rolled into a coil, then forged and pre-shaped, and only after these preliminary forming operations is the housing ring cut to final dimensions. This sequence allows the bulk of the shaping to be done efficiently through forming rather than subsequent machining.
3Ease of manufacture
If wire bundle as starting material is used, then procurement and warehousing are simplified, but additional cold forming steps are required
Solution Approach 1:
The wire bundle serves multiple functions in the process: it is the raw material stock, the forming medium, and the precursor to the final product. The same wire bundle undergoes rolling to form coils, forging to create density, and cutting to produce individual housing rings, eliminating the need for separate preparation of different material forms.
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
Enables the efficient and cost-effective production of a housing ring in a single operation, simplifying procurement, warehousing, and processing by exclusively using cold forming techniques, resulting in a finished product without mechanical post-processing.
Implementation Method 1
exclusively by cold forming
Implementation Method 2
The starting point for carrying out the method is a blank 1. This blank 1 is produced by cutting off a wire section from a wire that is wound into a bundle
Implementation Method 3
The blank 1 is then flat-upset in a method step of setting, namely to form flat blank end faces 3 and 4
Implementation Method 4
In a next process step, the intermediate product 5 is then subjected to combined cup extrusion, as a result of which cup-shaped recesses 6 and 7 are made in the end faces 3 and 4
Data Source
Figure 1
Figure 2
AI summary
The method involves separating blank (1) from a bundle of wire by scissors, planar dipping of the blank front faces (3,4) by setting. The method involves combining cup impact extrusion, punching, hollow backward pressing, forming a circumferential ring groove (12) by tossing and reducing rolling edges. The wire is a steel wire.