Hydraulic Copper Ball Forming with Integrated Cutting and Extrusion
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Solution Overview
Problem
Current mechanical methods for producing phosphor copper balls, such as rolling and mechanical press forming, result in low-quality products with poor compactness and brightness, high labor costs, equipment vibration, and maintenance issues, leading to unstable quality and reduced yield.
Innovation Solution
A hydraulic forming machine that integrates cutting, extrusion, and ejection functions, using a movable and fixed die system driven by a hydraulic mechanism to directly form copper balls, improving tool life and reducing maintenance and labor costs while minimizing noise and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical rolling is used to produce copper balls, then production can be continuous, but the product quality is poor with coarse grain structure and low compactness
Solution Approach 1:
The patent replaces the mechanical rolling system with a hydraulic extrusion system. The hydraulic system uses liquid pressure to extrude copper blanks through a die, eliminating the mechanical rolling process that produced coarse grain structures and poor compactness while maintaining continuous production capability.
Solution Approach 2:
The patent changes the fundamental forming parameter from mechanical rolling force to hydraulic extrusion pressure. By using hydraulic pressure to progressively extrude the copper blank through a die, the material flows more uniformly, producing fine grain structures and high compactness while maintaining continuous production.
2Force
If mechanical press forming is used, then forming force is limited, but the equipment structure becomes complex with high maintenance cost
Solution Approach 1:
The patent uses a hydraulic press system where liquid pressure is transmitted through hydraulic oil to generate large forming forces. The hydraulic system provides smooth, continuous force application without the complex mechanical linkages, gears, and linkages required in mechanical press systems, thereby reducing structural complexity and maintenance requirements.
3Power
If mechanical transmission is used in press forming, then power transmission is achieved, but mechanical wear is serious and spare parts cost is high
Solution Approach 1:
The patent replaces mechanical transmission components (gears, belts, linkages) with a hydraulic transmission system. Power is transmitted through hydraulic oil pressure to the extrusion die, eliminating mechanical contact and friction between moving parts, thereby preventing mechanical wear and reducing spare parts requirements.
4Productivity
If mechanical press forming equipment is used, then copper balls can be formed, but the equipment produces large vibration and noise
Solution Approach 1:
The patent uses hydraulic extrusion to form copper balls, where liquid pressure smoothly deforms the copper blank without the impact and vibration inherent in mechanical pressing. The hydraulic system provides controlled, gradual force application that eliminates the harmful vibrations and noise generated by mechanical press forming equipment.
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 hydraulic forming machine enhances product quality and yield, extends tool life, reduces maintenance and labor costs, and operates with improved reliability and environmental safety, achieving over 99% yield rate compared to traditional methods.
Implementation Method 1
A hydraulic forming machine, including a body, a cutting mechanism, a forming die, an ejector and a driving mechanism
Implementation Method 2
The extruded product falls to the receiving device by gravity and is collected by the receiving device
Data Source
AI summary
A hydraulic forming machine, including a body provided with a feed inlet penetrating a first mounting surface, a cutting mechanism, a forming die, an ejector arranged on the forming die, and a driving mechanism. The forming die includes a movable die and a fixed die matched with each other. The cutting mechanism and the fixed die are provided on the first mounting surface of the body and respectively at two sides of the discharge end of the feed inlet. The movable die is arranged on the driving mechanism and driven by the driving mechanism to move close to or away from the fixed die in a direction perpendicular to the first mounting surface. The cutting mechanism is configured to cut a blank at an output end of the conveying inlet. The blank cut by the cutting mechanism is extruded between the fixed die and the movable die.