Hydraulic Press Die Alignment for Accurate Symmetric Pressing
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Solution Overview
Problem
In pressing processes using a press machine, elastic deformation of dies and frames leads to reduced processing accuracy and increased energy loss due to relative inclination between the dies, necessitating methods to improve accuracy and minimize energy consumption.
Innovation Solution
A pressing method utilizing a hydraulic cylinder to align dies symmetrically around a workpiece center axis, with a frame and dies designed for rotational symmetry, and a radial direction positioning process to minimize inclination and energy loss, employing a link mechanism or laser displacement sensors for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressing is performed using a conventional press machine with dies and frame, then the workpiece can be processed, but elastic deformation occurs in the dies and frame due to processing reaction, causing relative inclination between dies and reducing processing accuracy
Solution Approach 1:
The invention applies asymmetry principle by intentionally designing the frame structure with different stiffness characteristics in different directions. The frame is made asymmetric in terms of structural reinforcement, with additional bracing and support elements positioned to compensate for the elastic deformation and relative inclination that occur during pressing operations, thereby maintaining die alignment accuracy.
Solution Approach 2:
The invention changes physical parameters of the frame and die structure, specifically increasing the thickness and stiffness of frame members, adding reinforcement ribs, and modifying material properties to reduce elastic deformation. These parameter changes allow the frame to maintain its geometric stability under pressing loads, preventing relative inclination between dies.
2Productivity
If the second die and first die are brought close together using conventional pressing methods, then pressing can be performed, but a large force is required and energy loss increases due to relative inclination
Solution Approach 1:
The asymmetric frame design directs structural reinforcement to areas experiencing maximum stress and deformation, creating an optimized load path that reduces the overall force required for pressing. This asymmetric reinforcement pattern minimizes energy loss by preventing relative inclination that would otherwise require additional force to overcome.
Solution Approach 2:
The invention converts the harmful effect of elastic deformation into a beneficial outcome by designing the frame to anticipate and compensate for the deformation pattern. The frame structure is pre-configured with asymmetric reinforcement that transforms the potential energy loss from deformation into maintained alignment, reducing the additional force needed to correct inclination during pressing.
3Manufacturing precision
If the frame and dies are designed with high stiffness to prevent elastic deformation, then processing accuracy can be maintained, but the complexity and cost of manufacturing increases
Solution Approach 1:
Instead of uniformly increasing the stiffness of the entire frame structure, the invention applies asymmetric reinforcement only in specific critical areas where elastic deformation and relative inclination occur. This targeted approach maintains processing accuracy while avoiding the unnecessary complexity and cost of reinforcing the entire frame structure uniformly.
Solution Approach 2:
The frame structure is designed with local quality variations, where specific regions receive enhanced reinforcement (thicker members, added bracing) precisely where needed to prevent deformation, while other regions maintain their original simpler design. This localized approach to increasing stiffness reduces overall manufacturing complexity compared to a uniformly reinforced frame.
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 approach enhances processing accuracy while minimizing energy loss by ensuring precise alignment and reducing elastic deformation-induced errors during pressing operations.
Implementation Method 1
a hydraulic cylinder configured to generate a force in a direction in which the second die approaches the first die
Data Source
AI summary
A method of performing pressing on a workpiece using a press machine. The pressing method includes: performing pressing on the workpiece between a lower die and an upper die by causing the upper die to approach the lower die by using the hydraulic cylinder in a state in which the workpiece is disposed between the lower die and the upper die, and performing the pressing on the workpiece between the lower die and the upper die, in a state in which a shape of each of the frame, the lower die and the upper die has a rotationally symmetric shape about the reference axis and in which the workpiece center axis coincides with the reference axis.