Impact Head Geometry for Uniform High-Velocity Metal Forming
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Solution Overview
Problem
High velocity forming (HVF) processes face challenges in controlling energy distribution to work materials, leading to potential tool deformation, rebound issues, and reduced product quality, along with a risk of the plunger striking the tool multiple times, which can result in weakened or uneven products and apparatus fatigue.
Innovation Solution
The method involves using an impact head with a larger base region compared to the impact end, positioned closer to the tool, to distribute kinetic energy directly and evenly across the tool's working surface, and incorporating damping elements to control movement and prevent multiple strikes, thereby reducing tool deformation and apparatus wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a plunger is used to drive the tool at high velocity in HVF, then high kinetic energy is transferred to the work material, but the plunger may strike the tool multiple times causing product defects and apparatus wear
Solution Approach 1:
A tool rest is introduced as an intermediary component between the plunger and the tool. The tool rest supports the tool during the forming operation, ensuring that the tool maintains proper positioning and does not rebound to strike the plunger again. This mediator prevents multiple strikes while allowing the high kinetic energy transfer needed for HVF.
Solution Approach 2:
The tool rest is positioned to preemptively counteract any potential rebound movement of the tool before it can strike the plunger again. By providing continuous support during the stroke, the system prevents the harmful multiple-strike condition from occurring in the first place.
2Strength
If the tool is made with high stiffness to withstand the strike from the plunger, then tool deformation is reduced, but the tool mass increases requiring higher plunger capacity
Solution Approach 1:
The tool rest provides supportive cushioning to the tool during the impact event. This external support structure shares the load with the tool, allowing the tool itself to be lighter while still withstanding the plunger strike without excessive deformation. The tool rest absorbs some of the impact forces that would otherwise require the tool to be more massive.
3Manufacturing precision
If high kinetic energy is applied to the work material in a very short time, then complex shapes can be formed with close tolerances, but excessive deformation in the tool may occur
Solution Approach 1:
The tool rest acts as a mediator that stabilizes the tool during the high-energy impact. It provides additional support that prevents excessive tool deformation while allowing the high kinetic energy to be transferred to the work material for achieving close tolerances and complex shapes.
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 the quality of formed products by ensuring uniform energy distribution, reducing the risk of tool deformation and rebound, and extending the lifespan of apparatus components by preventing multiple strikes between the plunger and tool.
Implementation Method 1
The impact head (4'') is arranged so as for kinetic energy from a strike by the plunger (2) on the impact head to be distributed directly and evenly over a working surface of the tool (4'), so as to form a work material (W)
Implementation Method 2
a first dampening element (32') arranged between the tool housing (34) and a surface of the impact head and tool combination (4) facing away from the work material (W), and a second dampening element (32'') arranged between the tool housing (34) and a surface of the impact head and tool combination (4) facing towards the work material (W)
Data Source
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AI summary
The invention involves a method of material forming, by means of a movable tool (4) and a drive unit, the method comprising moving the drive unit to provide kinetic energy to the tool (4), for the tool (4) to strike a work material (W), so as to form the work material (W), the method comprising providing an impact head (4'') between the drive unit and the movable tool (4'), and providing the kinetic energy to the tool (4') by the drive unit striking the impact head (4"), the impact head (4") extending in the direction of the stroke from an impact end (46) to a base region (48), where the base region (48) is closer to the tool than the impact end (46), the method comprising arranging the impact head (4") so that the impact end (46) has laterally, in relation to the direction of the stroke, a smaller extension than the base region (48). A corresponding apparatus is also defined.