Impact Head Damping in High-Velocity Material Forming
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Solution Overview
Problem
High velocity forming (HVF) processes face challenges in controlling energy delivery to work materials, leading to potential rebound issues and reduced product quality, along with increased wear on apparatus components.
Innovation Solution
A method and apparatus for material forming using a movable impact head and tool combination, where kinetic energy is provided by a drive unit, and the return movement of the impact head and tool combination is dampened to prevent rebound and improve control over the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a plunger is driven by hydraulic pressure to transfer high kinetic energy to a tool, then the tool can strike the workpiece with sufficient force, but the tool may be struck more than one time due to rebound, causing impaired product properties
Solution Approach 1:
A resilient element (spring) is arranged between the tool and tool housing to provide beforehand cushioning. When the tool strikes the workpiece and rebounds, the spring absorbs the rebound energy and prevents the tool from striking the workpiece a second time, thus avoiding impaired product properties while maintaining sufficient forming force
2Strength
If the tool possesses high stiffness to avoid excessive deformation at strike, then the tool can withstand the impact force, but the tool mass increases, requiring higher capacity drive system
Solution Approach 1:
The resilient element provides beforehand cushioning that allows the tool to have high stiffness for withstanding impact forces while the spring absorbs excess energy, preventing the need for increased tool mass to handle rebound conditions
3Reliability
If damping element is arranged between impact head and drive unit, then rebound is prevented and energy control is improved, but the apparatus complexity increases
Solution Approach 1:
A damping element is introduced as an intermediary component between the impact head and drive unit. This mediator absorbs and controls rebound energy, improving energy control and preventing multiple strikes, while being integrated into the existing apparatus structure to minimize complexity increase
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 method and apparatus effectively prevent rebound and improve energy control, resulting in higher quality products with tighter tolerances and extended apparatus lifespan by reducing unnecessary deformation and wear.
Implementation Method 1
moving the drive unit to provide kinetic energy to the impact head and tool combination, for the impact head and tool combination to strike a work material
Implementation Method 2
a return movement of the movable impact head and tool combination, away from the work material, after the strike of the work material by the impact head and tool combination, is dampened
Implementation Method 3
The dampening arrangement may comprise a first dampening element arranged between a surface of the impact head and tool combination, facing away from the work material, and a component of the apparatus
Data Source
AI summary
A method for material forming uses a movable tool and a drive unit the method including moving the drive unit to provide kinetic energy to the tool, for the tool to strike a work material, so as to form the work material the method including providing an impact head between the drive unit and the movable tool, and providing the kinetic energy to the tool by the drive unit striking the impact head, the impact head (extending in the direction of the stroke from an impact end to a base region, where the base region is closer to the tool than the impact end. The method includes arranging the impact head so that the impact end has laterally, in relation to the direction of the stroke, a smaller extension than the base region.