Impact Head Return 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 transferred to the impact head and tool, and the return movement is dampened to prevent rebound and improve control over energy delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If kinetic energy is imparted to a tool in HVF to achieve high velocity forming, then material deformation and forming quality are improved, but the risk of excessive tool deformation and multiple strikes increases
Solution Approach 1:
A tool rest is provided that limits the movement of the tool towards the workpiece. The tool rest acts as a pre-positioned cushion or barrier that prevents the tool from moving beyond a predetermined position, thereby eliminating the risk of multiple strikes while allowing the tool to deliver sufficient kinetic energy for high velocity forming.
2Strength
If a tool with high stiffness is used to prevent excessive deformation during strike, then tool durability is improved, but the system complexity and drive capacity requirements increase
Solution Approach 1:
The system is segmented into distinct functional components: the tool, the tool rest, and the drive unit. The tool rest is separated from both the tool and the workpiece, creating an independent element that limits tool movement. This segmentation allows each component to be optimized independently, reducing the need for excessively stiff tools and simplifying the overall drive system requirements.
3Manufacturing precision
If the plunger is designed to strike the tool only once, then product quality is improved, but control over energy delivery and rebound prevention becomes more difficult
Solution Approach 1:
The tool rest provides a mechanical feedback mechanism by physically limiting the tool's movement. When the tool approaches the predetermined position, the tool rest exerts a counteracting force that prevents further movement, thereby controlling the strike sequence and preventing rebound without requiring complex control systems.
4Weight of moving object
If lighter tools are used in HVF to reduce system mass, then energy efficiency is improved, but the risk of tool deformation and multiple strikes increases
Solution Approach 1:
The tool rest serves as a pre-positioned protective barrier that compensates for the reduced mass and stiffness of lighter tools. By limiting the tool's movement beforehand, the tool rest ensures that even lighter tools cannot cause multiple strikes or excessive deformation, thereby maintaining reliability while allowing the use of lighter, more energy-efficient tools.
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 the quality of formed parts by ensuring controlled energy delivery and reducing wear on apparatus components, thereby enhancing the overall efficiency and precision of high velocity forming processes.
Implementation Method 1
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
Data Source
AI summary
A method for material forming, by means of a movable impact head and tool combination and a drive unit, the method including 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, so as to form the work material. 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.