Inclined Ring Material Geometry for Dead-Metal-Free Forging
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Solution Overview
Problem
The forging process for manufacturing ring molded articles often results in 'dead metal' regions with reduced mechanical characteristics due to material adherence to molds and uneven temperature distribution, leading to increased excess material and difficulty in forming convex portions.
Innovation Solution
A method where the ring material is supported by outer and inner peripheral sides of the molds, with one half section inclined relative to the center axis by 7-40 degrees, allowing for reduced dead metal regions and improved strain distribution during forging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ring material is forged between two molds with concave portions, then the convex portions of the ring molded article are formed and mechanical strength is improved, but dead metal regions are generated with reduced mechanical characteristics
Solution Approach 1:
The ring material is preliminarily shaped into a ring form with inclined half-section (7-40 degrees) before the forging process. This preliminary shaping ensures that during forging, the material flows more uniformly into the mold cavities, preventing dead metal region formation while still achieving the desired convex portions and high mechanical strength
Solution Approach 2:
The invention changes the geometric parameters of the ring material by creating an inclined half-section at 7-40 degrees. This parameter modification alters the material flow characteristics during forging, enabling complete cavity filling without generating dead metal regions, thus maintaining high mechanical characteristics throughout the article
2Shape
If the ring material is placed inside two molds for forging, then the convex portions are formed, but it becomes difficult to impart strain to the surface region which contacts the mold
Solution Approach 1:
The ring material is designed with an asymmetric inclined half-section (7-40 degrees) rather than a symmetric vertical section. This asymmetry ensures that during forging, the material flows preferentially toward the mold cavities, allowing strain to be imparted to surface regions that would otherwise be protected by mold contact, while still forming the required convex portions
3Productivity
If the ring material is forged between two molds, then the ring molded article is produced, but excess material must be removed by cutting after forging
Solution Approach 1:
The ring material is preliminarily shaped with the correct inclination (7-40 degrees) and dimensions before forging. This preliminary action ensures that the material volume and shape are optimized for the final product, enabling near-net-shape forging that minimizes or eliminates the need for subsequent cutting operations, thereby improving productivity and reducing material loss
Solution Approach 2:
By changing the geometric parameters of the ring material (inclination angle of 7-40 degrees, specific dimensions), the invention enables the material to flow and solidify in a way that closely matches the final product geometry. This parameter optimization achieves near-net-shape forging, eliminating excess material and removing the need for post-forging cutting operations
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 enables the efficient production of ring molded articles with reduced dead metal regions, enhanced mechanical strength, and accurate formation of convex portions, achieving near-net-shape forging.
Implementation Method 1
the ring material being then forged so as to be pressed by the two molds in a direction of a center axis of the ring material
Data Source
AI summary
Various implementations include a ring material used for producing a ring molded article. The ring molded article has two convex portions which respectively protrude on opposite sides of the ring molded article in a direction of a center axis thereof and extend in a direction of a circumference of the ring molded article. A straight line passing through centers of gravity of first and second side regions is inclined by an angle relative to the center axis of the ring material, the first and second side regions are obtained by virtually dividing a one half section of the ring material based on a middle of a maximum height of the ring material in the direction of the center axis of the ring material, and a range of the angle is 7 degrees to 40 degrees.