Lateral Extrusion of Thin-Walled Preforms Preventing Wall Buckling
Solution Overview
Problem
Existing methods for producing mechanical components, such as gearwheels, using lateral extrusion face limitations due to the risk of buckling in thin-walled preforms with large height-to-thickness ratios, restricting the size and geometry of the components that can be produced.
Innovation Solution
The method involves supporting the wall regions of the preform with support bodies during the forming process to prevent buckling, allowing for the production of components with varying wall thicknesses and larger structures by using a tool with a die cavity that can accommodate the preform's height without additional wall construction, enabling the formation of structures with increased wall thickness and complex geometries like gearwheel teeth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a thin-walled hollow body with large height-to-thickness ratio is used as preform, then the volume of material available for forming increases, but the risk of buckling during lateral extrusion increases
Solution Approach 1:
The preform is preliminarily formed with a controlled height-to-thickness ratio (x/t1 ≤ 2.3) before the lateral extrusion process. This preliminary dimensional control prevents buckling during subsequent forming operations while still providing sufficient material volume for creating complex component geometries and structures.
2Volume of moving object
If the height of the preform is increased to provide more material volume, then larger structures can be formed, but the wall thickness must be increased proportionally to avoid buckling
Solution Approach 1:
The invention changes the critical parameter from wall thickness to height-to-thickness ratio control. By maintaining x/t1 ≤ 2.3 rather than simply increasing wall thickness, the process enables formation of larger structures with varied wall thicknesses through material flow into die cavities, achieving both large volume and structural complexity without proportional wall thickness increases.
3Ease of manufacture
If conventional lateral extrusion is used on thin-walled preforms, then the manufacturing process is simple, but the dimension of the structure to be filled is extremely limited
Solution Approach 1:
The forming process is segmented into controlled stages using multiple die cavities positioned at different locations and depths. Material flows sequentially into different cavity segments, enabling formation of complex multi-dimensional structures while maintaining process simplicity through systematic arrangement of forming zones.
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 allows for the production of components with increased wall thickness and complex geometries without buckling, enabling the formation of larger structures and more versatile gearwheel shapes, such as elliptical or eccentric designs, while maintaining the stability of the forming process.
Implementation Method 1
support bodies (42, 44) to support (38) the wall regions (5) of the preform (2) to be formed
Implementation Method 2
a component is compressed along a first spatial direction by the application of considerable compressive forces
Implementation Method 3
the material flows into cavities which are provided by a tool transverse to the first spatial direction
Data Source
AI summary
The invention relates to a component, a method, and a tool for forming, in particular for the lateral extrusion or upsetting of thin-walled preforms to form components having a structure formed thereon, in particular having a toothing, wherein, by carrying out the method according to the invention and by using the tool according to the invention, buckling of the wall of the preform during the forming process to form the component according to the invention is prevented.