Layered Forging Die Assembly for Faster Cavity Manufacturing
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Solution Overview
Problem
The existing forging die manufacturing process is time-consuming and costly due to the difficulty in cutting and sourcing expensive tool steel, leading to high storage and maintenance costs, as well as the need for multiple dies to produce a single part.
Innovation Solution
Forging dies are assembled from individual layers rather than solid blocks, allowing for faster production and reduced costs by using a first and second die half with layers cut to form sections of the die cavity, which are then stacked and fastened together, enabling easier maintenance and disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If forging dies are made by removing material from a solid block of tool steel, then the die cavity can be formed to shape parts, but the manufacturing process becomes slow and time-consuming
Solution Approach 1:
The forging die is divided into multiple separate layers that are stacked together to form the complete die cavity. Each layer can be manufactured independently and then assembled, eliminating the need to remove material from a solid block. This segmentation allows for faster manufacturing while maintaining the required die cavity precision.
Solution Approach 2:
The invention transitions from a three-dimensional solid block approach to a multi-layered stacked structure. By distributing the die cavity formation across multiple two-dimensional layers that are stacked in sequence, the manufacturing process becomes more efficient while achieving the same functional result.
2Strength
If expensive grade tool steel is used to make forging dies, then desirable mechanical properties are achieved, but material costs and sourcing difficulty increase
Solution Approach 1:
Different layers of the forging die can be made from different materials with different properties. This allows each layer to be optimized for its specific function, using expensive high-strength materials only where necessary and cheaper materials elsewhere, thereby reducing overall material costs while maintaining required mechanical properties.
Solution Approach 2:
The forging die is constructed as a composite structure with multiple layers that can be made from different materials. This composite approach allows optimization of each layer's material selection based on local requirements, reducing the need for uniformly expensive tool steel throughout the entire die structure.
3Stability of the object's composition
If forging dies are made from solid blocks, then structural integrity is maintained, but storage and maintenance costs increase due to refurbishment needs
Solution Approach 1:
The forging die is segmented into multiple replaceable layers. When wear or damage occurs, only the affected layer needs to be removed and replaced, rather than refurbishing or replacing the entire solid block die. This maintains structural integrity while significantly reducing maintenance time and cost.
Solution Approach 2:
Worn or damaged layers can be discarded and replaced with new layers, while the remaining intact layers are retained and reused. This selective replacement approach reduces maintenance costs and waste compared to refurbishing or replacing the entire die structure.
4Shape
If multiple different forging dies are used to produce a finished part, then complex part geometries can be achieved, but costs and manufacturing time increase
Solution Approach 1:
The forging die is segmented into multiple layers that can be selectively configured to produce different part geometries. By rearranging or selecting different layer combinations, a single die structure can produce multiple part variations, eliminating the need for multiple separate forging dies and improving manufacturing efficiency.
Solution Approach 2:
The multi-layer die structure is designed to be universal and adaptable, capable of producing different part geometries by reconfiguring the layers. This multi-functionality allows a single die assembly to replace multiple specialized dies, reducing costs and manufacturing time for complex parts.
Data Source
AI summary
Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.