Layered Forging Die Assembly for Faster Tooling Replacement
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Solution Overview
Problem
The conventional 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 finished parts.
Innovation Solution
Forging dies are assembled from individual layers, which are cut to form sections of the die cavity and stacked together, allowing for faster production and reduced material costs, with the option to replace worn layers rather than entire die halves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If forging dies are made by removing material from a solid block of tool steel, then the die structure is strong and durable, but the manufacturing process is slow and time-consuming
Solution Approach 1:
The die cavity is divided into multiple separate plates, each cut to form a section of the cavity. These plates are then stacked and fastened together to assemble the complete die, eliminating the need to machine the entire cavity from a single solid block and significantly reducing manufacturing time.
Solution Approach 2:
Multiple separately manufactured die plates are combined through stacking and fastening to form a complete die assembly, achieving both rapid manufacturing and structural integrity through the integrated assembly.
2Strength
If expensive tool steel is used to make forging dies, then the die has sufficient strength and durability, but the material cost and sourcing difficulty increase
Solution Approach 1:
Different plates within the die assembly can be made from different materials or grades of steel, allowing critical load-bearing areas to use high-strength tool steel while less critical areas use more economical materials, reducing overall material cost while maintaining necessary durability.
3Strength
If traditional forging dies are used, then the die can be made strong, but storage and maintenance costs are high due to required refurbishment
Solution Approach 1:
The die is segmented into multiple replaceable plates, allowing individual worn plates to be removed and replaced without refurbishing the entire die assembly, significantly reducing maintenance time and costs.
Solution Approach 2:
Worn or damaged die plates can be discarded and replaced with new or refurbished plates, eliminating the need for costly and time-consuming refurbishment of the entire die while maintaining die strength and performance.
4Shape
If multiple different forging dies are used to produce finished parts, then the required part complexity is achieved, but the total cost and time increase
Solution Approach 1:
A single die assembly with multiple configurable plates can perform the functions of multiple traditional dies, as the plates can be arranged and configured to create different cavity shapes, reducing the number of dies needed and improving production efficiency.
Data Source
Figure 1
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AI summary
Forging dies (12) are formed from a plurality of layers (24, 28, 44, 46) 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 (18, 20). 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.