Linear Molding Element for Rotationally Symmetrical Metal Components
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Solution Overview
Problem
Existing methods for producing rotationally symmetrical metal components, such as axle or pivot pins, face challenges in achieving high accuracy and reducing process times, especially with complex geometries, due to the limitations of pressure rollers in flow-forming processes.
Innovation Solution
The use of linear molding elements with unrolled contours that are moved tangentially and synchronously with the rotating blank to shape the component, allowing for precise transfer of complex geometries and reducing process times by dividing the molding elements into segments for different axial sections and varying tangential speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure rollers are used in flow-forming process, then rotationally symmetrical components can be produced, but manufacturing precision and process time are insufficient for complex geometries
Solution Approach 1:
The molding element is divided into multiple segments along the axial direction, with each segment corresponding to a different axial section of the blank. This segmentation allows independent shaping of different sections, enabling complex geometries to be formed with high precision while reducing the overall process time through parallel processing capabilities.
Solution Approach 2:
The invention transitions from traditional radial pressure application to tangential linear molding. The molding element moves tangentially along the surface of the rotating blank, converting the forming action into a linear motion that better suits complex geometry formation and improves both precision and efficiency.
2Manufacturing precision
If traditional flow-forming with pressure rollers is used, then production can be maintained, but accuracy and process time are not optimized for complex geometries
Solution Approach 1:
The molding element is designed to move tangentially along the surface of the rotating blank at synchronized speed. This dynamic linear motion allows the contour to be imprinted continuously and accurately onto the blank, significantly improving contour accuracy while reducing the time required compared to static or slow pressure roller methods.
Solution Approach 2:
The molding element contains a contour that corresponds to the unrolled contour of the desired component. This contour is directly copied onto the rotating blank through tangential contact, ensuring high accuracy in reproducing complex geometries without requiring multiple adjustment steps.
3Productivity
If segmented molding elements are used for different axial sections, then parallel shaping increases productivity, but device complexity increases
Solution Approach 1:
The molding element is divided into multiple segments along the axial direction, with each segment corresponding to a different axial section of the blank. This segmentation allows independent shaping of different sections, enabling complex geometries to be formed with high precision while reducing the overall process time through parallel processing capabilities.
Solution Approach 2:
The segmented molding element structure allows the same basic design to be used for different axial sections by simply changing or repositioning segments. This multi-functionality increases productivity for producing different component variants while keeping the overall device structure manageable through modular design.
4Manufacturing precision
If tangential movement of molding element is used, then complex geometries can be formed with high accuracy, but mechanical load on receptacle increases
Solution Approach 1:
The molding element is designed to move tangentially along the surface of the rotating blank at synchronized speed. This dynamic linear motion allows the contour to be imprinted continuously and accurately onto the blank, significantly improving contour accuracy while reducing the time required compared to static or slow pressure roller methods.
Solution Approach 2:
Two molding elements are arranged to act on opposite sides of the blank. The forces exerted by these opposing molding elements counterbalance each other, reducing the net mechanical load on the rotatable receptacle while maintaining the high accuracy benefits of tangential molding action.
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 method enables the production of rotationally symmetrical components with high accuracy and reduced process times, particularly suitable for complex geometries, by precisely molding the contours onto the blank, minimizing mechanical load, and increasing production capacity through parallelization of preforming and final shaping steps.
Implementation Method 1
a blank made of metal is arranged on a rotatable holder, is set in rotation and is flow-formed over driven or free-running rollers
Implementation Method 2
it has been found that by using a linear molding element, which has a shaping contour that corresponds to the unrolled contour of the component to be produced or a preform of the component to be produced, the shaping of the rotationally symmetrical component or a preform of the component can be achieved with less process time and with high accuracy
Data Source
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AI summary
The invention relates to a method for producing rotationally symmetrical components made of metal, in particular steel, in which a blank is arranged on a first receptacle for rotation therewith, the receptacle is made to rotate about an axis of rotation, and so the blank is set in rotation about this axis of rotation. In addition, the invention relates to a device for producing a rotationally symmetrical component made of a metal, in particular steel, from a blank, comprising a receptacle for a blank made of metal, in particular steel, which is rotatable about an axis of rotation, and forming means, with which a contour can be formed into the blank. The object of providing a method and a device for producing rotationally symmetrical components with which rotationally symmetrical components made of metal, in particular steel, even of a complex geometry, can be produced with sufficient accuracy and reduced process times, is achieved with a method by at least one linear moulding element being moved tangentially in relation to the surface of the synchronously rotating blank with a contour that at least partially comprises an unrolled outer contour of the rotationally symmetrical component or a preform of the component, wherein the linear moulding element is at the same time pressed against the blank in such a way that an impression of the contour of the moulding element is at least partially formed into the blank during the tangential movement.