One-Piece Lock Striker Cold Upset Forming
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Solution Overview
Problem
The existing methods for producing lock holders, such as those used in motor vehicle locking systems, face challenges with high forming forces and tool stresses, requiring large machines and resulting in material inefficiencies and complex post-processing steps.
Innovation Solution
A method involving cold upsetting of a metallic starting blank, where the blank is strain-hardened to form a one-piece lock holder with specific mechanical properties, reducing forming forces and enabling the use of lower-strength materials, and allowing for efficient production with smaller machines and minimal tool stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cold extrusion or cold upsetting is used to massively reshape a starting blank, then a one-piece lock holder can be produced with improved mechanical properties, but high forming forces are required resulting in high tool stress
Solution Approach 1:
The starting blank is pre-shaped into a T-shaped semi-finished product with a bead of material positioned on the lock shackle leg before the main forming operation. This preliminary configuration allows the bead to act as a material reservoir during subsequent forming, reducing the need for high forming forces while still achieving the desired final shape and mechanical properties
Solution Approach 2:
The invention changes the physical state and configuration of the starting material by heating it to processing temperatures above the recrystallization temperature before forming. This thermal parameter change makes the material more formable, reducing the forming forces and tool stress required while still achieving the desired mechanical properties in the final lock holder
2Shape
If hot forging with temperatures above recrystallization temperature is used, then the lock holder can be formed with complex shapes, but the process requires high energy input and complex heating/cooling cycles
Solution Approach 1:
Instead of heating the entire starting blank uniformly to high temperatures, the invention applies localized heating or heating only for the duration necessary to achieve the required formability. The bead of material is positioned to provide localized material flow where needed, reducing the overall energy input required while still achieving complex shapes
3Productivity
If massive forming into a T-shaped semi-finished product is used, then time-consuming post-processing can be saved, but high forming forces are required
Solution Approach 1:
The T-shaped semi-finished product with the bead of material is created as a preliminary configuration that inherently contains the material needed for the final forming operation. This preliminary action eliminates the need for additional material addition or complex post-processing, while the bead configuration reduces the forming force required by providing material flow paths that reduce resistance during forming
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 results in lock holders with optimized strength and fatigue properties, reduced production costs, and improved material utilization, while minimizing tool stress and enabling the use of lower-strength starting materials, achieving enhanced mechanical performance and efficient production.
Implementation Method 1
A method is proposed for producing a lock holder, in which a lock holder is formed from a starting blank essentially in the form of a block or cylinder by cold upsetting in such a way that the lock holder is strain-hardened
Implementation Method 2
The forming process through plastic change of a given solid starting blank is fundamentally associated with the problem that high forming forces are required
Data Source
Figure 1
Figure 2a~3b
AI summary
The invention relates to a method for producing a one-piece lock striker and to a lock striker produced according to said method. The lock striker (1) comprises a base plate (1) and a lock bracket (3). A metal starter blank (11) is formed into a lock striker by cold forming, in particular by cold upsetting. The starter blank (11) is substantially block-shaped or cylindrical and is formed in such a way that the lock striker (1) becomes strain-hardened.