Metal End Press-Splitting for Uniform Deep Grooves and Flanges
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Solution Overview
Problem
Existing methods for machining the outer circumference of metal rods and pipes are inadequate for forming smooth and uniform deep grooves or recesses, as they require complex molds and are not suitable for small-volume production or irregular shapes, limiting their applicability and flexibility.
Innovation Solution
A method using continuous press-splitting with a slitting punch and optimized clamping die structures to form deep grooves, recesses, and flanges on the outer circumference of metal ends, allowing for adjustable depth and shape, and enabling easy joining with other materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If forging forming by plastic deformation using a punch or die is used, then metal rods and pipes can be processed, but it is difficult to form smooth and uniform deep grooves or recesses and requires complex molds
Solution Approach 1:
The invention divides the forming process into two distinct stages: first creating a groove shape through press splitting, then forming the final smooth shape through secondary plastic deformation. This segmentation allows each stage to be optimized independently, achieving smooth deep grooves without requiring complex single-step molds
Solution Approach 2:
The press splitting operation performs a preliminary groove formation that prepares the metal structure before the final shaping operation. This preliminary action creates a pre-formed groove that guides subsequent deformation, enabling smooth final shapes with simpler tooling
2Productivity
If conventional cutting or forging methods are used, then metal processing can be performed, but mass productivity is not improved and manufacturing costs are reduced
Solution Approach 1:
The invention merges two operations (press splitting and plastic deformation) into a single integrated process flow that can be performed continuously on production lines. This combination eliminates the need for separate machining operations, improving mass productivity while keeping tooling relatively simple and cost-effective
Solution Approach 2:
The invention changes the fundamental processing parameter from traditional cutting or single-step forging to a two-stage press splitting and deformation process. This parameter change enables continuous production with standardized tooling, reducing per-unit costs while increasing overall productivity
3Adaptability or versatility
If methods suitable for circular metal materials are used, then brake shoe edges can be machined, but they cannot process metal plates with rectangle, polygon, or ellipse shapes, or metal rods with various cross sections
Solution Approach 1:
The press splitting tooling is designed with universal applicability to handle multiple cross-sectional shapes (circular, rectangular, elliptical, polygonal) through adjustable clamping and positioning mechanisms. This multi-functionality maintains processing reliability across different geometries while expanding the range of applicable workpiece shapes
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 enhances mass productivity, reduces manufacturing costs, and facilitates strong and reliable joining of metal components with other materials by forming smooth, uniform features on metal ends, expanding its application to various environments and shapes.
Implementation Method 1
performing press-splitting using a slitting punch more than once; the position of clamping dies, which pinch a metal plate or a metal rod, is moved at every press-splitting operation step
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3C
AI summary
Provided are a method for machining the outer circumference of a metal end cross-section , the method being capable of easily forming at least any of a deep groove, a deep recess, and a flange which are smooth and uniform in the longitudinal direction of a metal rod or metal pipe in the periphery of the cross-section of any of the end part of the metal rod or metal pipe, the drawn end part of the metal rod or metal pipe, and the hub hole forming part of the metal pipe; and a method for joining a metal component obtained by the machining method with another member. The machining method of the present invention is characterized in that: splitting is advanced by successively repeating press forming operation multiple times by using a slitting punch, in which a tip part has a sharp cutting edge, and the cutting edge is formed so as to have a shape equal to or partly equal to the outer shape of the cross section of a metal end part and so as to have a diameter smaller than the outer diameter of the cross section of the splitting object; and in order to control the depth of metal cracking cleft created with each press forming operation, a pressing die for pinching the outside of a metal rod or at least a pressing die of one side of pressing dies for pinching the inside and the outside of a metal pipe is disposed while its position is moved according to the distance of a split portion.