Metal Peening Impactor Geometry for Precision Forming
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Solution Overview
Problem
Conventional metal peening systems have limitations in processing both thin and thick metal parts, requiring substantial time and high investment, and struggle with precision and surface damage, especially when forming parts with varying geometries and materials.
Innovation Solution
A metal peening system with a driven member featuring multiple impact features, such as asymmetrical or non-round impact surfaces, and a controller with adjustable parameters to apply impacts across a range of energies and reciprocation rates, allowing for precise processing of metal workpieces from thin sheet metal to materials over one inch thick.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shot peening is used on thinner material, then processing effectiveness is improved, but precision control deteriorates
Solution Approach 1:
The impactor is segmented into multiple impactors arranged in a circular array, with each impactor delivering controlled impacts. This segmentation allows the system to maintain precision control while processing thin materials effectively, as each individual impactor can be precisely positioned and controlled
Solution Approach 2:
The system employs dynamic control of impactor reciprocation rates and feed rates that can be adjusted based on material thickness and desired outcome. This dynamic adjustment capability enables precise control during processing of thin materials while maintaining high productivity
2Productivity
If large shot peening is used on thicker materials, then processing capability is improved, but surface damage worsens
Solution Approach 1:
Different impactors in the circular array can deliver impacts with varying energies and characteristics tailored to specific locations on the workpiece. This local quality approach allows thick materials to be processed effectively while controlling surface damage by adjusting impact parameters for each specific area
Solution Approach 2:
The system can change impact parameters such as impactor reciprocation rate, feed rate, and impact energy dynamically during processing. This enables the system to process thick materials with high capability while maintaining surface quality by adjusting parameters to prevent excessive surface damage
3Manufacturing precision
If ultrasonic peening or laser peening is used, then processing precision is improved, but processing time increases substantially
Solution Approach 1:
The circular array of impactors enables continuous processing of the workpiece as the array rotates and progresses along the workpiece surface. This continuous action maintains high processing precision while significantly reducing processing time compared to sequential ultrasonic or laser peening methods
Solution Approach 2:
The system performs preliminary positioning and setup of the circular impactor array before processing begins. This preliminary action enables the system to achieve precise processing outcomes while maintaining continuous high-speed operation during the actual peening process, reducing overall processing time
4Device complexity
If conventional peening machines are used, then device simplicity is maintained, but adaptability to different part geometries deteriorates
Solution Approach 1:
The circular array of impactors is designed to be universally applicable to various workpiece geometries including curved surfaces, flat surfaces, and complex shapes. The array can be positioned and oriented to accommodate different part geometries while maintaining a relatively simple overall device structure
Solution Approach 2:
The system transitions from conventional single-point or linear impact delivery to a three-dimensional circular array configuration. This dimensional change enables the system to adapt to various part geometries by positioning the circular array at different orientations and distances from the workpiece surface, increasing versatility without substantially increasing device complexity
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
The system enables broader types and geometries of metal parts to be formed with improved precision and surface finish, reducing processing time and costs, while minimizing surface damage and energy loss during the peening process.
Implementation Method 1
a driven member for applying multiple impacts to a surface of the workpiece
Implementation Method 2
mechanically processing, such as by impact peening, metal workpieces into final metal components
Data Source
AI summary
A driven member of a metal peening machine is disclosed. The metal peening machine is configured to drive the driven member into contact with a work surface of a metal workpiece to deform the metal workpiece. The driven member includes a shaft with an impact end. The driven member includes least one of a plurality of impact features, an impact feature with a non-flat impact surface, a non-round impact feature, and an asymmetrical impact feature that is coupled to and protrudes from the impact end of the shaft. The at least one of the plurality of impact features, the impact feature with a non-flat impact surface, the non-round impact feature, and the asymmetrical impact feature define at least one impact surface to be driven into contact with the work surface of the metal workpiece.