Solid Metal Protrusion Forming by Lateral Press Flow
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Solution Overview
Problem
Conventional methods for forming protrusions on metal plates or rods face challenges such as cracking, breaking, wall thinning, and limited height and shape options, particularly when using thin metal plates or small-diameter rods, which restricts the formation of high-quality, high-strength protrusions suitable for precision components like current collecting terminals.
Innovation Solution
A method involving press molding where the outer peripheral end parts of the metal workpiece are pressed from a horizontal direction into through-holes in a support die and pressure die, allowing for the formation of solid protrusions without thinning the metal plate or reducing the rod diameter, with the process performed at a temperature below the metal's softening point and using a system comprising a support die, pressure die, and press molding machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional press molding is used to form protrusions on metal plates, then protrusions can be formed, but the metal plate becomes thinner and may crack or break
Solution Approach 1:
The invention changes the pressing direction from vertical (perpendicular to the metal plate surface) to horizontal (parallel to the metal plate surface). The outer peripheral end parts of the metal workpiece are pressed from the horizontal direction into through-holes in the support die and pressure die, allowing protrusion formation without vertical compression that causes thinning and cracking.
Solution Approach 2:
Instead of pressing the metal plate from the vertical direction into a die cavity (conventional method), the invention presses from the horizontal direction and forms protrusions by material flow into through-holes. This inverted approach prevents wall thinning while achieving the same protrusion formation goal.
2Length of moving object
If conventional press molding is used to form high protrusions, then protrusion height can be increased, but the metal plate becomes thinner and quality deteriorates
Solution Approach 1:
By changing the pressing direction to horizontal and using through-holes in the dies, the invention enables formation of high protrusions without the vertical compression that causes thinning. The metal material flows horizontally into the through-holes, maintaining plate thickness while achieving greater protrusion heights with improved quality.
3Shape
If conventional methods are used for thin metal plates, then protrusions can be formed, but cracking and breaking occur
Solution Approach 1:
The horizontal pressing direction eliminates vertical compression stresses that cause cracking in thin metal plates. The metal material flows laterally into the through-holes under controlled pressure, forming protrusions without the tensile and compressive stresses that lead to cracking and breaking in conventional vertical pressing methods.
4Shape
If conventional press molding is used, then protrusions can be formed, but post-processing like polishing and cutting is required
Solution Approach 1:
The horizontal pressing method with through-holes produces protrusions with smoother surfaces and more uniform shapes compared to conventional vertical pressing. This reduces or eliminates the need for post-processing operations like polishing and cutting, thereby improving manufacturing efficiency and productivity.
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 formation of high-quality, solid protrusions with increased height and uniformity, reducing the need for post-processing like polishing and cutting, and allows for various shapes and positions, expanding the applicability to both general-purpose and precision metal components without the need for heating or complex temperature control.
Implementation Method 1
pressing each cross section of outer peripheral end parts of the metal workpiece from a direction perpendicular or oblique to an upright direction of the protrusions to be formed on one surface of the metal workpiece by press molding... undergoing plastic flows into one or more through-holes formed as recessed parts
Data Source
AI summary
Solid metal protrusions are formed by a method including: clamping and fixing the metal workpiece with a support die and a pressure die; pressing each cross section of an outer peripheral end parts of the metal workpiece fixed with the support die and the pressure die at a temperature lower than a softening point of a metal used as the metal workpiece from a direction perpendicular or oblique to an upright direction of the protrusions to be formed on one surface of the metal workpiece by press molding using a pressing die or a pressing jig; undergoing plastic flows of metal into through-holes formed as recessed parts that serve as female molds for forming the protrusions in at least one of the support die and the pressure die; and forming solid protrusions on the surface of the metal workpiece.