Metal Protrusion Forming by Lateral Pressing Into Through-Holes
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Solution Overview
Problem
Conventional methods for forming protrusions on metal plates or rods face challenges such as cracking, breaking, and restricted height and diameter, especially when using thin metal plates or small-diameter rods, leading to inferior quality and complex processes.
Innovation Solution
A method involving pressing the outer peripheral end parts of a metal workpiece from horizontal directions into through-holes acting as female molds, allowing for solid protrusion formation without thinning the metal plate or reducing the rod diameter, using a system with a support die, pressure die, and a pressing die to achieve high-quality protrusions at temperatures below the metal's softening point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional press molding methods are used to form protrusions on thin metal plates, then protrusions can be formed, but the metal plate becomes thinner and the protrusions are restricted in height and diameter
Solution Approach 1:
Instead of pressing from the conventional vertical direction, the invention presses the outer peripheral end parts of the workpiece from horizontal directions toward the center, causing metal flow into through-holes acting as female molds. This inverted pressing direction enables formation of high protrusions without thinning the metal plate or restricting protrusion dimensions.
Solution Approach 2:
The invention introduces horizontal pressing directions perpendicular to the conventional vertical pressing direction. By applying pressure from multiple horizontal directions simultaneously, metal flows radially into the through-holes, enabling formation of tall protrusions while maintaining plate thickness.
2Ease of manufacture
If conventional press molding is used on thin metal plates, then protrusions can be formed, but cracking and breaking occur
Solution Approach 1:
The pressing action is segmented into multiple horizontal directions rather than a single vertical force. This distributes the deformation stress uniformly across the metal plate, preventing concentration of stress that causes cracking and breaking in conventional single-direction pressing.
Solution Approach 2:
The invention changes the pressing parameters by applying force from horizontal directions at temperatures below the metal's softening point, rather than conventional vertical pressing. This parameter change enables formation of intact protrusions without cracking while maintaining process simplicity.
3Manufacturing precision
If conventional methods are used to form high protrusions, then protrusions can be formed, but post-processing like polishing and cutting is required
Solution Approach 1:
The through-holes acting as female molds guide the metal flow to automatically form protrusions with uniform shape and size. The process self-regulates the protrusion formation without requiring subsequent polishing or cutting operations, eliminating post-processing steps while maintaining high uniformity.
4Strength
If conventional press molding is used, then protrusions can be formed, but the metal plate must be heated to high temperatures
Solution Approach 1:
The invention replaces thermal energy with mechanical energy by applying horizontal pressing forces at temperatures below the metal's softening point. The mechanical pressure from multiple directions provides sufficient ductility for metal flow without requiring high-temperature heating, enabling cold-forming of protrusions.
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
Enables the formation of high-quality, solid protrusions with increased height and uniformity, reducing the need for post-processing like polishing and cutting, and lowering manufacturing costs by simplifying the process and eliminating the need for heating, thus applicable to various metal components including precision parts.
Implementation Method 1
pressing end cross sections of two or more outer peripheral end parts... to cause metal plastic flow of the metal workpiece into said one of more female molds
Data Source
AI summary
Solid metal protrusions are formed by the method including: clamping and fixing the metal workpiece between a support die and a pressure die; pressing end cross sections of two or more outer peripheral end parts of the metal workpiece fixed between 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.