Modular Forging Mandrel with Interchangeable Segments
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Solution Overview
Problem
The existing forging mandrel systems require separate mandrels for different inner contours of hollow bodies, leading to increased effort and storage needs, as well as inefficient material utilization and thermal management.
Innovation Solution
A modular forging mandrel design featuring a uniform mandrel core with interchangeable segments that can be adjusted radially and thermally managed, allowing adaptation to various inner diameters and shapes without replacing the core, and utilizing spacers and wedge gears for precise diameter control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate forging mandrels are used for different inner contours of hollow bodies, then the inner shape of the hollow body can be accurately formed, but the storage effort and device complexity increase
Solution Approach 1:
The forging mandrel is divided into a mandrel core and interchangeable mandrel segments. The mandrel segments can be exchanged to form different inner contours, eliminating the need for completely separate mandrels for each hollow body shape. This segmentation allows the same core to serve multiple purposes while maintaining manufacturing precision.
Solution Approach 2:
The mandrel core is designed as a universal component that can accommodate multiple types of mandrel segments. This multi-functionality allows a single core to be used for producing different hollow body inner contours by simply changing the segments, thereby reducing the total number of mandrels needed while maintaining shape accuracy.
2Manufacturing precision
If separate forging mandrels are used for different inner contours, then the inner shape accuracy is maintained, but the storage space and time effort increase
Solution Approach 1:
By segmenting the mandrel into interchangeable parts, the conversion between different inner contours becomes a matter of swapping segments rather than replacing entire mandrels. This significantly reduces the time and effort required for conversion while maintaining the accuracy needed for different inner contours.
Solution Approach 2:
Multiple mandrel segments for different inner contours are pre-prepared and can be quickly exchanged. The segmentation allows for preliminary preparation of various segments, so when conversion is needed, the appropriate segment is already ready to be installed, minimizing conversion time while preserving contour accuracy.
3Duration of action of stationary object
If heat-resistant material is used for the entire mandrel, then the service life is improved, but the material cost and weight increase
Solution Approach 1:
Heat-resistant material is applied locally only to the mandrel segments that come into contact with the hot workpiece, rather than the entire mandrel. The mandrel core can be made of less expensive, lighter material. This local application of heat-resistant material extends service life where needed while reducing overall material quantity and cost.
4Duration of action of stationary object
If the entire mandrel is cooled, then the service life under thermal load is extended, but the energy consumption and system complexity increase
Solution Approach 1:
Cooling is applied locally to the mandrel segments rather than the entire mandrel. Since only the segments are exposed to high temperatures during forging, cooling them locally is sufficient to extend their thermal service life. This approach reduces the energy required for cooling compared to cooling the entire mandrel assembly.
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 efficient production of hollow bodies with diverse internal dimensions and shapes, reduces material waste, and improves thermal management by allowing selective use of heat-resistant materials only where needed, while facilitating easy conversion and extended mandrel life through adaptable cooling/heating.
Implementation Method 1
the mandrel segments can be arranged in a thermally insulated manner relative to the mandrel core, so that the mandrel core can be largely relieved of higher thermal loads
Implementation Method 2
there are favorable conditions for any cooling or heating of the mandrel segments, which can be connected to corresponding cooling or heating devices via lines provided in the mandrel core for a cooling or heating medium
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The device has central forging tools symmetrically arranged about a forging axis and provided with a forging mandrel (3). The forging mandrel includes a mandrel core (7) and mandrel segments (8) that are provided around circumference of the mandrel core and interchangeably held on the mandrel core. The mandrel segments form mold surfaces (9) for a hollow chamber of a hollow body and thermally insulated-arranged opposite to the mandrel core. The mandrel segments are connected to a cooling or heating device and form-fittingly inserted in sectioned grooves of the mandrel core.