Orifice Plate Shear Drop Reduction via Ultrafine Grain Steel
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Solution Overview
Problem
The manufacturing of orifice plates using conventional press shearing methods results in large shear drops, fracture surfaces, and burrs, leading to flow rate fluctuations, and existing precision methods like shaving and fine blanking are costly and difficult to implement, especially for thin materials.
Innovation Solution
The use of ultrafine grain steel with an average crystal grain size of 3 µm or less, manufactured through continuous precision multi-shot punching, which minimizes shear drop and maintains uniformity in the cut end surface, reducing flow rate fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional press shearing is used to manufacture orifice plates, then manufacturing cost is low and process is simple, but the cut end surface has large shear drop, fracture surface, and burr causing flow rate fluctuations
Solution Approach 1:
The invention changes the material parameter by using ultrafine grain steel with average crystal grain size of 3 μm or less. This material parameter change enables conventional press shearing to produce cut end surfaces with minimal shear drop and fracture surface, achieving high precision without complex processes like shaving or fine blanking.
2Manufacturing precision
If shaving method is used to reduce shear drop and fracture surface, then cut end surface quality improves, but production cost increases and number of working processes increases
Solution Approach 1:
By changing the material parameter to ultrafine grain steel, the invention eliminates the need for multiple shaving processes. The improved material structure allows single-pass press shearing to achieve the same cut end surface quality that would otherwise require repeated shaving operations, thereby improving productivity.
3Manufacturing precision
If fine blanking method is used to minimize shear drop and fracture surface, then cut end surface quality improves, but die and punch cost increases and manufacturing difficulty increases
Solution Approach 1:
The invention changes the material parameter to ultrafine grain steel, which allows conventional press shearing dies and punches to produce high-quality cut end surfaces. This eliminates the need for expensive, difficult-to-manufacture fine blanking tools while achieving the same precision results.
4Manufacturing precision
If clearance between punch and die is reduced to improve cut end surface quality, then shear drop decreases, but die life shortens due to contact during processing
Solution Approach 1:
By changing the material parameter to ultrafine grain steel, the invention enables use of larger punch-die clearance without compromising cut end surface quality. The improved material structure prevents excessive shear drop even with larger clearance, thereby reducing die contact and extending die life.
Data Source
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AI summary
An orifice plate for liquid injection made of plate-shaped stainless steel, wherein an orifice is formed by shearing, is characterized in that the average crystal grain size of the stainless steel is 3 µm or less. The thickness of the plate-shaped stainless steel is 1.2 mm or less, and preferably 0.1 mm or less. The aspect ratio of the orifices is 0.8 or lower. The orifices are formed orthogonal to the plate surface, or slanted by 50° or at smaller angles. The plate-shaped stainless steel has a composition containing C, Mn, and Si.