Plastic Twisting Die for Threaded Rod Forming With Lower Friction
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Solution Overview
Problem
The production of helically-shaped members, such as threaded fasteners and rods, using traditional steel twisting-dies is inefficient due to high friction, surface damage, and buckling issues, which complicates the manufacturing process and increases costs.
Innovation Solution
A plastic twisting-die with a lower modulus of elasticity and coefficient of friction is used to twist steel feed-wire, allowing for uniform helical grooves and reducing the need for complex machining, thereby alleviating buckling and surface damage, and enabling faster, more cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel twisting-die is used to deform steel feed-wire, then the wire can be twisted into helical shapes, but high friction causes surface damage and requires excessive force leading to buckling
Solution Approach 1:
The patent changes the material parameter of the twisting-die from steel to plastic, which fundamentally alters the friction characteristics. Plastic materials have lower coefficients of friction against steel, reducing the force required for wire deformation and eliminating surface damage while preventing buckling through reduced compressive forces.
Solution Approach 2:
The invention uses plastic material for the twisting-die, creating a composite material system where the plastic die interacts with steel feed-wire. This material combination optimizes the interaction by reducing friction and wear, allowing effective wire deformation without the harmful effects associated with steel-on-steel contact.
2Manufacturing precision
If multiple-segment machined metal twisting-dies are used, then helical grooves can be formed, but the machining and assembly process is intricate, slow and expensive
Solution Approach 1:
The patent changes the manufacturing approach by using plastic material that can be formed through molding processes rather than intricate machining. This allows helical grooves to be created more rapidly and cost-effectively while maintaining the necessary precision for wire deformation.
Solution Approach 2:
The invention employs plastic twisting-dies that are simpler and cheaper to manufacture, accepting that they may have shorter service lives compared to metal dies. This trade-off prioritizes rapid production and lower cost over long-term durability, significantly improving overall manufacturing productivity.
3Productivity
If flange-profiled steel wire is pushed through a steel die at high velocity, then commercially viable production rates are achieved, but friction increases beyond critical limits causing wire buckling
Solution Approach 1:
The patent changes the friction parameter by using plastic die material, which maintains lower friction coefficients even at high velocities. This allows commercially viable production rates to be achieved without the force increasing to critical levels that would cause wire buckling.
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 plastic twisting-die facilitates smoother deformation of steel feed-wire with reduced force, eliminating buckling and surface damage, and allows for higher throughput rates, improving production efficiency and cost-effectiveness.
Implementation Method 1
the coefficient of friction between the selected plastic material and metal, such as steel
Implementation Method 2
forcing the profiled feed-wire in an axial direction through the die body, whereby a plastic surface within at least one of the helical grooves deflects its respective flange thereby forcing the profiled feed-wire to helically deform
Data Source
AI summary
Method and means of manufacturing ties, fasteners and rods (15) having a plurality of longitudinal threads by forcing a coil of roll-profiled feed-wire made of steel (11) through a twisting-die made of plastic (1). Also described is: a twisting-die made of plastic (1) that is suitable for twisting profiled feed-wire (11) made of steel; a method of forming a plastic twisting die (1) using an driven tap (31) in the form of a twisted rod (15); and a helically-shaped member (15) having lead measurements (X) along the length of the helical thread that vary less than pitch measurements (Y) along the lengths of the helical threads.