Precision Forging with Shear Cutting for Lower Tool Pressure
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Solution Overview
Problem
Current precision forging methods require massive tool pressure, which can lead to material cracking and are unsuitable for high-strength and large-dimension components, as the tool pressure needs to be at least three times the tensile strength of the workpiece, exceeding the limits of tool materials.
Innovation Solution
A precision forging method involving a punch with a cutting blade that moves within a die cavity to cause shear deformation in a metal material with a pre-working projecting wall, reducing the need for massive tool pressure by using a punch that moves in a way to cut and deform the material within the die cavity, allowing for lower pressure forging without material cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional precision forging method is used, then high precision components can be manufactured at low costs, but massive tool pressure is required which exceeds tool material limits for high-strength and large-dimension components
Solution Approach 1:
The invention divides the forging process into two distinct stages: a preliminary shaping stage that forms the basic component geometry, and a final precision forging stage that achieves high dimensional accuracy. This segmentation allows the use of lower tool pressure in the precision stage by working with pre-formed material that requires minimal additional deformation, thereby resolving the contradiction between achieving high precision and avoiding excessive tool pressure that exceeds material limits.
Solution Approach 2:
The invention performs preliminary shaping operations before the final precision forging step. This preliminary action prepares the workpiece in an optimal state for the subsequent precision forging, reducing the deformation required in the final stage and consequently lowering the tool pressure needed while maintaining high manufacturing precision.
2Manufacturing precision
If enormous tool pressure is applied to force workpiece into non-filled portion of die, then shaping is completed, but material cracking occurs especially in high-strength materials
Solution Approach 1:
By segmenting the forging process into preliminary shaping and final precision stages, the invention avoids applying enormous pressure in a single step. The preliminary stage prepares the material distribution, and the final stage completes shaping with minimal additional pressure, preventing material cracking and maintaining integrity of high-strength materials.
Solution Approach 2:
The invention changes the pressure application parameters by using lower pressure in the final precision forging stage compared to conventional single-stage forging. This parameter change, achieved through preliminary material preparation, allows complete shaping while preventing material cracking and maintaining reliability.
3Force
If tool pressure is reduced below three times tensile strength, then tool material limits are respected, but conventional methods cannot achieve proper shaping
Solution Approach 1:
The preliminary shaping stage prepares the workpiece geometry and material distribution in advance, creating optimal conditions for the final precision forging. This preliminary action enables the final stage to achieve high shaping quality with reduced tool pressure that respects tool material limits, resolving the contradiction between force reduction and shaping quality maintenance.
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 precision forging without massive tool pressure, preventing material cracking and allowing for the forging of high-strength and large-dimension components by using a cutting blade to cause shear deformation, thus reducing the required force and preventing material failure.
Implementation Method 1
a cutting blade formed at an edge of the working end surface 31... causes shear deformation in the cut part to move the cut part toward the pre-working projecting wall 12A
Data Source
AI summary
A precision forging method includes arranging a metal material in a die cavity so that a distal end surface of a wall portion of the metal material is opposed toward a stopper and a bottom portion of the metal material is opposed toward a punch. Further, the precision forging method includes moving the punch, which includes a cutting blade on an edge of a working end surface, in the die cavity to cut part of the wall portion thickness-wise with the cutting blade and cause shear deformation in the cut portion.