Precision Forging With Shear Deformation to 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 not suitable for high-strength or large-dimension components, as the pressure needed is often three times or more than 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 the metal material, allowing for the formation of a metal flow without requiring excessive tool pressure, by arranging the metal material with a wall portion and a pre-working projecting wall in the die cavity and using a stopper to hold the material in place during forging.
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 enormous tool pressure is required which exceeds the withstanding pressure limits of tool material
Solution Approach 1:
A pre-working projecting wall is formed on the metal material before the main forging operation. This preliminary structure guides the material flow and reduces the pressure required during the final forging stage, allowing high-precision components to be manufactured without exceeding tool material pressure limits.
Solution Approach 2:
The forging process is divided into multiple stages: first forming a pre-working projecting wall, then using it to guide material flow during the main forging operation. This segmentation allows the enormous tool pressure to be distributed and managed, preventing excessive pressure on the tool material while achieving high precision.
2Manufacturing precision
If tool pressure is increased to force workpiece into non-filled portion of die, then shaping precision is improved, but material cracking occurs
Solution Approach 1:
The pre-working projecting wall is formed in advance to establish proper material flow paths before the main forging operation. This preliminary structure ensures that material flows smoothly into the non-filled portion of the die without requiring excessive pressure that would cause cracking, thus maintaining both shaping precision and material integrity.
Solution Approach 2:
The pre-working projecting wall acts as an intermediary structure that facilitates material flow from the wall portion into the non-filled portion of the die. This intermediary element guides the material flow in a controlled manner, preventing sudden stress concentrations that would cause cracking while ensuring complete filling for high precision.
3Adaptability or versatility
If conventional forging method is used, then basic shaping is achieved, but high-strength material and large-dimension components cannot be processed
Solution Approach 1:
The pre-working projecting wall is formed on the metal material before forging, creating a structure that guides material flow during the forging operation. This preliminary action reduces the tool pressure requirement, making it feasible to process high-strength materials and large-dimension components that would otherwise exceed tool material pressure limits.
Solution Approach 2:
The invention changes the physical state and flow characteristics of the metal material by forming a pre-working projecting wall first. This parameter change in the material's structural configuration allows subsequent forging to proceed with reduced pressure, expanding adaptability to high-strength and large-dimension components.
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 processing of high-strength and large-dimension components by distributing the force effectively through shear deformation, resulting in a more efficient and reliable forging process.
Implementation Method 1
the cutting blade cuts the part of the wall portion thickness-wise located in a moving path of the punch and causes shear deformation in the cut part
Data Source
Figure 1A~1C
Figure 2A~3B
Figure 4A~5
AI summary
A precision forging method includes arranging a metal material (10) in a die cavity (22) so that a distal end surface of circumferential wall (14) of the metal material (10) is opposed toward a stopper (24) and a bottom portion (12) of the metal material (10) is opposed toward a punch (30). Further, the precision forging method includes moving the punch (30), which includes a cutting blade (32) on an edge of a working end surface (31), in the die cavity (22) to cut part of the wall portion (14) thickness-wise with the cutting blade (32) and cause shear deformation in the cut portion.