Press Forging Mold Arrangement for Stress Reduction
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Solution Overview
Problem
Conventional press forging machines experience high stress and require oversized machinery due to the offset arrangement of dies, leading to potential breakage and inefficient use of pressing capability.
Innovation Solution
An apparatus with a bottom plate, guide columns, a central movable plate, and top plate arrangement allows for simultaneous intermediate forging and finishing, with molds aligned axially to eliminate anomalous stress and utilize the maximum required pressing force without oversizing the press.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the press construction uses a larger power pressing machine to prevent breakage risk, then the reliability is improved, but the device complexity and cost increase
Solution Approach 1:
The forming process is segmented into two independent operations: roughing operation in the first die and finishing operation in the second die. Each die performs a specific function independently, allowing the press to be sized for the maximum force required by a single operation rather than the sum of both operations, thereby reducing the required press size while maintaining reliability
Solution Approach 2:
The dies are arranged in a transverse configuration rather than in series along the pressing axis. This spatial arrangement allows both roughing and finishing operations to occur simultaneously or sequentially without requiring the press to handle cumulative forces, effectively utilizing the transverse dimension to reduce the pressing force requirement
2Adaptability or versatility
If the press dies are arranged in an offset relationship to perform roughing and finishing operations, then the manufacturing capability is improved, but the press construction is subjected to very high stress
Solution Approach 1:
The forming process is divided into separate roughing and finishing operations performed in different dies. The roughing die performs the initial shaping while the finishing die performs the final forming, allowing each die to be optimized for its specific operation and reducing the stress on the press construction
Solution Approach 2:
The dies are arranged transversely or in an offset relationship rather than in series along the pressing axis. This allows the press to apply force to one die at a time, preventing the cumulative stress that would result from sequential operations, while still achieving both roughing and finishing capabilities
3Manufacturing precision
If the pressing machine molds are made with enlarged size and strong auxiliary guides, then the manufacturing precision is improved, but the device complexity and cost increase
Solution Approach 1:
The forming process is segmented into roughing and finishing operations, with each die optimized for its specific function. The roughing die handles the initial shaping with less precision requirements, while the finishing die performs the high-precision final forming, allowing each die to be sized appropriately for its task rather than both dies being oversized
Solution Approach 2:
The roughing operation is performed as a preliminary action before the finishing operation. This preliminary shaping removes excess material and establishes the basic geometry, reducing the amount of material and complexity that the finishing die must handle, thereby allowing for a more compact and simpler finishing die design
Data Source
Figure 1
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AI summary
Press (1) for simultaneously rough-pressing and finishing/embossing a workpiece, comprising a bottom plate (13), to be clamped to a base plate (14) on a press bed (15), two or more guide columns (10), a central middle movable plate (8) and a top plate (16) to be clamped to the press ram or slide (12), wherein: between the bottom plate (13) and the middle movable plate (8) one of a pair of workpiece finishing or rough-pressing half-molds is arranged, and between said middle plate (8) and top plate (16) the other of a pair of workpiece rough-pressing or finishing half-molds is arranged, such that the location of said finishing or rough-processing molds between said middle movable plate (8) and bottom plate (13) is an indifferent one.