Radial Hydraulic Forge With Variable Die Displacement
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Solution Overview
Problem
Existing radial forging methods either suffer from removability issues or are not conducive to near-net shape production, leading to loss of crystallographic texture and strength in forged materials, as they do not allow for variable radial displacement in closed-die forging.
Innovation Solution
A radial forge system with a hydraulically driven upper and lower platen, a master gear with a central aperture, and radially mounted hydraulic rams, enabling independent actuation and variable radial displacement to produce near-net or net shape workpieces, with the option for removably mountable dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a closed die is used for radial forging, then the workpiece can be formed to near-net shape, but the die cannot be removed from the groove
Solution Approach 1:
The die is divided into multiple segments that can be independently moved. The segmentation allows the die to be opened into the groove by moving individual segments, enabling workpiece removal while maintaining the closed-die near-net shape capability during forging operations
Solution Approach 2:
The die transitions from a static closed structure to a dynamic configurable structure. The die segments can be moved between closed positions (for near-net shaping) and open positions (for workpiece removal), providing dynamic adaptability to different operational requirements
2Manufacturing precision
If machining is performed after forging, then the workpiece can be precisely shaped, but the crystallographic texture is removed
Solution Approach 1:
Traditional machining operations are replaced with advanced radial forging processes that can achieve near-net or net shape production. The radial forge system uses controlled radial compression and deformation to precisely shape the workpiece while preserving the beneficial crystallographic texture through plastic deformation rather than material removal
3Manufacturing precision
If variable radial displacement is implemented, then near-net shape production is achieved, but the device complexity increases
Solution Approach 1:
The hydraulic system is designed with multi-functionality, where a single integrated system performs multiple functions including axial compression, radial compression, and die positioning. This universal approach reduces the need for separate specialized mechanisms, thereby managing complexity while achieving variable radial displacement for near-net shape production
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
Enables the production of workpieces with preserved crystallographic texture and strength by allowing for variable radial displacement, addressing the removability and near-net shape challenges in existing radial forging methods.
Implementation Method 1
an upper ram (113) having a hydraulically driven platen (115); a lower platen (114) opposing the upper platen (115)
Implementation Method 2
a thrust bearing (122) supporting the master gear (124)
Data Source
AI summary
A radial forge is provided with variable radial displacement. The forge includes upper and lower frames having upper and lower double acting hydraulically driven rams. The forge also includes a horizontal master gear mounted on a circular thrust bearing to provide rotational freedom. One or more radial hydraulically drive rams are mounted to the master gear. Accordingly, the master gear serves as a gantry for positioning the radial rams. A billet may be centrally located between the inwardly directed radial rams and may be supported by the lower ram. The upper ram is aligned with the lower ram so that actuating the upper ram and/or lower ram compresses the billet between them and forces the billet to flow into and fill radial dies removably affixed to the radial rams.