Radial Forging Pass Scheduling Across Spiral, Straight, and Flat Modes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing radial forging processes are limited in achieving optimal workpiece quality and productivity due to the fixed nature of tool interaction, particularly in shaping processes like spiral and straight modes, which restrict feed rate and surface finish, while flat mode is underutilized.
Innovation Solution
A method employing a radial forging machine that alternates between spiral, straight, and flat modes of operation in consecutive passes, optimized by a pass schedule calculation program, allowing for adaptable tool interaction and material-specific process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spiral forging mode is used to ensure complete surface coverage, then surface quality is improved, but feed rate is limited by maximum tool length and rotation angle
Solution Approach 1:
The patent applies dynamics by making the forging mode changeable during the process. The system dynamically switches between spiral forging mode (for surface quality) and straight forging mode (for productivity) based on the current shaping requirements and tool position, allowing optimal performance characteristics to be utilized at different stages of the forging cycle
Solution Approach 2:
The patent implements periodic action by alternating between different forging modes in a structured sequence. The control device periodically switches between spiral and straight forging modes according to a predetermined schedule or real-time conditions, combining the surface quality benefits of spiral mode with the productivity advantages of straight mode in repeated cycles
2Productivity
If straight mode is used to increase feed rate, then productivity is improved, but complete over-forging of workpiece surface is not achieved
Solution Approach 1:
The patent merges two previously separate forging modes (spiral and straight) into a single integrated process. By combining the high-productivity straight mode with the comprehensive surface coverage of spiral mode in an alternating sequence, the system achieves both complete surface over-forging and high feed rates that neither mode could achieve alone
3Manufacturing precision
If finishing process is applied to optimize surface, then surface quality is improved, but additional process steps are required
Solution Approach 1:
The patent makes the radial forging machine universal by enabling it to perform both rough shaping and finishing operations within the same device. The control device selects appropriate forging modes (spiral for finishing, straight for roughing) based on the current process stage, allowing one machine to replace what would traditionally require separate finishing equipment and process steps
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
Enhances product quality and shortens the process chain by optimizing local shape changes and adapting to material-specific requirements, ensuring efficient through-forging and surface finish.
Implementation Method 1
radial forging of a workpiece from an initial state to an end state by means of a radial forging machine, comprising forging tools
Data Source
AI summary
A method for radial forging a workpiece from an initial state to an end state, preferably follows a pass schedule multiple times from an initial state to an end state, by means of a radial forging machine with forging tools, preferably four forging tools, arranged around the periphery of the workpiece. The radial forging machine is designed and configured to perform the radial forging in at least three modes of operation, A) radial forging in spiral mode, B) radial forging in straight mode and C) radial forging in flat mode. The shaping of the workpiece from an initial state to an end state is a sequence of radial forging passes. At least two of the three different modes of operation are applied in succession.