Ring-Shaped Member Forming With Depression Punching and Ironing
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Solution Overview
Problem
Conventional methods for manufacturing ring-shaped members, particularly those made of high-hardness materials, face challenges such as increased forming loads, reduced material yield, and susceptibility to damage like cracks, leading to higher costs and lower product quality.
Innovation Solution
A method involving forming a depression in a workpiece, punching out its bottom portion, and deforming the circumferential wall to enlarge the axial length, using controlled metal flow patterns to reduce forming loads and improve material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the reduction in cross section of the workpiece is increased to make the inner diameter of the recessed portion closer to the inner diameter of the raceway, then the machining allowance is reduced, but the forming load increases
Solution Approach 1:
The forming process is divided into multiple stages: first forming a recessed portion with a smaller inner diameter, then performing an ironing process to gradually enlarge the inner diameter to the target dimension. This segmentation allows the total deformation to be distributed across multiple steps, reducing the forming load in each individual step while achieving the desired precision.
Solution Approach 2:
The recessed portion is formed in advance with a controlled inner diameter that is intentionally smaller than the final target dimension. This preliminary action creates a workpiece configuration that requires smaller deformation in subsequent ironing steps, thereby reducing the forming load while maintaining the ability to achieve precise final dimensions.
2Manufacturing precision
If an extrusion process is used to expand the inner diameter of the recessed portion, then the inner diameter can be increased, but material yield is reduced and a large load is required to punch out the thick bottom portion
Solution Approach 1:
Instead of using an extrusion process that pushes material outward and creates a thick bottom portion requiring punching, the invention uses an ironing process that draws material inward and upward. This inverted approach eliminates the need to punch out a thick bottom portion, improving material yield by incorporating all material into the final product.
3Ease of manufacture
If a high-power press is used to handle increased forming loads, then the forming process can be completed, but manufacturing costs increase and device complexity increases
Solution Approach 1:
The forming process is segmented into multiple steps with progressively increasing complexity: recess formation followed by ironing. Each step uses a press with power appropriate for that specific deformation magnitude, avoiding the need for a single high-power press and thereby reducing overall device complexity and manufacturing costs.
4Manufacturing precision
If the workpiece is subjected to high forming loads, then the desired shape can be achieved, but the workpiece becomes more susceptible to damage such as cracks
Solution Approach 1:
The total deformation required to achieve the desired shape is segmented into multiple smaller deformation steps. By distributing the strain across multiple low-load steps rather than one high-load step, the workpiece is less susceptible to cracking and damage, improving reliability while still achieving the target shape accuracy.
Solution Approach 2:
The recessed portion is formed in advance as a preliminary structure that facilitates subsequent ironing. This preliminary configuration allows the material to be gradually drawn into the final shape through controlled deformation, preventing sudden stress concentrations that could cause cracks and thereby protecting workpiece integrity.
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 approach reduces manufacturing costs and enhances product quality by minimizing material waste and preventing damage, while maintaining precise control over the metal flow patterns.
Implementation Method 1
deforming the circumferential wall in accordance with relative movement between the workpiece and a third member to enlarge an axial length of the circumferential wall
Data Source
AI summary
A method for manufacturing a ring-shaped member includes preparing a workpiece, pressing a first member against the workpiece to form a depression having a depth in an axial direction in the workpiece, punching out a bottom portion of the depression in the workpiece using a second member, and deforming a circumferential wall in accordance with relative movement between the workpiece and a third member.