Rolling Die Grooves With Varying Profile Angles
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Solution Overview
Problem
Existing rolling dies often result in suboptimal material displacement during thread formation, leading to uneven die load, reduced thread quality, and increased die wear, particularly when producing screws with large pitches and high thread flank heights, which can necessitate longer dies and lower production rates.
Innovation Solution
The rolling die features grooves with a continuously decreasing profile angle and variable width along the forming area, allowing for uniform stress distribution and improved material displacement, reducing the stress on the highly loaded calibration area and enabling the production of screws with large pitches and high thread flank heights without significant die length increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rolling dies with constant profile angles are used, then the die structure is simple, but the material displacement is suboptimal leading to uneven die load and reduced thread quality
Solution Approach 1:
The patent applies the dynamics principle by transitioning from static constant profile angles to dynamic continuously varying profile angles along the groove length. The profile angle changes continuously from the inlet area through the forming area to the calibration area, allowing the die to adapt its geometry to the material flow requirements at each position, thereby optimizing material displacement and achieving more uniform die load distribution while improving thread quality.
Solution Approach 2:
The patent implements parameter changes by varying the profile angle parameter continuously along the groove length rather than maintaining constant values. This continuous parameter variation allows optimization of the forming process at different positions, improving material flow and thread quality without requiring fundamentally complex die structures.
2Duration of action of stationary object
If rolling dies with discontinuous angle changes are used, then the die design is simpler, but the stress on material is uneven causing increased die wear and reduced lifetime
Solution Approach 1:
The patent applies dynamics by implementing continuous variation of the profile angle along the groove length, replacing discontinuous angle changes. This continuous dynamic geometry allows stress to be distributed more uniformly along the forming path, reducing peak stresses and preventing localized wear, thereby extending die lifetime while maintaining a manageable design complexity.
3Manufacturing precision
If longer rolling dies are used to produce screws with large pitch and high thread flank height, then thread quality improves, but production rate decreases
Solution Approach 1:
The patent applies parameter changes by continuously varying the profile angle along the groove length, which optimizes material displacement and forming efficiency. This allows high-quality thread formation with large pitch and high flank height to be achieved in a shorter die length, maintaining production rate while ensuring thread quality.
Data Source
AI summary
A rolling die for forming a screw thread on a screw blank is disclosed. The rolling die has a plurality of grooves, where the grooves each have two flanks as seen in cross-section. At least a portion of each of the grooves has a forming area in which the size of a profile angle enclosed by the flanks decreases continuously along the grooves.