Rotary Extrusion of Cabin Sections With Variable Wall Thickness
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Solution Overview
Problem
Existing methods for forming irregularly-shaped thin-walled cabin section workpieces result in material wastage, reduced bearing capacity, and prolonged production processes due to the inability to achieve varying wall thickness through forward and reverse extrusion, cutting off the streamline and requiring excessive material for the barrel body.
Innovation Solution
A rotary extrusion forming method using a male die, female die, upper die assembly, and rotation driving device, where the female die rotates and the male die moves vertically and horizontally to machine the inner side walls of a hollow truncated cone-shaped blank, allowing for one-time heating and forming with improved material utilization and reduced machining stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If forward extrusion and reverse extrusion are used to form irregularly-shaped thin-walled cabin section workpieces, then the forming process is simplified, but it is impossible to achieve varying wall thickness and the streamline is completely cut off resulting in reduced bearing capacity
Solution Approach 1:
The patent inverts the traditional extrusion approach by using rotary extrusion where the die rotates around the workpiece instead of the workpiece being pushed through a linear die. This allows continuous streamline formation while achieving varying wall thickness, resolving the contradiction between process simplicity and bearing capacity.
Solution Approach 2:
The patent introduces dynamic rotation of the female die around the male die during the extrusion process. This dynamic motion enables the formation of irregular shapes with varying wall thickness while maintaining material flow continuity, thus preserving streamline integrity and bearing capacity.
2Ease of manufacture
If the barrel body has the maximum wall thickness required for forming, then the forming process is simplified, but material is wasted
Solution Approach 1:
The patent applies local quality by enabling different wall thicknesses in different regions of the workpiece through rotary extrusion. The female die's rotation allows precise control of material flow to achieve thin walls where needed and thick walls where required, eliminating the need to use maximum wall thickness throughout and reducing material waste.
Solution Approach 2:
The patent changes the extrusion parameters dynamically during the forming process by rotating the female die at controlled speeds and adjusting the extrusion pressure. This allows optimization of material distribution to achieve the required wall thickness variations with minimal material waste.
3Ease of manufacture
If traditional extrusion methods are used for irregularly-shaped thin-walled cabin section workpieces, then the forming process is established, but the production process takes too long
Solution Approach 1:
The patent applies preliminary action by pre-heating the blank to its forming temperature before extrusion and pre-positioning the male and female dies. This preparation reduces the actual forming time and eliminates the need for intermediate heating steps, thereby improving production efficiency while maintaining the established forming process.
Solution Approach 2:
The patent achieves continuity of useful action through the rotary extrusion process where the female die continuously rotates around the male die, maintaining constant material flow and forming action. This eliminates idle time and intermittent operations present in traditional methods, significantly improving productivity.
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 method reduces material consumption, shortens production time, enhances mechanical performance by maintaining uniform deformation, and avoids the decline in load-bearing capacity caused by cutting, while employing an isothermal forming process to improve deformation uniformity and reduce wall thickness differences.
Implementation Method 1
heating the prepared blank to a molding temperature and holding, and preheating the female die and the male die to above the molding temperature and holding
Implementation Method 2
The blank is heated to a molding temperature and held at the temperature for 4 to 6 hours
Data Source
AI summary
The present disclosure provides a rotary extrusion forming method for a cabin section workpiece, comprising the following steps of: first preparing a hollow truncated cone-shaped blank; heating the prepared blank to a molding temperature and holding, and preheating a female die and a male die to above the molding temperature and holding; assembling an upper die assembly on a press; applying lubricant on the female die and the male die, and placing and fixing the blank into a die cavity of the female die; starting up a rotation driving device to drive the female die to rotate on a lower die base, so that the female die drives the blank to rotate; starting up the press to make the male die move down to a machining position of the blank in the female die cavity through the upper die assembly, and machining inner side walls of the blank.