Rotary Forging Apparatus with Material Elevation Mechanism

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Solution Overview

Problem

Conventional rotary forging methods face challenges when dealing with large materials, including high frictional forces, potential plastic deformation, and cracking, especially when using large dies and rotating mechanisms, which increase costs and reduce efficiency.

Innovation Solution

A method and apparatus that involve separating the material from the lower die using an elevation device, rotating it around its center, and then repositioning it, allowing for controlled rotation without frictional interference and enabling efficient forging without requiring large-scale mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a large die is used for both upper and lower dies to rotate-forging a large material, then the material can be forged, but the weight of the dies increases and the costs increase

Engineering Contradiction:

Improvesize of material to be forgedVSAvoidweight of dies

Core Design Contradiction:

Quantity of substanceVSWeight of stationary object

Solution Approach 1:

The patent extracts the rotary mechanism from the die structure and places it on the material itself. The material is rotated while being pressed by fixed upper and lower dies, eliminating the need for large, heavy rotary dies. This separation of rotation function from the die structure resolves the contradiction between processing large materials and maintaining manageable die weight.

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If rotational mechanism is arranged in upper or lower die to rotate large material, then rotary forging can be performed, but the mechanism becomes extremely large and production costs increase

Engineering Contradiction:

Improverotary forging capabilityVSAvoidsize of rotary mechanism

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Instead of rotating the dies to forge the material, the patent inverts the approach by rotating the material itself while using fixed dies. This inversion eliminates the need for complex rotary mechanisms in the dies, simplifying the device structure while maintaining rotary forging capability.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If material is rotated while placed on lower die, then rotary forging can be performed, but high frictional force prevents easy rotation and control

Engineering Contradiction:

Improveease of rotationVSAvoidfrictional force

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by lifting the material off the lower die surface before rotation. This preliminary separation eliminates the frictional contact that would otherwise hinder rotation, allowing the material to be rotated freely in the air before being placed back on the die for forging.

Inventive Principle:

Principle #10Preliminary action

4Speed

If high rotational force is applied to rotate material, then rotation can be achieved, but unintended plastic deformation and cracking occur

Engineering Contradiction:

Improverotation speedVSAvoidmaterial integrity

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent introduces an intermediary element (such as a support surface or lifting mechanism) that enables rotation without direct frictional contact. This intermediary allows the material to be rotated smoothly with minimal force, preventing the high stresses that would cause plastic deformation or cracking while still achieving the necessary rotation speed.

Inventive Principle:

Principle #24Intermediary (Mediator)

5Productivity

If pressing surfaces are provided to lower die to improve efficiency, then forging efficiency increases, but material cannot be rotated due to intrusion between pressing surfaces

Engineering Contradiction:

Improveforging efficiencyVSAvoidease of rotation

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent applies preliminary action by separating the material from the lower die before rotation occurs. This timing separation allows the material to be rotated in the air without interference from the pressing surfaces, then placed back on the die for forging, thus maintaining both high efficiency and ease of rotation.

Inventive Principle:

Principle #10Preliminary action

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 prevents frictional forces and deformation, allowing for easy rotation of large materials and efficient forging, reducing the need for large-scale rotary mechanisms and lowering production costs.

Implementation Method 1

a lifting process for lifting and separating the material to be forged from the lower die by using elevation means

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS10576531B2Method and apparatus for producing forging by rotary forging

Publication Date: 2020.03.03 PROTERIAL LTD

AI summary

A cycle is repeated a plurality of times, which includes a forging process for placing a material to be forged in a lower die and pressing the material to be forged in this state and then separating an upper die from the material to be forged; an elevation process for lifting the material to be forged by using an elevation device to separate the material to be forged from the lower die; a rotation process for rotating the material to be forged around its center by using a rotation device; and a lowering process for placing the material to be forged rotated by the elevation device in the lower die.