Rotatable Ball Tool Head for Vibration-Stable Separation Disc Forming
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Solution Overview
Problem
Existing methods for manufacturing conical separation discs by flow forming over a mandrel face issues such as incomplete elevation formation, tool head breakdown due to heat generation, and the need for frequent tool head replacement, along with vibrations during the process.
Innovation Solution
A tool head comprising a ball element, a holding device, and a fixating element that allows for detachable and rotational arrangement, which reduces vibrations and enables effective heat dissipation, and a method involving fluid pressure to complete separation discs with high precision and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a roller is used to press the workpiece over the mandrel, then the separation disc can be manufactured, but the elevations may not reach the required height due to incomplete filling of depressions
Solution Approach 1:
The patent replaces the traditional roller with a ball element that has a spherical contact surface. This spherical geometry provides better conformity to the workpiece and mandrel surfaces, enabling more complete filling of the depressions and formation of elevations that reach the required height for proper disc spacing.
2Productivity
If a roller is used to press the workpiece over the mandrel, then the separation disc can be manufactured, but vibrations are generated during the process
Solution Approach 1:
The ball element's spherical geometry provides more uniform contact and pressure distribution compared to a roller, reducing mechanical instability and vibrations during the pressing operation while maintaining manufacturing capability.
3Productivity
If a roller is used to press the workpiece over the mandrel, then the separation disc can be manufactured, but the tool head breaks down due to large heat generation
Solution Approach 1:
The ball element reduces the contact area and improves pressure distribution, which decreases friction and heat generation during the pressing operation, preventing tool head breakdown while maintaining manufacturing capability.
4Productivity
If a roller is used to press the workpiece over the mandrel, then the separation disc can be manufactured, but the complete tool head must be replaced when the roll is worn out
Solution Approach 1:
The ball element is designed as a separate, detachable component that can be independently replaced without replacing the entire tool head. This segmentation allows for easier maintenance and repair, reducing downtime and costs when wear occurs.
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
The solution ensures complete elevation formation, reduces vibrations, eliminates the need for frequent tool head replacement, and effectively dissipates heat, resulting in high-tolerance, high-surface-finish separation discs.
Implementation Method 1
A known method for pressing separation discs with integrally formed elevations involves flow forming of a sheet metal blank or workpiece over a mandrel to produce a separation disc with integrally formed elevations
Implementation Method 2
activating a fluid pressure on the ball element
Data Source
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AI summary
The invention relates to a tool head (1) for manufacturing a separation disc (2), the tool head (1) comprises: a ball element (4) configured to bear on a work piece (6) to form the separation disc (2) on a rotating mandrel (7); and a holding device (8) for holding the ball element (4); wherein the tool head (1) further comprises a fixating element (10) for detachably and rotatably arrange the ball element (4) at the holding device (8). The invention further relates to a method for manufacturing a separation disc (2) using a tool head (1).