Rotating Die Profile Forming for Controlled Plastic Deformation
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Solution Overview
Problem
Existing extrusion and pultrusion devices face challenges in optimizing the profile definition zone for materials that undergo plastic deformation, leading to issues with production quality and device durability under high pressure and temperature conditions.
Innovation Solution
A device with a rotating die and counter-bearing configuration that controls maximum and minimum pressure in the first and second channel sections, allowing for precise plastic deformation of materials, optimizing the transition from a master profile to a final profile based on material properties and process conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotating die is used in the second channel section to exert pressure on the material, then production speed and quality are improved, but the risk of material rupture and device damage increases under high pressure
Solution Approach 1:
The profile definition zone is divided into two distinct channel sections: a first channel section with static walls for initial shaping, and a second channel section with a rotating die for final profiling. This segmentation allows each section to perform its specific function optimally while distributing the deformation load, preventing material rupture.
Solution Approach 2:
The first channel section performs preliminary deformation of the material before it enters the second channel section. By pre-shaping the material in a controlled manner with static walls, the material is better prepared for the subsequent high-pressure deformation in the rotating die, reducing the risk of rupture.
2Manufacturing precision
If the rotating die exerts high pressure to achieve precise plastic deformation, then manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The second channel section employs a rotating die that can rotate about an axis, introducing dynamic capability to the extrusion process. This rotation allows the die to exert pressure on the material in a controlled, cyclic manner, achieving precise plastic deformation while distributing the mechanical load over time, thereby managing device complexity.
Solution Approach 2:
The system allows for adjustment of operational parameters including the rotation speed of the die, the pressure exerted on the material, and the geometric configuration of the channel sections. By optimizing these parameters, high manufacturing precision is achieved while avoiding excessive device complexity through parameter tuning rather than structural complexity.
3Loss of substance
If the first channel section is optimized for minimum side leakage, then material utilization is improved, but the load rate control becomes more difficult
Solution Approach 1:
The first channel section is designed with specific geometric features including tapered walls and optimized cross-sectional dimensions that vary along the length of the channel. These local geometric variations control the flow of material, minimizing side leakage while maintaining proper load rate distribution to the second channel section.
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
Ensures high-quality production of profile products with controlled deformation, reducing the risk of material rupture and device damage while maintaining high production rates.
Implementation Method 1
for forming a profile product made from a plastically deformable material
Data Source
AI summary
A method and an extrusion- or pultrusion device for forming a profile product made from a plastically deformable material and/or viscoplastic material in a production direction, the device comprising, a rotating die, extending in a radial direction and a width direction, having two opposite first and second side walls and an outer circumferential surface extending in the width direction there between. The rotating die comprises a first side portion in connection to the first side wall and a second side portion in connection to the second side wall and a mid-portion extending between the first and second side portions, and a profile definition zone having a longitudinal direction coinciding with the production direction, a height direction and a width direction being perpendicular to the height direction, comprising a through channel comprising a first channel section followed by a second channel section downstream the first channel sectionwith reference to the production direction. The rotating die is rotatable about an axis extending across the production direction and arranged to allow the outer circumferential surface to, while the rotating die rotates, exert a pressure onto a surface of the material when fed through the profile definition zone.