Integrated Scale Removal and Cooling Before Metal Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing forming systems face challenges in efficiently removing scales from heated metal products and improving cooling efficiency before machining, while also minimizing the number of required devices and facilities.
Innovation Solution
A forming system that integrates a forming device, a first scale removing unit for removing scales and cooling the product, and a machining unit, where the scale removing unit can collectively perform scale removal and cooling, reducing the need for additional devices and facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate devices are provided for scale removal and cooling, then scale removal and cooling can be performed individually, but the number of devices and facilities required increases
Solution Approach 1:
The patent combines the scale removal function and cooling function into a single integrated device. The scale removing unit includes a scale removal mechanism and a cooling mechanism that work together in one device, eliminating the need for separate scale removal equipment and separate cooling equipment, thus reducing the total number of devices while maintaining effective scale removal and cooling capabilities
Solution Approach 2:
The scale removing unit is designed with multi-functionality, serving both as a scale removal device and a cooling device. By equipping the scale removing unit with both scale removal capabilities and cooling capabilities, the system achieves universal functionality that reduces device complexity while ensuring reliable scale removal and cooling operations
2Productivity
If machining is performed on high-temperature formed products, then processing time is reduced, but machining accuracy decreases due to cooling contraction
Solution Approach 1:
The patent applies preliminary cooling action by incorporating a cooling mechanism in the scale removing unit that cools the formed product immediately after forming and before machining. This preliminary cooling stabilizes the product dimensions and reduces thermal contraction during subsequent machining operations, thereby improving machining accuracy without significantly extending processing time
Solution Approach 2:
The cooling mechanism operates continuously during the scale removal process, maintaining continuous cooling action throughout the scale removal operation. This continuous cooling ensures that the formed product remains at a stable temperature during machining preparation, preventing thermal expansion and contraction issues that would compromise machining accuracy
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
Effectively removes scales and enhances cooling efficiency of formed products before machining, thereby reducing the number of devices needed and improving processing accuracy.
Implementation Method 1
a first scale removing unit that removes scales from a formed product removed from the forming die
Implementation Method 2
cools the formed product
Data Source
AI summary
A forming system includes a forming device that forms a heated metal material with a forming die, a first scale removing unit that removes scales from a formed product removed from the forming die and cools the formed product, and a machining unit that machines the formed product that has been scale-removed and cooled by the first scale removing unit.