Scroll Rotor Mold with Variable Land Section for Uniform Forging
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Solution Overview
Problem
Existing methods for fabricating scroll rotors, such as typical forging and closed-die forging, result in uneven wrap part heights, material wastage, increased molding loads, and operational hazards due to bulging caused by back pressure, which complicates product withdrawal and requires additional maintenance.
Innovation Solution
A mold with a spiral extrusion passage and adjustable land section length and taper, allowing controlled material flow and reduced contact pressure, eliminating the need for back pressure equipment and simplifying the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If typical forging process is used, then the manufacturing process is simple, but the wrap part height becomes uneven and material wastage increases
Solution Approach 1:
The extrusion passage is designed with varying cross-sectional area along its length, creating different flow resistance characteristics in different sections. This local variation in geometry allows differential material flow control, ensuring uniform wrap part height despite the complex spiral shape.
Solution Approach 2:
The land length and cross-sectional area of the extrusion passage are optimized as key parameters. By adjusting these geometric parameters, the material flow speed and pressure distribution are controlled, achieving both height uniformity and reduced material wastage without complicating the overall forging process.
2Manufacturing precision
If closed-die forging is used to make wrap part height even, then manufacturing precision improves, but molding load increases rapidly and mold damage risk increases
Solution Approach 1:
The extrusion passage is divided into multiple sections with different cross-sectional areas and land lengths. This segmentation allows progressive material flow control, distributing the molding load throughout the process rather than concentrating it at the final stage, thus preventing sudden load spikes and mold damage.
3Manufacturing precision
If back pressure is applied to minimize height unevenness, then manufacturing precision improves, but device complexity increases and additional maintenance is required
Solution Approach 1:
The mold design itself provides the necessary flow control function through the optimized extrusion passage geometry. The varying cross-sectional area and land length create inherent flow resistance that automatically regulates material flow, eliminating the need for separate back pressure generation equipment and its associated complexity.
4Manufacturing precision
If back pressure is applied, then manufacturing precision improves, but contact pressure increases and product withdrawal becomes difficult
Solution Approach 1:
The extrusion passage geometry is locally optimized with specific cross-sectional areas and land lengths that control material flow and pressure distribution. This localized geometric control achieves height uniformity while preventing excessive contact pressure that would hinder product withdrawal.
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 minimizes wrap part height unevenness, reduces material wastage, enhances operational convenience by facilitating easier product withdrawal, and simplifies the molding process without additional equipment maintenance, thereby improving efficiency and economic competitiveness.
Implementation Method 1
The land section has a taper, the width of which decreases along the direction in which the extruded material flows when the material is being extruded
Implementation Method 2
molding a scroll rotor by deforming the material by applying a pressure to the material with a punch
Implementation Method 3
the extrusion outlet having a spiral extrusion passage conforming to a wrap part of a scroll rotor
Data Source
AI summary
A mold for forging a scroll rotor capable of controlling material flow speed by adjusting a land section, a molding device applying same, and a method for manufacturing the mold. In the mold, a die includes an extrusion unit having a molding space therein and a spiral-shaped extrusion passage provided in the lower portion thereof so as to correspond to a wrap portion disposed in the scroll rotor. A punch is connected to the die to be in close contact with the inner circumference of the molding space and to be able to slide up and down. The lower portion has a shape corresponding to the upper surface of the flange portion of the scroll rotor and a boss portion. The extrusion passage has a land section in direct contact with the extrusion material. The height of a land of the land section varies along the spiral direction.