Segmented Forging Die Layout for Misalignment-Free Workpiece Removal
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Solution Overview
Problem
Existing forging tools face challenges with misalignment and difficulty in removing workpieces due to uneven load distribution and potential damage to the tool, especially when using multi-axis forging techniques.
Innovation Solution
The forging tool design incorporates a cuboidal forging space formed by multiple dies with inclined surfaces and a cylindrical member, allowing for even load distribution and easy separation of dies, reducing misalignment and tool damage, and facilitating easy removal of the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single upper anvil is inserted into the compression chamber, then the structure is simple, but misalignment occurs due to deformation and load concentration damages the workpiece
Solution Approach 1:
The upper anvil is divided into multiple anvils (first upper anvil and second upper anvil) that are inserted into respective compression chambers. Each anvil independently supports a portion of the workpiece, distributing the load and preventing misalignment even when deformation occurs. This segmentation resolves the contradiction by maintaining structural simplicity while improving alignment reliability through distributed support.
2Ease of manufacture
If load is applied with one surface contact, then the application is simple, but load concentration causes workpiece sticking and difficulty in removal
Solution Approach 1:
The single-point load application is segmented into multiple contact points through the use of multiple upper anvils and lower anvils. Each anvil pair contacts a different region of the workpiece, distributing the load across multiple surfaces. This prevents localized sticking and allows easy removal by uniformly reducing contact pressure across all anvil-workpiece interfaces.
Solution Approach 2:
Different regions of the workpiece receive localized load application through separate anvil pairs. The first and second upper anvils apply load to different areas, creating a distributed stress field that prevents concentrated sticking. This local quality approach maintains manufacturing simplicity while dramatically improving workpiece removability.
3Device complexity
If compression recess is provided at one end edge portion, then the structure is simple, but misalignment due to inclination causes projecting corner damage
Solution Approach 1:
The single compression recess is segmented into multiple compression chambers with separate recesses. The first compression recess and second compression recess are positioned at different locations, allowing distributed load application that prevents workpiece inclination. This eliminates the projecting corner damage caused by misalignment while maintaining reasonable structural simplicity through modular recess design.
Data Source
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AI summary
A forging tool 10 is to forge a workpiece W in a cuboidal forging space S by using first to sixth wall surfaces 21 to 26. The forging tool 10 includes a first die 30, a second die 40, and a third die 60. The first die 30 forms the first wall surface 21 and the second wall surface 22 adjacent to the first wall surface 21. The second die 40 forms the third wall surface 23 and the fourth wall surface 24 adjacent to the third wall surface 23. The third die 60 forms the sixth wall surface 26 in a region surrounded by a contact surface 61 when bottom surfaces 32, 42 of the first die 30 and the second die 40 are brought into contact with the contact surface 61. The first die 30 forms a triangular region 25a two sides of which are a line of intersection of the fifth wall surface 25 with the first wall surface 21 and a line of intersection of the fifth wall surface 25 with the second wall surface 22, the second die 49 forms a triangular region 25b two sides of which are a line of intersection of the fifth wall surface 25 with the third wall surface 23 and a line of intersection of the fifth wall surface 25 with the fourth wall surface 24, and the workpiece W is pressed between the fifth wall surface 25 and the sixth wall surface 26.