Segmented Inner Die for Copper-Beryllium Forging Shape Stability
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Solution Overview
Problem
The existing forging method for copper-beryllium alloys, which involves repeated press-deformation from orthogonal axes, faces challenges in maintaining the rectangular parallelepiped shape and efficiency, leading to deformation issues and increased production time.
Innovation Solution
A forging method and die design where the inner die is composed of multiple parts fitted into the outer die, dispersing stress evenly and preventing breakage, allowing for more efficient deformation and shape stability, with a specific volume ratio and pressurization strategy to ensure consistent plastic strain across axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If repeated press-deformation from X, Y, and Z axes is performed to achieve uniform hardness and prevent working strain, then the bulk body maintains uniform properties, but the rectangular parallelepiped shape becomes deformed and production efficiency decreases
Solution Approach 1:
The inner die is divided into multiple die parts (first die member and second die member) that can be separated at corner portions. This segmentation allows the work to be press-deformed while maintaining shape stability, as the divided die structure better accommodates the deformation forces without causing the work to lose its rectangular parallelepiped shape.
Solution Approach 2:
The die parts are specifically designed with different configurations at different locations - the corner portions are separated while the face portions maintain contact. This local differentiation allows the work to be uniformly press-deformed across all axes while preventing shape deformation, achieving both uniform hardness and shape stability.
2Device complexity
If the inner die is designed as a single integrated structure, then the die structure is simple, but stress concentration during pressurization causes die breakage
Solution Approach 1:
The inner die is segmented into multiple die parts that are fitted into the outer die. These divided die parts disperse the stress applied during pressurization of the work, preventing stress concentration that would lead to die breakage. The segmentation improves reliability while maintaining reasonable structural simplicity.
Solution Approach 2:
The die structure transitions from a single integrated form to a multi-part configuration. This parameter change in the die structure allows stress to be distributed across multiple components rather than concentrated in one piece, significantly improving breakage resistance during high-pressure forging operations.
3Productivity
If working speed is increased to improve production efficiency, then productivity increases, but the rectangular parallelepiped shape of the bulk body becomes deformed
Solution Approach 1:
The segmented inner die structure enables faster press-deformation cycles without shape deformation. The divided die parts can be configured to apply force more uniformly and efficiently, allowing increased working speed while maintaining the rectangular parallelepiped shape of the work throughout the process.
Solution Approach 2:
The die parts are pre-configured in specific positions and orientations before the press-deformation process. This preliminary arrangement ensures that when pressurization occurs at high speed, the work is deformed uniformly without shape distortion, enabling increased productivity while maintaining shape stability.
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 enhances the efficiency of the forging process by maintaining shape stability, reducing die breakage, and enabling more efficient production with improved uniformity and durability of the copper-beryllium alloy products.
Implementation Method 1
the stress applied to the inner die during pressurization of the work can be dispersed to the outer peripheral side more evenly by the plurality of die parts
Implementation Method 2
a plastic strain is applied to a rectangular parallelepiped bulk body made from a copper-beryllium alloy through press-deformation from X, Y, and Z axes orthogonal to each other
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
A forging method according to the present invention is characterized by including the steps of placing a work W having a first shape which is a rectangular hexahedron in a work space 45 of a forging die 20 which has a rectangular opening, which is formed by rectangular plane wall portions, and which is provided with the work space 45 to hold the work in a placement step and applying a plastic strain to the work W by deforming the placed work W into a second shape which is a rectangular hexahedron in a working step, wherein the placement step and the working step are performed at least two times. For example, the work is press-deformed in the work space of the forging die and, thereby, the shape stability can be further ensured. Also, the forging die 20 has a structure in which a plurality of die parts are fitted into the inner periphery of the outer die, so that, for example, the stress applied to the inner die 50 during pressurization of the work W can be dispersed to the outer peripheral side more evenly by the plurality of die parts and breakage of the die and the like can be further suppressed.