Segmented Counterholder Mandrel for Continuous Hollow Shaft Forging
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Solution Overview
Problem
Existing methods for producing hollow shafts with varying internal and external diameters require multiple re-clamping setups, leading to increased handling outlay, longer cycle times, and higher costs.
Innovation Solution
A device comprising centrally symmetric forging tools and a counterholder mandrel with two parts, allowing for continuous production by axial and radial movements, enabling the production of hollow shafts with varying diameters without re-clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple re-clamping setups are used to produce hollow shafts with varying diameters, then manufacturing precision can be maintained, but handling outlay increases and cycle time lengthens
Solution Approach 1:
The counterholder mandrel is divided into multiple axially displaceable segments (first counterholder segment, second counterholder segment, etc.), each capable of independent axial movement. This segmentation allows each segment to be positioned independently to define different internal diameters at different axial locations of the hollow shaft, enabling varying diameter production without re-clamping while maintaining manufacturing precision.
Solution Approach 2:
The counterholder segments are designed with dynamic axial adjustability through drive mechanisms (motors, lead screws, or cam mechanisms) that enable continuous or stepped axial positioning during the forging process. This dynamic adjustment capability allows the internal cavity shape to be changed on-the-fly between forging passes, eliminating the need for re-clamping operations and reducing cycle time while maintaining dimensional accuracy.
2Manufacturing precision
If multiple re-clamping setups are used to produce hollow shafts with varying diameters, then manufacturing precision can be maintained, but handling outlay increases
Solution Approach 1:
The counterholder mandrel is divided into multiple axially displaceable segments (first counterholder segment, second counterholder segment, etc.), each capable of independent axial movement. This segmentation allows each segment to be positioned independently to define different internal diameters at different axial locations of the hollow shaft, enabling varying diameter production without re-clamping while maintaining manufacturing precision.
Solution Approach 2:
The counterholder device with multiple adjustable segments serves multiple functions: it defines the internal cavity shape, supports the blank from the inside, and enables varying diameter production all within a single clamping setup. This multi-functionality eliminates the need for multiple specialized clamping fixtures, reducing handling complexity while maintaining manufacturing precision.
3Manufacturing precision
If multiple re-clamping setups are used to produce hollow shafts with varying diameters, then manufacturing precision can be maintained, but production costs increase
Solution Approach 1:
The counterholder mandrel is divided into multiple axially displaceable segments (first counterholder segment, second counterholder segment, etc.), each capable of independent axial movement. This segmentation allows each segment to be positioned independently to define different internal diameters at different axial locations of the hollow shaft, enabling varying diameter production without re-clamping while maintaining manufacturing precision.
Solution Approach 2:
The forging process continues without interruption or re-clamping by using the axially adjustable counterholder segments to define different internal cavity shapes between passes. The blank remains clamped throughout, and the counterholder segments are repositioned axially between forging operations, maintaining continuous productive action and improving production efficiency while preserving dimensional 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
Facilitates low handling outlay, shorter cycle times, and reduced costs by enabling continuous production of hollow shafts with varying diameters.
Implementation Method 1
at least the external part is designed to be able to move axially relative to the internal part
Implementation Method 2
at least two forging tools, which are arranged centrally symmetrically about a forging axis and can be driven in the sense of radial working strokes
Data Source
AI summary
A device and method for continuously producing an at least partly hollow shaft having a varying inner diameter includes forging tools that are arranged centrally symmetrically about a forging axis and are driven radially, a clamping chuck for holding an at least partly hollow cylindrical blank, and a counter-holder for axially supporting the blank. The counter-holder has a base and a counter-holder mandrel arranged on the base and extending axially into a central cavity in the blank. The mandrel is formed of at least two parts, wherein a first part of the counter-holder mandrel constitutes an inner part and a second part of the counter-holder mandrel constitutes an outer part surrounding the inner part. At least the outer part can be moved axially relative to the inner part.