Segmented Shaping Jaw for Rotary Kneading Tool Wear Reduction
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Solution Overview
Problem
The existing rotary swaging tools with one-piece mold jaws made of hard metal are expensive due to their high-quality material properties, which lead to significant wear during relative movements, particularly with wedges for radial adjustment, resulting in high maintenance costs.
Innovation Solution
The mold jaw design features a structurally separate shaping surface and jaw base body, allowing for different material configurations, where the shaping surface is made of hard metal and the jaw base body is made of less abrasive and cost-effective materials like hardened steel or powder metallurgical SPM steel, with a securing element for play-free mounting and easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If forming jaws are made of hard metal with high-quality material properties, then forming force transmission is reliable, but wear during relative movements increases and cost increases
Solution Approach 1:
The forming jaw is divided into two separate components: a base body and a forming surface. The base body is made of less abrasive material (hardened steel or SPM steel) while the forming surface is made of hard metal. This segmentation allows each component to be optimized for its specific function, reducing overall wear while maintaining reliable force transmission.
Solution Approach 2:
Different materials are used for different parts of the forming jaw. The forming surface that contacts the workpiece is made of hard metal for reliable force transmission, while the base body is made of less abrasive material to reduce wear during relative movements. This local quality differentiation resolves the contradiction between reliability and wear.
2Reliability
If forming jaws are made of hard metal, then forming force transmission is reliable, but cost increases
Solution Approach 1:
The forming jaw is segmented into a base body and a forming surface that can be manufactured separately. This allows the expensive hard metal to be used only where necessary (forming surface), while the base body uses more cost-effective materials, thereby reducing overall manufacturing cost while maintaining reliability.
Solution Approach 2:
Hard metal material property is applied locally only to the forming surface where it is most needed for reliable force transmission, rather than throughout the entire forming jaw. This local application of high-quality material reduces cost while preserving the necessary reliability.
3Reliability
If forming jaws are made of hard metal, then forming function is optimized, but wear on contact components increases
Solution Approach 1:
The forming jaw is segmented into a base body and forming surface. The base body is made of less abrasive material that contacts the wedge and guide surfaces, reducing abrasion on these components. The forming surface made of hard metal maintains optimal forming function, thus resolving the contradiction.
Solution Approach 2:
Different material properties are assigned to different regions: the base body uses less abrasive material to minimize wear on contact components, while the forming surface uses hard metal for optimized forming function. This local differentiation eliminates the harmful abrasion effect on contact components.
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
A forming jaw (3) of a rotary kneading tool for forming a plastically deformable, preferably metallic, workpiece comprises a jaw base (13) and a forming body (14) that is structurally separate from the jaw base (13) and mounted on the jaw base (13), preferably connected to the jaw base (13). The forming body (14) is bounded on one side of the workpiece by a forming surface (15) designed for forming the workpiece. A rotary kneading tool comprises at least one forming jaw (3) of the aforementioned type.