Tubular Shaft Flange Forming With Wall Thickness Retention
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Solution Overview
Problem
Existing spinning devices face challenges in forming flange portions on cylindrical base materials for shafts, leading to reduced deformation resistance and strength due to thin-walled sections, which can compromise the ability of the shafts to withstand actual usage environments.
Innovation Solution
A spinning device and method that involves a flange forming section, where the large-diameter portion of a tubular base material is pressed along the center axis to form a flange portion, maintaining the wall thickness by partially crushing and reducing the diameter of the large-diameter portion, allowing the surplus volume to be deformed into a flange, thus preventing significant reduction in wall thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a flange portion is formed by conventional spinning methods on a cylindrical base material, then the flange portion can be formed, but the wall thickness is significantly reduced leading to decreased deformation resistance and strength
Solution Approach 1:
The method performs preliminary action by forming a large-diameter portion and small-diameter portion on the base material before forming the flange portion. This preliminary shaping allows the subsequent flange forming process to maintain wall thickness by controlling material flow and distribution, thereby preserving deformation resistance while achieving the desired flange shape.
Solution Approach 2:
The invention applies parameter changes by modifying the diameter parameters of the base material to create large-diameter and small-diameter portions. This parameter variation enables controlled material redistribution during flange forming, preventing excessive thinning and maintaining adequate wall thickness for structural strength.
2Quantity of substance
If thin-wall working is performed to reduce wall thickness, then material usage is optimized, but the mechanical strength and deformation resistance are compromised
Solution Approach 1:
The method applies local quality by creating distinct large-diameter and small-diameter portions at specific locations on the base material. This localized diameter variation enables precise control over material flow and wall thickness distribution, allowing thin-wall sections where appropriate while maintaining adequate thickness in load-bearing areas to preserve mechanical strength.
3Strength
If the large-diameter portion is pressed in the center axis direction, then the flange portion is formed with maintained wall thickness, but the diameter of the large-diameter portion is reduced
Solution Approach 1:
The invention converts the harmful effect of diameter reduction into a beneficial outcome. By intentionally reducing the diameter of the large-diameter portion during pressing, the method redistributes material volume to maintain wall thickness in the flange portion. The diameter reduction is not treated as a defect but as a mechanism to achieve the desired wall thickness preservation and flange formation.
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
The solution enables easy formation of flange portions while maintaining the wall thickness of the base material, enhancing the mechanical strength of the formed product to withstand usage environments effectively.
Implementation Method 1
pressing the large-diameter portion in a center axis direction of the base material while contacting an outer peripheral portion of the small-diameter portion
Data Source
AI summary
A spinning device includes a flange forming section that, in a state where a base material having a tubular shape and including at least a large-diameter portion and a small-diameter portion is relatively rotated, forms a flange portion protruding in a direction away from a center axis by pressing the large-diameter portion in a center axis direction of the base material while contacting an outer peripheral portion of the small-diameter portion.