Mandrel-Free Spin Forming With Localized Heating
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Solution Overview
Problem
Conventional spinning forming methods require a mandrel to form depressions and projections on plates, which increases manufacturing costs and limits the ability to create arbitrary shapes due to the need for specific mandrel designs, making it difficult to form features aligned in radial directions.
Innovation Solution
A two-step spinning forming method where a processing tool contacts the plate's main surfaces while rotating, with localized heating on the opposite side, allowing for the formation of level-changing portions without a mandrel, enabling arbitrary depressions and projections in any direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mandrel is used to form depressions and projections on the plate, then the plate can be formed with specific shapes, but the manufacturing cost increases and the ability to create arbitrary shapes is limited
Solution Approach 1:
The invention extracts and eliminates the mandrel from the forming system. Instead of using a mandrel to define the shape, the plate is formed by direct contact with a processing tool that applies localized force and heat. This removal of the mandrel eliminates the cost and complexity of manufacturing custom mandrels for each shape while maintaining the ability to form arbitrary shapes through controlled processing.
Solution Approach 2:
The invention replaces the mechanical mandrel system with a combination of localized mechanical force (processing tool contact) and thermal energy (heating). The processing tool applies force to specific regions of the plate while heating softens the material, allowing deformation without requiring a physical mandrel template. This substitution enables greater design flexibility and reduces manufacturing costs.
2Shape
If a mandrel is used to form the plate, then depressions and projections can be formed, but it is difficult to form features aligned in radial directions
Solution Approach 1:
The invention introduces dynamic control to the forming process. The processing tool can move in multiple directions (radial, tangential, axial) while the plate rotates on the main shaft. This dynamic positioning allows the formation of features in any orientation, including radial directions that are difficult to achieve with a stationary mandrel. The system adapts its geometry through motion rather than requiring a complex fixed mandrel structure.
3Adaptability or versatility
If the plate is formed without a mandrel using localized heating, then arbitrary shapes can be created, but the plate material needs to be heated to appropriate temperature
Solution Approach 1:
The invention applies heating locally to specific regions of the plate rather than heating the entire plate. The heating device targets only the areas where the processing tool will apply force, softening the material locally to facilitate deformation. This localized heating approach enables arbitrary shape formation while minimizing energy consumption and avoiding unnecessary thermal effects in other regions of the plate.
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 method allows for the cost-effective formation of plates with complex shapes by eliminating the need for a mandrel, reducing deformation risks, and enabling precise control over the direction and complexity of formed features.
Implementation Method 1
a heater provided at an opposite side from the processing tool across the plate locally heats a position of the second main surface of the plate, the position being located on the circumference defined by a position of the plate at which the processing tool contacts the plate
Data Source
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AI summary
A spinning forming method of the present invention includes a first forming step and a second forming step, in each of which a plate (W) fixed to a main shaft is formed while being rotated. In the first forming step, a processing tool is brought into contact with a first main surface (S1) of the plate (W) to form a first level-changing portion (41) extending from the first main surface (S1) toward a second main surface (S2). In the second forming step, the processing tool is brought into contact with the second main surface (S2) at an outer peripheral side of the first level-changing portion (41) to form a second level-changing portion (51) extending in an opposite direction to the first level-changing portion (41).