Spinning Forming Tool Edge Separation Control
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Solution Overview
Problem
Conventional spinning forming methods result in the formation of press marks on plates due to the separation of processing tools at the outside edge of the formation target region, leading to unwanted depressions.
Innovation Solution
The method involves moving the processing tool from the inside edge to the outside edge of the plate while rotating, with the tool standing by at the outside edge or reducing its speed near the edge to prevent press mark formation, and using a trapezoidal forming roller for precise shaping without a shaping die, allowing for local heating to enhance processing intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the processing tool is separated from the plate immediately after reaching the outside edge of the formation target region, then the processing time is reduced, but a press mark is formed at the separation position
Solution Approach 1:
The processing tool performs a preliminary action by applying a gentle pressing force just before separation to gradually reduce the depression depth, preventing the formation of a press mark at the separation position while minimizing additional processing time
Solution Approach 2:
The axial sending speed and pressing force of the processing tool are dynamically adjusted during the separation phase, reducing the pressing intensity as the tool approaches the outside edge to prevent press mark formation while maintaining efficient processing
2Productivity
If the processing tool is pressed against the plate at constant speed, then the processing efficiency is high, but a depression corresponding to the tool shape is formed at the separation position
Solution Approach 1:
The processing tool transitions from constant speed pressing to variable speed pressing with reduced axial sending speed near the outside edge, dynamically adjusting parameters to prevent press marks while maintaining overall processing efficiency
Solution Approach 2:
The axial sending speed and radial traveling speed are reduced when the processing tool is located in the vicinity of the outside edge, changing the processing parameters to prevent press mark formation while minimizing impact on productivity
3Manufacturing precision
If a shaping die is used in conventional spinning forming, then the forming precision is improved, but the manufacturing cost increases
Solution Approach 1:
The shaping die is extracted/removed from the spinning forming process, and the forming precision is maintained through alternative means such as controlled processing tool parameters and multi-stage processing without requiring expensive specialized tooling
Solution Approach 2:
The processing tool is designed to perform multiple forming operations without requiring a permanent shaping die, using a cost-effective approach that eliminates the need for expensive, specialized forming tools while maintaining acceptable precision through process control
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 effectively prevents the formation of press marks and reduces manufacturing costs by eliminating the need for shaping dies, while ensuring precise shaping and reduced warp-up of the plate.
Implementation Method 1
forming a formation target region of a plate into a tapered shape by using a processing tool while rotating the plate
Implementation Method 2
The pressing of the processing tool against the plate may be performed while locally heating a portion of the plate, the portion being located on a same circumference as a portion of the plate against which portion the processing tool is pressed
Data Source
Figure 1
Figure 2A~2B
Figure 3~5
AI summary
A spinning forming method is a method of forming a formation target region of a plate into a tapered shape by using a processing tool while rotating the plate. The processing tool is moved from an inside edge of the formation target region to an outside edge of the formation target region while being pressed against the plate. The plate is rotated in a state where a position of the processing tool is fixed at the outside edge.