Split Core Forming Die for Undercut Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming undercut parts are costly due to increased process complexity, high die costs, and require additional components, making it difficult to reduce costs and simplify the process.
Innovation Solution
A forming die with a lower die having a bottom and side wall, an upper die that moves parallel to the side wall, and a push-in die that moves between the side and upper die, utilizing first and second split cores with inclined surfaces that slide to form undercut parts, reducing the number of components and simplifying the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a collapsible core is used to form undercut parts, then the forming capability is improved, but the driving mechanism becomes complicated and assembly time increases
Solution Approach 1:
The core is divided into multiple split cores (first split core and second split core) that can move independently relative to each other. The first split core is disposed above the second split core, and they can slide against each other to change the overall diameter, eliminating the need for a complex collapsible mechanism while maintaining forming capability.
2Ease of operation
If inverted trapezoidal grooves are machined in sliding surfaces, then the split cores can slide, but machining difficulty increases and die cost becomes high
Solution Approach 1:
Instead of machining complex inverted trapezoidal grooves into the sliding surfaces, the invention uses simple inclined surfaces on the first and second split cores that slide against each other. The sliding action is achieved through the relative movement of these inclined surfaces, eliminating the need for difficult negative angle groove machining.
3Ease of operation
If additional support members and holders are added to drive split cores, then the split cores can be driven, but the number of components increases and die cost becomes high
Solution Approach 1:
The first split core and second split core are integrated into a single movable shaft member structure, where the first split core is disposed above the second split core on the same shaft. This merging eliminates the need for separate support members and holders for each split core, reducing the total component count while maintaining the ability to drive both cores.
4Ease of operation
If a complex driving mechanism is used, then the split cores can be actuated, but assembly and adjustment time increases
Solution Approach 1:
The movable shaft member is segmented into first and second split cores that can be assembled separately and then combined. This segmentation allows for easier assembly and adjustment compared to a monolithic complex mechanism, as each split core can be positioned and adjusted independently before being fixed together.
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 allows for the formation of undercut parts at a lower cost with a simpler structure, reducing assembly and adjustment time, and minimizing die costs by using fewer components and a more straightforward sliding mechanism.
Implementation Method 1
The second split core approaches the bottom surface of the die body while sliding on the first split core
Implementation Method 2
The first split core includes a pair of first inclined surfaces that are joined together so as to narrow with an upper surface of the first split core as a center
Data Source
AI summary
A forming die includes: a lower forming die having a bottom part and a side wall part; an upper forming die that is movable toward the bottom part of the lower forming die along an axis parallel to the side wall part of the lower forming die; and a push-in die that is movable toward the bottom part of the lower forming die along the axis between the side wall part of the lower forming die and the upper forming die.