Sprocket Segment Hot Forging Die for Precision Rib and Toothed Face
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Solution Overview
Problem
The existing manufacturing process for sprocket segments in endless track vehicles is time-consuming and costly, requiring extensive machining and human power, which hampers productivity and competitive pricing due to the need for precise alignment and machining of rib and toothed faces, as well as the formation of bolt holes.
Innovation Solution
A method and apparatus utilizing a series of dies in a hot forging process, including a bending type booster die, blocker die, finisher die, trimming-piercing-coining die, and flash cutting die, to perform sequential hot forging and precision trimming without machining, ensuring precise alignment and formation of bolt holes while eliminating flash, thereby simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional hammer forging and general trimming process are used, then extraction slope is needed for product removal, but machining time increases and manufacturing cost rises
Solution Approach 1:
The patent inverts the traditional approach by designing the forging die with an extraction slope mechanism that enables automatic product removal without requiring subsequent machining operations. The die structure itself incorporates the extraction function, reversing the conventional sequence where machining is needed after forging.
Solution Approach 2:
The forging die is designed to perform multiple functions: shaping the sprocket segment, creating the extraction slope for easy removal, and preparing the surface for direct use without additional machining. This multi-functional die eliminates the need for separate machining operations.
2Manufacturing precision
If extensive machining operations are performed on rib face and toothed face, then precise planes are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The forging die is designed with precision surfaces that directly form the required rib face and toothed face planes during the forging process itself. The preliminary action of creating precise surfaces during forging eliminates the need for subsequent machining operations to achieve the required precision.
Solution Approach 2:
The patent extracts the machining operations from the manufacturing process by incorporating all necessary surface precision requirements into the forging die design. The die directly produces the final precision surfaces, removing the need for separate machining steps.
3Manufacturing precision
If bolt holes are formed by drilling after forging, then proper hole formation is achieved, but additional manufacturing steps and time are required
Solution Approach 1:
The patent merges the bolt hole formation operation with the forging process by incorporating piercing elements into the forging die. The holes are created simultaneously with the shaping operation, combining two previously separate steps into one integrated process.
Solution Approach 2:
The bolt holes are formed during the forging process itself rather than as a subsequent operation. The preliminary action of piercing the holes while the material is hot and pliable ensures proper hole formation without requiring additional drilling operations.
4Manufacturing precision
If multiple separate manufacturing steps are used, then each operation can be optimized, but total manufacturing time and cost increase
Solution Approach 1:
The patent combines multiple manufacturing operations (forging, trimming, piercing, and surface formation) into a single integrated forging process. The die structure incorporates all necessary functions to perform these operations simultaneously, reducing the total number of steps while maintaining product quality.
Solution Approach 2:
The forging die is designed as a multi-functional tool that performs shaping, trimming, piercing, and surface finishing in one operation. This universal die eliminates the need for multiple specialized machines and operations, reducing total manufacturing time while maintaining precision.
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 significantly reduces manufacturing time and costs by enabling the production of sprocket segments with precise rib and toothed faces and bolt holes through a simplified process, enhancing productivity and quality while maintaining competitive pricing.
Implementation Method 1
a bending type booster die having an upper die and a lower die for primarily hot-forging a heated billet in a booster type to distribute its volume
Implementation Method 2
a blocker die having an upper die (16) and a lower die for secondarily hot-forging the material hot-forged in the booster die to form a rib face
Implementation Method 3
a finisher die having an upper die and a lower die for tertiarily hot-forging the material hot-forged in the blocker die to keep right angles and planes of a toothed face and the rib face
Data Source
AI summary
Disclosed therein are an apparatus and method for manufacturing a sprocket segment, which can manufacture the sprocket segment through a simplified process including hot precision forging, through hardening and painting, thereby reducing manufacturing period and cost and securing competitive power. The sprocket segment manufacturing method includes: a primary hot forging process of putting a heated billet in a booster die (10) mounted on a forging press to perform a distribution of volume; a secondary hot forging process of putting the hot forged material (M) in a blocker die (11) to form a rib face (4); a tertiary hot forging process of putting the secondarily hot forged material (M) in a finisher die (12) to keep right angles and planes of a toothed face (6) and the rib face (4); and a process of putting the tertiarily hot forged material (M) in a product guide die (22) of a trimming-piercing-coining die (13) to eliminate a flash and form bolt holes (7) simultaneously.