Square Ram Segmented Mold for Curved Surface Forming
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Solution Overview
Problem
Current methods for forming curved surface board parts in shipbuilding, such as multi-ram and multi-point board formation, face challenges with crumpling, deformation, and dents due to point-based contact, which are not adequately addressed by existing technologies.
Innovation Solution
A curved surface forming device using adjustable segmented molds with square rams that swing and are height-adjustable, arranged in an interlaced manner to provide maximum press-fit area and prevent inclined swinging, allowing for dense arrangement with minimal clearance and surface-based contact to reduce defects during board formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If spherical or disk-shaped rams are used for multi-point board formation, then the contact area with the plate is increased, but the plate still generates harmful crumpling and deformation due to point-based contact and instability of compressed parts
Solution Approach 1:
The mold is divided into multiple independent square rams arranged in a matrix pattern, where each ram contacts the plate at a specific location. This segmentation allows for distributed pressure application while maintaining stability through the collective arrangement of multiple contact points forming a square pattern.
Solution Approach 2:
The invention uses square-shaped rams instead of spherical or disk-shaped rams. The square geometry provides asymmetric contact characteristics that prevent rotation and inclined swinging, ensuring stable vertical compression and eliminating the harmful effects caused by rotational instability of circular rams.
2Area of stationary object
If spherical rams capable of swinging along with the plate shape are used, then the contact area is larger, but additional rubber pads or elastic pads are required under the plate to maintain smoothness, and crumpling and deformation still occur
Solution Approach 1:
The mold consists of multiple independent square rams arranged in a matrix, allowing the contact area to be increased through proper arrangement rather than using large spherical rams. This segmentation eliminates the need for additional rubber pads or elastic pads while maintaining plate smoothness.
Solution Approach 2:
Instead of using large spherical rams that require additional cushioning components, the invention inverts the approach by using multiple small square rams that inherently provide stable contact without requiring rubber pads or elastic pads, thus simplifying the device structure.
3Area of stationary object
If disk-shaped rams are used for board formation, then the contact area is larger than point contact, but many parts of the plate exposed between every two disk rams fail to be pressed, leading to crumpling and deformation
Solution Approach 1:
The mold is segmented into multiple square rams arranged in a dense matrix pattern, ensuring that the entire plate surface is covered and pressed uniformly. The square arrangement with appropriate spacing eliminates uncovered areas between rams that occur with disk-shaped rams, achieving uniform pressure distribution across the entire plate surface.
Solution Approach 2:
The invention transitions from circular symmetry of disk rams to a square matrix arrangement, adding dimensional organization that ensures complete coverage of the plate surface. The square grid pattern in two dimensions ensures no gaps exist between adjacent rams, achieving uniform pressure distribution.
4Manufacturing precision
If integral type molds are used for punching formation, then high precision and good quality are achieved, but the mold manufacturing cost is high and the production period is long
Solution Approach 1:
The mold is segmented into multiple independent square rams that can be manufactured separately and assembled into a matrix arrangement. This segmentation reduces the complexity and cost of manufacturing each individual component compared to a single integral mold, while still achieving high forming precision through the collective action of multiple rams.
Solution Approach 2:
The square rams are designed to be capable of swinging or moving independently, providing dynamic adaptability to the plate surface. This dynamic capability allows the segmented mold to achieve forming precision comparable to integral molds while maintaining the manufacturing advantages of modular components.
Data Source
AI summary
A curved surface forming device for an adjustable segmented mold board with square rams, consisting of an upper group and a lower group of adjustable molds (4) whose height can be adjusted, and a loading mechanism. The adjustable molds (4) are arranged in the loading mechanism and at least one group of adjustable molds (4) can move up and down under the drive of the loading mechanism. The upper group and the lower group of the adjustable molds (4) are respectively provided with M×N and (M−1)×(N−1) square rams (1) capable of swinging. The upper and the lower square rams (1) are arranged in an interlaced manner in both transverse and longitudinal directions. The square rams (1) are composed of a square plate (a) and the sphere (b) with the pressure imposition surface being a plane or a curved surface. The curved surface forming device can eliminate the crumpling and deformation generated in the board punching, reduce dents and improve processing quality.