Steering Knuckle Pre-Forging with Mandrel Shaping
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Solution Overview
Problem
The production of forged components for commercial vehicles, such as steering knuckles, involves high material usage and lengthy processing times due to mechanical post-processing, leading to increased costs and environmental impact, while cast products compromise on material strength and resilience.
Innovation Solution
A method that involves pre-forging with a semi-finished contour smaller than the final contour, using a mandrel or hollow mandrel to shape the part, reducing material usage and eliminating the need for extensive machining, thereby saving time and material while maintaining precision and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical post-processing is used to achieve final contour, then manufacturing precision is improved, but processing time increases and material consumption increases
Solution Approach 1:
The patent applies preliminary action by performing pre-forging to create a semi-finished blank that is closer to the final contour before machining. This preliminary shaping reduces the amount of material removal needed in subsequent machining operations, thereby decreasing processing time while maintaining the required manufacturing precision for features like bearing mounts
2Manufacturing precision
If mechanical post-processing is used to achieve final contour, then manufacturing precision is improved, but material consumption increases
Solution Approach 1:
The pre-forging step creates a semi-finished blank with a contour that more closely approximates the final product shape. This preliminary action reduces the volume of material that must be removed during machining, thereby decreasing raw material consumption while still achieving the precise dimensions required for critical features
3Loss of substance
If casting is used instead of forging, then material savings are achieved, but material strength and resilience decrease
Solution Approach 1:
The patent changes the physical state and processing parameters by using warm or hot forging instead of cold forging. This parameter change allows the material to be more formable, enabling the production of complex geometries with less material removal, thereby achieving material savings similar to casting while maintaining the superior material strength and resilience characteristics of forged components
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 reduces raw material consumption, shortens production times, decreases manufacturing costs, and minimizes environmental impact while enhancing the strength and precision of the finished product by optimizing die filling and material displacement.
Implementation Method 1
the material is displaced by the forming and in particular the insertion of the tool(s) and thus the grain of the material is kept parallel to the surfaces
Data Source
Figure 1a~1e
Figure 2a~2f
Figure 3a~3b
AI summary
A method according to the invention for producing forged parts with a prescribed end contour comprises the following steps: pre-forging of a blank in order to obtain a forged part and subsequent reshaping of the forged part in a die, wherein one or a plurality of tools are inserted into the forged part during the reshaping and, in the process, the material of the forged part is displaced in a manner such that the specified end contour is obtained.