Swaging Die Holder with Stress Relief Slot and Reusable Insert
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional die holders for swaging operations face issues with stress concentration leading to crack or breakage, and the need for complete replacement due to chip-off and clash during sliding and swaging, without the option of reusing or re-sharpening inserts treated with cryogenic or heat to prevent distortion.
Innovation Solution
A swaging die holder design featuring an elliptical die holder slot, stress relief slot, radius curve, and a recess with a dove tail shape to accommodate a reusable and replaceable insert made of High-Speed Steel (HSS) with cobalt content, which can be re-grinded or re-sharpened, and treated with cryogenic or heat temperatures to prevent distortion, and includes a packing shim for worn-out inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional die holders are used for swaging operations, then the swaging process can be performed, but stress concentration leads to crack or breakage of the die holder
Solution Approach 1:
The die holder is divided into two main segments: a reusable holder body and replaceable inserts. The holder body contains recesses that accommodate inserts with swaging surfaces. This segmentation allows the holder body to be retained and reused while only the inserts need replacement when worn, preventing complete die holder failure and improving reliability.
Solution Approach 2:
The patent applies parameter changes through cryogenic or heat treatment of the insert faces to prevent distortion during swaging operations. This thermal parameter change enhances the material properties of the inserts, increasing their strength and resistance to stress concentration, thereby preventing crack or breakage.
2Productivity
If conventional die holders are used, then swaging operations can proceed, but chip-off and clash during sliding and swaging require complete replacement of the die holder
Solution Approach 1:
The die holder is segmented into a reusable holder body and replaceable inserts. When chip-off or clash occurs during sliding and swaging, only the inserts need to be replaced rather than the entire die holder. This reduces material loss and maintains productivity by allowing quick insert replacement.
Solution Approach 2:
The patent implements a system where worn inserts are discarded and replaced, while the holder body is recovered and reused. This approach minimizes material loss by retaining the majority of the die holder structure and only replacing the consumable insert components that undergo wear during swaging operations.
3Manufacturing precision
If inserts are treated with cryogenic or heat to prevent distortion, then swaging precision is improved, but the inserts cannot be reused or re-sharpened
Solution Approach 1:
The die holder system is segmented into a reusable holder body and replaceable inserts. The inserts are designed to be replaced when worn, while the holder body with its precision-machined recesses is retained and reused. This segmentation allows the precision-critical components (holder recesses) to be preserved while the consumable inserts are replaced, maintaining manufacturing precision across multiple production cycles.
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 prevents complete die holder replacement by allowing for the reuse and re-sharpening of inserts, reducing stress concentration, chipping, and distortion, thus enhancing operational efficiency and cost-effectiveness in producing various profiles and sizes for flexible shafts used in industrial applications.
Implementation Method 1
The insert is further re-grinded or re-sharpened for same or other profile applications of the flexible shaft. The die holders are treated with cryogenic or heat or sub-zero temperatures to avoid distortion in shape or profile at the end of the flexible shaft during operating condition.
Data Source
AI summary
The present invention discloses a swaging die holder for the flexible shaft operations. In the preferred embodiment, the swaging die holder comprises of an elliptical die holder slot, a stress relief slot, a radius curve, a recess and an insert. The die holder slot at top of the die holder allows each die holder to mount to the machine. The insert is adapted through the recess at the bottom of each die holder and designed to produce the different output profiles at the end of the flexible shaft. The insert is made of HSS material with cobalt content to achieve optimal life. The insert is further re-grinded or re-sharpened for same or other profile applications of the flexible shaft.