Synchronized Metal Melt Shaping for Shorter Production Cycles
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Solution Overview
Problem
Existing metal processing systems face long production cycle times due to the need for extensive post-processing to achieve desired quality, especially for large or high-quality workpieces.
Innovation Solution
A metal processing and forming system and method that synchronously forms and shapes an initial melt of metallic material using a forming device and shaping device, controlled by a control device, before solidification, to reduce cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If post-processing steps are performed to achieve desired quality (surface roughness, appearance, mechanical properties), then the quality of the workpiece is improved, but the production cycle time increases significantly
Solution Approach 1:
The patent applies preliminary action by performing shaping operations on the metallic material while it is still in molten or semi-molten state, before complete solidification occurs. This allows the workpiece to be shaped during the forming process itself rather than requiring separate post-processing steps after cooling, thereby achieving desired surface quality and geometry without extending the production cycle time
Solution Approach 2:
The patent merges the forming process and shaping process into a single integrated operation. The shaping device operates concurrently with the forming device, combining what were traditionally sequential operations (forming then post-processing) into simultaneous actions, thus eliminating the time loss associated with separate post-processing steps while maintaining workpiece quality
2Manufacturing precision
If the size of the workpiece is large or the quality requirement is high, then the workpiece quality is improved, but the post-processing time increases
Solution Approach 1:
The shaping device performs surface shaping and finishing operations on the metallic material during the forming process, while the material is still in a semi-molten or plastic state. This preliminary shaping action eliminates the need for extensive post-processing of large or high-quality workpieces, as the desired surface quality and geometry are achieved during forming rather than requiring additional time-consuming operations afterward
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 system significantly reduces production cycle time by simultaneously forming and shaping the initial melt, enhancing mechanical strength and surface roughness of the workpiece.
Implementation Method 1
forming an initial melt of the metallic material
Implementation Method 2
before the initial melt is solidified
Data Source
AI summary
A metal processing and forming system and a metal processing and forming method for forming a workpiece on a workbench are provided. The system includes a forming device, a shaping device, and a control device. The forming device is configured for providing a metallic material according to a processing path and forming an initial melt of the metallic material. The shaping device is configured for shaping the initial melt. The control device is coupled to the forming device and the shaping device and configured for synchronously controlling the forming device and the shaping device. The control device controls the shaping device to shape the initial melt, before the initial melt is solidified, to form the workpiece.