Tubular Case Flange Cold Forging for Stronger Spindle Housings
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Solution Overview
Problem
Multi-process forging in the production of spindle housings leads to reduced mechanical properties, increased industrial waste, and higher production costs, posing safety risks due to thermal effects and working hardening.
Innovation Solution
A one-step cold forging process is employed to form a tubular case with a flange, using a pie-shaped blank material to fill a mold cavity and create a through hole, eliminating the need for multiple steps and reducing thermal distortions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-process forging is used to manufacture spindle housing, then the manufacturing flexibility and adaptability are improved, but the mechanical properties (Ultimate Tensile Strength, Yield Strength, Brinell hardness) deteriorate due to thermal effects and working hardening
Solution Approach 1:
The patent combines multiple separate forging processes into a single integrated cold forging operation. The multi-step process (crude embryo formation, secondary working, hole punching) is merged into one continuous cold forging operation that forms the complete spindle housing with all features in a single step, eliminating the need for multiple heating and cooling cycles that degrade mechanical properties
Solution Approach 2:
The patent changes the fundamental processing parameter from hot forging (multi-process) to cold forging (one-step). This parameter change eliminates thermal effects that cause mechanical property deterioration while maintaining the ability to achieve complex geometries through optimized die design and material flow control
2Adaptability or versatility
If multi-process working is adopted for spindle housing production, then the manufacturing adaptability is improved, but the production costs and industrial waste increase
Solution Approach 1:
The patent merges multiple separate manufacturing operations into a single cold forging process. The crude embryo formation, secondary working, and hole punching operations that were previously separate steps generating waste at each stage are combined into one continuous process that produces the final part in a single operation, eliminating intermediate waste generation
Solution Approach 2:
The patent eliminates the need to discard and reprocess material between multiple forging stages. The one-step cold forging process maintains material integrity throughout the operation, recovering what would otherwise be lost to thermal degradation and multiple handling operations, thereby reducing industrial waste
3Shape
If multi-process forging is used to manufacture tubular case, then the structural complexity and adaptability are improved, but the production time and manufacturing costs increase
Solution Approach 1:
The patent combines the formation of the tubular case body, flange, and through holes into a single cold forging operation. The complex geometry that would require sequential operations (forming the case, then adding flange, then punching holes) is achieved simultaneously through optimized die design that forms all features in one stamping action
Solution Approach 2:
The patent incorporates preliminary action by designing the cold forging die to pre-form all necessary features (case geometry, flange projections, through holes) in a single operation. The die cavity is designed with the final part geometry already embedded, allowing the material to flow and form all features simultaneously during the stamping process
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 method enhances product durability and safety, reduces waste, and lowers production costs by simplifying the manufacturing process and maintaining precise mechanical properties.
Implementation Method 1
pressurizing and cold forging the blank material, which causes the blank material to fill the entire mold cavity to form the tubular case with a tube head, a flange, and a tube body
Data Source
AI summary
There is provided a tubular case with a flange, comprising a tube head which is connected backward to a tube body. A flange extending outward is arranged at the connection between the tube head and the tube body, and a penetrated through hole is arranged inside the tube head and the tube body. The manufacturing method of the tubular case comprise of placing a blank material into the mold cavity for forming a tubular case; pressurizing and cold forging the blank material, which causes the blank material to fill the entire mold cavity to form the tubular case with a tube head, a flange, and a tube body from top to bottom, with a space being arranged inside the tube head and the tube body; and ultimately, punching a hole inside the tubular case to form a through hole penetrating through the space inside the tube head and the tube body.