Tubular Internal Stop Forming by Axial Cold Calibration
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Solution Overview
Problem
Conventional methods for producing internal stops in tubular components are time-consuming and complex in terms of tool technology, particularly when dealing with high-strength steel alloys, which can result in surface defects like breakouts or pitting.
Innovation Solution
A method involving axial cold forming processes, where a tubular component is reduced in diameter using a first die, followed by a resetting process with a second die to form a conical area and a circumferential embossment, and then widened using an inner tool to create an internal stop within a mold cavity, allowing for precise calibration without radially displaceable punches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional rolling process is used to produce internal stop, then the internal stop can be formed, but the production time is excessive and tool technology complexity increases
Solution Approach 1:
The forming process is divided into multiple sequential steps: initial forming with a first tool to create a conical area, followed by a resetting process with a second tool, and final calibration with a third tool. This segmentation allows each tool to perform a specific function, reducing overall process complexity and time
Solution Approach 2:
The initial forming step creates a conical area that prepares the material for subsequent resetting and calibration operations. This preliminary shaping enables the final internal stop geometry to be achieved more efficiently with simpler tools
2Manufacturing precision
If roller burnishing is used on high-strength steel alloys, then surface finish can be improved, but surface breakouts or pitting and rolling in of foreign bodies occur
Solution Approach 1:
The conventional roller burnishing mechanical system is replaced with a calibration process using a calibrating tool that pushes against the internal stop geometry. This substitution eliminates the harmful mechanical rolling action while achieving the desired surface finish and geometric precision through controlled material displacement
Solution Approach 2:
The calibrating tool acts as an intermediary that transfers the final geometry to the internal stop area without directly rolling or burningishing the surface. This intermediary approach allows precise geometry transfer while avoiding surface damage
3Shape
If radial displacement tools are used for forming, then complex geometries can be achieved, but wall thickness variations increase
Solution Approach 1:
The process transitions from radial displacement to axial displacement for the final calibration step. The calibrating tool moves axially through the tubular component, pushing material to form the internal stop geometry. This dimensional change enables complex geometry formation while maintaining uniform wall thickness through controlled plastic deformation
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 reduces production time and complexity, avoids surface defects, and allows for the creation of precise internal stops in high-strength steel alloys with minimal wall thickness variations, making it cost-effective and efficient.
Implementation Method 1
an axial cold forming process is involved
Implementation Method 2
reducing an inner diameter of a first end of the tubular component by a relative movement between the tubular component and the first die in an axial direction
Implementation Method 3
forming the first conical area by a relative movement of a second die in the axial direction
Implementation Method 4
create in a longitudinal section of the first conical area a circumferential embossment on an outside and a bead on an inside
Implementation Method 5
widening the first end of the tubular component by inserting an inner tool axially into the first end
Implementation Method 6
widening the first end of the tubular component by inserting an inner tool axially into the first end of the tubular component
Implementation Method 7
while the tubular component is supported on an outside in a mold cavity of an outer tool
Data Source
AI summary
An inner diameter of a first end of a tubular component, positioned in relation to a first die, is reduced through relative movement between the tubular component and the first die such as to produce a first conical area between first and second ends of the tubular component. The first conical area is then formed through relative movement of a second die to create in a longitudinal section of the first conical area an outer circumferential embossment and an inner bead having an inner diameter smaller than the inner diameter of the first end. The first end is widened through insertion of an inner tool, while the tubular component is supported on an outside in a mold cavity of an outer tool. An inner contour with an internal stop is formed as an outer surface of the first end of the tubular component rests flatly in the mold cavity.