Forging Die Vent Cleaning with Ultrasound to Prevent Air Pockets

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Solution Overview

Problem

Forging die vents clog due to residue accumulation, leading to air pocket formation, which affects metal part geometry, increases manufacturing costs, and reduces productivity, as existing methods like increasing vent diameter or manual cleaning are inefficient and hazardous.

Innovation Solution

A device comprising an injection pump for aqueous solution, an ultrasound generator, and a valve system for cleaning vents by injecting an aqueous solution and ultrasound waves, allowing for automated and efficient removal of residues without stopping production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual cleaning methods are used to remove residues from vents, then cleaning effectiveness is improved, but productivity is reduced and safety risks increase

Engineering Contradiction:

Improvevent cleaning effectivenessVSAvoidmanufacturing productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical cleaning operations with an automated ultrasonic cleaning system. The ultrasonic generator produces high-frequency vibrations that automatically remove residues from vent channels without requiring operator intervention, thereby maintaining cleaning effectiveness while eliminating productivity loss and safety risks associated with manual cleaning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cleaning system is integrated into the die itself, with ultrasonic transducers mounted directly on the die surface. This allows the die to clean its own vent channels automatically during or between forging operations, eliminating the need for separate manual cleaning operations and maintaining continuous productivity.

Inventive Principle:

Principle #25Self-service

2Reliability

If vent diameter is increased to prevent clogging, then residue accumulation is reduced, but metal part geometry precision deteriorates

Engineering Contradiction:

Improvevent anti-clogging performanceVSAvoidmetal part geometry

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Instead of relying on increased vent diameter as a mechanical solution to prevent clogging, the patent employs ultrasonic vibration technology to actively remove residues from the vent channels. This allows maintenance of small, precision-critical vent diameters while preventing clogging through automated residue removal rather than increased clearance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The ultrasonic cleaning system performs preliminary or continuous cleaning of vent channels to prevent residue accumulation before it can cause clogging. This proactive approach maintains vent patency without requiring larger dimensions, thereby preserving the precision geometry of metal parts while preventing clogging issues.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If manual cleaning is performed to remove clogs, then vent functionality is restored, but operating safety deteriorates

Engineering Contradiction:

Improvevent functionalityVSAvoidoperator safety

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The die incorporates ultrasonic transducers that automatically clean its own vent channels without human intervention. This self-cleaning capability restores and maintains vent functionality while completely eliminating operator exposure to hot metal environments, molten metal splashes, and other hazardous conditions associated with manual cleaning operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces dangerous manual cleaning operations with an automated ultrasonic cleaning system integrated into the die. The ultrasonic vibrations automatically remove residues and restore vent functionality without requiring operators to handle hot dies or exposed vents, thereby eliminating safety hazards while maintaining vent performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables regular and effective cleaning of vents, preventing clogs and maintaining productivity by removing residues before they accumulate, ensuring consistent air flow and reducing the risk of air pocket formation and metal part defects.

Implementation Method 1

an ultrasound generator, suitable for generating ultrasound waves within the vent

Methodology Applied

Scientific EffectUltrasound: Ultrasound

Implementation Method 2

generating ultrasound waves within the vent

Methodology Applied

Scientific EffectAcoustic cavitation: Acoustic Cavitation

Implementation Method 3

a pump for injecting an aqueous solution, suitable for injecting the aqueous solution into the vent

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS20230083765A1Device for cleaning the vent of a forging die and method for using said device

Publication Date: 2023.03.16 SAFRAN AIRCRAFT ENGINES SAS

AI summary

A device for cleaning a vent of a first forging die suitable for receiving, between the first die and a second die, a metal blank to be shaped in order to produce a metal part, the device for cleaning including a pump for injecting an aqueous solution, suitable for injecting the aqueous solution into the vent, an ultrasound generator, suitable for generating ultrasound waves within the vent, an air intake suitable for ensuring a venting of the vent, and a valve system for alternately controlling at least the injection of aqueous solution and ultrasound and the venting of the vent.