Warm Forming Process with Incremental Force Application
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Solution Overview
Problem
Current forming methods, particularly hot forming, are energy-intensive, result in material loss due to scaling, and offer limited formability at high costs, while cold forming lacks sufficient deformation capability and requires high forming forces.
Innovation Solution
A forming process that operates within a temperature range of 50°C to 450°C, applying a constant forming force incrementally to a continuously changing partial surface of the workpiece, achieving high formability comparable to hot forming without the energy and material losses associated with scaling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot forming is used to achieve high formability, then the formability is improved, but energy consumption increases and material loss occurs due to scaling
Solution Approach 1:
The patent applies parameter changes by operating in the warm forming temperature range (50°C to 450°C) instead of traditional hot forming temperatures. This temperature parameter change enables high formability while avoiding the energy consumption and scaling issues associated with high-temperature hot forming. The warm temperature range optimizes material deformability without causing excessive oxidation or energy waste.
2Manufacturing precision
If hot forming is used to achieve high formability, then the formability is improved, but material loss occurs due to scaling
Solution Approach 1:
The patent changes the temperature parameter from high-temperature hot forming to warm forming (50°C to 450°C). This parameter change reduces material oxidation and scaling, thereby minimizing material loss while maintaining high formability. The warm temperature range is sufficient to improve material deformability without causing the excessive oxidation that leads to material loss in traditional hot forming.
3Use of energy by moving object
If cold forming is used to reduce energy consumption, then energy consumption is reduced, but formability is insufficient and high forming forces are required
Solution Approach 1:
The patent applies parameter changes by introducing warm forming temperatures (50°C to 450°C) as an intermediate state between cold and hot forming. This temperature parameter change enhances material deformability and formability compared to cold forming, while requiring significantly less energy than hot forming. The warm temperature range optimizes the balance between formability and energy consumption.
4Manufacturing precision
If warm forming is used to achieve high formability with reduced energy consumption, then formability is improved and energy consumption is reduced, but the forming force application method becomes complex
Solution Approach 1:
The patent applies segmentation by dividing the forming surface into multiple partial surfaces and applying forming forces sequentially to each region. This segmentation approach enables effective deformation at warm temperatures by distributing the total forming force across multiple localized applications, achieving high formability while managing the complexity of force application through systematic regional processing.
Solution Approach 2:
The patent applies periodic action through repeated cycles of forming force application and release across different partial surfaces. Each cycle deforms a specific region, and subsequent cycles address remaining regions or apply additional deformation as needed. This periodic approach achieves cumulative deformation效果 while maintaining control over the complex forming 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 achieves high formability with reduced energy consumption and tool wear, minimizing material loss and machining rework, while maintaining high accuracy and lower forming forces, effectively combining the advantages of hot and cold forming.
Implementation Method 1
the workpiece is brought to a specific temperature range and formed by means of a forming tool
Data Source
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AI summary
The invention relates to a forming method, wherein a workpiece (2) is formed by means of a forming tool (1) in a wobble process or rotary forging process at low temperatures, for example in the range of lukewarm forming or medium-temperature forming. Because the forming force (F) is not transferred to the entire forming surface at the same time, but acts successively on a sub-surface (7) that changes incrementally or continuously until the entire forming surface is loaded with the forming force (F) at least once, surprisingly high degrees of deformation can be realized using comparably low force application.