Washer Forming With Arcuate Longitudinal Members for Higher Material Yield
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Solution Overview
Problem
Conventional methods for manufacturing washers result in poor material yield due to wastage during the punching process, especially when forming annular or semicircular shapes from plate materials.
Innovation Solution
A method involving the preparation of longitudinal members with crest and valley portions, including projections and recesses, which are then deformed to form a semicircular washer shape, allowing for improved stress dispersion and material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If annular shape is punched out in the forming material, then a washer can be manufactured, but most of the forming material is wasted
Solution Approach 1:
The forming material is divided into multiple longitudinal members with crest and valley portions, allowing the material to be utilized more efficiently. Instead of punching out a complete annular shape from a single piece, the washer is formed by deforming multiple segmented longitudinal members that are arranged side-by-side, significantly reducing material waste.
Solution Approach 2:
The invention transitions from a two-dimensional punching approach to a three-dimensional deformation approach. By forming longitudinal members with crest and valley portions and then deforming them into arcuate shapes, the washer is created through spatial transformation rather than simple planar punching, enabling better material utilization.
2Ease of manufacture
If semicircular shapes are punched out and two semicircular members are joined, then a washer can be manufactured, but most of the forming material is wasted
Solution Approach 1:
Instead of using two large semicircular members that require joining, the invention segments the forming material into multiple narrower longitudinal members. These segmented members are arranged side-by-side and deformed together, eliminating the need for joining operations and reducing material waste in the process.
Solution Approach 2:
Multiple longitudinal members are merged together in the lateral direction to form the complete washer structure. By combining these segmented members through deformation rather than joining, the invention achieves both material efficiency and structural integrity without requiring separate joining operations.
3Loss of substance
If the longitudinal member is deformed to arcuate shape, then material yield is improved, but stress concentration may occur in the deformation zones
Solution Approach 1:
The longitudinal member is designed with varying local properties through the crest and valley portions. The crest portions have different deformation characteristics compared to the valley portions, allowing stress to be distributed more evenly throughout the structure during arcuate deformation, preventing stress concentration at specific locations.
Solution Approach 2:
The introduction of curved crest and valley portions in the longitudinal member creates a more gradual transition during deformation. This curvature design helps distribute stress more uniformly across the deformed structure, preventing sharp stress concentrations that would occur with abrupt geometric changes.
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 approach enhances material yield by reducing waste, effectively dispersing stress, improving lubricity, and preventing peeling of metallic materials, while maintaining the washer's functionality in receiving loads and sliding on shafts.
Implementation Method 1
a deformation step of deforming the longitudinal member such that the one side surface and the other side surface are arcuate as viewed in one direction orthogonal to the lateral direction and to the longitudinal direction
Data Source
AI summary
A method of manufacturing a washer capable of improving a material yield is provided. The method includes: a preparation step of preparing a longitudinal member which includes an upper crest portion and a lower crest portion formed on at least one of an upper surface and a lower surface of the longitudinal member, and an upper valley portion and a lower valley portion continuous to the upper crest portion and the rower crest portion in the right-left direction, respectively, the upper valley portion and the lower valley portion provided with projections, respectively; and a deformation step of deforming the longitudinal member such that the upper surface and the lower surface are arcuate as viewed in the direction from the front to the rear.