Wire Forming Device Axial Mold Movement
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Solution Overview
Problem
Existing methods for producing wire-shaped bodies often result in irregular compression along the axial length due to frictional forces between the preliminary product and the negative mold, leading to varying flow resistance when used as filters or in other applications.
Innovation Solution
The negative mold is axially moved during the forming process to minimize frictional forces between the expanding sections of the preliminary product and the mold, ensuring uniform compression and consistent flow resistance along the length of the wire-shaped body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the preliminary product is compressed axially by a stationary negative mold, then the wire shaped body is formed, but frictional forces cause irregular compression and varying flow resistance along the axial length
Solution Approach 1:
The negative mold is made movable in the axial direction during the upsetting process, transforming from a stationary to a dynamic system. This axial movement of the negative mold prevents the buildup of frictional forces between the preliminary product and mold surface, allowing uniform compression along the axial length while maintaining the desired wire shaped body geometry
Solution Approach 2:
The axial movement of the negative mold acts as an intermediary mechanism that mediates between the compression force application and the preliminary product. By moving the mold axially, it prevents direct frictional contact that would otherwise create irregular compression, thereby achieving uniform flow resistance without requiring changes to the preliminary product or compression force distribution
2Shape
If the preliminary product is expanded radially outwards during compression, then the final external shape is achieved, but friction between expanded sections and mold increases, causing unintended supporting effects and non-uniform compression
Solution Approach 1:
The negative mold is made movable in the axial direction during the upsetting process, transforming from a stationary to a dynamic system. This axial movement of the negative mold prevents the buildup of frictional forces between the preliminary product and mold surface, allowing uniform compression along the axial length while maintaining the desired wire shaped body geometry
Solution Approach 2:
Instead of trying to control friction in the radial direction where the preliminary product expands against the mold, the solution moves the negative mold in the axial dimension. This dimensional shift in movement allows the mold to escape from the friction zone created by radial expansion, preventing the harmful supporting effects while still achieving the required external shape
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 results in a wire-shaped body with uniform compaction and consistent flow resistance, reducing material usage and weight while maintaining equivalent flow behavior, and allowing for targeted adjustment of flow and heat transfer characteristics.
Implementation Method 1
frictional forces are prevented at least between the expanding section of the preliminary product and the moving section of the negative mold
Implementation Method 2
The preliminary product is formed in a correspondingly designed forming device into the finished wire form body by plastic deformation
Data Source
Figure 1a~1b
Figure 1c~2
Figure 3~4
AI summary
The invention relates to a method for producing a formed wire body, an intermediate product (28) manufactured from at least one wire being axially compressed by a forming device (10), at least sections of said intermediate product being radially outwardly expanded against a negative mold (18) of the forming device such as to give it its final outer shape. At least sections of the negative mold (18) are carried along during compression such as to avoid any frictional forces at least between the expanding section of the intermediate product (28) and the moving section of the negative mold (18), or such as to at least reduce the frictional forces with respect to the axial movement of the intermediate product that act on the intermediate product during compression.