Workpiece Elevation Forming with Two-Step Depression Preforming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming elevations in components, such as toothing formations, often require high mechanical loading and subsequent machining for dimensional accuracy, and there is a desire to minimize forces during the forming operation.
Innovation Solution
A method involving two steps: first producing depressions with varying dimensions in a workpiece, followed by forming elevations from the regions between these depressions, with the depressions being oriented and sized to facilitate controlled material flow and reduced mechanical loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cold-forming or hot-forming operations are used to produce elevations in components, then the components achieve structural form, but high mechanical forces are required and dimensional accuracy is insufficient requiring follow-up machining
Solution Approach 1:
The forming process is divided into two distinct steps: first producing depressions with varying dimensions, then forming elevations from material between the depressions. This segmentation allows each step to be optimized independently, reducing the mechanical forces required while achieving high dimensional accuracy for complex components like toothing formations.
Solution Approach 2:
The first step performs preliminary forming by creating depressions with controlled dimensions before the final elevation forming. This preliminary action prepares the workpiece in an optimized state, enabling the second step to achieve precise dimensional accuracy with reduced mechanical loading compared to direct single-step forming.
2Manufacturing precision
If follow-up machining is performed to achieve dimensional accuracy, then manufacturing precision is improved, but production time and process complexity increase
Solution Approach 1:
The two-step forming process performs preliminary dimensioning in the first step and final precision forming in the second step, achieving high dimensional accuracy directly in the forming process itself. This eliminates or reduces the need for follow-up machining operations, thereby improving production efficiency while maintaining manufacturing precision.
3Device complexity
If uniform depressions are produced in the first step, then the forming process is simpler, but the ability to produce complex elevation shapes with controlled material flow is limited
Solution Approach 1:
The first step produces depressions with locally varied dimensions - different sizes and spacing in different regions of the workpiece. This local variation in depression characteristics enables controlled material flow during the second step, allowing production of complex elevation shapes while maintaining a relatively simple two-step overall process structure.
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
Reduces mechanical loading on the workpiece and tool, allowing for more accurate and efficient production of complex components with minimal force application.
Implementation Method 1
the material of the elevations to flow in a lateral direction and therefore in a different direction to that in which a pressing force is active
Data Source
AI summary
The invention relates to a method for creating elevations (21) in a workpiece (1) by forming techniques. In a first step, depressions (11, 12) are created, with dimensions that differ from dimensions of depressions (20) to be created between the elevations (21). In a second step, the elevations (21) are created from regions (13) between the depressions (11, 12). The invention also relates to an apparatus for implementing the method and to a product thereby created.