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Figure 2 shows an exploded view of the die assembly. In this figure, some of the outermost bars were sectioned to present a continuous surface to the jaws – either between two opposite edges or between the middle of two opposite faces. In the composite die example, the impression consists of half a sphere attached to two cylindrical axial sections (Fig. The second refers to external means to be employed to contain such forces. The first refers to the special shapes of the tessellating bars to provide an interlocking action. In special or extreme cases in which the die assembly might be insufficient to withstand the shattering forces developing in the die, two different solutions could be explored.
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A third cylindrical element added for stability is hot-mounted to develop an interference fit upon cooling. The first two have corresponding conical surfaces so that circumferential constraining stresses are generated by axially pressing the external collet on the internal one. The central bar block is enclosed in a set of four jaws constrained by three concentric rings. Anatomy of a Composite DieĪ simple design for the working fixture was developed. One can expect that substantial gains can be realized, however, at least in special classes of composite dies to be determined in different industries. It is difficult to quantify in abstract the amount of potential savings.
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The bar size to be selected in any specific case is open. In special cases, some could be different (an example follows). In a given die, all the bars could be identical. The requirement to meet is that of tessellation, defined by Wikipedia as “the tiling of a plane using one or more geometric shapes, called tiles, with no overlaps and no gaps.” Consequently, round bars are excluded, but square, rectangular or hexagonal shapes could be considered. Bar stumps, taken as a bunch of contiguous units axially aligned in the vertical direction, could be a good element choice. Tessellating Planeĭie materials could be selected from a large range of suitable tool-steel types. This kind of pondering brought about the idea of trying a composite die, assembled with standard repetitive elements, to be enclosed in a fixture strong enough to withstand the high cyclical stresses of forging work. A substantial reduction of this wasted time will shorten manufacturing times and significantly reduce costs.Īs a retired engineer, I found myself musing and playing with the challenge of finding ways to shorten that wasted time.
FORGING DIE DESIGN HANDBOOK DRIVERS
One of the main time and cost drivers of the industry is the exceedingly long lead time from order to supply of tool-steel blocks for forging dies. My involvement with forging, although indirect, was sufficiently close to the real thing because it dealt with the procedures used to approve forging processes for demanding items like turbine disks. This idea for a new method of forging parts matured from an intuition to a patent application. patent application has been filed for this die system design, which is outlined here in conceptual form. A new design technique in forging dies has been proposed in which a tessellating field of stacking or interlocking steel shapes comprises the working faces of a forging die.