Basic Principles for Design of Wedge Rolling Die
Wedge rolling die is a kind of metal forming die, which can shear and extrude metal material in the form of rolling. Wedge rolling die has the advantages of high extrusion ratio and energy saving. It can not only improve the performance and quality of equipments, but also reduce the production cost and improve the work efficiency.
A wedge rolling die is composed of upper and lower dies, punch, countersink and peripheral components. The upper and lower dies are the key components of the wedge rolling die. The upper die includes a die body, a punching bar and a countersink bar, and the lower die includes a die body and a counter-punching bar. The materials of the upper and lower dies are generally selected according to the material of the workpiece and the performance requirements.
The punching bars and the countersink bars of the upper die are connected to the upper die body and inserted into the slot of the lower die body. The punching bars and the countersink bars extend through the slot and move up and down to form the mating surface between the upper and lower dies. As the upper and lower dies rotate, the punching bars and the countersink bars shear and extrude the workpiece along the surface to obtain the desired shape and size.
In the design of wedge rolling die, there are three main principles, namely, principle of minimum width, principle of complete extrusion and principle of minimum number of punches.
The principle of minimum width requires that the width of the die gap between the upper and lower dies should be kept as small as possible. Too small width will hinder the extrusion of material, while too large width will cause the extrusion surface of material to become uneven. The width of the die gap should be selected according to the shaping characteristics of the material.
The principle of complete extrusion requires that the extrusion depth of the workpiece should be equal to or greater than the thickness of the workpiece, in order to achieve the best results.
The principle of minimum number of punches requires that the number of punches should be as few as possible in order to reduce the cost of tooling and minimize the wear and tear on the punches.
The above are three basic principles for the design of wedge rolling die. It is necessary to combine the principles with the specific requirements to design a die that meets the needs of the application.
