Abstract: Electro-magnetic devices are provided, having conductive elements and leads of multiple thicknesses. Templates are provided for making electro-magnetic devices, formed by an extrusion process, a skiving process, a swaging process, 3D printing, or a machining process. The multi-thickness electro-magnetic devices may comprise a conductive element having an increased thickness area, and one or more leads having at least one decreased thickness area, having a thickness less than the increased thickness area. An electro-magnetic device may be provided comprising a conductive element having an increased thickness encased in a body formed from a core material, and leads or lead portions connected to the conductive element having a decreased thickness.

Abstract: A method for manufacturing the structural member (1), the method including: a first step in which the pad (15, 15A, 15B, 15C, 21) presses the forming material (16) against the punch (13) to raise a portion corresponding to a flange to be formed in ends of at least the gutter bottom (2) and the ridge (3a, 3b) in a direction opposite to the pressing direction, the pad (15, 15A, 15B, 15C, 21) bends an end of a portion to be formed into the ridge (3a, 3b) in the pressing direction and restrains at least a part of the end, and the punch (13) and the die (14) carry out press forming to form an intermediate product while a region other than an end in a portion to be formed into the gutter bottom (2) remains unrestrained.

Abstract: A producing method of the press formed product includes a preparation step of preparing a metal sheet as a starting material; and a press working step of performing press working on the starting material. The press working step includes: during a time period from when pushing-in of the starting material into the die by the punch is started or immediately thereafter until the pushing-in of the punch with respect to the die reaches a predetermined distance short of a bottom dead point for the pushing-in, holding the pad at a position distant from the punch by the predetermined distance; when the pushing-in of the punch with respect to the die reaches the predetermined distance short of the bottom dead point, receiving the pad in the die; and continuing the pushing-in of the punch with respect to the die and the pad to the bottom dead point.

Abstract: A press-forming apparatus is an apparatus for producing a press-formed product having a hat-shaped cross section that has an external shape that curves in an L shape along a longitudinal direction in a planar view, and includes a punch, a first blank holder, a second blank holder, a preceding portion, a second die and a pad. When pushing the punch into a die to form a metal plate into the press-formed product, a first guide face of the preceding portion precedes a second guide face of the second die, and thereafter sliding of the first blank holder and the preceding portion relative to the punch is restricted and pushing of the punch into the die is continued in the restricted state to form the press-formed product. By this means, the press-formed product in which cracks and wrinkles are reduced is obtained.

Abstract: Mechanical properties, in particular torsional rigidity and absorbed energy properties in axial crushing, of a joint structure body including a joint formed by joining members are further improved. Provided is a first member, a second member, an end of the second member being thrust against a surface of the first member, and a joint that joins the first member and the second member are included. The joint includes an end flange that is formed continuously along the end of the second member and of which at least one part overlaps the surface of the first member and a unit joint that joins the end flange and the first member. The end flange is formed continuously to at least one part of the end of the second member via a rising curved surface portion and the rising curved surface portion includes a wall-thickened portion of which a sheet thickness is made larger than a sheet thickness of the second member.

Abstract: A manufacturing method provides a high-quality material for ring rolling. The manufacturing method of the material for ring rolling includes a step of heating a disk-shaped material for hot forging to a hot working temperature, a step of arranging the material for hot forging onto a lower die having a convex portion with a truncated conical shape, a step of forming a thin portion by pressing a center portion of the material for hot forging by using an upper die having a convex portion with a truncated conical shape, and a step of manufacturing a material for ring rolling by removing the thin portion wherein a center of gravity on a half section of the material for ring rolling is located so as to be closer to an outer peripheral surface of the half section than a center of the half section in a thickness direction of the half section.

Abstract: The invention relates to a component, a method, and a tool for forming, in particular for the lateral extrusion or upsetting of thin-walled preforms to form components having a structure formed thereon, in particular having a toothing, wherein, by carrying out the method according to the invention and by using the tool according to the invention, buckling of the wall of the preform during the forming process to form the component according to the invention is prevented.

Abstract: A forging device capable of producing a high-quality forged article while simplifying the structure is provided. The forging device of the present invention includes a punch 1, a die 2 having a shaping hole 22 and a helical blade portion 23 formed on an inner peripheral surface of the shaping hole, a back pressure generation mechanism 15, and a back pressure transmission mechanism. The back pressure transmission mechanism includes a rotation-side transmission member having a back pressure plate 40 and a non-rotation-side transmission member. The back pressure plate 40 is arranged in the shaping hole 22 in a fitted manner.

Abstract: A spline member manufacturing apparatus includes a shaving punch, a shaving die, a spline punch, and a stripper. The stripper supports a first surface of a base plate portion and an outer circumferential surface of a boss portion. The shaving punch is advanced relatively, while a material and the stripper are being pressed so that cutout portions are formed in an outer circumference portion of the base plate portion by the shaving punch and the shaving die. The shaving punch is further advanced relatively while the outer circumferential surface of the base plate portion is held by the shaving die, so that a spline portion is formed by inserting the spline punch along the inner circumferential surface of the boss portion.

Abstract: Methods are taught for manufacturing a work having a peripheral flange by pressing a sheet material may include half die cutting the material so as to simultaneously form inner and outer circumferential surface of the peripheral flange while the peripheral flange is simultaneously subjected to isostatic pressures that are directed from the flange inner surface to the flange outer surface or from the flange outer surface to the flange inner surface.

Abstract: A press-formed member includes a first wall with a first thickness, a second wall with a second thickness, and a first corner portion. The first corner portion is disposed between the first and second walls, with the first corner portion having an increased thickness formed by pressure-forming such that the increased thickness of the first corner portion is larger than the first and second thicknesses of the first and second walls adjacent to the first corner portion. In a manufacturing method for the press-formed member, a preliminary body structure to be deformed is provided, and the thickness of the first corner portion of the preliminary body structure is increased by applying pressure to the preliminary body structure.

Abstract: A sprocket is formed by fine-blanking a steel plate using a die having a cutting edge shaped to produce rounded edges on the back sides of the sprocket tooth heads, and protrusions on the front sides. Thereafter the edges of the front sides of the sprocket tooth heads are formed in a press so that the protrusions are removed, and the edges of the front sides of the sprocket tooth heads have a rounded cross-sectional shape substantially the same as that of the edges of the front sides.

Abstract: A process for cold forging a metal fastener such as a self-clinching standoff includes a punch and die set at the final head trimming station which produces the shear burr only on the underside of the fastener head where it is not visible after installation. A knock-out pin which is reciprocal within the bore of the punch forcibly ejects the fastener through a passage in the die to a point beyond an opposite side of the die. A stripper sleeve which is reciprocal about the outside surface of the punch then moves from a retracted position over the end of the punch pushing a residual scrap ring from around the outside of the punch.

Abstract: A formation tool is used for deforming sheet metal on punching machines. The formation tool has an upper or top die tool and a lower or bottom die tool. Toward the top die, there is an upper mold insert movable relative to a holding-down device, and toward the bottom die, a lower mold insert movable relative to a stripper plate. The deformation of the metal sheet is effected upward with respect to a punching stroke plane. The formation tool has a lifting device for aiding in lifting the lower mold insert from an initial position which is at or below the punch stroke plane before a deforming operation, to a level above the punching stroke plane.

Abstract: A process for cold forging a metal fastener such as a self-clinching standoff includes a punch and die set at the final head trimming station which produces the shear burr only on the underside of the fastener head where it is not visible after installation. A knock-out pin which is reciprocal within the bore of the punch forcibly ejects the fastener through a passage in the die to a point beyond an opposite side of the die. A stripper sleeve which is reciprocal about the outside surface of the punch then moves from a retracted position over the end of the punch pushing a residual scrap ring from around the outside of the punch.

Abstract: A press working apparatus is provided that can prevent interference between the die and the punch and thus obtain a good sheared surface of a product. One embodiment is a press working apparatus comprising a lower mold frame on which a die is mounted, a sheet material being laid on the die; an upper mold frame movable toward and away from the lower mold frame; and a punch mounted on the upper mold frame for carrying out a predetermined press working on the sheet material laid on the die when the upper mold frame approaches proximately to the lower mold frame. Either the die or the punch can be freely displaced in its horizontal plane, and the press working apparatus further comprises a positioning apparatus for setting the relative position of the die and the punch.

Abstract: Disclosed herein are a helical gear forging apparatus wherein a forming introduction portion thereof, used to form gear teeth of the helical gear, is variable in shape on the basis of the desired helix angle of the gear-teeth so as to constantly keep a predetermined outer diameter of the formed gear teeth, thereby enabling easy forming of the helical gear irrespective of a variation of the helix angle, and a forging method using the same. The forging apparatus comprises a gear die having a gear teeth forming section defined at an inner circumference thereof for forming gear teeth of the helical gear, a collar die integrally formed at an upper end of the gear die, a lower die located below the gear die, a punch located above the collar die and adapted to push a stock into the collar die, and a knock-out located below the lower die and adapted to discharge the molded stock to the outside.

Abstract: A device, such as an inner race of a torque converter's overrunning clutch, is formed by powder metallurgy. The race includes oil grooves and chamfers formed in each face by forging. The oil grooves on the first face open onto the chamfer. The chamfer on the second face is interrupted at the oil grooves such that each oil groove opens onto the diametral surface. A forge assembly for forming the race includes a die assembly including a discontinuous lower chamfer tool, an upper punch including groove tools and a continuous chamfer tool, and a lower punch including groove tools and radially extending teeth disposed at the oil grooves and capable of extending into the gaps of the lower chamfer tool. A method for forming the race includes employing the die assembly to forge the oil grooves and chamfers into the preform and remove flash by conventional grinding processes.

Abstract: The invention relates to a method and an apparatus for producing a workpiece with internal toothing, especially an internal geared wheel, by using a cup shaped preform (N) with a substantially cylindrical side wall (N1) and a mandrel (5) with an external profile (6) according to the internal toothing to be produced, as well as with a forming tool which reduces the outside diameter of the cylindrical side wall during an advancing movement, as a result of which the material of the cylinder wall region flows into the external profile (6) of the mandrel (5). In accordance with the invention, the forming tool is configured as a drawing ring (14) ensuring the ironing of the cylinder wall region (N1) during an advancing movement and that two tool elements act upon the preform (N) during the ironing, which tool elements produce axial compressive stresses in the cylinder wall region (N1) of the preform.

Abstract: Method and apparatus for producing a thin walled tubular product with thickened flange. A first stage metalworking (drawing) of a circular plate material A is done by using a first die set 22 having a conical die 24 and a drawing punch 26 is done in a manner that the end of the blank plate is remained on the conical surface 24-1 of the die, so that a semi-finished tubular product A1 with a inclined flange A1-1 is obtained. Then, a second stage metalworking (drawing) of the semi-finished tubular product A1 is done by a second die set 32 having a shaping punch 34 and a restraint die 36. The semi-finished tubular product A1 is held by the restraint die 36 and the shaping punch 34 is introduced into the semi-finished tubular product A1 for effecting a wall thickness reduction under ironing principle while forming a stepped portion.

Abstract: An annular excess portion is disposed, a spline forming male mold is passed through a boss of a sheet metal-made rotary member in which a root portion of the boss and a peripheral portion are previously displaced, and the boss is set to a stationary mold with being fitted into a boss fitting hole of a rotary member holding mold. Thereafter, the annular excess portion is clamped between a pressing mold and the stationary mold to be deformed into a flat shape, and the root portion of the boss is squeezed into spline forming grooves to be plastically deformed, thereby forming a boss spline. According to the configuration, increase in thickness os a sheet metal blank is avoided, the strength of the boss is ensured, and weight reduction is achieved. The production efficiency can be remarkably improved, and cutting chips are eliminated, so that adverse influence on the working environment can be avoided.

Abstract: By press-fitting a cylindrical blank into a die with one of a pair of punches, and at the same time press-fitting small diameter end portions and tapered portions of the pair of punches into both ends of the cylindrical blank while restraining both end surfaces of the blank with cylindrical members movable on the outsides of the punches, the external circumferential surface of the blank is finish molded to the required diameter by the internal circumferential surface of the die and, at the same time, tapered surfaces are formed on the inner circumferential surface in both ends of the blank. The process produces a bushing with its internal surfaces accurately coaxial, and with the external surface accurately formed to the required diameter.

Abstract: A stock inserted into a die is sandwiched between a punch and a knock-out, a predetermined pressing force is applied to the knock-out, and a pressing force larger than the sum of the pressing force of the knock-out and a pressing force for forming is applied to the punch to effect a forming work, whereby the forming accuracy can be enhanced and a final product can be obtained by going through only a slight finishing work.

Abstract: An upset forging die device and method are provided for upset-forging a raw material that is being filled in a cavity of a lower molding die at a portion between an upper punch of an upper molding die provided on a slide and a lower punch of the lower molding die provided on a bolster. The upper and lower punches are provided with an upper pin and a lower pin respectively so that a first end of each pin is protruded and withdrawn from each of end surfaces of the upper and lower punches and the pins are vertically movable in the upper and lower punches respectively, while a second end of the upper and lower pins is applied with a back-pressure.