Systems and methods for improving backward flow forming of shafts

Abstract

An apparatus for backward flow forming a material may comprise a mandrel having a headstock at a proximate end of the mandrel, the mandrel configured to rotate about an axis, a plurality of rollers disposed radially outward of the mandrel configured to exert force on the material to form a work piece at a plastic deformation zone, wherein the work piece flows from the plastic deformation zone between the plurality of rollers and the mandrel toward a distal end of the mandrel, and a catcher, coaxial to the mandrel, and removably coupled to the work piece at a traveling end of the work piece.

What is claimed is: 
     
         1 . A control system for backward flow forming of shafts comprising:
 a first sensor in electronic communication with a controller, the first sensor configured to measure at least one of a tension parameter, a deflection parameter, a catcher parameter, or an apparatus parameter;   a catcher drive system in electronic communication with the controller; and   a tangible, non-transitory memory configured to communicate with the controller, the tangible, non-transitory memory having instructions stored thereon that, in response to execution by the controller, cause the controller to perform operations comprising:
 receiving, by the controller, an external command and the catcher parameter; and 
 controlling, by the controller, the catcher drive system in response to the catcher parameter and the external command. 
   
     
     
         2 . The control system of  claim 1 , wherein the first sensor measures the at least one parameter within a plastic deformation zone. 
     
     
         3 . The control system of  claim 2 , wherein the first sensor measures the at least one parameter within a localized zone of shear bands. 
     
     
         4 . The control system of  claim 1 , wherein the catcher drive system includes a catcher disposed coaxial to a mandrel and configured to removably couple to a traveling end of a workpiece coupled to the mandrel. 
     
     
         5 . The control system of  claim 4 , wherein the catcher is configured to travel with the traveling end of the workpiece. 
     
     
         6 . The control system of  claim 4 , wherein the catcher is configured to exert a tension in the workpiece. 
     
     
         7 . The control system of  claim 6 , wherein the catcher is configured to deflect the traveling end of the workpiece with respect to a longitudinal axis by oscillating with respect to the longitudinal axis. 
     
     
         8 . The control system of  claim 7 , wherein the deflection of the traveling end with respect to the longitudinal axis is 5° to 15°. 
     
     
         9 . The control system of  claim 4 , wherein controlling, by the controller, the catcher drive system further comprises sending a command to the catcher drive system to begin an oscillation of the catcher. 
     
     
         10 . The control system of  claim 4 , wherein controlling, by the controller, the catcher drive system further comprises sending a command to the catcher drive system to adjust a tension applied by the catcher. 
     
     
         11 . The control system of  claim 4 , wherein controlling, by the controller, the catcher drive system further comprises sending a command to the catcher drive system to alter an oscillation angle of the catcher. 
     
     
         12 . The control system of  claim 11 , wherein the oscillation angle of the catcher is determined based on causing the traveling end of the workpiece to deflect 5° to 15° with respect to a longitudinal axis. 
     
     
         13 . The control system of  claim 4 , wherein the operations further comprise interpreting, by the controller, the at least one parameter from the sensor to determine a tension applied by the catcher. 
     
     
         14 . The control system of  claim 13 , wherein controlling, by the controller, the catcher drive system further comprises sending a command to the catcher drive system to adjust a catcher position based on the tension applied. 
     
     
         15 . The control system of  claim 14 , wherein controlling, by the controller, the catcher drive system further comprises sending a command to the catcher drive system to adjust a catcher tension based on the tension applied. 
     
     
         16 . The control system of  claim 14 , wherein the controller dynamically adjusts the catcher position based on the tension applied. 
     
     
         17 . The control system of  claim 15 , wherein the controller dynamically adjusts the catcher tension based on the tension applied. 
     
     
         18 . The control system of  claim 16 , wherein the controller dynamically adjusts the catcher position in order to maintain a constant tension. 
     
     
         19 . The control system of  claim 17 , wherein the controller dynamically adjusts the catcher tension in order to maintain a constant tension. 
     
     
         20 . The control system of  claim 1 , wherein the external command is at least one of start flow forming or stop flow forming.