Description:Complete Specification:

The following specification describes and ascertains the nature of this invention and the manner in which it is to be performed.
Field of the invention
[0001] This invention is related to a modular die set for a common rail during a forging process.

Background of the invention
[0002] In general, during hot forging process of Rail, there will be chances of wear and tear on dies (both top and bottom dies), which requires frequent change in the die set.

[0003] A korean patent application KR20210122118 discloses a method for producing forged parts and a four-die forging device for performing the same, which can be utilized in the field of metal forming and used in forging and press forging plants in machine manufacturing and the metal industry. A working zone of one pair of dies is spaced apart from a working zone of another pair of dies in a longitudinal axis direction of the forging device. Each die has a working zone with a flat face whose length ranges from 0.3 to 0.5 of the thickness of the forging device. In addition, the working zones of respective pairs of dies are arranged on opposite sides of a vertical symmetry plane of the forging device. As a result, it is possible to achieve improvement in the quality of produced forged products, improvement of productivity of a forging process.
Brief description of the accompanying drawings
[0004] Figure 1 illustrates a modular die set for a common rail in accordance with an embodiment of the invention; and
[0005] Figure 2 illustrates the modular die set with the common rail in accordance with this invention.

Detailed description of the embodiments
[0006] Figure 1 illustrates a modular die cast for a common rail during a forging process according to one embodiment of the invention. The modular die cast 10 comprises a first die 12 and a second die 14. The second die 14 is fixed on the first die 12 such that, the second die 14 comprises a cut-out 16 corresponding to a profile 18 of the common rail 11. The first die 12 is made as fixed die and the second die 14 is made as a replaceable die.

[0007] Further the construction of the modular die cast 10 is explained in detail. The modular die cast 10 comprises a cavity 20 made in said first die 12 for receiving the second die 14, such that the second die 14 is fastened on the first die 12 using at least one fitting element 22. The at least one fitting element 22 is chosen from a group of fitting elements comprising a bolt, a nut, a screw, a fastener. According to one embodiment of the invention, the at least one fitting element 22 is a bolt and the modular die cast 10 disclosed in the present invention uses four bolts for fastening the second die 14 in the cavity 20 of the first die 12. As mentioned above since the first die 12 is made as a fixed die, for replacing or removing the second die 14 from the first die 12, the bolts 22 are loosened and a new or repaired second die 14 is fitted on the first die 12.

[0008] The dimensions and shape of the cavity 20 made in the first die 12 is made corresponding to dimensions and shape of the second die 14. The cavity 20 is made from one end to another end (i.e.., along the length) of the first die 12 for accommodating the second die 14, as shown in the figure 1. During a detection of any wear or tear of the second die 14, the second die 14 is pulled out from the cavity 20 by loosening the fitting element 22 and the new or repaired second die 14 is fitted back into the cavity 20 without disturbing the first die 12.

[0009] According to one embodiment of the invention, the first die 12 and the second die 14 is made of a heat -resistant material, one such material being an alloy steel. However, it is to be understood that the material of the modular die cast 10 is not restricted to only alloy steel but can be of any other material that is known to a person skilled in the art and which can resist an extremely hot temperature.

[0010] The dimensions of the second die 14 and the cut-out 16 present in the second die 14 is made based on the common rail 11 design. For instance, the common rail 11 design will be different based on the number of cylinders used.

[0011] The design of a mounting bracket 11(a) in the common rail 11 is replicated in the cut-out 16, such that, the forging of the common rail 11 will be made effectively. I.e.., for a common rail 11 designed for a four-cylinder vehicle, the shape, and the dimensions of the second die 14 and the cavity 20 is made according to that particular common rail 11 design. As the cavity 20 on the first /fixed die 12 is made along the length, multiple varieties of the second die 14 can be fitted on the first die 12 based on the requirement.

[0012] A method of manufacturing the modular die cast 10 is explained in detail. The cavity 20 is made along the length of the first die 12 for accommodating the second die 14. The second die 14 is fitted onto the first die 12 using at least one fitting element 22 and by a fitting technique, wherein one such fitting technique is chosen from a group of fitting techniques comprising a screw fit, a bolt-fit, using a fastener and the like. Once the modular die cast 10 is ready with the second die 14 being fitted on the first die 12, the common rail 11 is positioned inside the modular die cast 10, ie., inside the cut-out 16 made in the second die 14 and the common rail 11 is forged in the modular die cast 10.

[0013] With the above disclosed modular die cast 10, an increase of the life of the first die 12 (fixed die) and a reduction in the changeover frequency of the first die 12 (fixed die) can be achieved. A reduction in the cycle time for changeover of the die cavity can also be obtained. The above disclosed modular die cast 10 helps in providing a low-cost solution by reducing the die material cost and thus reducing the overall forging cost. A reduction in the manufacturing time of the first die 12 and the re-sinking frequency of the first die 12 is also achieved by using the above disclosed the modular die cast 10.

[0014] Embodiments explained in the description above are only illustrative and do not limit the scope of this invention. Many such embodiments and other modifications and changes in the embodiment explained in the description are envisaged. The scope of the invention is only limited by the scope of the claims
, Claims:We Claim:
1. A modular die cast (10) for a common rail (11) during a forging process, said modular die cast (10) comprising:
- a first die (12);
characterized in that:
- a second die (14) fixed on said first die (12) such that, said second die (14) comprises a cut-out (16) corresponding to a profile (18) of said common rail (11).

2. The modular die cast (10) as claimed in claim 1, wherein said first die (12) is made as a fixed die and said second die (14) is made as a replaceable die.

3. The modular die cast (10) as claimed in claim 1, wherein a cavity (20) is made in said first die (12) for receiving said second die (14), such that said second die (14) is fastened on the first die (12) using at least one fitting element (22).

4. The modular die cast (10) as claimed in claim 3, wherein said at least one fitting element (22) is chosen from a group of fitting elements comprising a bolt, a nut, a screw, a fastener.

5. The modular die cast (10) as claimed in claim 3, wherein dimensions and shape of said cavity (20) of said first die (12) is made corresponding to dimensions and shape of said second die (14).

6. The modular die cast (10) as claimed in claim 1, wherein said second die (14) is made to be removed and replaced upon detecting a wear and tear on said second die (14).

7. The modular die cast (10) as claimed in claim 1, wherein said first die (12) and said second die (14) is made of heat-resistant material, one such material being an alloy steel.

8. The modular die cast (10) as claimed in claim 1, wherein dimensions of said second die (14) is made based on said common rail (11) design.

9. The modular die cast (10) as claimed in claim 1, wherein multiple varieties of said second die (14) is fitted on said first die (12) based on a requirement.