Aluminum Plate Forming With Localized Current at Bend Zones
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Solution Overview
Problem
The low formability of aluminum plates at room temperature leads to cracking during the press forming process, necessitating warm forming, which increases processing time and costs due to the need for uniform heating of the entire plate.
Innovation Solution
An apparatus and method that apply electrical currents to specific points on the aluminum plate during the forming process using a die with embedded electrodes, enhancing elongation and formability without altering the product shape, by applying primary and secondary currents at strategic stages of the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If warm forming is used to improve aluminum plate formability, then elongation and crack resistance are improved, but processing time and cost increase due to uniform heating requirements
Solution Approach 1:
The patent divides the heating process into two segments: (1) uniform preheating of the entire aluminum plate to a baseline temperature, and (2) localized application of electrical current to specific regions requiring enhanced elongation. This segmentation eliminates the need for continuous uniform heating at high temperatures, reducing overall processing time while maintaining formability where needed.
Solution Approach 2:
The patent applies electrical current locally to specific regions of the aluminum plate during forming, rather than heating the entire plate uniformly. The electrode is positioned to deliver current precisely to areas requiring enhanced ductility, such as high-stress zones, thereby improving formability only where necessary and reducing energy consumption and processing time.
2Reliability
If warm forming is used to enhance aluminum plate elongation, then crack resistance during forming is improved, but manufacturing cost increases due to heating equipment and energy consumption
Solution Approach 1:
The patent replaces the mechanical/thermal heating system with an electrical current system for localized elongation enhancement. Instead of using heating equipment to maintain high temperatures throughout the forming process, electrical current is applied directly to the aluminum plate to induce plastic deformation and improve elongation only in critical areas, significantly reducing energy consumption and equipment costs.
Solution Approach 2:
The patent changes the physical parameter used to enhance elongation from thermal energy (temperature) to electrical energy (current). By applying electrical current directly to the aluminum plate during forming, the material's ductility is enhanced through electro-plastic deformation, eliminating the need for expensive heating equipment and reducing overall manufacturing costs.
3Productivity
If room temperature forming is used to reduce processing time and cost, then productivity is improved, but formability deteriorates leading to cracking
Solution Approach 1:
The patent applies electrical current in advance to high-stress regions of the aluminum plate before the main forming operation begins. This preliminary action enhances the ductility and elongation of the material in critical areas, preventing cracks during subsequent room-temperature forming while maintaining high productivity and avoiding the need for slow warm forming processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly enhances the process speed and reduces costs by restoring elongation to near-original levels, allowing for efficient room-temperature forming of aluminum plates with improved formability, comparable to steel plates of the same strength.
Implementation Method 1
an electrode unit inserted into the lower die and exposed on the upper surface of the lower die to apply a current to a bent portion of the product shape
Data Source
AI summary
An apparatus for forming an aluminum plate is provided. The apparatus includes an upper die that has a bottom surface that corresponds to a top shape of a product shape to be formed and descends by a press to press the aluminum plate. The apparatus also includes a lower die that has an upper surface that corresponds to a bottom shape of the product shape and an electrode unit that is inserted into the lower die and is exposed on the upper surface of the lower die to apply a current to a bent portion of the product shape.