Angled Stop Mechanism for Die Alignment and Wear Reduction
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Solution Overview
Problem
Existing forming die assemblies for manufacturing pressware containers from paperboard suffer from significant wear-related damage and misalignment issues due to the repeated impact of angle iron stops, leading to decreased product quality, increased maintenance costs, and production downtime.
Innovation Solution
The implementation of an improved stop mechanism with angularly inclined internal and external contact faces on the outer and inner die rings, respectively, which increases the surface area of contact and maintains better alignment of die components, reducing wear and misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If angle iron stops are used to limit the travel of outer die rings, then the forming die assembly can maintain component positioning, but significant wear-related damage occurs due to repeated impact
Solution Approach 1:
The stop mechanism is changed from a conventional angle iron design to a curved stop with specific geometric parameters (radius of curvature, contact surface area). This parameter change allows the stop to absorb impact energy more effectively while reducing wear on both the stop and the die components, thus maintaining positioning stability without the harmful wear effects
Solution Approach 2:
The curved geometry of the stop is designed to provide cushioning effect before the actual impact occurs. The curved surface allows for a more gradual deceleration of the outer die ring, reducing the peak impact forces that cause wear and damage, while still effectively limiting the travel distance
2Device complexity
If conventional stops with small contact surface area are used, then the structure remains simple, but misalignment of die components occurs due to concentrated impact forces
Solution Approach 1:
The stop design transitions from a linear contact (small surface area) to a curved surface contact (increased dimensional contact area). This dimensional change distributes the impact forces across a larger surface area, reducing concentrated stresses that cause misalignment, while the curved geometry itself provides the alignment function through its predetermined radius
3Strength
If hardened steel extrusion stops are used, then the stop mechanism is durable, but wear damage transfers to the softer die components
Solution Approach 1:
The contact surface parameters of the stop are optimized to distribute loads more evenly. The curved geometry with increased contact area reduces the contact pressure on the die components, preventing wear transfer even when using hardened steel material for the stop
Solution Approach 2:
The curved stop design provides a cushioning effect that reduces peak impact forces before they are transferred to the die components. This preliminary energy absorption prevents the hardened steel stop from transmitting excessive forces that would cause wear on the softer die components
Data Source
AI summary
A die assembly for producing paperboard pressware includes an obliquely angled, continuous ring, and/or annular stop member between an inner die member and an outer die ring. Increased surface area of contact between stop components provides greater wear resistance, and the angled contact face maintains alignment of the die components.