Non-Uniform Arc Punch Head for Wide Plate Bending
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Solution Overview
Problem
Conventional bending-press forming techniques face challenges in efficiently producing thick steel pipes with large diameters, requiring high press pressure and resulting in increased production costs and potential degradation of steel plate characteristics, while also risking punch deformation and wear due to excessive bending moments.
Innovation Solution
A bending-press forming tool with a non-uniform circular arc working surface, comprising a main and sub circular arc with radii corresponding to the steel pipe's inner diameter, reduces the working width to less than 0.90 times the feed pitch, minimizing excessive bending moments and maintaining the steel plate's original strength and weldability without the need for additional heating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the working width of the punch head is increased to bend wider steel plates, then the productivity is improved, but the bending moment acting on the punch increases causing punch deformation and wear
Solution Approach 1:
The punch head working surface is designed with non-uniform circular arc where different regions have different radii. The central region has a larger radius (R1) for primary bending contact, while the width end regions have smaller radii (R2) to reduce contact area and bending moment at those locations. This local variation in geometric properties allows the punch to handle wider plates without excessive bending moment at the ends.
2Productivity
If the number of bending times is increased to achieve efficient production, then the productivity is improved, but the manufacturing complexity increases
Solution Approach 1:
The invention changes the geometric parameters of the punch head working surface from a uniform circular arc to a non-uniform circular arc with varying radii. This parameter change allows the punch to achieve the desired bending effect in fewer operations by optimizing the contact geometry, thereby improving productivity without significantly increasing process complexity.
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
This approach allows for efficient bending of wider steel plates with improved roundness and extended punch life, reducing production costs and maintaining the steel's mechanical properties, while preventing punch deformation and wear.
Implementation Method 1
forms a cylindrical shape by performing three-point bending a plurality of times
Data Source
Figure 1~2
Figure 3(a)~3(c)
Figure 4
AI summary
[PROBLEM] Disclosed is a bending-press forming punch which is hardly affected by the bending moment and can obtain a cylinder with good roundness. [SOLUTION] Provided is a bending-press forming punch which includes a pair of left and right dies 1 that are disposed at intervals along a widthwise direction of a plate material S to support the plate material S at two locations; and a punch 2 that is movable in a direction of getting close to or away from the dies 1 and sequentially presses the plate material S in the widthwise direction while interposing the plate material together with the dies 1 to perform the bending, wherein the punch 2 includes a punch head 2a having a working surface K which comes into direct contact with the plate material S to press the plate material S into a concave shape, and a punch supporter which is held by connection to the punch head 2a to support the punch head 2a. Moreover, the punch head 2a has a working surface K having a working surface center O which matches an axis q of the punch supporter 2b and being formed by a non-uniform circular arc in which a radius in a central region in the widthwise direction is a maximum radius.