Arc Washer Nesting Layout for Higher Material Yield
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing arc-shaped washers result in low material yield due to clearances between adjacent washers, leading to wasted material and inefficiencies in the manufacturing process.
Innovation Solution
A method involving the preparation of a panel-shaped material, where a first washer is cut out using a die, and a second washer is cut out from a partially overlapping area, with the outer peripheral cut-away portion of the second washer contacting the inner peripheral face of the first washer, to improve material yield and reduce clearance between washers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If washers are manufactured by stamping material with clearances between adjacent washers, then the manufacturing process is simple, but material yield is low due to wasted material at clearance portions
Solution Approach 1:
The invention divides the washer manufacturing process into two distinct cutting operations: a first cutting-out step that creates the main washer body, and a second cutting-out step that creates additional washers from remaining material. This segmentation allows optimization of material usage by strategically positioning the second washer to overlap with the first, thereby reducing clearance waste and improving material yield while maintaining manufacturing simplicity
Solution Approach 2:
The invention utilizes the two-dimensional plane of the panel-shaped material more efficiently by positioning the second washer in a partially overlapping area with the first washer. This dimensional arrangement allows the outer peripheral cut-away portion of the second washer to contact the inner peripheral face of the first washer, maximizing material utilization and reducing waste without complicating the manufacturing process
2Productivity
If clearances are maintained between adjacent washers during stamping, then manufacturing is easier, but productivity is reduced due to lower material yield
Solution Approach 1:
The manufacturing process is segmented into two cutting-out steps using separate dies: the first die creates the primary washer, and the second die creates an additional washer from the remaining material. This segmentation enables better material utilization by positioning the second washer to partially overlap the first, thereby improving productivity through enhanced material yield while keeping each cutting operation relatively simple
Solution Approach 2:
The first washer is cut out completely before the second washer is created from the remaining material. This preliminary action allows the second die to be positioned optimally to maximize material usage, with the outer peripheral cut-away portion of the second washer contacting the inner peripheral face of the first washer, thereby improving productivity without significantly increasing overall process complexity
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
There is provided a method of manufacturing washers with improved material yield. The method includes: a preparing step S1 of preparing a material 1 having a panel shape; a first cutting-out step S12 of cutting out a first thrust washer 10 having a substantially arc shape from the material 1; and a second cutting-out step S13 of cutting out a second thrust washer 10 from a portion of the material 1 in contact with a portion from which the first thrust washer 10 is cut out.