Battery Metal Member Thin-Part Forming With Lower Coining Load
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Solution Overview
Problem
Existing methods for forming thin parts on metal plates, particularly steel plates, require high processing loads and multiple steps, leading to increased man-hours and costs, and are prone to damage the die set due to high surface pressures.
Innovation Solution
A method involving a punch and die configuration where the punch shoulder and die shoulder have specific geometric relationships, allowing the workpiece to be compressed under lower loads, with the material flowing along the die shoulder, reducing the need for multiple forming steps and minimizing die set damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If multiple coining steps are performed to form the thin annular part, then the processing load applied to each annular protrusion is reduced, but the man-hours and manufacturing cost are increased
Solution Approach 1:
The forming process is divided into two distinct stages: a preliminary coining step that creates initial deformation with reduced load, and a final coining step that completes the thin part formation. This segmentation allows each step to operate under optimized conditions, reducing the load per step while maintaining overall efficiency.
Solution Approach 2:
The preliminary coining step performs initial deformation of the metal plate before the final coining step. By pre-deforming the material and creating initial stress concentrations, the subsequent final coining requires significantly less force to complete the thin part formation, thereby reducing the processing load.
2Force
If the overlapping amount between punch and die is minimized, then the processing load is reduced, but the material flow is insufficient and the thin part cannot be properly formed
Solution Approach 1:
The forming process is divided into two distinct stages: a preliminary coining step that creates initial deformation with reduced load, and a final coining step that completes the thin part formation. This segmentation allows each step to operate under optimized conditions, reducing the load per step while maintaining overall efficiency.
Solution Approach 2:
The preliminary coining step performs initial deformation of the metal plate before the final coining step. By pre-deforming the material and creating initial stress concentrations, the subsequent final coining requires significantly less force to complete the thin part formation, thereby reducing the processing load.
3Strength
If a steel plate is used instead of aluminum alloy plate, then the strength and durability of the battery case are improved, but the processing load and difficulty of forming the thin part are significantly increased
Solution Approach 1:
The forming process is divided into two distinct stages: a preliminary coining step that creates initial deformation with reduced load, and a final coining step that completes the thin part formation. This segmentation allows each step to operate under optimized conditions, reducing the load per step while maintaining overall efficiency.
Solution Approach 2:
The preliminary coining step performs initial deformation of the metal plate before the final coining step. By pre-deforming the material and creating initial stress concentrations, the subsequent final coining requires significantly less force to complete the thin part formation, thereby reducing the processing load.
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
Enables the formation of thin parts on metal plates, especially steel, with reduced loads and simplified processes, thereby minimizing die set damage and lowering production costs.
Implementation Method 1
sandwiching and compressing a portion of the workpiece by the punch shoulder and the die shoulder, thereby forming a thin part
Data Source
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AI summary
A method for manufacturing a metal member (20) includes the steps of: preparing a workpiece (40); and disposing the workpiece (40) between a punch (31) including a punch top surface (311), a punch shoulder (312), and a punch side surface (313), and a die (32) including a die flange surface (321), a die shoulder (322), and a die side surface (323), causing the punch (31) and the die (32) to approach relative to each other, and sandwiching and compressing the workpiece (40) by the punch shoulder (312) and the die shoulder (322), thereby forming a thin part (231) on the workpiece (40). Portions of the punch shoulder (312) and the die shoulder (322) that form the thin part (231) on the workpiece (40) have an arc shape or a tapered shape as viewed in a cross section, and are configured to satisfy Cpd ≤ 1.00, 0.10 × Cpd ≤ w1, and w1 < w2.