Bending Die with Segmented Laser Heating for Brittle Materials

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Solution Overview

Problem

Bending processes using brittle materials like magnesium, titanium, and high-strength steels often result in material breakage or cracking due to insufficient plastic deformability, as these materials do not have favorable mechanical properties for bending, and existing methods for improving these properties, such as selective heating, are not optimally suited for practical use on common bending machines.

Innovation Solution

A bending die arrangement with controlled local generation of radiation using multiple diode laser bars and beam influencing elements, allowing for adjustable radiation distribution and shielding to minimize radiation exposure and ensure safe operation, enabling the use of brittle materials by optimizing the heating process for different workpiece dimensions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a single highly concentrated bundled radiation source is used, then the radiation energy required for heating is concentrated, but the radiation danger to users in the vicinity increases significantly

Engineering Contradiction:

Improveradiation energy concentrationVSAvoidradiation danger to user

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The single concentrated radiation source is divided into multiple individually controllable radiation sources arranged along the bending recess. Each source can be independently activated or deactivated, allowing the radiation field to be segmented both spatially and temporally, thus reducing the hazard zone while maintaining heating effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the bending recess can be equipped with radiation sources according to the specific heating requirements of different workpiece positions. This allows radiation to be applied locally only where needed, reducing overall radiation exposure while achieving effective heating at the forming zone.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If radiation is distributed over the entire length of the bending die, then the method is suitable for various workpiece sizes, but the radiation energy required increases and safety is compromised

Engineering Contradiction:

Improvesuitability for different workpiece sizesVSAvoidradiation exposure

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The bending die is divided into multiple sections, each with its own controllable radiation source. This segmentation allows the system to activate only the sections needed for the current workpiece size, maintaining versatility while minimizing radiation exposure by keeping unused sections deactivated.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The radiation sources are equipped with individual control mechanisms that allow dynamic activation and deactivation based on the workpiece dimensions and positioning. This dynamic control enables the system to adapt to different workpiece sizes while radiating energy only where and when needed, reducing overall exposure.

Inventive Principle:

Principle #15Dynamics

3Object-affected harmful factors

If multiple individually controllable radiation sources are used, then radiation can be adapted to workpiece size and safety is improved, but the device complexity increases

Engineering Contradiction:

Improveradiation safetyVSAvoidnumber of radiation sources and control mechanisms

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Each radiation source unit is designed as a modular component that can serve multiple functions: heating, and when deactivated, serving as a radiation shield. This multi-functionality reduces the need for separate shielding components, thereby limiting device complexity while maintaining safety.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The radiation sources are integrated into the bending die structure in a nested arrangement, where the radiation-emitting components are housed within the die body. This nesting allows the bending die to serve as both the forming tool and the housing for the radiation sources, reducing overall device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Ease of manufacture

If a two-part bending die design with beam distribution arrangement is used, then radiation can be guided through the die, but the mechanical stability of the bending die decreases

Engineering Contradiction:

Improveradiation guidance capabilityVSAvoidmechanical stability of bending die

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The radiation guidance functionality is merged into a single-integral bending die design, where the radiation sources and beam distribution channels are incorporated directly into the die body as one unified structure. This eliminates the need for separate two-part designs with complex interfaces, thereby maintaining mechanical stability while achieving radiation guidance capability.

Inventive Principle:

Principle #5Merging (Combining)

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 allows for safe and efficient bending of brittle materials by reducing radiation exposure and ensuring uniform heating, thereby minimizing the risk of material breakage and improving the mechanical properties of the workpieces, making the process more practical and adaptable for various workpiece sizes.

Implementation Method 1

a high-energy radiation 19 is directed through a beam exit opening 18 to the underside 20 of a workpiece 2, by means of which the workpiece 2 is heated locally

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Laser

Implementation Method 2

at least one beam influencing arrangement 23, which deflects and expands a concentrated beam of rays 40 introduced into the bending die arrangement 3 to form radiation fans 24

Methodology Applied

Scientific EffectOptical deflection and expansion: Lens

Implementation Method 3

an adjustable shielding element 49 is provided on the bending die 7 between the beam exit opening 18 and the contact surface 11 to cover sections of the bending recess 12

Methodology Applied

Scientific EffectRadiation absorption: Absorption (EM radiation)

Data Source

PatentEP2448689B1Device and method for bending a workpiece

Publication Date: 2015.02.25 TRUMPF MASCHEN AUSTRIA

Figure 1~3
Figure 2~4
Figure 5~6

AI summary

The invention relates to a method for bending a flat workpiece (2), comprising the discharge of high-energy radiation (19) in the form of at least one ray fan (24) from a bending recess (12) of a snaker arrangement (3) having a snaker (7) onto a workpiece (2) bearing against a contact surface (11) of the snaker (7) for the local heating thereof before and/or during a bending process. The one or more ray fans (24; 24a, 24b,...) are produced by a number of optionally activatable radiation sources (22a, 22b,...) which are arranged within the snaker arrangement (3) along the bending recess (12) or are caused by the distribution of a radiation beam (40) that is introduced from a radiation source (39) arranged outside the snakers (7a, 7b,...) via a number of radiation influencing arrangements (23a, 23b,...) within the snakers (7a, 7b,...), and the exiting radiation (19) is thereby adjusted to the bending length (21) of the workpiece to be bent (2) via the number of ray fans (24, 24a, 24b,...).