Progressive Die for Brake Plate Forming with Localized Stretching Control
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Solution Overview
Problem
The existing stretching dies for brake plate formation, which use a single hemispheric punch, result in uniform but inadequate stretching, leading to localized defects and difficulties in meeting dimensional tolerances, requiring extensive reworking and simulation efforts to achieve optimal results.
Innovation Solution
A progressive die with multiple adjustable punches, including central, peripheral, and lateral punches, allows for localized and controlled stretching and deep drawing of sheet steel, enabling better material distribution and adjustment for precise brake plate formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single hemispheric punch is used for stretching, then uniform stretching is obtained on the sheet steel, but localized defects occur and dimensional tolerances cannot be met
Solution Approach 1:
The single punch is divided into multiple punches (first punch, second punch, third punch, fourth punch) arranged at different positions. Each punch independently stretches a specific region of the sheet steel, allowing localized control of deformation to achieve both uniform overall stretching and precise local dimensional tolerances.
Solution Approach 2:
Different punches are positioned to apply stretching forces to different areas of the sheet steel based on local requirements. This enables specific regions to receive tailored stretching intensities, preventing localized defects while maintaining overall uniformity and meeting critical dimensional tolerances in high-deformation areas.
2Ease of manufacture
If a single punch is used, then the stretching die structure is simple, but extensive reworking and simulation efforts are required to achieve optimal results
Solution Approach 1:
The punching system is segmented into multiple independently adjustable punches. Each punch can be individually positioned and adjusted without affecting others, enabling rapid setup and optimization. This segmentation reduces the need for extensive reworking of a single complex punch surface and minimizes simulation iterations.
Solution Approach 2:
The punches are designed with adjustable positions and configurations, allowing dynamic adaptation to different sheet steel regions. This adjustability enables quick optimization during setup without requiring complete reworking of the die structure, significantly reducing time loss during the setup phase.
3Shape
If uniform stretching is applied, then material must flow during deep drawing, but small radius punches prevent material flow causing folding and excessive stretching
Solution Approach 1:
Multiple punches with different positions and radii are used to create a graduated stretching pattern. This segmentation allows material to flow progressively from regions with larger punch radii toward regions with smaller radii during deep drawing, preventing sudden material starvation or excess that causes folding and excessive stretching defects.
Solution Approach 2:
Each punch is configured with specific radius and positioning tailored to local material flow requirements. This local optimization ensures that material distribution during subsequent deep drawing is controlled and balanced, preventing defects in critical areas while maintaining overall shape quality.
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 solution enhances material distribution and thickness control, reducing defects and improving the morphology for subsequent deep drawing operations, with a 12% increase in material thickness in critical areas compared to traditional methods.
Implementation Method 1
stretching of the sheet steel; deep drawing; The lateral punches (5, 6, 7, 8) are four lateral punches disposed in diametrally opposite positions with respect to the center of the central punch (2)... Each lateral punch (5, 6, 7, 8) has a shape with hemispheric head... the lateral punches (5, 6, 7, 8) are positioned in the areas where the final shape is obtained with subsequent deep drawing operations
Data Source
Figure 1~1-4
Figure 2~2A
Figure 3
AI summary
A progressive die (100) that allows to localize and control the stretching of the sheet steel during forming of a brake plate, comprising: a central punch (2) fastened on a lower base of the die, in a way to be adjusted in height with shims; peripheral punches (3, 4) mounted on the lower base of the die, in a way to be individually adjusted in height with shims; and lateral punches (5, 6, 7, 8) mounted on the central punch (2) in a way to be individually adjusted in height with shims, regardless of the adjustment of the peripheral punches (3, 4).