Sheet Metal Casket Shell Forming with Pivoting Dies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing process for forming sheet metal casket shells is labor-intensive, requires multiple handling steps, leading to potential damage and energy consumption, and has complex welding operations due to intricate profiles, resulting in inefficiencies and increased costs.
Innovation Solution
A method using a female and male die system to pivot and fold sheet metal into casket shell portions, reducing the number of sheets handled and welding locations, with welds placed on less conspicuous surfaces, and employing roll forming for desired profiles, thereby simplifying the manufacturing process and reducing material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate sheets are used for side walls and end walls, then the casket shell can be formed with distinct panels, but the number of handling steps increases and labor intensity increases
Solution Approach 1:
The patent combines multiple separate sheet metal panels (side walls and end walls) into a single integrated sheet metal structure. By forming the casket shell from one continuous piece of sheet metal through folding and welding operations, the number of handling steps is reduced from multiple separate panel manipulations to a single integrated forming process, thereby improving productivity while maintaining ease of manufacture through the unified structure.
2Manufacturing precision
If sheets are moved between multiple presses for blanking and stamping, then the desired profile can be achieved, but the parts are susceptible to dents and dings
Solution Approach 1:
The patent performs the desired profile forming through roll forming before the blanking and stamping operations. By pre-forming the cross-sectional profile of the sheet metal while it is still in a more stable, less manipulated state, the subsequent blanking and stamping operations can be performed with fewer handling steps, reducing the susceptibility to dents and dings while maintaining the required manufacturing precision of the final profile.
3Shape
If corners contain intricate profiles, then the casket shell achieves desired aesthetic and structural features, but the welding operation complexity increases
Solution Approach 1:
The patent segments the casket shell construction into distinct modular sections: side walls with pre-formed profiles and end walls with corners. By separating the corner formations into distinct end wall panels that are folded and welded to the side walls, the intricate corner profiles are achieved through controlled folding operations rather than complex welding, thereby reducing welding operation complexity while maintaining the desired shape and aesthetic features.
4Strength
If welding is performed on all four corners, then the shell structure is complete, but the number of welding locations increases energy consumption
Solution Approach 1:
The patent extracts and eliminates unnecessary welding operations by utilizing the inherent strength of the roll-formed profiles and strategic folding. Instead of welding all four corners, the design relies on profile interlocking and selective welding at critical joints only, thereby maintaining the required structural strength while significantly reducing the number of welding locations and associated energy consumption.
Data Source
AI summary
A method of forming a portion of a sheet metal casket shell comprises supporting a piece of sheet metal on one side with a female die having a center die portion and opposite end die portions configured to pivot relative to the center die portion, supporting the piece of sheet metal on the opposite side with a male die having a center die portion and opposite end die portions, and pivoting the end die portions of the female die relative to the center die portion of the female die to cause the opposite ends of the piece of sheet metal to fold around the end die portions of the male die. The method can be repeated with a second piece of sheet metal thereby forming two shell halves which can be welded together to form the shell.