Clinching Die Inserts for Wear Resistance and Cost Reduction
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Solution Overview
Problem
The existing dies for clinching tools face high operational costs and reduced service life due to wear and tear, particularly in the spring sleeve, which requires frequent replacement and uses expensive high-quality materials for radial flexibility and stress absorption.
Innovation Solution
A die configuration featuring a bushing with inserts made of harder materials surrounding the anvil, allowing only the highly stressed areas to be made of hard materials, which can be replaced independently of the spring sleeve, reducing costs and extending service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the spring sleeve is made of high-quality hard material to resist wear, then the wear resistance is improved, but the manufacturing cost increases
Solution Approach 1:
The patent applies local quality by making only the inserts (which contact the workpiece) from hard wear-resistant material, while the bushing and spring sleeve are made from cheaper materials. This localized application of high-quality material precisely where needed reduces overall manufacturing cost while maintaining wear resistance at the critical contact points.
Solution Approach 2:
The patent uses composite materials by combining different materials in the die structure - the bushing is made from one material, the inserts from a harder wear-resistant material, and the spring sleeve from another material. This composite approach allows each component to be optimized for its specific function while controlling overall cost.
2Duration of action of stationary object
If the entire die is made of high-quality material to increase service life, then the service life is improved, but the manufacturing cost increases
Solution Approach 1:
The patent segments the die into replaceable inserts that can be independently replaced when worn. This segmentation allows only the high-wear insert areas to be made from expensive hard material, while the bulk of the die structure uses cheaper materials, significantly reducing manufacturing cost while maintaining service life through modular replacement.
Solution Approach 2:
The patent employs disposable/replaceable inserts that are designed to be replaced rather than the entire die. These inserts are made from hard wear-resistant material to maximize their limited service life, while the main die body remains cost-effective. When inserts wear out, they are replaced without replacing the entire expensive die structure.
3Ease of manufacture
If only critical areas are made of hard material, then the manufacturing cost is reduced, but the wear resistance in high-stress areas may be insufficient
Solution Approach 1:
The patent precisely identifies the inserts as the local areas requiring hard wear-resistant material, since these are the only parts that directly contact and work on the workpiece. The bushing and spring sleeve, while important for structural function, do not require the same level of wear resistance, allowing cost-effective material selection in those areas.
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 configuration reduces manufacturing costs and increases the die's service life by allowing only the inserts to be replaced, maintaining high-quality material usage in high-wear areas, thus enhancing the tool's competitiveness and operational efficiency.
Implementation Method 1
the die is elastic in the radial direction, so that an embossing section is set that can absorb the highest forces in the axial direction. The radial elasticity prevents temporary tangential stresses occurring during the connection process
Implementation Method 2
a bushing (1) arranged between the anvil (4) and the spring sleeve (3), which is provided at its free end with inserts (2) which surround the anvil (4) and are made of a harder material than the bushing (1)
Data Source
Figure 1~4
Figure 5~10
Figure 11~12
AI summary
A die for a joining tool, in particular for clinching, with an anvil (4) forming the bottom (41) of a die (50) and a spring sleeve (3) surrounding the anvil (4), which has a plurality of slots (32) extending in an axial direction (A) by which a radial expansion of the spring sleeve (3) is enabled, is characterized in that a bushing (1) arranged between the anvil (4) and the spring sleeve (3), which is provided at its free end (17) with inserts (2) surrounding the anvil (4) and made of a harder material than the bushing (1).