Connector Bridge Pressure Forming for Burr-Free Sheet Separation
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Solution Overview
Problem
Existing methods for separating plate-like workpieces, such as sheet metal, often require significant post-processing to completely disconnect workpiece parts connected by connecting webs, leaving behind traces or requiring excessive effort.
Innovation Solution
A forming tool with specific geometry and motion, where forming members displace material from the connecting web during pressure forming, creating a breakage zone that minimizes residual traces on the workpieces, allowing for complete separation with minimal post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional forming tools with chamfered punch tips are used to reduce connecting web cross-section, then the connecting webs can be detached with minimal effort, but burrs remain on the workpiece parts that require additional machine removal
Solution Approach 1:
The invention changes the geometric parameters of the forming tool by providing two offset forming elements instead of a single chamfered punch tip. This dual-element configuration with specific offset distance creates a different deformation pattern that eliminates burr formation while maintaining easy detachability of the connecting webs.
Solution Approach 2:
The forming action is segmented into two separate forming elements working in sequence on opposite sides of the connecting web. This segmentation allows the first element to create the initial deformation while the second element completes the forming process without generating burrs, dividing the harmful effect into controlled stages.
2Reliability
If the connecting webs are dimensioned sufficiently large to prevent breaking under handling stresses, then the sheet metal parts can be handled together with the residual grid, but the connecting webs occupy more space and require more material
Solution Approach 1:
The invention applies preliminary forming action to reduce the cross-section of the connecting webs after they have performed their handling function. The forming elements are positioned to act on the connecting webs in a controlled sequence, first ensuring structural integrity during handling, then systematically reducing the cross-section to minimize material consumption.
Solution Approach 2:
The forming process is made dynamic through the sequential action of two offset forming elements. The first forming element initiates the cross-section reduction while the second element completes the forming, creating a dynamic progression that optimizes material removal efficiency and minimizes waste.
3Productivity
If forming elements are positioned to reduce connecting web cross-section effectively, then the connecting webs can be detached easily, but the forming tool experiences wear and requires maintenance
Solution Approach 1:
The offset forming elements are designed to work in a sequence where the first element performs the primary forming action and the second element completes the process. This self-service arrangement distributes the mechanical stress and wear across two elements, reducing the maintenance burden on each individual element while maintaining high productivity.
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 complete separation of workpiece parts with minimal residual traces and reduced effort, maintaining the quality of the separation surface and extending the life of the forming tool by dissipating material particles during processing.
Implementation Method 1
the forming elements penetrate it and displace material from the connecting web. Due to the geometry of the forming elements of the forming tool, the plasticized material of the connecting web is displaced away from the workpiece part(s) adjacent to the connecting web.
Implementation Method 2
This creates a fracture zone on the connecting web with a reduced cross-section compared to the rest of the connecting web. Once all connecting webs between the sheet metal parts of the processed sheet and the surrounding residual grid have been pressure-formed in this manner, simply shaking the unit consisting of sheet metal parts and residual grid is sufficient to destroy the connecting webs at the fracture zones
Data Source
Figure 1~2
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AI summary
A forming tool (13) for pressure forming a connecting web (23) between incompletely separated workpiece parts (18, 20) of a machined plate-like workpiece, in particular a sheet (15), comprises two tool parts (11, 12), each of which is provided with a forming element (24, 25). The tool parts (11, 12) can be moved towards each other along a stroke axis (14) with a machining stroke into a stroke end position. Each of the forming elements (24, 25) has a forming surface (40, 41, 42, 43) on a web side (33, 34, 37, 38) facing away from the relevant workpiece part (18, 20). This forming surface extends from an end face (26, 27) of the forming element (24, 25) along the stroke axis (14) away from a workpiece side (31, 32, 35, 36) facing the relevant workpiece part (18, 20). A pressure forming process for a connecting web (23) is carried out using the forming tool (13).The method for pressure forming a connecting web (23) is part of a method for separating machining of plate-like workpieces, in particular for separating machining of sheet metal (15) and also part of a method for machining plate-like workpieces, in particular for machining sheet metal (15), in the course of which, in addition to the separating machining, further workpiece machining, in particular edge machining, is carried out.