Contoured Metal Sheet Bending for Sharp Folds Without Kinking
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Solution Overview
Problem
Existing methods for bending contoured metal sheets, such as corrugated metal sheets, struggle to produce sharp angle bends without kinking or damaging the sheets, and require expensive long tools for deep bends, limiting the flexibility and cost-effectiveness of the process.
Innovation Solution
A method and apparatus that secure a first sheet section between a securing and engagement member, position a second sheet section between a forming and seating member, and move these sections relative to each other to bend the first sheet section at a selected angle, allowing the second sheet section to transform its profile into a symmetrical mirror image, using small tools and enabling bends at any desired point along the sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a forming member with a contour shaped to transform the full profile of the metal sheet is used, then the contoured profile can be transformed into a symmetrical mirror profile, but the tool length becomes very long for deep bends, increasing tooling costs
Solution Approach 1:
The tool is divided into two separate members: a forming member that creates the bend and a backing member that provides support. This segmentation allows the forming member to be short while still achieving deep bends, as the backing member extends to provide the necessary support throughout the bend depth without requiring the forming member itself to be long.
Solution Approach 2:
The backing member acts as an intermediary element that mediates between the forming member and the metal sheet. It provides the necessary support and counterforce during the bending process, enabling the forming member to create sharp angle bends and deep profile transformations with a short tool length.
2Shape
If contoured metal sheets are bent at non-zero angles to the longitudinal axis, then sharp angle bends can be formed, but the sheets are prone to kinking and damage due to the contoured profile
Solution Approach 1:
The backing member provides localized support at the bend location, with its contour specifically designed to match and support the contoured profile of the metal sheet at the bending zone. This localized support prevents kinking and damage while allowing sharp angle bends to be formed, maintaining sheet integrity during the bending process.
Solution Approach 2:
The backing member is positioned in advance to provide support before the forming member applies the bending force. This preliminary positioning ensures that the contoured profile is properly supported during the bending process, preventing kinking and damage before they can occur.
3Ease of manufacture
If small tools are used for bending, then tooling costs are reduced, but the ability to produce deep bends is limited by the tool size
Solution Approach 1:
The bending tool is segmented into a short forming member and a separate backing member. The forming member can be small and inexpensive, while the backing member provides the extended support needed for deep bends. This segmentation allows small, cost-effective tools to produce deep bends that would otherwise require long, expensive tools.
Solution Approach 2:
The solution moves from a single-dimension constraint (forming member length) to a two-dimension solution by introducing the backing member that extends in a different spatial dimension. This allows the forming member to remain short while the backing member provides the necessary support length for deep bends.
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 the production of sharp angle bends in contoured metal sheets with continuous contours, reducing tooling costs and allowing bends at any point along the sheet, while maintaining a neat join at intersections, without the limitations of tool size or material deformation.
Implementation Method 1
transforming the contoured profile of the second sheet section into a symmetrical mirror image of the contoured profile of the first sheet section
Implementation Method 2
moving the forming section and the securing section relative to one another to bend the first sheet section the selected angle relative to the second sheet section
Data Source
AI summary
A method of bending a contoured metal sheet, the contoured metal sheet having a longitudinal axis extending along the length of the contoured metal sheet comprising:securing a first sheet section of the contoured metal sheet in a securing section between a securing surface of a securing member and an engagement surface of an engagement member;positioning at least part of a second sheet section of the contoured metal sheet in a forming section between a forming member having a pressing surface and a seating member having a seating surface;moving the forming section and the securing section relative to one another to: bend the first sheet section the selected angle relative to the second sheet section over a first bending edge; and feed the second sheet section from between the pressing surface and the seating surface, over a second bending edge, to between a forming surface and a backing surface; andpositioning a following section substantially adjacent to the second bending edge to cooperate with the forming surface to engage and compress a portion of the second sheet section of the contoured metal sheet therebetween when the relative movement between the securing section and the forming section moves the backing surface to a position remote from the forming surface of the forming member.