Cooking Vessel Hot Stamping With Controlled Wall Deformation
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Solution Overview
Problem
Existing methods for manufacturing cooking vessels using hot stamping often result in undesired deformation, particularly at the base of the side wall, leading to irregular dimensions and wall thickness variations, which complicates the production of consistently shaped containers.
Innovation Solution
The method involves using aluminum and steel plates arranged in parallel planes, where the steel plate is struck towards the aluminum plate at a temperature where the aluminum is softened, followed by deformation of the aluminum plate to form the bottom and side wall, ensuring controlled deformation and repeatability of shape, and compatibility with induction heating by using ferritic stainless steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hot stamping is used to manufacture the container, then productivity is improved, but manufacturing precision deteriorates due to random deformation
Solution Approach 1:
The steel plate is pre-formed into a cup shape with a curved bottom before the stamping process. This preliminary shaping creates a predetermined geometry that guides the subsequent deformation of aluminum layers, ensuring consistent container shapes while maintaining high productivity through efficient hot stamping.
Solution Approach 2:
The patent utilizes temperature as a critical parameter by heating the aluminum plates to their plastic deformation temperature range during stamping. This thermal parameter change allows the aluminum to deform controllably over the pre-formed steel cup, achieving precise shape consistency without compromising manufacturing speed.
2Productivity
If the steel plate is struck at high force to form the container, then productivity is improved, but manufacturing precision deteriorates due to exaggerated deformation
Solution Approach 1:
The patent changes the thermal parameter by heating aluminum plates to their plastic deformation temperature before stamping. This thermal softening allows the aluminum to deform smoothly and controllably under the striking force, preventing exaggerated deformation and maintaining dimensional accuracy while enabling rapid forming.
Solution Approach 2:
The pre-formed steel cup acts as an intermediary tool that mediates the deformation process. Its curved bottom geometry guides the aluminum layers to deform in a controlled manner, distributing the striking force evenly and preventing localized exaggerated deformation while maintaining high forming speed.
3Ease of manufacture
If aluminum-based plates are used instead of stainless steel, then manufacturing cost is reduced, but manufacturing precision deteriorates due to deformation control issues
Solution Approach 1:
The patent applies thermal parameter changes by heating the aluminum-based plates to their plastic deformation temperature range during stamping. This thermal treatment temporarily alters the material properties, making the aluminum more ductile and easier to deform controllably over the steel cup, thereby achieving precise dimensional control while using cost-effective aluminum materials.
Solution Approach 2:
The pre-formed steel cup serves as an intermediary form tool that provides geometric guidance for aluminum deformation. Its predetermined curved bottom shape ensures that aluminum layers deform consistently and accurately, overcoming aluminum's inherent deformation control challenges while maintaining cost advantages.
4Strength
If the bottom thickness is increased to reduce deformation, then strength is improved, but manufacturing precision deteriorates due to material usage variations
Solution Approach 1:
The steel plate is pre-formed with a specifically designed curved bottom geometry before aluminum layers are stamped. This preliminary action creates an optimized thickness distribution pattern that provides enhanced strength and thermal shock resistance in critical areas while maintaining uniform and precise thickness control throughout the bottom structure.
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 approach effectively controls deformation, ensures consistent shape and material efficiency, enhances resistance to thermal shocks, and reduces manufacturing complexity and costs, while maintaining compatibility with induction heating.
Implementation Method 1
heated to at least a softening temperature of the plate of aluminum
Implementation Method 2
the steel-based plate is struck towards the metal plate
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
This is to make a cooking vessel. To do this: - an aluminum plate (30c) is placed in parallel planes between a metal plate (30a) and a steel plate (30b1, 30b2), - the plates (30a, 30b, 30c ), - at a temperature where the aluminum plate (30c) is softened, the steel plate (30b) is struck towards the metal plate (30a), - the metal plate (30a) is deformed so as to form a bottom (3) and a side wall (5) of the container (1).