Deep-drawing Device with Adjustable Lamellar Gaps for Multi-Web Forming
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Solution Overview
Problem
Deep-drawing processes face limitations in simultaneous production of multiple webs due to material deformation flow limits, leading to inefficiencies and increased production time in industrial mass production.
Innovation Solution
A deep-drawing device with adjustable and displaceable lamellar gaps allows for simultaneous shaping of multiple webs by transitioning from a receiving position to an end position, enabling increased material utilization and reduced production time, featuring a tool with lamellae of different thicknesses and compression springs for enhanced accuracy and ease of folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If simultaneous deep-drawing of multiple grooves is performed, then productivity is improved, but material deformation flow limit is exceeded causing tearing
Solution Approach 1:
The metal sheet is pre-shaped to be wavy before deep-drawing, creating material reserves in the wave valleys that prevent tearing during simultaneous deep-drawing of multiple grooves. This preliminary shaping action prepares the material in advance to accommodate the deformation requirements of multiple simultaneous operations.
Solution Approach 2:
The tool incorporates displaceable lamellae that can dynamically adjust their position and spacing during the deep-drawing process. This allows the tool to adapt to material flow requirements while maintaining simultaneous deep-drawing of multiple grooves, preventing material tearing through dynamic adjustment rather than static fixed positions.
2Strength
If individual web formation in succession is performed, then material strength limit is not exceeded, but productivity deteriorates
Solution Approach 1:
Multiple individual deep-drawing operations that were previously performed in succession are merged into a single simultaneous operation. The tool design with multiple displaceable lamellae allows all grooves to be formed at the same time, combining what were separate sequential operations into one unified process, thereby dramatically increasing productivity while maintaining material integrity through the pre-shaped wavy structure.
Solution Approach 2:
The wavy pre-shaping of the metal sheet is performed before the deep-drawing operation, preparing the material in advance to enable simultaneous multi-groove formation. This preliminary action creates the necessary material reserves that allow multiple operations to occur simultaneously without exceeding material strength limits.
3Device complexity
If fixed tool recesses are used, then device complexity is reduced, but adaptability deteriorates
Solution Approach 1:
The tool transitions from fixed recesses to displaceable lamellae that can dynamically adjust their position. This dynamic capability allows the same tool to accommodate different profile requirements and workpiece geometries, significantly increasing adaptability while the lamellae return to a standard configuration for routine operations, balancing complexity and versatility.
Solution Approach 2:
The tool is divided into multiple independent displaceable lamellae segments. This segmentation provides adaptability by allowing individual lamellae to be positioned independently to create different groove patterns and profiles. The segmented structure enables versatile configuration options while maintaining manageable device complexity through modular design.
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 method enables faster, more economic production with increased accuracy and reduced need for re-finishing, allowing for simultaneous and homogeneous deep-drawing of multiple webs without exceeding material strength limits, resulting in improved productivity and dimensional accuracy.
Implementation Method 1
The deep-drawing device features a tool with displaceable lamellae and compression springs
Data Source
AI summary
The invention relates to a deep-drawing method and a corresponding deep-drawing device. The deep-drawing device has at least two projections (112) and at least two corresponding lamellar gaps (102) in a die (106), the width and positioning (Pi) of the lamellar gaps (102) being adjustable. Folding of a metal sheet (10) is brought about by closing the lamellar gaps (102). During the subsequent deep-drawing process, the projections (112) are lowered into corresponding recesses (103). Flat metal sheets (10) as well as previously corrugated metal sheets (10) can be folded and deep drawn by means of the deep-drawing device and the deep-drawing method.