Double-Action Die Forming of Thick Aluminum Alloy Corners
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Solution Overview
Problem
Existing forming devices struggle to form corner portions of metal members made from aluminum alloys with large plate thicknesses due to high deformation resistance, making it difficult to achieve desired shapes.
Innovation Solution
A forming device with a forming die that includes a first and second main die and a movable double-action die, which presses the metal material against a corner portion forming surface to facilitate deformation, even with high resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional forming die is used to form corner portions of aluminum alloy metal members with large plate thicknesses, then the forming process is simple, but the high deformation resistance prevents achieving desired shapes
Solution Approach 1:
The forming die is divided into multiple independent dies: a first die and a second die that can move relative to each other. This segmentation allows each die to perform specific functions - the first die provides the corner portion forming surface while the second die applies targeted pressure to push the corner portion corresponding part against the forming surface, enabling precise shape formation despite high deformation resistance
Solution Approach 2:
The second die is designed to be movable relative to the first die, allowing dynamic adjustment during the forming process. This mobility enables the second die to apply variable pressure and positioning forces to overcome the high deformation resistance of thick aluminum alloy plates, ensuring the corner portion is properly formed against the forming surface
2Manufacturing precision
If pressure is applied to deform thick aluminum alloy corner portions, then shape formation is achieved, but deformation resistance remains high making the process difficult
Solution Approach 1:
The forming system applies force locally at the corner portion through the second die rather than distributing force uniformly across the entire metal member. This localized force application concentrates the deformation effort exactly where needed - at the corner portion corresponding part - enabling effective shaping of thick aluminum alloy without requiring excessive overall force
Solution Approach 2:
The corner portion forming surface acts as an intermediary between the two dies and the metal material. By providing a specifically shaped surface that the corner portion corresponding part is pushed against, it facilitates controlled deformation and enables precise shape formation while reducing the force required compared to direct forming without a dedicated forming surface
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
The device effectively forms corner portions of aluminum alloy metal members into desired shapes by reducing deformation resistance and ensuring precise alignment with the forming surface.
Implementation Method 1
the metal material is pressed by the double-action die such that a corner portion corresponding part corresponding to the corner portion in the metal material is pushed against the corner portion forming surface
Data Source
AI summary
A forming device that forms a metal member from a metal material of an aluminum alloy, the forming device includes: a forming die that is curved to be recessed in a cross-sectional view and that includes a corner portion forming surface for forming a corner portion of the metal member, in which the forming die includes a first main die and a second main die that face each other, and a double-action die that is movable relative to the first main die and the second main die, and the metal material is pressed by the double-action die such that a corner portion corresponding part corresponding to the corner portion in the metal material is pushed against the corner portion forming surface.