Double-Layered Metal Blanking Process for Thin Lamina Production
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Solution Overview
Problem
The existing blanking process for metal parts is limited by the minimum thickness of the basic material, which affects the production rate and quality of the blanked parts, especially for larger sized parts, and the standard blanking process is inefficient in producing thin lamina for electric motor applications.
Innovation Solution
The novel process uses double-layered basic material clamped between a blanking punch and a counter punch, allowing for higher clamping forces and enabling the production of thinner blanked parts with improved surface quality and shape accuracy, potentially doubling the production rate compared to standard fine-blanking processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the basic material thickness is reduced to produce thinner blanked parts, then the production rate and electric efficiency are improved, but the material becomes too thin for proper handling and may deform during blanking
Solution Approach 1:
The patent combines multiple thin layers of basic material (typically 2-10 layers) into a stacked assembly that is blanked together as a single unit. This merging approach allows each individual layer to remain thin for high productivity and efficiency, while the stacked assembly provides sufficient thickness for stable handling and accurate blanking without deformation.
2Productivity
If multiple blanking stations are arranged in parallel to increase production rate, then several blanked parts are formed per stroke, but the dimensions of the blanking device are limited
Solution Approach 1:
Instead of expanding the blanking device horizontally by adding multiple blanking stations in parallel, the patent utilizes the vertical dimension by stacking multiple layers of basic material one on top of another. This allows the single blanking station to process multiple layers simultaneously, effectively increasing production rate without increasing the device's footprint area.
3Productivity
If the basic material is too thin, then production rate increases, but the material may deform when supplied to the blanking device or during blanking
Solution Approach 1:
The patent merges multiple thin layers into a stacked assembly that maintains structural stability during handling and feeding. The combined assembly has sufficient rigidity to prevent deformation, while still allowing each individual layer to remain thin for high production rate and electric efficiency in the final product.
Solution Approach 2:
The patent performs preliminary stacking and alignment of multiple basic material layers before the blanking operation. This preliminary action ensures that the thin layers are properly positioned and stabilized in a stacked configuration, preventing deformation during subsequent handling and blanking processes.
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 allows for the production of high-quality, thin blanked parts with increased production rates, surpassing standard blanking processes for larger sized parts, and is economically viable for parts with a critical size diameter of 125 mm or more, where the thickness of the blanked part plays a crucial role in determining the efficiency.
Implementation Method 1
the double layered basic material is firmly clamped from both sides thereof between the blanking punch and the counter punch of the blanking device in addition to a clamping force exerted by and between the blanking die and the blank holder, to press and hold the two layers thereof together when these are moved relative to the blanking die
Data Source
Figure 1~2
Figure 3~4D
Figure 4E~6
AI summary
The present disclosure relates to a process for the blanking of metal parts (10; 11). According to the present disclosure a double layered basic material (51) with two preferably essentially identical, mutually stacked individual layers (50) is placed and clamped partly between a blanking die (80) and a blank holder (70) and partly between a blanking punch (30) and a counter punch (40) that are moved relative to the blanking die (80) and the blank holder (70) over a distance corresponding to at least a thickness of the double layered basic material (51) whereby two blanked parts (10; 11) are cut and separated from the double layered basic material (51).