Dynamic Actuator Bending Tool for Over 180 Degree Forming
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Solution Overview
Problem
Existing press forming tools are limited in achieving bend angles greater than 180° due to the static nature of the lower tool and the spring back of materials, which restricts the maximum sustainable bend angle to less than 180°.
Innovation Solution
A bending tool with a press recess defined by a plurality of actuators that are deflectable about a deflector, allowing for dynamic movement to form a recess that can accommodate bend angles beyond 180°, featuring low friction surfaces and a spring bias to facilitate greater deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a static lower tool with a fixed V-profile is used, then the tool structure is simple and stable, but the maximum bend angle is limited to less than 180° due to spring back
Solution Approach 1:
The lower tool is transformed from a static structure to a dynamic one by introducing multiple actuators that can deflect about a deflector. This allows the tool to adapt its geometry during operation, enabling bend angles exceeding 180° while maintaining structural stability through controlled movement of individual actuator elements.
Solution Approach 2:
The lower tool is divided into multiple separate actuator elements rather than being a single rigid structure. Each actuator can move independently about the deflector, allowing the tool to accommodate complex bending geometries while maintaining overall structural integrity and enabling greater bend angles.
2Adaptability or versatility
If parallel sided tools are used to increase bend angle beyond 150°, then the bend angle capacity is improved, but spring back still limits the maximum sustained bend angle to less than 180°
Solution Approach 1:
The dynamic actuator system allows the tool to maintain precise control over the bending process even at angles exceeding 180°. The actuators can be positioned and held at specific angles, compensating for spring back effects and achieving accurate sustained bend angles that would be impossible with static tools.
Solution Approach 2:
The tool enables change in the bending parameters by allowing the actuator geometry to vary during the process. The actuators can be deflected to different angles and positions, changing the effective bending geometry to achieve and sustain precise bend angles beyond 180° despite material spring back.
3Device complexity
If the upper tool is entrant in nature engaging the lower tool, then the tool arrangement is simple, but the maximum bend angle is limited to around 180°
Solution Approach 1:
By making the lower tool dynamic with deflectable actuators, the system overcomes the geometric limitations of the simple entrant upper tool configuration. The actuators can adjust their positions to accommodate bend angles beyond 180° while maintaining the simplicity of the upper tool design.
Solution Approach 2:
The solution adds a new dimension of movement to the lower tool through the deflectable actuators rotating about the deflector. This additional degree of freedom allows the system to achieve bend angles exceeding 180° without complicating the upper tool's entrant geometry.
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 formation of materials with bend angles exceeding 180° in a single operation, reducing reliance on multi-staged processes and enhancing component quality by allowing for greater flexibility and control over the bending process.
Implementation Method 1
the actuators deflectable about the respective deflector to receive the material to be formed upon pressing about the receiving opening to form the press recess
Implementation Method 2
the actuators deflectable about the respective deflector
Data Source
AI summary
It is difficult to bend materials for forming beyond 180° in terms of bend angle due to the entrant nature of prior press forming arrangements including a press tool with a press recess of a static nature. By providing a press recess which is formed from actuators allowed to dynamically shift about a deflection member it is possible as a press tool engages and forces a material to be formed into the press recess to envelope the press tool and therefore achieve greater than 180° bending angles. The actuators are formed in a stack with alternate left right presentation of shaped receiving apertures which include an actuator surface 34 engaged by the material to be formed in order to cause the necessary deflections during the pressing process.