Elastomeric Stamp Forming Tools for Uniform Pressure on Large Parts
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Solution Overview
Problem
Current stamp forming technologies using metal die sets face challenges in achieving uniform pressure distribution for large-scale parts, leading to material consolidation issues and void formation, which are exacerbated by the rapid deterioration of elastomeric inserts in demanding thermal and mechanical environments.
Innovation Solution
The use of a tooling set with an elastomeric layer positioned between stamping tools to balance pressures and deform uniformly, allowing for consistent compression and deformation of workpieces across different forming faces, thereby improving pressure distribution and extending the lifespan of the elastomeric inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If matched metal die sets are used for stamp forming large-scale parts, then structural strength and durability are improved, but uniform pressure distribution deteriorates leading to material consolidation issues and void formation
Solution Approach 1:
The patent replaces rigid metal die sets with flexible elastomeric stamping tools that can conform to the workpiece surface. The elastomeric material deforms under compression to distribute pressure uniformly across the part surface, eliminating the pressure variations that cause void formation while maintaining sufficient forming force for large-scale parts
2Reliability
If stamping pressure is increased to overcome nonuniform pressure distribution, then material consolidation is improved, but part thinning becomes excessive
Solution Approach 1:
The patent changes the fundamental parameter of tool compliance from rigid to flexible. The elastomeric material's ability to deform allows it to adapt to surface variations and maintain uniform contact pressure without requiring excessive compression forces, thereby achieving good material consolidation while preventing excessive part thinning
3Manufacturing precision
If elastomeric inserts are used to achieve uniform surface pressures, then manufacturing precision is improved, but insert lifespan deteriorates due to rapid deterioration in thermal and mechanical environments
Solution Approach 1:
The patent employs composite tooling systems that combine elastomeric materials with supportive structures. This composite approach maintains the pressure-uniforming benefits of elastomeric inserts while providing structural support that reduces mechanical stress and thermal degradation, thereby extending insert lifespan beyond the less than ten cycles achieved with traditional elastomeric inserts
4Manufacturing precision
If elastomeric inserts are replaced frequently to maintain part quality, then manufacturing precision is preserved, but productivity deteriorates due to expensive and time-consuming replacement
Solution Approach 1:
The patent designs elastomeric stamping tools as integral or easily replaceable components that maintain their pressure-distributing functionality over extended periods. The improved material formulation and structural design reduce degradation rates, allowing inserts to survive many more than the traditional ten cycles before replacement is needed, thereby significantly improving productivity
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 enhances the quality of large-scale parts by ensuring uniform pressure distribution, reducing void formation, and extending the lifespan of elastomeric inserts, making the process more efficient and cost-effective.
Implementation Method 1
an elastomeric layer that deforms during compression of a workpiece. The elastomeric layer(s) balancing pressures on the workpiece that would otherwise be caused by compression between forming faces of the stamping tools
Data Source
AI summary
A tooling set for stamp forming a workpiece includes a first stamping tool, a second stamping tool and an elastomeric layer between the first and second stamping tools. The first stamping tool defines a first forming face. The second stamping tool defines a second forming face. The elastomeric layer defines first and second compliant stamping surfaces. A method for stamp forming a workpiece includes positioning a workpiece between the first stamping tool and the elastomeric layer and compressing the workpiece between the first forming face and the first compliant stamping surface in response to the first and second stamping tools being approximated. A system for stamp forming a workpiece includes the tooling set.