Electrical-Assisted Incremental Forming of Sheet Metal
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Solution Overview
Problem
Current metal deformation processes require high forces and energy, leading to increased manufacturing costs and tool wear, and elevated temperature methods suffer from drawbacks such as tool adhesion and decreased dimensional accuracy.
Innovation Solution
Applying an electrical direct current through the metal workpiece during deformation using a computer numerical controlled machine with an arcuate tipped tool and electrodes, reducing the energy required for deformation and enhancing ductility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional metal deformation processes are used, then the required force for deformation increases, but manufacturing cost and tool wear increase
Solution Approach 1:
The patent replaces conventional mechanical deformation systems with an electrical-assisted system. Electrical current is passed through the workpiece during deformation to reduce flow stress, substituting part of the mechanical force requirement with electrical energy input. This reduces the required deformation force while maintaining manufacturing efficiency.
Solution Approach 2:
The patent changes the physical state parameters of the metal during deformation by applying electrical current. The electrical energy alters the material's flow stress characteristics, enabling deformation at lower forces. This parameter change allows the same deformation to be achieved with reduced mechanical input.
2Force
If elevated temperatures are used to reduce deformation force, then energy consumption increases, but tool adhesion and dimensional accuracy worsen
Solution Approach 1:
The patent substitutes thermal softening with electrical-assisted deformation. Instead of heating the material to reduce flow stress, electrical current is applied during deformation to achieve the same effect without temperature increase. This eliminates thermal-related problems such as tool adhesion and dimensional inaccuracies while maintaining reduced force requirements.
Solution Approach 2:
The patent changes the approach to modifying material properties during deformation. Rather than changing temperature parameters, the patent applies electrical current parameters to alter flow stress characteristics. This parameter substitution achieves force reduction without the detrimental effects of thermal processing.
3Force
If larger equipment is used to increase deformation force capacity, then equipment size increases, but energy consumption and manufacturing cost increase
Solution Approach 1:
The patent changes the energy input parameters by introducing electrical current during deformation. This electrical energy input modifies the material's resistance to deformation, allowing smaller equipment to achieve the same deformation force capacity. The parameter change from purely mechanical to electro-mechanical energy input reduces overall energy consumption.
Solution Approach 2:
The patent substitutes mechanical force amplification with electrical energy input. Instead of using larger equipment to provide greater deformation force, the system uses electrical current to reduce material resistance. This substitution allows smaller, more energy-efficient equipment to perform the same deformation tasks.
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 process lowers the energy needed for deformation, increases workability, and reduces springback, allowing for more efficient and cost-effective metal forming without the need for elevated temperatures.
Implementation Method 1
Troitskii found that electric current pulses reduce the flow stress in metal
Implementation Method 2
the electrical effects could not be explained by microstructure changes alone
Data Source
AI summary
A process and apparatus for forming a sheet metal component using an electric current passing through the component. The process can include providing an incremental forming machine, the machine having at least one arcuate tipped tool and at least electrode spaced a predetermined distance from the arcuate tipped tool. The machine is operable to perform a plurality of incremental deformations on the sheet metal component using the arcuate tipped tool. The machine is also operable to apply an electric direct current through the electrode into the sheet metal component at the predetermined distance from the arcuate tipped tool while the machine is forming the sheet metal component.