Expandable Core Piercing of Radial Walls Without Burrs
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Solution Overview
Problem
Existing methods for producing sheet metal rings with holes are inefficient as they require sequential punching and bending, which can lead to distortion and burr formation during hole punching.
Innovation Solution
A slew-actuated stamping station that applies radially outward pressure using an expandable core and employs slew-actuated punches to simultaneously pierce multiple holes in a radial wall, preventing distortion and burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential punching is used to create holes in sheet metal rings, then manufacturing simplicity is maintained, but productivity is reduced and manufacturing precision deteriorates due to distortion and burr formation
Solution Approach 1:
The expandable core is inserted into the ring before the punching operation and expanded to apply radial support pressure to the inner surface of the ring wall. This preliminary action of providing support before punching prevents distortion and burr formation during the subsequent hole piercing process, thereby improving manufacturing precision while maintaining high productivity through simultaneous multi-hole punching
2Productivity
If multiple holes are punched sequentially, then device complexity is minimized, but loss of time increases and productivity decreases
Solution Approach 1:
Multiple punching operations are merged into a single simultaneous operation by positioning multiple punches around the expandable core. All punches operate at the same time to create multiple holes in one action, eliminating the sequential timing delays and significantly reducing total processing time while increasing productivity
3Manufacturing precision
If radial support pressure is applied during piercing, then manufacturing precision is improved by preventing distortion and burrs, but device complexity increases due to expandable core mechanism
Solution Approach 1:
The core is designed to be expandable rather than static, allowing it to transition from a compact storage state to an expanded support state during the punching operation. This dynamic capability enables the core to provide radial support pressure exactly when needed during piercing, improving hole quality without requiring a permanently complex support structure
Data Source
AI summary
A slew-actuated stamping station includes an expandable core configured to apply radially outward pressure to a radially inward facing surface of a radial wall, and at least one slew-actuated punch for piercing, along a radially inward direction, a respective hole in the radial wall. A method for piercing a radial wall includes simultaneously (a) applying radially outward pressure against a radially inward facing surface of the radial wall, and (b) driving a slew to actuate at least one punch to pierce, along direction opposite the radially outward pressure, at least one hole in the radial wall. A method for forming an object, having a radial wall with holes, includes forming a ring with a radial wall, and piercing at least one hole in the radial wall with at least one slew-actuated punch.