Eyelet High Edge Manufacturing via Punch-Die Folding
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Solution Overview
Problem
Existing eyelet manufacturing methods result in a cylindrical portion with a circular head crown having an oblique edge, which increases the horizontal volume and reduces connection capacity, and are costly when attempting to achieve a higher edge height, leading to poor cutting quality and increased wear on supports.
Innovation Solution
A method involving in-line processes from a metal sheet to create a cylindrical portion with a circular head crown and a straight edge, achieved through a series of drawing operations, cutting, and an off-line process using a punch and die to fold the edge, resulting in an edge height of at least 1.8 mm, enhancing connection and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a punch-die cutting operation is used to create the eyelet edge, then the manufacturing process is simple and cost-effective, but the edge becomes oblique and folds outwards, increasing horizontal volume and reducing connection capacity
Solution Approach 1:
The manufacturing process is divided into two separate stages: an in-line process that creates the basic eyelet structure with a flat edge, and a subsequent off-line process that folds the edge to the desired configuration. This segmentation allows each process to be optimized independently - the cutting process remains simple and cost-effective while the folding process creates the precise edge geometry needed for connection.
Solution Approach 2:
The in-line process prepares the eyelet with a flat edge and proper structural formation before the final edge configuration is applied. By performing the basic shaping and cutting operations first, the subsequent folding operation can focus solely on creating the precise edge geometry without the complexity of simultaneous cutting and folding.
2Ease of operation
If the edge height is increased to improve connection capacity, then the horizontal volume required increases, but this leads to poor cutting quality and increased wear on supports
Solution Approach 1:
By separating the cutting operation from the edge-forming operation, the process allows for higher edge heights without compromising cutting quality. The cutting is performed on the flat sheet material where precision is maintained, and the subsequent folding creates the vertical edge height needed for connection capacity.
Solution Approach 2:
The edge is transformed from a horizontal feature to a vertical feature through the folding operation. Instead of increasing horizontal volume to achieve connection capacity, the process creates vertical edge height by folding the material upwards, thereby improving connection capacity without increasing horizontal dimensions or compromising cutting precision.
3Length of stationary object
If a round can machining process is used to achieve high edge height, then the edge height can be increased to about 2 mm, but the manufacturing cost increases significantly and the product becomes heavier
Solution Approach 1:
The complex round can machining process is replaced with a combination of simple punch-die cutting followed by a folding operation. Instead of using expensive rotational machining to create the edge height, the process uses material deformation through folding to achieve the same functional result at much lower cost and with less material removal.
Solution Approach 2:
The process changes the fundamental approach to creating edge height from material removal (machining) to material deformation (folding). This parameter change allows achieving the same edge height with significantly less material consumption, lower manufacturing cost, and without increasing product weight.
4Ease of operation
If the edge is folded outwards to create connection capacity, then the connection can be made, but the horizontal volume increases and the appearance is less desirable
Solution Approach 1:
The folding operation creates vertical edge height instead of horizontal extension. By folding the edge upwards to form a vertical wall, the process achieves connection capacity through vertical dimension rather than horizontal volume, thereby maintaining a compact horizontal footprint while providing sufficient connection surface area.
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 method produces eyelets with improved edge height and connection quality, reducing wear on supports and allowing for better coupling with washers or inserts, while maintaining affordability and reducing the risk of insert breakage.
Implementation Method 1
folding the edge of the flat head crown by means of the combined action of a punch and a die
Data Source
AI summary
There is described a method for obtaining an eyelet (1) consisting of a cylindrical portion (2) with a circular head crown (3) having a a straight edge (4) made in one piece, the height (h) of which is equal to at least 1.8 mm, which includes a series of in-line processes from a metal sheet (20) having a thickness from 0.25 to 0.40 mm, to obtain an intermediate eyelet (9) with flat head crown (10), and a further off-line process on said intermediate eyelet (9) with flat head crown (10), consisting in folding (30) the edge (4) of the flat head crown (10) by means of the combined action of a punch (11) and a die (12).