Fine-Blanked Tooth Thickening for Contact Area
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Solution Overview
Problem
In fineblanking technology, the edge indentation and cutting burr issues lead to reduced contact area on functional surfaces, necessitating thicker materials and increased costs, while existing solutions either rework parts or compromise dimensional accuracy.
Innovation Solution
A method and device that partially thicken functional surfaces of fine-blanked parts using an upsetting head to increase the contact area without affecting dimensional accuracy, by clamping the blank on flat sides and applying an upsetting force horizontally to the tooth, allowing symmetrical thickening up to 30%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the sheet thickness is reduced to save material and reduce costs, then material utilization improves, but the edge indentation increases and functional surface contact area decreases
Solution Approach 1:
The invention applies preliminary upsetting deformation to the blank before fine blanking cuts the tooth geometry. This pre-forming action creates a material volume in mirrored form on the feed side that compensates for the inevitable edge indentation during cutting, allowing thinner material to achieve the required functional surface contact area after cutting
2Manufacturing precision
If re-cutting or re-shaving is performed to eliminate edge indentation, then manufacturing precision improves, but manufacturing complexity and costs increase
Solution Approach 1:
Instead of performing corrective operations after cutting (re-cutting or re-shaving), the invention performs the compensating deformation before cutting. The upsetting head creates the material compensation in advance, eliminating the need for additional machining processes and tools that would increase manufacturing complexity
3Manufacturing precision
If massive forming is performed before fine blanking to compensate for edge pull-in, then manufacturing precision improves, but dimensional accuracy deteriorates
Solution Approach 1:
The invention applies forming only to specific areas of the blank that will compensate for edge indentation in the tooth geometry, rather than massive forming of the entire blank. The upsetting head is adapted to the shape of the tooth and applies localized deformation, creating material volume only where needed while preserving the dimensional accuracy of other parts of the component
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 contact area on functional surfaces while reducing material thickness, saving material and improving economic and dimensional accuracy of fine-blanked parts.
Implementation Method 1
upsetting the tooth by applying an upsetting force tailored to the material of the blank and the tooth shape in such a way that the force is directed horizontally to the flat sides in the core of the tooth
Data Source
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AI summary
The method involves completely cutting a blank (7) from band strips in a fine cutting stage. The blank is clamped at a flat side (FSD) between a compression plate and an ejector such that a tooth (2) of the blank is not clamped and remains accessible for a shaping operation. The tooth is compressed by subjection with compression force (PSK) such that the force is directed into a core of the tooth by a compressing head (18) horizontal to the flat side. The tooth is symmetrically thickened in a measurement of upto 30 percentage compared to an initial thickness of the blank. An independent claim is also included for a device for performing a method for increasing a bearing area of a flat fine blanked part.