Fine blanking edge reduction compensation via two-stage forming
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Solution Overview
Problem
Fine blanking techniques result in edge reduction, particularly in corner areas, which limits material utilization and forces the use of thicker raw materials, leading to increased production costs and reduced functionality of parts.
Innovation Solution
A method involving a two-stage process where a material allowance is added to the blank contour before fine blanking, with a virtual simulation determining the necessary allowance to compensate for edge reduction, and a forming process in the second stage shifts this material to fill up the reduction, allowing for precise control and elimination of edge reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fine blanking is performed with standard cutting parameters, then the cutting process is simple and fast, but edge reduction occurs particularly in corner areas leading to loss of material and reduced functionality
Solution Approach 1:
The patent applies preliminary action by performing a pre-forming step before the actual cutting operation. This pre-forming creates a material volume in mirror-image form on the side of the expected reduction, which compensates for the edge reduction that will occur during cutting. The preformed area is also supported by the preforming element during the cutting process, ensuring precise compensation without affecting the cutting speed or simplicity.
2Reliability
If thicker raw material is used to compensate for edge reduction, then functionality is maintained, but material costs increase and material utilization decreases
Solution Approach 1:
The patent applies parameter changes by modifying the blank contour parameters before cutting. Instead of using thicker material, the method calculates and adds a specific material allowance to the blank contour based on simulation of the expected reduction. This allowance is precisely controlled to compensate for edge reduction while maintaining optimal material utilization and avoiding the need for thicker raw material.
3Manufacturing precision
If additional machining operations are performed to remove reduction, then edge quality is improved, but production costs increase and productivity decreases
Solution Approach 1:
The patent performs the compensation action preliminarily during the forming stage, before cutting. By creating the mirror-image material volume in advance and supporting it during cutting, the method eliminates the need for subsequent re-cutting or shaving operations to remove reduction, thereby maintaining high productivity while achieving the desired edge quality.
4Loss of substance
If material allowance is added to blank contour, then edge reduction is compensated, but the blank size increases before cutting
Solution Approach 1:
The patent applies parameter changes by precisely calculating the material allowance based on simulation of the expected reduction. The allowance is not a uniform increase but a specifically shaped addition to the blank contour that exactly compensates for the predicted edge reduction. This ensures minimal increase in blank volume while achieving effective compensation.
Data Source
AI summary
The invention relates to a method and a device for influencing the cut and functional face, especially the reduction, during fine blanking of a finished part, for example, a gear, cut out of a metal strip, wherein the metal strip is clamped during closure between an upper part at least comprising a cutting punch and guide plate for the cutting punch and a lower part at least comprising a die plate and ejector and in a first working stage a blank with reduction is cut out of the metal strip.The invention has the task of providing a method and a device for purposefully influencing the cut and functional face, especially the reduction, during the production of finished parts, like gears, making it possible to purposefully influence or totally eliminate the edge reduction, while simultaneously maintaining the functional surfaces and saving material.This task is solved by cutting out the blank with a defined material allowance relative to the contour of the finished part, at least in the area of the reduction, the size of which within the first working stage is adjusted to a stipulated degree to a material volume that fills up, compensates or exceeds the volume deficit occurring due to the reduction to a preset value and by subsequently during a second working stage shifting this material volume in a forming process opposite the cutting direction of the first working stage on the cutting line of the blank to purposefully fill up the developed reduction.