Forming Device for Connection Protrusions on Reinforcement Elements
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Solution Overview
Problem
Current methods for producing connecting attachments on reinforcement elements, particularly with materials like AlMgSc, magnesium, or titanium, are costly and inefficient due to multiple process steps and difficulty in cold forming, which limits the use of these materials in composite structures.
Innovation Solution
A forming device utilizing a pressure wave generation system and a mask device with recesses to shape reinforcement elements, allowing for the creation of connecting lugs on materials previously difficult to form, such as AlMgSc, Mg, or Ti, by deforming them with magnetic pulses and cutting them to size in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional welding or sintering methods are used to produce connecting attachments on reinforcement plates, then the connection attachments can be produced, but the production cost increases and multiple process steps are required
Solution Approach 1:
The patent combines cutting and forming operations into a single punching process. The punch tool simultaneously cuts the reinforcement plate and forms the connecting attachments in one operation, eliminating the need for separate welding or sintering steps and reducing overall process complexity
Solution Approach 2:
The patent replaces thermal joining methods (welding or sintering) with a cold forming mechanical process. By using a punch tool to directly form the connecting attachments through mechanical force, the need for thermal processes and associated equipment is eliminated
2Productivity
If punching out is used to form connection lugs on materials like AlMgSc, magnesium or titanium, then the process is simpler, but these materials would tear during forming
Solution Approach 1:
The patent changes the forming parameters by using a progressive deformation approach with a specifically designed punch tool geometry. The punch tool features a gradual deformation zone that allows high-strength materials to be formed without exceeding their ductility limits, preventing tearing while maintaining process simplicity
Solution Approach 2:
The punch tool is designed with different geometric features at different locations: a gradual deformation zone for forming the connecting attachments and a sharp cutting edge for clean separation. This local differentiation of tool geometry allows the material to be formed in one location without tearing while being cleanly cut in another location
3Ease of manufacture
If multiple process steps are used to produce connecting attachments, then the attachments can be created, but the production time increases
Solution Approach 1:
The patent merges cutting and forming operations into a single punching step. The punch tool performs both functions simultaneously during one tool pass, eliminating the need for sequential welding or sintering operations and significantly reducing production time
Solution Approach 2:
The punch tool is pre-designed with integrated cutting edges and forming surfaces that prepare and form the connecting attachments in one operation. The tool geometry is optimized in advance to perform multiple functions during a single pass through the reinforcement plate
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 method reduces production costs and time by enabling the formation of connecting attachments on high-strength materials that were previously challenging to shape, improving material choice and process efficiency while maintaining material integrity.
Implementation Method 1
at least one pressure wave generation device (18) for generating at least one pressure wave directed at a first broad side (44) of a reinforcement element (14)
Implementation Method 2
The pressure wave generating device (18) is preferably formed with a coil device (32) with at least one coil (34). The reinforcing element (14) is advantageously deformed by a magnetic pulse.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a forming device (10) for producing connection attachments (16) on reinforcing elements (14), comprising at least one pressure wave generating device (18) for generating at least one pressure wave directed towards a first broad side (44) of a reinforcing element (14), and a mask device (20) to be arranged on a second broad side (46) of the reinforcing element (14) opposite the first broad side (44), wherein the mask device (20) is formed with a forming block (30) which has recesses (28) formed for producing predetermined connection attachment shapes.