Pressure Forming Tool for Sheet Metal Connecting Web Detachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for pressure forming connecting webs in sheet metal processing lack force-dependent control, leading to inefficient detachment and potential damage during handling.
Innovation Solution
A forming tool with a portal-like first tool part and a second tool part with a continuously flat contact surface, allowing for force-dependent control of the machining stroke and enabling easy release of connecting webs after pressure forming, while minimizing material residue on workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connecting web is dimensioned sufficiently large to prevent breaking during handling, then the reliability of connection is improved, but the ease of detachment deteriorates
Solution Approach 1:
The connecting web is divided into two regions with different cross-sectional dimensions: a first region with larger cross-section for reliable connection during handling, and a second region with reduced cross-section for easy detachment. This segmentation allows the same component to satisfy both contradictory requirements at different locations.
Solution Approach 2:
Different regions of the connecting web are given different local properties: the first region maintains original dimensions for strength, while the second region has reduced dimensions for easy breaking. This local differentiation resolves the contradiction between overall reliability and localized ease of detachment.
2Ease of operation
If a forming tool with chamfered punch tip and die recess is used to reduce connecting web cross-section, then the detachment ease is improved, but the device complexity increases
Solution Approach 1:
The invention extracts only the essential forming action needed to create the reduced cross-section region, eliminating the need for complex chamfered punch tips and die recesses. The forming tool applies pressure to reduce the cross-section of the connecting web in the second region without requiring the complicated structural features of prior art tools.
3Manufacturing precision
If the forming punch is moved close to the bearing surface to reduce connecting web thickness, then the manufacturing precision of cross-section reduction is improved, but the risk of damage to workpiece parts increases
Solution Approach 1:
The forming process is designed to reduce the cross-section of the connecting web in the second region before final separation occurs. This preliminary action creates the weakened region that will later break easily, while the controlled forming distance prevents damage to the workpiece parts during the forming operation.
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
Enables precise control over the pressure forming process, allowing for efficient detachment of connecting webs with minimal residual material on workpieces, enhancing handling and reducing tool wear.
Implementation Method 1
the connecting web is compressed, reducing its thickness, between the forming punch and the forming die
Implementation Method 2
the connecting web is bent over an edge formed on the forming die by the bearing surface and a lateral boundary surface of the die recess
Data Source
Figure 1~2
Figure 3~5
Figure 6~9
AI summary
A forming tool (13) for pressure forming a connecting web (23) between incompletely separated workpiece parts (18, 20) of a machined plate-like workpiece, in particular a sheet (15), comprises two tool parts which, during pressure forming of the connecting web (23), are assigned to opposite sides of the connecting web (23) along a stroke axis (14). A first of the tool parts has a forming element (24), and the second tool part (12) is provided with a bearing surface (27) extending transversely to the stroke axis (14) and facing the free end of the first tool part. The bearing surface (27) of the second tool part (12) is designed as a continuously flat surface.During the pressure forming of the connecting web (23), the bearing surface (27) of the second tool part (12) faces the forming element (24) of the first tool part along the stroke axis (14) with a surface area that is aligned with the remaining bearing surface (27) of the second tool part (12) in the transverse direction of the stroke axis (14). A pressure forming process for a connecting web (23) is carried out using the forming tool (13). This pressure forming process for a connecting web (23) is part of a process for machining plate-like workpieces, in particular for machining sheet metal (15), and also part of a process for machining plate-like workpieces, in particular for machining sheet metal (15), in which, in addition to the machining, further workpiece machining, in particular edge machining, is carried out.