Forming Tool Cooling via Rear Spray Evaporation
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Solution Overview
Problem
Existing forming and cooling technologies for metal components, particularly in forming presses, are complex, costly, and inefficient, especially in series production, requiring significant coolant usage and structural effort, and are not well-suited for high-throughput manufacturing of components like armor steel.
Innovation Solution
A forming press with a multi-part forming tool and a cooling device that uses a spray coolant applied to the rear side of the tool molds, allowing for efficient heat extraction through evaporation, reducing coolant requirements and simplifying the cooling system, enabling flexible operation and high-throughput production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant is sprayed directly onto the component during forming, then cooling efficiency is improved, but the forming press becomes complex and suitable only for open-tool configurations
Solution Approach 1:
The invention introduces a carrier plate as an intermediary between the die/punch and the coolant supply. The carrier plate carries cooling channels that are sealed against the die or punch, allowing coolant to be conveyed through the forming tool itself rather than spraying directly onto the component. This mediator enables efficient cooling while maintaining a simple, integrated forming press design.
Solution Approach 2:
The invention uses hydraulic cooling channels integrated into the carrier plate to convey coolant through the forming tool. This hydraulic system allows for efficient heat removal from the component during forming without requiring complex spray systems or open-tool configurations, resolving the contradiction between cooling efficiency and device complexity.
2Temperature
If the lower forming tool is completely covered by coolant bath, then both tool and component are cooled directly, but structural effort and coolant exchange requirements increase considerably
Solution Approach 1:
The invention segments the cooling function by separating the coolant application from the forming tool structure. Instead of using a complete coolant bath that requires substantial structural support, the cooling function is divided into integrated cooling channels within the carrier plate, providing direct cooling only where needed at the component-tool interface.
Solution Approach 2:
The invention transitions from a three-dimensional coolant bath approach to a two-dimensional planar cooling channel system integrated into the carrier plate. This dimensional change allows for efficient cooling without the structural complexity and coolant volume requirements of a complete bath system.
3Temperature
If coolant channels are formed in contact surface between stamp/die and carrier plate, then cooling is achieved, but sealing requirements and complexity increase
Solution Approach 1:
The invention merges the cooling channels directly into the carrier plate structure, eliminating the need for separate sealing arrangements between the stamp/die and carrier plate. The cooling channels are integrated into the contact surface itself, combining the cooling function with the structural carrier plate and reducing sealing complexity.
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 solution simplifies the cooling process, reduces coolant usage, and allows for flexible operation, enabling efficient high-throughput production of metal components while maintaining quality and reproducibility, particularly in series production of armor components.
Implementation Method 1
A forming press with a multi-part forming tool and a cooling device that uses a spray coolant applied to the rear side of the tool molds, allowing for efficient heat extraction through evaporation
Data Source
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AI summary
The method involves deformation and cooling of armor components (B) in a material-deforming tool (10) in a heated state. The material-deforming tool with the components is cooled with a coolant i.e. pure water, after removal and before insertion of the components. The coolant is applied as atomized spray (N) on idle rear outer surfaces (8) of the tool. The atomized spray is produced by micro atomization of the coolant by nozzles (13) i.e. micro nozzles. The micro nozzles are distributedly arranged over a surface opposite to the outer surface of the tool. An independent claim is also included for a deformation press.