Forming Tool Temperature Control via Segmented Cooling Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing forming tools face issues with temperature-related deformation and cracking in high-deformation areas due to heat buildup from friction, leading to reduced tool lifespan and potential damage from pressure loads, and existing solutions like introducing cooling channels or replacing tools are either risky or economically unsatisfactory.
Innovation Solution
A forming tool with temperature control devices, such as blind holes and baffle plates, is introduced in critical areas to regulate temperature, and a method for retrofitting existing tools with these features, using a medium to adjust temperature and seal porous materials to prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are introduced into the forming tool, then temperature control is improved, but the cast structure is weakened and reliability deteriorates
Solution Approach 1:
The forming tool is divided into modular segments (die segments, insert segments) that can be independently manufactured and assembled. Temperature control channels are integrated into individual segments rather than requiring modifications to the entire cast structure, preserving the integrity of each segment while enabling localized cooling.
Solution Approach 2:
Temperature control channels are nested within the forming tool segments during manufacturing. The channels are created as internal features of the segments themselves, allowing cooling functionality to be embedded without adding external components that would compromise structural strength.
2Temperature
If the forming tool is completely replaced with optimized inserts, then temperature control capability is improved, but manufacturing cost increases significantly
Solution Approach 1:
Temperature control channels are pre-integrated into the forming tool segments during initial manufacturing. This preliminary integration eliminates the need for costly post-manufacturing modifications or complete tool replacements, as the cooling capability is built-in from the start.
Solution Approach 2:
Temperature control is implemented locally in specific high-deformation areas of the forming tool rather than throughout the entire tool. This localized approach reduces material and manufacturing costs compared to comprehensive tool replacement, while addressing the critical thermal management needs where they occur.
3Temperature
If multiple bores are created for cooling circuits, then temperature control is improved, but the cast structure is weakened
Solution Approach 1:
Multiple cooling bores are nested within individual tool segments during a single manufacturing process. This nesting approach allows multiple channels to be created without requiring multiple separate drilling operations that would progressively weaken the structure, as all channels are formed together in the segment's initial fabrication.
Solution Approach 2:
The cooling circuit is segmented into multiple independent channels within separate tool segments. Each segment with its internal bores can be manufactured independently and then assembled, distributing the structural stress and avoiding the need to create multiple intersecting bores in a single monolithic structure.
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 allows for continuous temperature adjustment and improved heat transfer, reducing the risk of cracking and tool damage, enabling higher production efficiency and tool longevity without weakening the cast structure.
Implementation Method 1
at least one recess (14) is provided in the die (11), the male die (13) and/or the blank holder (12) for temperature control, which can be flushed with a medium
Implementation Method 2
The surface of the tool within the recess can be sealed with a sealant. This offers advantages, particularly if the tool is made of a porous material such as cast material
Data Source
Figure 1~2
AI summary
The invention relates to a forming tool for shaping a workpiece (20), in particular a flat metal sheet, comprising a female die (11), a blank holder (12), and a male die (13), all of which are movable relative to one another, characterized in that the female die (11), the blank holder (12) and/or the male die (13) can be temperature-controlled in at least some portions thereof.