Guided Keeper Locking Collar for Metal Forming Dies
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Solution Overview
Problem
Current metal forming dies are labor-intensive and costly to design, manufacture, and repair due to custom-made components and complex machining requirements, with a high risk of tool failure from loose screws and guide pins.
Innovation Solution
A modular guided keeper assembly with a locking collar system that includes a disc-shaped collar body, retainer ring groove, and socket head cap screws to securely fasten guide pins, preventing unintentional unfastening and providing precise alignment and support, which can be efficiently manufactured using CNC lathes without additional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-made components and complex machining are used for metal forming dies, then precision and reliability are improved, but manufacturing cost and labor intensity increase substantially
Solution Approach 1:
The die set is divided into modular components including standardized keepers, guide pins, and punching stations that can be independently manufactured and assembled. This segmentation allows each component to be produced using standard machining processes rather than custom handcrafting, reducing labor intensity while maintaining precision through modular assembly.
Solution Approach 2:
Standardized keepers and guide pins are designed with universal dimensions and features that can be used across multiple die sets and applications. This universality eliminates the need for custom-made components for each die, reducing manufacturing complexity and labor requirements while maintaining reliability through consistent, repeatable designs.
2Manufacturing precision
If custom-made components are handcrafted and individually installed, then precision alignment is achieved, but lead time and manufacturing cost increase
Solution Approach 1:
Keepers and guide pins are pre-manufactured with precision features and pre-assembled into modular units before being installed in the die set. This preliminary preparation of components with precise alignment features built-in eliminates the need for time-consuming on-site alignment and fitting, reducing lead time while maintaining manufacturing precision.
Solution Approach 2:
The die set is segmented into pre-assembled modular units with precision alignment features integrated into each module. This allows precision alignment to be achieved through modular assembly rather than through time-consuming individual component fitting and adjustment, significantly reducing lead time while maintaining alignment accuracy.
3Ease of operation
If traditional fastening methods are used for guide pins, then assembly is simple, but screw loosening and tool failure risk increase
Solution Approach 1:
The fastening system uses split lock nuts with split designs that provide dynamic locking action. As the nut is tightened, the split creates elastic deformation that generates continuous radial pressure and friction force, dynamically preventing loosening from vibration and thermal cycling while maintaining ease of assembly and disassembly.
Solution Approach 2:
A keeper component serves as an intermediary element between the guide pin and die members. The keeper includes integrated fastening features such as slots and clearance holes that work with lock nuts and guide pin extensions to create a positive retention system, preventing screw loosening while maintaining simple assembly procedures.
Data Source
AI summary
A locking collar assembly for metal forming dies includes a disc-shaped locking collar with a cylindrical outer surface closely received in a collar bore in one face of a first die member. A circular recess in the outer face of the locking collar has an internal retainer ring groove. A counter bore shaped fastener hole extends through the collar and a part of the recess, and has shank, head and shoulder portions. A socket head cap screw is inserted in the fastener hole with a threaded end anchored in a threaded end aperture in one of the guide pins, with the head seated on the shoulder of the fastener hole. A retainer ring is mounted in the collar ring groove and overlies the cap screw head to positively prevent the cap screw from unintentionally unfastening from the guide pin.