Head Suspension Cutting Using First Plate as Die
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Solution Overview
Problem
The existing methods for cutting half-finished head suspensions into individual units require high accuracy and frequent maintenance of tools, increasing the number of manufacturing processes and costs.
Innovation Solution
A method where a laminated material, composed of first and second plates, is held between a pad and a clamp base, with the first plate functioning as a die to cut the protrusions of the second plate, reducing the need for precise positioning and maintenance of tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cutting tools (die, pad, punch) are used to cut half-finished head suspensions, then cutting can be performed, but high positioning accuracy cannot be maintained without frequent maintenance and increased process complexity
Solution Approach 1:
The first plate serves as its own cutting die, eliminating the need for separate precision tools. The workpiece (first plate) performs the cutting function for itself by cutting the protrusion of the second plate, thereby self-servicing the positioning and cutting operation without requiring externally maintained tools.
Solution Approach 2:
The first plate serves multiple functions: it is both the workpiece being processed and the cutting tool (die). This multi-functionality eliminates the need for separate dedicated cutting tools, reducing device complexity while maintaining cutting precision through the inherent positioning of the laminated structure.
2Ease of manufacture
If traditional cutting tools are used, then cutting can be performed, but tool maintenance frequency increases
Solution Approach 1:
The cutting operation uses the first plate itself as the cutting edge, eliminating separate movable cutting tools that would require maintenance. Since the first plate is stationary and serves as the die, there are no moving cutting tools to wear or maintain.
Solution Approach 2:
The first plate functions as a disposable or single-use die for the cutting operation. Rather than maintaining expensive precision tools, the system uses the workpiece itself as a single-use cutting element that does not require repeated maintenance cycles.
3Manufacturing precision
If precise positioning is required for cutting, then cutting accuracy improves, but the number of manufacturing processes increases
Solution Approach 1:
The positioning and cutting functions are merged into a single operation. The laminated structure of the first and second plates provides inherent positioning, and the first plate simultaneously performs both positioning and cutting, eliminating separate positioning and cutting steps.
Solution Approach 2:
The laminated structure of the first and second plates is prepared in advance with the first plate positioned relative to the second plate. This preliminary positioning is built into the laminated material itself, so no additional positioning operations are needed during the cutting process.
Data Source
AI summary
A method of cutting a laminated material 10A made of at least first and second plates that are laid one on another and fixed together includes holding the laminated material 10A between a pad 71 and a clamp base 73, so that an edge 14a of the first plate 14 is positioned between an edge 71a of the pad 71 and an edge 73a of the clamp base 73; and cutting a protrusion of the second plate 12 protruding from the edge 14a of the first plate 14 by moving a punch 75 along the pad 71 in a direction from the second plate 12 toward the first plate 14 and by using the first plate 14 as a die to cut the protrusion of the second plate 12. The method is capable of precisely cutting the protrusion of the second plate 12 protruding from the edge 14a of the first plate 14 through a reduced number of processes.