Heated Punch Hole Forming for Thin Workpiece Accuracy
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Solution Overview
Problem
Existing punch hole forming methods face challenges in maintaining the temperature of relatively thin workpieces during punching, leading to reduced deformability and increased deformation resistance, which can result in inaccurate hole formation and reduced punch and die lifetimes due to thermal damage.
Innovation Solution
A method and device that maintain the workpiece at a specific temperature (TO) between 300°C and 950°C, achieved by heating the die and punch, to suppress temperature decrease and deformation, while applying a controlled load to prevent buckling and ensure accurate hole formation with a larger aspect ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the workpiece is placed on a die and punched at room temperature, then the punching process is simple, but the temperature of the workpiece decreases due to the die and punch, reducing deformability and making it difficult to punch
Solution Approach 1:
The workpiece is heated to temperature TO before being placed on the die and during the punching process. This preliminary heating action ensures the workpiece maintains sufficient deformability throughout the punching operation, preventing temperature decrease that would otherwise reduce deformability and make punching difficult.
2Stability of the object's composition
If the workpiece is excessively heated to maintain deformability, then the deformability increases, but the plate shape cannot be kept and the workpiece undergoes deformation such as warping
Solution Approach 1:
The workpiece is heated to a specific temperature parameter TO (300°C to 950°C) which is optimized to provide sufficient deformability for punching while preventing excessive heating that would cause warping or shape deformation. This precise parameter control resolves the contradiction between needing high deformability and maintaining shape stability.
3Duration of action of stationary object
If the punch is cooled to prevent thermal damage, then the punch lifetime increases, but the workpiece temperature decreases further reducing deformability
Solution Approach 1:
The workpiece is pre-heated to temperature TO before punching begins. This preliminary heating compensates for any cooling effect from the punch, ensuring the workpiece maintains sufficient temperature and deformability throughout the punching process while allowing the punch to be cooled for extended lifetime.
4Force
If a large load is applied by the punch to ensure hole formation, then the punching force is sufficient, but the thin workpiece undergoes deformation and the hole diameter accuracy decreases
Solution Approach 1:
The workpiece is heated to temperature TO, which reduces its deformation resistance and allows sufficient punching force to be applied without causing excessive deformation. This temperature parameter change enables both adequate punching force and maintained hole diameter accuracy in thin workpieces.
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 approach reduces deformation resistance, allowing for easier and more accurate punching of thin workpieces with larger aspect ratios, extending the life of the punch and die by minimizing thermal damage and enabling efficient formation of multiple holes simultaneously.
Implementation Method 1
the workpiece is placed on a die heated to a temperature TD... the workpiece is kept at a temperature TO by placing the workpiece on the die heated to a temperature TD
Data Source
AI summary
A punch hole forming method and a punch hole forming device that can suppress a decrease in the temperature of a workpiece due to a machining tool when a hole is formed by punching the workpiece using the machining tool. In the punch hole forming method, when a workpiece that is a plate-like member having a thickness of 0.01 mm or more and 1 mm or less is placed on a die, and a hole is formed by punching the workpiece in the thickness direction using a punch, the workpiece is kept at a temperature at which the workpiece can be punched at least during formation of the hole.