Hot Forming Tool Descaling Device for Scale Removal
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Solution Overview
Problem
Hot forming processes for producing lightweight structural components in vehicle construction face challenges due to scale formation on tool surfaces, leading to tool wear, contamination, and reduced service life, which increases costs and environmental concerns.
Innovation Solution
A forming tool with a descaling device that removes scale and scale dust from the sheet metal part before forming, using suction and blow-out nozzles, air curtains, or dry ice cleaning, integrated into the tool to prevent scale deposition on active surfaces, thereby extending tool life and ensuring a clean working environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot forming process is used to produce lightweight structural components, then component weight is reduced and mechanical properties are improved, but scale formation occurs on tool surfaces leading to tool wear and contamination
Solution Approach 1:
The descaling device is integrated into the forming tool to remove scale from the sheet metal part before it contacts the tool's active surfaces. This preliminary cleaning action prevents scale deposition on the tool, eliminating the harmful effect while maintaining the hot forming process benefits
Solution Approach 2:
The descaling device acts as an intermediary between the heated sheet metal part and the forming tool surfaces. It intercepts and removes scale deposits before they can contaminate the tool, protecting the tool surfaces from wear and contamination
2Object-affected harmful factors
If scale deposits are removed from tool cavities using compressed air or dry ice, then tool contamination is reduced, but system downtime increases and employee health may be impaired
Solution Approach 1:
Instead of cleaning the tool after scale deposits accumulate, the descaling device performs preliminary cleaning of the sheet metal part before it enters the tool. This prevents scale from reaching the tool cavities in the first place, eliminating the need for subsequent cleaning operations and associated downtime
Solution Approach 2:
The system becomes self-servicing by continuously removing scale at the point of origin. The descaling device operates automatically during the forming process, maintaining clean conditions without requiring external intervention or system shutdowns
3Temperature
If inserts with integrated cooling systems are used for shaping components, then cooling efficiency is improved, but wear of inserts increases due to scale deposits
Solution Approach 1:
The descaling device removes scale from the sheet metal part before it contacts the inserts with cooling systems. This preliminary removal prevents scale from depositing on the inserts, protecting them from abrasive wear and extending their service life while maintaining cooling efficiency
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
The solution significantly reduces tool wear, minimizes contamination, extends the service life of processing tools, improves occupational safety, and enhances manufacturing efficiency by preventing scale buildup, leading to improved quality and reduced downtime.
Implementation Method 1
The descaling device removes scale and scale dust from the heated sheet metal part directly at the point of origin or immediately before hot forming
Implementation Method 2
The formed workpieces are cooled by means of a cooling unit located in a closed tool body. As a result, components with particularly high mechanical properties, in particular with high strength, can be produced
Data Source
Figure 1~3
AI summary
The invention relates to a moulding tool (10) for producing hot-formed components (17), in particular moulded sheet metal parts consisting of steel, aluminium, magnesium or a combination thereof, said tool comprising a lower tool part (12u) and an upper tool part (12o) which are displaceable relative to one another and have corresponding active areas for forming the component (17). At least some sections of at least the active area of one tool part (12u, 12o) can be cooled and the moulding tool is provided with at least one pickling device (18, 18').