Hot Stamping Die Slides for Backdraft-Free Part Removal
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Solution Overview
Problem
Conventional hot forming processes face challenges in removing steel components with angled forming surfaces due to backdraft conditions, necessitating post-forming or secondary operations outside the die to achieve desired shapes and material properties.
Innovation Solution
A forming device with an upper cam slide and lower fill slide designed to form complex shapes without backdraft, allowing for direct removal of components by retracting the lower fill slide after forming, thus achieving desired shapes and material properties within the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the die is designed with angled forming surfaces to achieve desired shape and material properties, then the component quality is improved, but the component cannot be removed from the forming device due to backdraft condition
Solution Approach 1:
The forming device is segmented into multiple independent slides (upper cam slide, lower fill slide, and ejection slide) that can move separately. This allows the lower fill slide to retract and the ejection slide to move independently to eject the component, resolving the backdraft issue while maintaining the angled forming surfaces for quality components
Solution Approach 2:
The die design transitions from a static structure to a dynamic one where slides can move during the forming and ejection cycles. The lower fill slide retracts after forming, and the ejection slide dynamically positions itself to enable component removal, allowing both complex shaping and easy ejection
2Ease of operation
If the die is designed for convenient removal of the component, then ease of operation is improved, but post forming or secondary operations are required outside the forming device to achieve desired shape and material properties
Solution Approach 1:
The forming and ejection functions are merged into a single integrated forming device. The multiple slides work together within one device to both form the component with precise angles and material properties and then eject it conveniently, eliminating the need for secondary operations outside the device
3Manufacturing precision
If conventional die design is used with angled forming surfaces, then manufacturing precision is improved, but device complexity increases due to required post-forming operations
Solution Approach 1:
The forming device achieves multi-functionality by combining forming, quenching, and ejection capabilities in a single integrated system. The multiple slides perform different functions at different stages of the cycle, providing both precise shaping and convenient removal without requiring separate secondary operations, thus reducing overall process complexity
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
Enables the direct removal of steel components with angled surfaces from the forming device without additional operations, ensuring precise shape and material properties are achieved in a single step.
Implementation Method 1
heating the blank in a furnace, and then transferring the heated blank to a forming device. The hot forming process next includes forming the blank in a die of the forming device while the blank is at a temperature ranging from 950° C to 1250° C
Implementation Method 2
The quenching step preferably includes contacting the hot formed component with sections of the die which are cooled by a fluid, such as water cooling, to also achieve the desired material properties
Data Source
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AI summary
A forming device (10) for hot forming a component (12), such as a steel door panel for a vehicle, is provided. The forming device includes an upper cam slide (16) and a lower fill slide (18) which form a heated steel blank into the component (12) therebetween. The upper cam slide (16) and the lower fill slide (18) are designed to form the desired shape and material properties in the component (12), such that no post forming operations are needed. The lower fill slide (18) also retracts from the upper cam slide (16) after forming the component (12), such that the component (12) can be easily removed from the forming device (10) and a backdraft situation is avoided.