Hydro-Mechanical Forming Tool with Segmented Liquid Injection
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Solution Overview
Problem
Hydro-mechanical drawing processes require long cycle times due to the substantial volume of liquid needed and the energy required to generate pressure, which can be inefficient with large presses and extensive equipment.
Innovation Solution
A hydro-mechanical forming tool with a movable counter punch and liquid container ring that minimizes liquid volume, focusing pressure application on specific areas through a system of channels and seals to reduce friction and cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large volume of liquid is used to fill the entire area below the blank for hydro-mechanical drawing, then the blank can be formed against the punch, but the cycle time becomes very long and substantial energy is required
Solution Approach 1:
The liquid application area is segmented from the entire blank area to only the critical local regions requiring forming. The system uses localized liquid injection at specific positions (e.g., through the punch or at the die entry radius) rather than filling the entire space below the blank, thereby reducing the liquid volume that needs to be pumped and drained during each cycle while still achieving the necessary forming pressure where needed.
Solution Approach 2:
The system applies liquid pressure locally at specific areas of the blank rather than uniformly across the entire blank area. This allows the forming process to focus hydro-mechanical force only where tight local radii or complex features require assistance, reducing overall liquid volume while maintaining forming quality in critical regions.
2Stress or pressure
If a large volume of liquid is used for hydro-mechanical drawing, then sufficient pressure can be applied to form tight local radii, but the equipment size must be significantly increased
Solution Approach 1:
The system segments the pressure application to localized areas through targeted liquid injection, eliminating the need for a large press that would be required to apply maximum pressure across the entire blank surface. The press only needs to generate sufficient pressure for the localized hydro-mechanical assistance, significantly reducing equipment size.
Solution Approach 2:
By applying liquid pressure only at specific locations where tight local radii or complex features are present, the system achieves high forming pressure where needed without requiring the overall press capacity that would be necessary if the entire blank area required maximum pressure.
3Manufacturing precision
If hydro-mechanical drawing is used to achieve deeper drawing of the blank, then elongation can be increased, but the cycle time becomes very long due to substantial liquid volume
Solution Approach 1:
The system uses segmented liquid application at critical forming zones to achieve the necessary hydro-mechanical assistance for deep drawing features, reducing the overall liquid volume from hundreds of liters to a much smaller amount while maintaining the capability to form deep or complex geometries.
Solution Approach 2:
By concentrating liquid pressure at specific areas where deep drawing or complex features are present, the system achieves the necessary elongation and forming depth without requiring uniform liquid pressure across the entire blank, thereby reducing cycle time associated with pumping and draining large volumes of liquid.
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 tool reduces cycle time and energy consumption by minimizing liquid volume and applying pressure only where needed, allowing for more efficient forming of metal blanks with reduced equipment requirements.
Implementation Method 1
The liquid is compressed and forms the blank against the punch
Implementation Method 2
The liquid flows underneath the flange of the blank, as it is drawn, and lifts the area where the blank enters the die cavity. The liquid under the flange eliminates or reduces friction at the entry into the die cavity
Data Source
AI summary
A hydro-forming tool for use in a method of forming a blank into a liquid filled chamber. The chamber is formed by a container ring and a moveable wall that together define a variable volume chamber for containing the liquid. The wall is moveable relative to the container ring to provide a chamber in which the volume of liquid required to back up the blank is minimized. The liquid reduces friction at the chamber entry rim. Liquid may be ported through a counter punch to hydro-form the blank into the detail forming areas.