Incremental Forming Tool Coating to Prevent Metal Plate Adhesion
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Solution Overview
Problem
The incremental forming method requires a large amount of energy and a facility for heating metal plates with high melting points, making it inefficient and costly, and existing solutions complicate the process with adhesion issues between the tool and the metal.
Innovation Solution
A rod-shaped incremental forming tool with a hard film containing crystalline carbon on its surface, where the surface roughness is controlled to have an Rpk of 0.15 μm or less and Ra of 0.2 μm or less, preventing adhesion without the need for additional facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricating oil is supplied to prevent adhesion between metal plate and incremental forming tool, then adhesion is prevented, but the process complexity and facility requirements increase
Solution Approach 1:
The incremental forming tool itself provides the adhesion prevention function through its surface hard film with controlled roughness, eliminating the need for external lubricating oil supply facilities. The tool surface serves dual purposes: forming the workpiece and preventing adhesion through its inherent surface properties.
Solution Approach 2:
The surface roughness of the tool is precisely controlled within specific ranges (Ra: 0.05-0.5μm, Rz: 0.2-2.0μm) to optimize both adhesion prevention and workpiece surface quality. By adjusting the surface roughness parameters, the tool achieves effective adhesion prevention without requiring additional facilities.
2Reliability
If the surface roughness of the incremental forming tool is reduced to prevent adhesion, then adhesion is prevented, but the workpiece surface quality deteriorates due to tool marks
Solution Approach 1:
The surface roughness is controlled within an optimal range (Ra: 0.05-0.5μm, Rz: 0.2-2.0μm) that balances adhesion prevention and surface quality. This parameter optimization ensures that the tool surface is smooth enough to prevent adhesion but not so smooth that it creates visible tool marks on the workpiece.
Solution Approach 2:
A hard film is formed on the surface of the incremental forming tool to create a localized region with different properties. This hard film layer provides the necessary surface characteristics for adhesion prevention while maintaining overall surface quality, allowing the bulk material to retain its forming capabilities.
3Manufacturing precision
If a hard film with controlled surface roughness is formed on the incremental forming tool, then adhesion is prevented and workpiece surface quality is improved, but the manufacturing complexity of the tool increases
Solution Approach 1:
The surface roughness parameters are precisely controlled within specific ranges to achieve the desired balance between adhesion prevention and surface quality. This parameter control is implemented through standardized surface treatment processes, making the manufacturing feasible despite the added 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
The tool achieves a smooth worked surface without additional facilities, reducing energy consumption and adhesion, enabling the formation of complex shapes with improved load-bearing capacity and surface quality.
Implementation Method 1
a hard film that contains crystalline carbon... on a surface thereof... preventing adhesion without the need for additional facilities
Implementation Method 2
The free curved surface part is made of at least a hard metal base material and has a hard film that contains crystalline carbon
Implementation Method 3
A surface of the hard film has an Rpk (average reduced peak height) of 0.15 μm or less... and it also has an Ra (arithmetic average roughness) of 0.2 μm or less
Data Source
AI summary
An incremental forming tool of the present invention includes a holding portion attached to an incremental forming apparatus and a free curved surface part for pressing a metal plate.The free curved surface part is made of at least a hard metal base material and a surface of the free curved surface part is covered with a hard film.The surface of the hard film has an Rpk of 0.15 μm or less, the Rpk is defined by JIS B 0671 and is calculated from a material ratio curve of a roughness curve, and has an Ra of 0.2 μm or less, the Ra is defined by JIS B 0601 and is calculated from a roughness curve. Therefore, a molded product having a smooth worked surface with no roughness can be produced without adding any extra equipment for preventing adhesion.