Automatic Indexing Dimpler Cam Mechanism for Sheet Metal Nesting
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Solution Overview
Problem
In die stamping manufacturing, closely stacked metal workpieces often stick together due to their configuration, making it difficult to separate them after the stamping operation.
Innovation Solution
An automatic indexing dimpler is employed, featuring a piston with a dimpling end plate and a cam mechanism that rotates in discrete increments, allowing dimples to change position and orientation between operations, creating space between workpieces and preventing them from sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple stamped metal workpieces are closely stacked following a stamping operation, then productivity is improved by efficient stacking, but the workpieces tend to nest together causing difficulty in separation
Solution Approach 1:
The dimpler creates dimples in the workpiece during the stamping operation itself, before stacking occurs. This preliminary action of creating surface features prevents the nesting problem that would otherwise occur during subsequent stacking and separation operations
Solution Approach 2:
The dimpler introduces localized surface features (dimples) at specific locations on the workpiece. These localized changes in surface geometry create air gaps and prevent complete contact between stacked workpieces, solving the separation difficulty without affecting the overall workpiece design
2Device complexity
If a fixed dimpler configuration is used, then device complexity is reduced, but the dimples cannot change position or orientation between operations
Solution Approach 1:
The dimpler incorporates a cam mechanism with eccentric lobes that converts rotational motion into variable linear displacement. This dynamic mechanism allows the dimple position and orientation to change between operations while maintaining a relatively simple overall device structure
Solution Approach 2:
The cam mechanism introduces rotational motion as an additional degree of freedom to control dimple positioning. By rotating the cam to different angular positions, the linear displacement of the dimple tool varies, enabling multiple dimple locations and orientations from a single mechanism
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 automatic indexing dimpler effectively prevents sheet metal blanks from sticking together by positioning dimples differently on each workpiece, facilitating easier separation and improving the efficiency of the stamping process.
Implementation Method 1
The automatic indexing dimpler may employ a cam operably connected to the end plate. The cam may include a set of cam grooves for receiving a cam follower. The cam follower may be configured to track within the cam grooves so as to cause the cam and end plate to rotate in discrete increments about a longitudinal axis of the cam as the piston and end plate are moved in a longitudinal direction.
Data Source
AI summary
An automatic indexing dimpler includes a housing having an interior channel substantially centered along a longitudinal axis. A cam is slidably and rotatably disposed within the interior channel. The cam includes a first longitudinal groove, a second longitudinal groove and an angled groove adjoining the first longitudinal groove at a groove bottom end and the second longitudinal groove at a groove top end. Each longitudinal groove defines a discrete indexing position. A cam follower attached to the housing engages the first and second longitudinal grooves and the angled groove to operably rotate the cam about the longitudinal axis as the cam follower tracks along the angled groove from the groove bottom end to the groove top end. At least one dimple engagable with a workpiece and operable for forming a recessed region in the workpiece is operably connected to the cam for concurrent movement therewith.