Induction Sheet Forming With Insulated Dies for Uniform Heating
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Solution Overview
Problem
Existing sheet forming systems for aircraft and space applications are inefficient in heating and cooling materials homogeneously and quickly, limiting their ability to shape materials into precise forms.
Innovation Solution
A sheet forming system comprising a body with movable jaws, isolation sheets, and an induction heater that surrounds the workpiece, allowing for homogeneous heating and cooling, and enabling the use of different dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional heating methods are used in sheet forming systems, then the heating process is simpler to implement, but the heating speed and uniformity are insufficient
Solution Approach 1:
The patent replaces conventional thermal conduction heating with induction heating technology, using electromagnetic fields to directly heat the workpiece. This substitution enables rapid and uniform heating while maintaining system controllability, resolving the contradiction between heating speed and system complexity.
Solution Approach 2:
The patent incorporates insulation sheets between the heating elements and the workpiece to control heat distribution. This pre-arranged thermal management system ensures uniform heat distribution and prevents overheating, enabling faster heating cycles without compromising uniformity.
2Speed
If conventional cooling methods are used in sheet forming systems, then the cooling system is simpler to implement, but the cooling speed and uniformity are insufficient
Solution Approach 1:
The patent employs hydraulic cooling channels integrated into the die structure to achieve rapid and uniform cooling of the workpiece. The fluid circulation system provides efficient heat removal, enabling fast cooling cycles while maintaining uniform temperature distribution throughout the workpiece.
3Adaptability or versatility
If fixed dies are used in sheet forming systems, then the system structure is simpler, but the adaptability to different forming operations is limited
Solution Approach 1:
The patent employs movable and interchangeable dies mounted on the forming system, allowing rapid reconfiguration for different sheet forming operations. This dynamic setup enables the same system to accommodate various die sizes and configurations, significantly improving versatility without requiring a completely different system for each application.
Solution Approach 2:
The patent designs the forming system with universal mounting mechanisms and standardized interfaces that accommodate different die types and sizes. This universal approach allows a single system to perform multiple forming operations with different dies, enhancing adaptability while avoiding the need for multiple dedicated systems.
4Use of energy by moving object
If heating elements are placed in direct contact with the workpiece, then heating efficiency is higher, but heat distribution uniformity deteriorates
Solution Approach 1:
The patent introduces insulation sheets as intermediary elements between the induction heating elements and the workpiece. These sheets act as thermal mediators that distribute heat more uniformly across the workpiece surface while maintaining high heating efficiency through the electromagnetic coupling, resolving the contradiction between direct heating efficiency and temperature uniformity.
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 system achieves faster and more uniform heating and cooling of workpieces, allowing for precise shaping of materials, including metals and composites, into predetermined forms.
Implementation Method 1
Induction heating method can be used to render superplastic forming, the curing processes of composite materials and the heat treatment of thermoplastic materials more efficient
Implementation Method 2
Heaters consisting of induction coils are placed between the dies
Implementation Method 3
at least one duct extending along the length of the plates on each plate, through which a coolant can be passed
Implementation Method 4
at least two isolation sheets positioned on each plate so as to stay opposite to each other to provide isolation
Data Source
AI summary
A sheet forming system has a body, at least one lower jaw and/or at least one upper jaw, located on the body so as to stay opposite to each other and move towards each other to apply force for the shaping process, at least two plates located on the lower jaw and/or upper jaw to provide strength against the force applied by the lower jaw and/or upper jaw thereto, at least two isolation sheets located on each plate so as to stay opposite to each other to provide heat insulation, at least one male die and at least one female die positioned on the isolation sheet on the lower jaw and/or upper jaw, and being able to be placed into each other in a completely form compliant manner, at least one workpiece positioned between the male die and female die and being shaped by applying heat thereto.