Inner Rim Forming for Secure Bimetal Coin Blank Joining
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Solution Overview
Problem
Existing coin production methods face challenges in creating a secure connection between annular round blanks and round blank cores during the embossing process, leading to accidental separation of coin components.
Innovation Solution
A forming device and method that utilize a movable die and a holding sleeve to form an inner rim on the annular round blank, ensuring a precise and defined increase in the outside diameter, allowing for a more secure connection and precise positioning within the embossing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional joining devices are used to connect annular round blanks and round blank cores, then the coin production process can proceed, but the connection between parts is insufficient and accidental separation occurs during embossing
Solution Approach 1:
The inner rim is formed on the annular round blank before the embossing process, creating a preventive structural feature that ensures proper engagement with the round blank core. This preliminary forming action prevents connection failures during subsequent embossing operations by establishing the correct geometric configuration in advance.
Solution Approach 2:
The forming device applies localized deformation to create the inner rim structure at a specific region of the annular round blank. This local quality change concentrates the connection-critical features at the inner rim area, ensuring proper engagement with the round blank core without requiring complex overall structural changes.
2Manufacturing precision
If the annular round blank is formed with proper inner rim geometry, then the connection to round blank core is improved, but additional forming steps are required in the production process
Solution Approach 1:
The forming operation that creates the inner rim is merged with the existing embossing process by positioning the forming device within the embossing press. This combination allows the inner rim to be formed during the same operational cycle as the embossing, eliminating separate forming steps and maintaining production efficiency while achieving precise inner rim geometry.
Solution Approach 2:
The embossing press is made multi-functional by integrating the inner rim forming capability into its structure. The same press that performs embossing also forms the inner rim, allowing one piece of equipment to perform multiple functions and avoiding the need for additional dedicated forming machinery that would reduce productivity.
3Manufacturing precision
If a holding sleeve is used to constrain the annular round blank during forming, then the outside diameter precision is improved, but the device complexity increases
Solution Approach 1:
The holding sleeve acts as an intermediary element between the forming device and the annular round blank. It provides the necessary constraint and support during the forming operation, ensuring precise outside diameter control while transferring forces uniformly. This intermediary component simplifies the overall device design by concentrating the constraint function in a single, well-defined element.
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 solution enhances the connection between annular round blanks and round blank cores, preventing accidental separation and improving the precision of coin production by forming a secure inner rim during the embossing process.
Implementation Method 1
By means of the die (39), the annular round blank (31) is moved out of a transport plane (T) and into a forming position (U) towards the upper tool (38)
Implementation Method 2
Subsequently, the inner rim (31a) is formed with the aid of a forming tool (47, 72)
Implementation Method 3
the annular round blank (31) is moved out of a transport plane (T) and into a forming position (U) towards the upper tool (38) and into the interior of a holding sleeve (61)
Data Source
AI summary
A forming device and a method for forming an inner rim of an annular round blank. The forming device has a lower tool with a movable die and an upper tool arranged opposite the lower tool along a working axis A. By means of the die, the annular round blank is moved out of a transport plane T and into a forming position U towards the upper tool and into the interior of a holding sleeve. Subsequently, the inner rim is formed with the aid of a forming tool. After forming, the annular round blank is moved out of the forming position U and back into the transport plane T by means of the lower tool and/or the upper tool. The forming device and the forming method can occur while the round blanks are being fed to an embossing station while being transported by a revolving table.