Integrated Cutting Tool for Sheet Metal Blank Removal
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Solution Overview
Problem
Existing methods for producing sheet metal parts from strip material often result in high material waste due to the need for free cuts and connection points, which can lead to increased susceptibility to failure and limited applicability, especially when optimizing material consumption for complex or high-precision parts.
Innovation Solution
A method and system that stack and unstack cut blanks in the cutting plate, using a compact cutting tool design to ensure uniform transport and eliminate the need for complex separate removal devices, allowing for flexible positioning of blanks relative to the strip axis and enabling modular system design for efficient processing of various part geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If free cuts and connection points are used to transport parts through the tool, then material consumption is reduced, but the parts become more susceptible to failure and the applicability is limited
Solution Approach 1:
The patent combines the cutting function and blank removal function into a single integrated cutting tool. The cutting tool includes a cutting punch for cutting blanks and a blank remover that is integrated into the same tool structure, eliminating the need for separate removal devices. This merging resolves the contradiction by enabling complete blank removal without free cuts while maintaining structural integrity.
Solution Approach 2:
The patent extracts the blank removal function from a separate device and integrates it into the cutting tool itself. The blank remover is built into the cutting tool structure, allowing blanks to be completely removed after cutting without requiring additional external removal mechanisms or free cuts in the material.
2Ease of operation
If complex separate removal devices are used to remove blanks, then blank removal is effective, but the device complexity increases
Solution Approach 1:
The cutting tool integrates multiple functions including the cutting punch and the blank remover into a single tool structure. The blank remover is positioned within the cutting tool and operates automatically as part of the cutting cycle, eliminating the need for complex separate removal devices while maintaining effective blank removal.
Solution Approach 2:
The cutting tool performs blank removal automatically as part of its own operation cycle. The blank remover is activated by the pressing movement itself, and the spring-loaded mechanism automatically ejects blanks without requiring external intervention or complex separate removal systems.
3Loss of substance
If progressive composite tools with optimized strip layout are used, then material waste is reduced, but the strip may fall apart and susceptibility to failure increases
Solution Approach 1:
The patent extracts blanks completely from the strip material using the integrated blank remover. By removing blanks entirely rather than leaving connection points, the strip integrity is maintained while still achieving material optimization through efficient nesting arrangements.
4Loss of substance
If common cutting lines are used between parts, then material waste is minimized, but the part geometry applicability is limited
Solution Approach 1:
The integrated cutting tool with automatic blank removal enables flexible nesting arrangements of multiple parts on the strip without requiring common cutting lines. The complete removal capability allows parts to be positioned optimally for material efficiency while accommodating diverse part geometries that would not be possible with shared cutting lines.
Data Source
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AI summary
Method for producing deformed sheet metal parts comprises stacking plates in a stacking plate passage of a cutting plate over each other forming an easily wedged stacked block (30) of plates, joining a cut-out plate on the bur side of the lower plate of the block, loosening the upper plate from the block and removing from the block. An independent claim is also included for a system for carrying out the above method.