Interlocking Forming Devices for W-Shaped Plate Bending
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Solution Overview
Problem
Conventional methods for forming W-shaped metal parts require multiple processes, leading to prolonged working time, reduced productivity, increased risk of injuries, and compromised mechanical strength due to manual material handling and the creation of thin sections during drawing work, as well as weaknesses in bending resistance at slits punched for projection sections.
Innovation Solution
A forming apparatus and method that uses interlocking first and second forming devices to bend a plate-shaped material by pressing it not more than 180 degrees on both surfaces, with the devices coordinating their positions to maintain parallel surfaces and prevent material extension, thereby enhancing productivity and mechanical strength while reducing scratches and ensuring accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple processes are used to form W-shaped parts, then the required shape can be achieved, but the working time increases and productivity deteriorates
Solution Approach 1:
The patent combines multiple forming processes into a single integrated forming operation. The forming device simultaneously performs bending and projection formation in one process step, eliminating the need for separate operations and manual handling between steps, thereby reducing working time while maintaining shape accuracy
Solution Approach 2:
The patent prepares the plate-shaped material in advance by positioning it correctly on the forming device before the forming operation begins. The forming device is pre-configured with the necessary tooling to perform all required operations in sequence during a single cycle, eliminating setup time between processes
2Ease of operation
If manual material handling is performed between processes, then material can be repositioned, but safety deteriorates due to risk of injuries
Solution Approach 1:
The forming device automatically handles material repositioning through its integrated design. The plate-shaped material is fed automatically into the forming device, and the device itself performs all necessary repositioning and forming operations without requiring manual intervention, thereby eliminating safety risks associated with manual handling
Solution Approach 2:
The forming device acts as an intermediary between the material source and the final product. It automatically receives, repositions, and forms the plate-shaped material through a standardized feeding mechanism, eliminating the need for direct manual handling and transferring the material safely through automated means
3Shape
If drawing work is used to form projection sections, then the projection can be created, but the material is extended creating thin sections and deteriorating strength
Solution Approach 1:
Instead of using drawing work that pulls and extends the material (which creates thin sections), the patent uses a bending-based approach that folds or bends the material to create projection sections. This inverted approach maintains material thickness and cross-sectional area, preserving mechanical strength while achieving the required projection geometry
Solution Approach 2:
The patent changes the forming parameter from tensile drawing to compressive or bending forces. By applying bending forces instead of pulling forces, the material is deformed without being extended, maintaining its original cross-sectional dimensions and mechanical properties while still creating the desired projection sections
4Productivity
If slits are punched intermittently on the ridge line to form projection sections, then the projection can be formed in one process, but the bending resistance is weakened and mechanical strength deteriorates
Solution Approach 1:
The patent extracts or eliminates the slit-punching operation entirely from the forming process. Instead of punching slits in the ridge line area, the forming device uses alternative tooling or methods to create projection sections without compromising the structural integrity or bending resistance of the material
Solution Approach 2:
The patent employs asymmetric forming tooling or methods where the projection sections are formed by bending or folding the material in a controlled manner rather than creating symmetric slits. This asymmetric approach allows the material to maintain continuous grain structure and fiber continuity, preserving bending resistance while still achieving the required projection geometry
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 apparatus enables the efficient production of steel plate parts with high mechanical strength and accuracy in a single process, reducing the occurrence of scratches and maintaining the material's integrity without the need for manual handling or multiple processes.
Implementation Method 1
a first forming device to bend one surface of the plate-shaped material not more than 180 degrees by pressing the plate-shaped material
Implementation Method 2
bending one surface of the plate-shaped material not more than 180 degrees by pressing the plate-shaped material
Data Source
AI summary
A forming apparatus to bend a plate-shaped material, including: a first forming device to bend one surface of the plate-shaped material not more than 180 degrees by pressing the plate-shaped material; a second forming device to bend another surface of the plate-shaped material not more than 180 degrees by pressing the plate-shaped material; wherein the first and the second forming device perform bending while changing a relative position by interlocking with each other.