Ironing Mold Non-Parallel Clearance for Uniform Thickness
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Solution Overview
Problem
Conventional ironing molds with parallel outer and inner peripheral surfaces lead to uneven plate thickness distribution in formed portions, resulting in excessive load on surface-treated layers, generating powdery residue and minute pockmarks during the ironing process.
Innovation Solution
The inner peripheral surface of the ironing mold extends non-parallel to the outer peripheral surface, with a clearance that matches the uneven plate thickness distribution, ensuring a constant ironing amount and reducing the load on surface-treated layers, thereby minimizing powdery residue generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the outer peripheral surface of the punch and the inner peripheral surface of the pushing hole extend parallel to each other, then the clearance is uniform, but the thick part of the formed portion is subjected to excessive ironing load causing surface treated layer damage and powdery residue
Solution Approach 1:
The inner peripheral surface of the pushing hole is designed with non-uniform clearance distribution - smaller clearance at the front end side and larger clearance at the rear end side - to match the local plate thickness variation. This local adaptation ensures that each region receives appropriate ironing pressure without exceeding the surface treated layer's承受能力
Solution Approach 2:
The clearance parameter between the punch and die is varied along the pushing direction to compensate for plate thickness unevenness. By changing the clearance distribution from uniform to non-uniform, the ironing load is optimized to prevent surface treated layer damage while maintaining dimensional precision
2Ease of manufacture
If uniform clearance is used throughout the pushing direction, then the mold structure is simple, but excessive ironing load on thick parts generates powdery residue
Solution Approach 1:
The inner peripheral surface of the pushing hole is designed with non-uniform clearance distribution - smaller clearance at the front end side and larger clearance at the rear end side - to match the local plate thickness variation. This local adaptation ensures that each region receives appropriate ironing pressure without exceeding the surface treated layer's承受能力
Solution Approach 2:
The clearance parameter between the punch and die is varied along the pushing direction to compensate for plate thickness unevenness. By changing the clearance distribution from uniform to non-uniform, the ironing load is optimized to prevent surface treated layer damage while maintaining dimensional precision
Data Source
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AI summary
An ironing mold according to the present invention includes a punch that is inserted into a formed portion, and a die having a pushing hole into which the formed portion is pushed together with the punch. An inner peripheral surface extends non-parallel to an outer peripheral surface of the punch, and the inner peripheral surface is provided with a clearance that corresponds to an uneven plate thickness distribution, in the pushing direction, of the formed portion prior to the ironing relative to the outer peripheral surface to ensure that an amount of ironing applied to the formed portion remains constant in the pushing direction.