Laminated Cavity Tooling Segmentation for Repair
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Solution Overview
Problem
Existing tooling systems lack flexibility and efficiency in configurability and repair, limiting their applicability in various manufacturing processes such as hydroforming, compression molding, and stamping.
Innovation Solution
The use of laminated tooling with removable die layers that can be rearranged or replaced to form different tool configurations, allowing for multiple stages of manufacturing and enabling the formation of complex components through plastic deformation operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional solid tooling is used, then structural strength is maintained, but flexibility and repairability are reduced
Solution Approach 1:
The tooling is divided into multiple removable die layers that can be independently removed, replaced, or reconfigured. Each layer can be separately manufactured and maintained, allowing flexible adaptation to different production requirements while maintaining overall structural integrity through the layered assembly approach.
2Ease of repair
If traditional solid tooling is used, then manufacturing simplicity is maintained, but repair capability and configurability are reduced
Solution Approach 1:
The tooling is segmented into multiple removable die layers that can be independently removed, replaced, or reconfigured. This segmentation allows damaged layers to be replaced without affecting the entire tooling system, significantly improving repair capability while the modular nature keeps the overall system manageable.
Solution Approach 2:
Individual die layers can be discarded when damaged or obsolete and replaced with new or refurbished layers. This approach allows selective replacement of only the necessary components rather than replacing the entire tooling system, improving repair efficiency and reducing costs.
3Adaptability or versatility
If multiple tool configurations are used, then production versatility is improved, but device complexity and cost increase
Solution Approach 1:
The removable die layers are designed to be universally applicable across multiple tool configurations. The same set of layers can be recombined in different arrangements to create various tool configurations, allowing a single base tooling system to perform multiple functions and produce different component shapes without requiring separate dedicated tools for each configuration.
Solution Approach 2:
By segmenting the tooling into standardized removable layers, the system enables easy reconfiguration for different production needs. The layered structure allows rapid assembly and disassembly to create different tool configurations, providing high versatility without requiring multiple complete tool sets.
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
This approach provides flexibility in tool design, enables the production of complex components with varying shapes, and allows for rapid repair of damaged tooling by replacing individual layers, reducing the need for new tools and minimizing production costs.
Implementation Method 1
force is applied to the deformable workpiece causing it to plastically deform
Data Source
AI summary
In some examples, a laminated tooling die may include multiple sheets or plates used in conjunction in any of a number of forming operations such as, for example, hydroforming, compression molding, and stamping. The sheets or plates can include an open interior that, when used in conjunction with neighboring sheets, produce a cavity into which a deformable workpiece can be placed and subjected to the forming operation. In some examples, one or more sheets can be coupled with a heat exchanger to impart a heat transfer with the workpiece.