Localized Laser Heating for Low Ductility Material Forming
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Solution Overview
Problem
Materials with low ductility, such as aluminum and magnesium alloys, often crack or form defects when bent or folded due to their limited ability to deform under tensile stress, making it difficult to perform metalworking processes like roller hemming without introducing defects.
Innovation Solution
A method and apparatus that uses a heat source, such as a laser, to heat a localized portion of the material to a predetermined temperature, increasing its ductility, allowing for successful forming operations like roller hemming without surface cracks or defects. The heat source advances simultaneously with a forming element, like a roller, to achieve the desired temperature and ductility at the forming location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional hemming processes are used on low ductility materials, then the forming operation can be performed, but cracks or defects form in the material
Solution Approach 1:
The patent applies localized heating to change the temperature parameter of the low ductility material, which fundamentally alters the material's ductility characteristics. By heating the material to a predetermined temperature, the material transitions from a low ductility state to a high ductility state, enabling successful forming operations without cracks or defects.
Solution Approach 2:
The heating element performs preliminary action by heating the material before the forming element applies the forming operation. This preliminary heating prepares the material by increasing its ductility, ensuring the material is ready to undergo the subsequent forming process without developing cracks or defects.
2Reliability
If the material is heated to increase ductility, then forming without cracks is achieved, but heat distortion may occur
Solution Approach 1:
The heating element applies heat locally to only the specific portion of the material that requires forming, rather than heating the entire workpiece. This localized heating approach increases ductility where needed while minimizing thermal exposure to other areas, thereby reducing overall heat distortion and maintaining the structural integrity of the complete part.
Solution Approach 2:
The forming process is segmented into discrete zones: a heated high-ductility zone where forming occurs, and unheated low-ductility zones that maintain their original properties. This spatial segmentation allows the heated portion to be formed without cracks while the unheated portions remain undistorted, effectively isolating the heat-affected region.
3Adaptability or versatility
If traditional hemming methods are used, then equipment simplicity is maintained, but the process cannot handle low ductility materials effectively
Solution Approach 1:
The heating element and forming element are merged into a single integrated device that performs both heating and forming operations. This combination allows the equipment to handle low ductility materials effectively by providing localized heating before forming, while maintaining a relatively compact and manageable device structure that builds upon conventional hemming equipment.
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 enables the formation of materials with low ductility without surface cracks or defects, reducing cycle time and minimizing heat distortion, while maintaining the structural integrity of the material, particularly in roller hemming applications where extreme bends are formed.
Implementation Method 1
A method and apparatus that uses a heat source, such as a laser, to heat a localized portion of the material to a predetermined temperature
Implementation Method 2
heating a localized portion of the first sheet along the forming direction at a substantially constant predetermined distance in front of the forming element
Implementation Method 3
moving the forming element relative to the first sheet along a forming direction... to achieve the desired temperature and ductility at the forming location
Data Source
Figure 1a~1b
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AI summary
The invention provides an apparatus and a method of forming a material of low ductility including providing a first sheet made from a material of low ductility, providing an integrated forming device comprising a heat source and a forming element, and moving the forming element relative to the first sheet along a forming direction while simultaneously heating a localized portion of the first sheet along the forming direction at a substantially constant predetermined distance in front of the forming element. The predetermined distance is selected so as to yield a predetermined temperature to achieve a predetermined ductility at the localized portion of the first sheet when the forming element reaches the localized portion of the first sheet.