Laser-Scored Sheet Punching for Low-Wear Edge Quality
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Solution Overview
Problem
Conventional stamping and punching methods for sheet metal parts, particularly with thin sheets and difficult materials like electrical steels, face issues of high tool wear, unsatisfactory edge quality, and frequent tool refurbishment due to tight tolerances and high forces, making these processes untenable.
Innovation Solution
A method combining laser cutting and scoring with a flattening process before punching, allowing for relaxed tooling tolerances and reduced tool wear, using a laser to score and flatten the sheet material to facilitate separation with less force, and enabling the production of finished components with improved edge quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight clearances (5% to 15% of material thickness) are used between die and punch for stamping thin sheet stock, then manufacturing precision is improved, but tool wear increases and reliability deteriorates
Solution Approach 1:
The laser pre-cuts the sheet material along the component outline before stamping, creating a pre-formed groove that defines the separation line. This preliminary action eliminates the need for tight die-punch clearances during stamping, as the separation already occurred at the laser-cut groove, thereby reducing tool wear while maintaining edge quality
Solution Approach 2:
The laser-cut groove acts as an intermediary feature between the die and punch, providing a predefined separation path. The groove serves as a mediator that allows the stamping process to occur with larger clearances, since the actual separation happens at the groove rather than through direct die-punch contact
2Manufacturing precision
If tight clearances are used between die and punch for stamping thin sheet stock, then manufacturing precision is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The laser pre-cuts the sheet material along the component outline before stamping, creating a pre-formed groove that defines the separation line. This preliminary action eliminates the need for tight die-punch clearances during stamping, as the separation already occurred at the laser-cut groove, thereby reducing tool wear while maintaining edge quality
Solution Approach 2:
The laser-cut groove serves as a disposable feature that is created once and allows subsequent stamping operations to proceed with relaxed tolerances. The groove effectively replaces the need for precision-maintained tight clearances, reducing the frequency of tool refurbishment
3Productivity
If conventional stamping is used on difficult materials like electrical steels, then productivity is maintained, but manufacturing precision deteriorates due to high forces and tool wear
Solution Approach 1:
The laser pre-cuts the sheet material along the component outline before stamping, creating a pre-formed groove that defines the separation line. This preliminary action eliminates the need for tight die-punch clearances during stamping, as the separation already occurred at the laser-cut groove, thereby reducing tool wear while maintaining edge quality
Solution Approach 2:
The laser cutting process replaces the mechanical cutting action of the die and punch with a thermal process. The laser creates the separation groove through melting and vaporization rather than mechanical shearing, eliminating the high forces and associated tool wear that plague conventional stamping of difficult materials like electrical steels
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 method reduces tool wear and maintenance costs while producing components with satisfactory edge quality and planarity, even with generous tooling clearances, by using laser scoring and flattening to establish a predictable line of separation.
Implementation Method 1
The cutting process includes cutting a partial outline of the perimeter of the component using high power energy source, such as a laser beam
Implementation Method 2
dross or beads of molten materials which may form at the corners of the scored grooves
Implementation Method 3
The flattening process acts to return the cut and/or scored portion of the sheet material to substantially the original thickness by flattening proud features
Implementation Method 4
removing the component with compressed air or with an electromagnetic pulse
Data Source
AI summary
A system and process for fabricating components from sheet material. Various embodiments of the disclosure combine punching of components from sheet material with a scoring process that outlines the components prior to the punching operation. In addition, a system and process where the scored portion of the sheet material that includes the scored outline is subjected to a high compression flattening process prior to the punching operation is disclosed. Performing the flattening operation prior to the punching operation has the effect of streamlining the process. That is, the sheet material can be easily handled and conveyed from the scoring process, through the flattening process, and to the punching process without need for separate handling of the component.