Laser Scoring and Flattening for Low-Wear Sheet Punching
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Solution Overview
Problem
The existing methods for manufacturing sheet metal parts, particularly those made from thin sheets or difficult materials like electrical steels, face challenges due to tight tolerances required for stamping and punching, which lead to high tool wear and unsatisfactory edge quality.
Innovation Solution
A process that combines cutting, scoring, and separation with a flattening step, using high power energy sources like laser beams to cut and score the sheet material, followed by a flattening process to restore the material's original thickness and planarity, allowing for more generous die clearances and reduced tool wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight clearances (5% to 15% of material thickness) are used for die and punch in conventional stamping, then manufacturing precision of thin sheet components is improved, but tool wear increases significantly and tool life decreases
Solution Approach 1:
The laser pre-cuts the component outline and pre-punches holes before the stamping operation. This preliminary action removes the need for tight clearance stamping, as the laser has already created the separation. The stamping operation then only needs to complete the process with much larger clearances, dramatically reducing tool wear while maintaining edge quality.
Solution Approach 2:
The invention replaces the mechanical cutting action of conventional stamping with laser cutting for the outline and hole creation. The laser beam substitutes for the mechanical punch and die contact, eliminating the need for tight clearances and reducing mechanical stress on the tools.
2Manufacturing precision
If tight clearances are maintained for stamping difficult materials like electrical steels, then component shape accuracy is improved, but the forces required increase tool wear and require frequent refurbishment
Solution Approach 1:
The laser performs the difficult cutting action on electrical steels before stamping. The laser's ability to melt and vaporize material makes the subsequent stamping operation much easier, as the material has already been softened or separated by the laser energy.
Solution Approach 2:
The invention changes the physical state of the material through laser heating, transforming solid material into a softened or partially melted state that is easier to separate. This parameter change (temperature increase) makes the material more compliant and reduces the forces needed for subsequent stamping operations.
3Productivity
If conventional stamping is used on thin sheets, then production speed is maintained, but the tight tolerances required increase device complexity and cost
Solution Approach 1:
The laser system replaces the complex precision mechanical stamping system with a more flexible laser cutting approach. The laser's ability to maintain precision without tight mechanical clearances simplifies the overall system while maintaining high production speeds.
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 streamlines the manufacturing process, reduces the need for tight tolerances in tooling, decreases tool wear, and produces components with satisfactory edge quality and planarity, making it suitable for handling thin sheets and difficult materials.
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
Implementation Method 5
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.