Magnetic Tiled Backing Mat for Wear-Prone Incremental Sheet Forming
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Solution Overview
Problem
The continuous use of flexible resilient surface material layers in dual-sided incremental sheet forming systems leads to wear, particularly in the center of the work piece area, degrading the material's ability to maintain force concentration and leading to defects like wrinkling and tearing.
Innovation Solution
A tiled backing mat system is introduced, comprising individual tiles with a magnetic layer that can be releasably secured to a ferrous metallic plate, allowing for easy replacement of worn-out tiles without replacing the entire mat, ensuring consistent force concentration during the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a continuous flexible resilient surface material layer is used in the backing flat tool assembly, then the system provides flexible and compressible surface contact during forming, but the material layer wears out over time particularly in the center of the work piece area, degrading performance
Solution Approach 1:
The continuous flexible resilient surface material layer is divided into multiple discrete tiles that can be individually replaced. Each tile is a separate component with resilient material layers secured to a rigid plate, allowing worn tiles to be removed and replaced without replacing the entire backing mat assembly.
Solution Approach 2:
Worn or damaged resilient material layers on individual tiles are discarded and replaced with new tiles, while the rigid plate and functional tiles are retained and reused. This allows selective replacement of only the worn components rather than the entire assembly.
2Reliability
If the entire resilient surface material layer is replaced when worn, then consistent force concentration is restored, but the time and cost of replacement is increased significantly
Solution Approach 1:
The backing mat is segmented into individual replaceable tiles, allowing only the worn tiles to be replaced rather than the entire mat. This reduces replacement time and material cost while maintaining consistent force concentration through selective tile replacement.
Solution Approach 2:
spare tiles are prepared in advance with resilient material layers already secured to the rigid plate structure. When wear occurs, pre-prepared replacement tiles can be quickly installed without needing to prepare the entire mat assembly, reducing downtime.
3Ease of repair
If individual tiles are used instead of a continuous mat, then worn tiles can be replaced without replacing the entire mat, but the complexity of securing and positioning multiple tiles increases
Solution Approach 1:
Mechanical fastening systems (screws, clips, adhesives) are replaced with magnetic securing. The rigid plate contains ferromagnetic material and the tiles contain magnetic material, allowing tiles to be easily attached and detached through magnetic attraction without complex mechanical fastening mechanisms.
Solution Approach 2:
The magnetic strength parameter of the securing mechanism is optimized to provide sufficient holding force during forming operations while allowing easy removal when needed. This parameter adjustment enables simple tile replacement without requiring complex tools or procedures.
4Ease of operation
If magnetic material is used to secure tiles to the rigid plate, then easy replacement is enabled, but the magnetic force must be strong enough to prevent slippage during operation yet weak enough to allow removal
Solution Approach 1:
The magnetic field strength parameter is carefully selected and optimized. The magnetic material in the rigid plate and tiles is chosen to provide sufficient holding force to prevent slippage during high-force forming operations, while the magnetic attraction remains strong enough to securely hold tiles but can be overcome by deliberate manual removal forces.
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 tiled backing mat system maintains precise force concentration and prevents defects by enabling quick replacement of worn tiles, enhancing the durability and performance of the incremental sheet forming process.
Implementation Method 1
individual tiles with a magnetic layer that can be releasably secured to a ferrous metallic plate
Data Source
AI summary
A resilient compressible tiled backing mat system used in an Incremental Sheet Forming (ISF) System, the ISF system having a primary rigid forming tool assembly and a backing flat tool assembly including a flat rigid plate for releasably holding the tiled backing mat that is compressed in response to force provided through a work piece by the primary forming tool. The tiled backing mat includes a plurality of individual tiles arrayed in a packed or nested pattern and being releasably secured to the flat rigid plate via a magnetic layer of the tiles. Individual tiles are easily replaced if damaged or worn without replacing the entire mat. Tiled backing mat configurations can be sized according to the area of the flat rigid plated and/or the particular machine area required for forming a selected work piece.