Metal Forming System with Segmented Mold and Cooling Plate
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Solution Overview
Problem
Conventional metal forming systems are inefficient in reducing manufacturing lead time due to the need for cooling processes after high-temperature forming, which delays the demolding of metal parts and hampers mass production capabilities.
Innovation Solution
A metal forming system with a gantry means and platform design, featuring an upper mold base with an anti-sticking coating and adjustable longitudinal position, allowing for immediate mold opening and rapid demolding without cooling, facilitated by a toggle unit and longitudinally displacing units for precise mold locking and fluid pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-temperature heating is applied to the sheet metal during forming, then the formability and surface quality of the metal formed part are improved, but the manufacturing lead time increases due to the required cooling process before demolding
Solution Approach 1:
A cooling plate is introduced as an intermediary component between the sheet metal and the lower mold base. This cooling plate actively removes heat from the sheet metal during the forming process, enabling the sheet metal to cool sufficiently during the forming operation itself, thereby eliminating the need for a separate cooling period before demolding while maintaining high-temperature forming benefits
Solution Approach 2:
The cooling plate is pre-cooled before the forming operation begins. This preliminary cooling action allows the sheet metal to be rapidly cooled during forming, enabling immediate demolding without waiting for the metal to cool down naturally after high-temperature forming
2Device complexity
If a conventional single-point forming system is used, then the equipment complexity is low, but the productivity is limited due to sequential processing of individual parts
Solution Approach 1:
The lower mold base is segmented into multiple forming positions arranged in a matrix pattern, with each position capable of holding and forming a separate sheet metal. This segmentation allows multiple parts to be formed simultaneously in parallel, dramatically increasing productivity while maintaining a relatively simple overall system structure
Solution Approach 2:
The upper mold base is designed as a universal component that can form sheets at multiple positions. By combining a single upper mold base with multiple lower mold bases, the system achieves multi-functionality, allowing one forming mechanism to serve multiple forming positions simultaneously
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 design significantly reduces the manufacturing lead time of individual metal parts by enabling immediate demolding and rapid processing of subsequent parts, enhancing the efficiency of mass production while maintaining high-quality metal forming.
Implementation Method 1
a part of surface of the upper mold base is painted with an anti-sticking coating having an anti-sticking effect, by which the metal formed part in high-temperature state may be not stuck to the upper mold base
Implementation Method 2
the longitudinal position of the upper mold base is adjusted by the gantry means to determine whether a mold-closing or mold-opening state is presented between the upper mold base and the lower mold base
Implementation Method 3
a high-pressure fluid 180 is provided by a fluid supplier 18. This high-pressure fluid 180 may be injected into a chamber of the sealing mold 15 through at least one fluid passage 181 provided in the sealing mold 15, so as to apply fluid pressure to the sheet metal 11
Data Source
AI summary
The present invention provides a metal forming system, comprising a platform and a gantry means, in which the platform is provided with a plurality of lower mold bases bearing sheet metals, while the gantry means is provided with at least one upper mold base and a toggle unit. The gantry means is performing lateral displacement on the platform, so as to be displaced to a location above the lower mold base which is predetermined to operate. The toggle unit is for adjusting the longitudinal position of the upper mold base so as to change the distance between the upper mold base and the lower mold base, resulting in determining whether a mold-closing state or a mold-opening state. A metal forming operation is performed on the sheet metal between the upper mold base and the lower mold base so as to manufacture a metal formed part when the mold-closing state.