Micro-hole Formation on Metal Plates via Shearing
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Solution Overview
Problem
Conventional sound gobos face difficulties in maximizing micro-holes per unit area on metal plates, limiting their sound-absorption rate and increasing material and manufacturing costs.
Innovation Solution
A method using a shearing tool to create micro-holes on a metal plate with appropriate hardness and ductility, involving a series of steps to form a large number of micro-holes per square meter, including feeding the metal plate beyond a shearing edge, applying a shearing force with a punching head, and interconnecting spot-shaped cavities with linear grooves to create micro-holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional punching machines are used to punch holes on metal plates, then manufacturing process is simple, but the number of micro-holes per unit area is limited (40000-50000 holes/m²) and minimum hole diameter is large (0.45mm)
Solution Approach 1:
The punching head is divided into multiple unit blade portions (first blade, second blade, third blade, fourth blade) arranged in sequence. Each blade creates specific features (spot-shaped cavities or linear grooves) that collectively form micro-holes through their interconnection, enabling precise control of hole geometry and positioning
Solution Approach 2:
The invention transitions from conventional single-point punching to a multi-blade system that creates two-dimensional patterns of cavities and grooves. The blades are arranged with specific spacing to create interconnected features across the metal plate surface, effectively increasing hole density by utilizing spatial dimensionality
2Reliability
If more micro-holes are formed on the plate, then sound-absorption rate is improved, but material cost and manufacturing complexity increase
Solution Approach 1:
Multiple unit blade portions are combined into a single punching head assembly that operates simultaneously. The first and second blades create spot-shaped cavities while the third and fourth blades create linear grooves, and these features merge to form complete micro-holes in one processing pass, achieving high hole density without proportionally increasing manufacturing complexity
Solution Approach 2:
The invention optimizes material parameters by selecting metal plates with specific hardness (HRB 8-40) and ductility (4-30%) ranges. These parameter changes enable the material to withstand the shearing action of multiple blades while forming precise micro-holes, allowing increased hole density without requiring complex manufacturing processes
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 method allows for a significant increase in micro-holes per unit area, enhancing sound-absorption rates, reducing noise pollution effectively while minimizing material and manufacturing costs, and providing a lightweight, durable, and versatile sound-absorbing solution suitable for various environments.
Implementation Method 1
applying a shearing force to the workbench by the punching head; bearing the shearing force on the first surface on the metal plate
Implementation Method 2
deforming the metal plate by the shearing force, interconnecting the spot-shaped cavities arranged in a row on the second surface with the linear groove on the first surface, and forming a plurality of micro-holes
Data Source
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AI summary
A method of making micro-holes on a metal plate includes: (A) feeding a metal plate (2) on a workbench (1) forward to extend beyond a shearing edge (11); (B) locating a punching head (3) at a first position (Y1), and keeping a working space (S) between the punching head (3) and the workbench (1); (C) exerting a shearing force towards the workbench (1) by the punching head (3); (D) bending the metal plate (2) by the shearing force, and forming a plurality of spot-shaped cavities (4) arranged in a row on a second surface (22); (E) bearing a shearing force on the first surface (21) of the metal plate (2) to form a linear groove (5); (F) deforming the metal plate (2) by the shearing force to cause the spot-shaped cavities (4) arranged in a row to communicate with the linear groove (5) to form micro-holes (6); (G) the punching head (3) returning to the first position (Y1) and moving a working distance (T) to a second position (Y2); (H) feeding the metal plate (2) again; (I) the punching head (3) repeating the above steps at the second position (Y2); (J) the punching head (3) returning to the second position (Y2) and then moving back to the first position (Y1) to complete a processing cycle. The method can produce a maximum of micro-holes on a certain area of the metal plate (2), which can be used as a sound gobo with an enhanced sound-absorption rate.