Modular Die Tool Parts Exchange via Geometric Congruence
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Solution Overview
Problem
Existing metal blank manufacturing processes are inefficient due to the time-consuming and error-prone process of exchanging tool parts in a press, leading to improper alignment and incorrect dimensions in metal blanks.
Innovation Solution
A modular die system with frame lower and upper parts guided vertically, where tool parts are inserted and fixed using geometric congruence between tool parts and fixation parts, eliminating the need for direct alignment and fixtures between tool parts and frame parts, allowing for easy and fast exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tool parts are directly placed and aligned to press bed and press ram, then alignment precision can be maintained, but exchange time increases significantly
Solution Approach 1:
The die system is segmented into frame parts (fixed to press bed and ram) and separate tool parts (inserted into the frame). This allows tool parts to be pre-aligned within the frame structure, enabling quick exchange without direct alignment to the press bed and ram, thus reducing exchange time while maintaining precision through the frame's guiding structure.
Solution Approach 2:
The frame parts act as an intermediary between the press bed/ram and the tool parts. The frame provides a stable reference structure with guiding pillars that ensure proper alignment, eliminating the need for operators to manually align tool parts directly to the press components, thereby both reducing exchange time and maintaining alignment precision.
2Adaptability or versatility
If tool parts are frequently exchanged to manufacture different blank types, then production versatility improves, but alignment errors increase
Solution Approach 1:
Tool parts are pre-aligned and pre-fixed within the frame structure during setup. The frame includes guiding pillars and positioning features that automatically ensure correct alignment when tool parts are inserted. This preliminary alignment action eliminates the need for repeated alignment operations during frequent tool part exchanges, maintaining high alignment accuracy while enabling production versatility.
Solution Approach 2:
The frame structure with its guiding pillars and positioning features provides self-aligning capabilities. When tool parts are inserted into the frame, the structure automatically guides them into the correct position without requiring operator intervention for alignment. This self-service alignment mechanism ensures consistent accuracy regardless of how frequently tool parts are exchanged for different blank types.
3Reliability
If fixtures are used to fix tool parts to frame parts, then fixation reliability improves, but device complexity increases
Solution Approach 1:
The fixation mechanism is merged with the frame structure itself. Fixation parts are integrated into the frame, and tool parts have corresponding engagement features built into their design. This merging eliminates the need for separate, complex external fixtures while maintaining reliable fixation through the unified structure's inherent positioning and locking capabilities.
Solution Approach 2:
The tool parts and frame structure have complementary geometric features that enable self-fixation. The tool parts automatically engage with the frame's fixation parts through their inherent geometry when inserted into the correct position, eliminating the need for additional complex fixation devices or manual adjustment mechanisms, thus reducing overall device complexity while maintaining fixation reliability.
Data Source
AI summary
The disclosure relates to a modular die for blanking a sheet for manufacturing individual blanks successively by a stroke of a ram of a press on tool parts for the blanks, the die having frame part (1,2), tool parts (3,4) placed in a gap between the frame part (1,2), where the tool parts (3,4) is maintained in position in the gap (5) by fixation parts (8,9,10,11). The fixation parts (8,9,10,11) engage with lateral surfaces (12,13,14,15) of the tool parts (3,4). Surfaces of the fixation parts (8,9,10,11) has a geometry congruent with a geometry of lateral surfaces (12,13,14,15) of the tool part (3,4). The disclosure also relates to tool parts of the modular die, to a method for operating the modular die and to a use of the modular die for manufacturing, as example, brake shims.