Modular Stretch Block With 3D-Printed Exchangeable Forming Surfaces
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Solution Overview
Problem
Traditional stretch blocks used in sheet metal forming are labor-intensive, expensive, and have long lead times due to being made-to-order, and they can fail or become damaged, leading to increased costs and delays in mass-producing various components.
Innovation Solution
A modular stretch block system utilizing additive manufacturing techniques for constructing exchangeable forming components, which can be easily swapped and customized, reducing material usage and incorporating a universal interface block for mounting on a forming machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stretch blocks are made-to-order using conventional manufacturing methods, then manufacturing precision and reliability are improved, but production lead time and cost increase significantly
Solution Approach 1:
The stretch block is divided into a reusable support structure and interchangeable forming components. The forming components can be manufactured separately using additive manufacturing and quickly swapped out, eliminating the need to re manufacture the entire stretch block for different sheet metal shapes.
Solution Approach 2:
The invention changes the manufacturing method from conventional subtractive manufacturing to additive manufacturing for the forming components. This parameter change enables faster production of custom forming surfaces while maintaining the reliability of the overall stretch block system.
2Manufacturing precision
If traditional stretch blocks are custom-made for each sheet metal shape, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The support structure is designed as a universal base that can accommodate multiple different forming components. Each forming component is tailored to a specific sheet metal shape with high precision, while the universal support structure reduces overall device complexity and eliminates the need for multiple complete stretch blocks.
Solution Approach 2:
By separating the forming component from the support structure, the invention allows precision to be concentrated in the interchangeable forming surfaces while the support structure provides standardized, simpler functionality that can be reused across multiple configurations.
3Productivity
If traditional stretch blocks are used for mass production, then productivity is improved, but the risk of component failure and associated costs increase
Solution Approach 1:
The stretch block is segmented into a durable, reusable support structure and replaceable forming components. If a forming component fails during mass production, only that specific component needs to be replaced rather than the entire stretch block, minimizing downtime and maintaining productivity.
Solution Approach 2:
The invention enables easy replacement of worn or damaged forming components while recovering and reusing the expensive support structure. This reduces the overall cost of component failure and maintains continuous production capability.
Data Source
AI summary
An exchangeable forming component is configured for removable mounting relative to an interface block of a modular forming tool, with the interface block of the modular forming tool configured for removable mounting relative to a support structure to form a sheet metal component. The exchangeable forming component includes a component structure which is constructed using additive manufacturing, wherein the exchangeable forming component presents a first surface which provides an exchangeable forming surface shaped to form the sheet metal component, and a second surface configured to removably engage the support structure.