Multi-function mould for processing a steel strip and method for producing a washing machine drum
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Solution Overview
Problem
Traditional methods for producing washing machine drums require separate and contiguous operations for forming, blanking, and deep-drawing, leading to increased footprint, cost, and processing tolerances, with the blanking punch prone to strain and deformation.
Innovation Solution
A multi-function mould that integrates tools for forming, deep-drawing, and blanking in a single station, using sets of punches and dies that interact through hole patterns to perform these operations sequentially.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate and contiguous operations are used for forming, blanking, and deep-drawing in multiple stations, then each operation can be performed with dedicated tools, but the footprint, cost, and processing tolerances increase
Solution Approach 1:
The patent combines forming, blanking, and deep-drawing operations into a single integrated stamping tool with multiple punches and dies that operate simultaneously in one station, eliminating the need for separate processing stations and reducing the overall footprint
Solution Approach 2:
The stamping tool is designed as a multi-functional device where a single tool performs multiple operations (forming, blanking, and deep-drawing) on the sheet metal panel, making the processing bench more compact and economical
2Ease of manufacture
If separate stations are used for forming, blanking, and deep-drawing, then each operation can be optimized independently, but the processing time and costs increase
Solution Approach 1:
The patent merges multiple processing operations into a single stamping tool that performs forming, blanking, and deep-drawing simultaneously, reducing processing time and eliminating the need for multiple stations while maintaining operational optimization
Solution Approach 2:
The integrated stamping tool allows all operations to be performed in one continuous action without moving the panel between stations, eliminating idle time and improving productivity
3Ease of manufacture
If separate stations are used for forming, blanking, and deep-drawing, then each operation can be performed with specialized tools, but the manufacturing precision and repeatability decrease
Solution Approach 1:
The patent combines all processing operations in a single stamping tool, ensuring that the panel remains in the same position throughout all operations, which improves manufacturing precision and repeatability by eliminating positioning errors between stations
Solution Approach 2:
The integrated stamping tool acts as an intermediary system that coordinates all operations (forming, blanking, deep-drawing) within a single reference frame, maintaining consistent positioning and reducing cumulative tolerances
4Ease of manufacture
If traditional blanking is performed first with a protruding punch, then the blanking punch is subjected to considerable strain with risk of breakage or deformation
Solution Approach 1:
The patent combines blanking with deep-drawing in a single integrated operation where the blanking punch is supported by the deep-drawing die, distributing the strain and reducing the risk of punch breakage or deformation
Solution Approach 2:
The deep-drawing die acts as an intermediary support structure that provides guidance and support to the blanking punch during operation, reducing the strain on the punch and improving its durability
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 integrated mould reduces processing time and costs, enhances precision and repeatability, and minimizes plastic deformation, resulting in a more compact and economical production process with improved product quality.
Implementation Method 1
a hydraulic press (3), which carries a mould (10)
Data Source
AI summary
A mould for processing a metal panel by means of a hydraulic press includes a forming punch and a forming die, provided on their operating surfaces with corresponding hole patterns, a set of tubular deep-drawing punches disposed in the forming punch and movable relative thereto to protrude through its holes, a set of tubular deep-drawing dies disposed in the forming die in correspondence with its holes, and a set of blanking punches sized to be smoothly guided along the axial holes of the deep-drawing tools. The relative method of operation involves sequentially closing the mould, lowering the deep-drawing punches, lowering the blanking punches, raising the deep-drawing punches, raising the blanking punches and opening the mould.