Nibbler Assembly Arcuate Corners Elongated Hole Quality
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Solution Overview
Problem
Conventional nibbling operations in punch presses result in seam-like portions and inefficient hole formation due to lack of roll-over and fracture surfaces at corners, leading to aesthetic and efficiency issues, and existing solutions are either expensive or complex with low process efficiency.
Innovation Solution
A nibbler assembly with a die having a recessed upper surface and a punch with arcuate corners, allowing for consistent punching force and surface formation, minimizing seam-like portions and protrusions by deforming the material downward and creating fracture surfaces at corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional punch with rectangular configuration is used to punch holes, then the punching operation is simple and fast, but seam-like portions and protrusions are formed at the corners due to lack of roll-over and fracture surfaces
Solution Approach 1:
The punch is designed with arcuate corners instead of sharp rectangular corners. This local modification at the corner regions creates roll-over and fracture surfaces during punching, eliminating seam-like portions and protrusions while maintaining overall punching efficiency
Solution Approach 2:
The corners of the punch are rounded with an arcuate shape rather than being sharp or rectangular. This curvature enables the formation of roll-over surfaces at the corners of punched holes, preventing the formation of seam-like portions and improving surface quality without significantly reducing punching speed
2Productivity
If successive holes are punched with overlap to form elongated holes, then hole formation efficiency is improved, but seam-like portions are created at the overlap ends
Solution Approach 1:
The arcuate corner design of the punch specifically addresses the overlap regions where successive holes are formed. The rounded corners ensure that the ending portions of successive holes also develop roll-over and fracture surfaces, eliminating seam-like portions at overlap ends while maintaining the efficient successive punching process
3Manufacturing precision
If manual treatment with sander or file is applied to eliminate seam-like portions, then surface quality is improved, but process steps increase and efficiency decreases
Solution Approach 1:
The arcuate corner design of the punch performs the surface finishing action during the punching operation itself. The rounded corners create roll-over and fracture surfaces that automatically eliminate seam-like portions, so no subsequent manual sanding or filing is required. This preliminary action integrates finishing into the punching process, maintaining high efficiency while achieving excellent surface quality
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 solution achieves smooth finishing of overlaps between successive holes with improved process efficiency, reduced protrusions, and lower manufacturing costs compared to existing technologies.
Implementation Method 1
the die has an upper surface formed with a recess extending from an upper peripheral portion of the through opening at an upstream side of the feed direction towards the upstream of the feed direction, and the recess is dented downwardly than other portions of the upper surface
Implementation Method 2
the blade includes an upstream end portion in the feed direction provided with opposite corners each having an arcuate shape as viewed along the vertical direction
Data Source
Figure 1
Figure 2A~2C
Figure 3A~4B
AI summary
A nibbler assembly includes a punch (1) and a die (11). The die (11) includes a through opening (12) formed therein, which opening (12) has an oblong configuration as viewed along a vertical direction. The die (11) includes an upper surface formed with a recess (13) extending from an upper peripheral portion of the through opening (12) at an upstream side of a feed direction (A) towards the upstream of the feed direction (A). The recess (13) is dented downwardly compared with other portions of the upper surface. The punch (1) includes a blade (3) substantially matching in shape with the through opening (12). The blade (3) includes an upstream end portion (3a) in the feed direction (A) provided with opposite corners (4) each having an arcuate shape as viewed along the vertical direction. The punch (1) and the die (11) are operable to punch successive holes that at least partially have a overlap along the feed direction (A) so as to form an elongated hole in a sheet material (W).