Segmented Plastic-Coated Metalworking Tool for Sheet Forming Accuracy
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Solution Overview
Problem
Conventional metalworking tools face challenges in maintaining consistent forming quality and reducing deformation and surface defects in sheet metal components due to fluctuations in metal thickness and high frictional forces during processing.
Innovation Solution
A metalworking tool is designed with a base body having surface areas roughened and coated with layers of plastic, differing in material properties, coefficients of friction, and thickness, which are applied using an adhesive, allowing for variable contact areas and reduced hold-down forces, thereby minimizing deformation and surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a soft elastic plastic insert is used to compensate for sheet thickness variations, then forming quality is improved, but the plastic insert slips on the deep-drawing tool
Solution Approach 1:
The tool surface is divided into multiple areas with different plastic layer thicknesses. Areas with varying sheet thickness receive thicker plastic layers for compensation, while other areas have thinner layers. This segmented approach allows the tool to address thickness variations locally without causing slippage, as each area is optimized independently.
Solution Approach 2:
Different areas of the tool surface are equipped with plastic layers having different material properties, particularly different thicknesses. This local differentiation enables the tool to provide appropriate cushioning and friction characteristics in each specific area, preventing slippage where needed while maintaining forming quality throughout.
2Reliability
If the tool surface is roughened to prevent plastic insert slippage, then insert stability is improved, but frictional resistance increases causing deformation and surface defects
Solution Approach 1:
Instead of changing the surface roughness parameter, the invention changes the plastic layer thickness parameter. By controlling the thickness of the plastic layer applied to the roughened surface, the invention optimizes both stability and friction characteristics, reducing harmful frictional resistance while preventing slippage.
3Reliability
If hold-down forces are increased to prevent slippage and reduce friction, then insert stability is improved, but tensile stresses increase causing deformation
Solution Approach 1:
The plastic layer acts as a flexible film between the rigid tool surface and the sheet metal. This flexible layer absorbs and distributes forces, providing stability through adhesion to the roughened surface while reducing the transmission of high tensile stresses to the sheet metal, thereby preventing deformation.
4Ease of manufacture
If a uniform plastic layer is applied to the entire tool surface, then ease of manufacture is improved, but inability to compensate for local thickness variations reduces forming precision
Solution Approach 1:
The tool surface is divided into multiple areas with different plastic layer thicknesses. Areas with varying sheet thickness receive thicker plastic layers for compensation, while other areas have thinner layers. This segmented approach allows the tool to address thickness variations locally without causing slippage, as each area is optimized independently.
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 tool achieves reduced hold-down forces and tensile stresses, ensuring high dimensional accuracy and preventing deformation, while allowing for efficient processing of sheet metal components with consistent thickness and improved tribological conditions.
Implementation Method 1
a layer of plastic having at least one material property is applied to the at least one roughened area
Implementation Method 2
at least one area is roughened by a surface treatment measure
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e
AI summary
The invention relates to a method for producing a metalworking tool (6) which has a first mold part (4), a base body (2) made of metal being provided for producing the first mold part (4), a surface (8) of the base body ( 2) is divided into several areas, at least one area (10, 12) being roughened, and a layer (14, 16) made of plastic, which has at least one material property, being attached to the at least one area (10, 12). . A metalworking tool made by the method of the invention is also described.