Pre-thinning Plate Material for Precise 3D Forming
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Solution Overview
Problem
Existing methods for forming three-dimensional objects from plate-shaped materials are limited by material thickness, leading to inaccuracies and high technical complexity, making them unsuitable for precise shaping and large-scale production with sensitive surfaces.
Innovation Solution
The method involves reducing material thickness on the side facing away from the die before forming, allowing for precise shaping and reduced pressure requirements, enabling the creation of complex three-dimensional structures with minimal technical effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forming processes are used on plate-shaped material, then the material can be shaped into three-dimensional objects, but forming accuracy deteriorates as material thickness increases
Solution Approach 1:
The material thickness is reduced in the areas to be formed before the forming process takes place. This preliminary thinning allows the material to be more easily deformed and adapt precisely to the die surface during forming, thereby maintaining high forming accuracy even with thicker original material.
Solution Approach 2:
The material thickness reduction is applied locally only in the areas that will be formed, while other areas retain their original thickness. This selective thinning optimizes the forming process by making the material more formable where needed while maintaining structural integrity elsewhere.
2Ease of manufacture
If conventional forming processes are used, then three-dimensional objects can be produced, but the technical equipment required becomes complex and expensive
Solution Approach 1:
By pre-reducing the material thickness in the areas to be formed, the subsequent forming process requires less complex and expensive equipment. The preliminary thinning prepares the material so that simpler pressing devices can achieve the desired forming results without requiring sophisticated high-pressure equipment.
3Manufacturing precision
If material thickness is reduced before forming, then precise shaping and sharp-edged bends can be achieved, but additional processing steps are required
Solution Approach 1:
The material thickness reduction is performed as a preliminary step before forming, enabling precise shaping and sharp-edged bends to be achieved during the subsequent forming process. This preliminary preparation simplifies the forming operation itself.
Solution Approach 2:
The material parameter (thickness) is changed in the areas to be formed, transforming the material properties locally to enable precise shaping. This parameter change makes the material more susceptible to forming and allows for sharper, more accurate bends and edges.
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
This approach allows for the production of precise, sharp-edged three-dimensional objects with reduced material thickness, suitable for sensitive surfaces like mirror-polished metal, and requires less effort and pressure, enabling the creation of complex designs with various thickness reductions and surface features.
Implementation Method 1
The sheet metal to be formed is placed between a negative die and a positive male die and these are then pressed together under pressure
Implementation Method 2
pressure is exerted over the entire surface of the sheet metal blank by a fluid, such as liquid or gas, so that it deforms in accordance with the surface structure of the die
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a method for forming a plate-shaped material (1) into a three-dimensional object (11), wherein the material (1) is formed on a die (4) by applying pressure to a side of the plate-shaped material (1) facing away from the die (4). The method according to the invention is characterized in that, prior to forming, the material thickness of the plate-shaped material (1) is reduced in the areas to be formed on the side facing away from the die (4).Furthermore, the invention relates to a method for forming a plate-shaped material (1) into a three-dimensional object (11), wherein the plate-shaped material (1) is folded along one or more fold lines, which is characterized in that a linear reduction (2) of the material thickness is made in the plate-shaped material (1) in its areas to be formed before the forming process and then the material (1) is manually folded along this linear reduction (2) of material thickness.