Precision Blanking Die Segmentation for High-Speed Pressing
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Solution Overview
Problem
Existing methods for producing precision blankings in a die require complete opening of the die, limiting the number of press strokes and restricting use to low-speed presses, while also risking damage to functional surfaces due to relative movements perpendicular to the material strip.
Innovation Solution
The method involves an incomplete compound die cut using a specially shaped cutting edge of the blanking punch and die plate, keeping the precision blanking connected to the material strip by partial connecting parts, allowing it to be moved in the strip's running direction for separation without vertical shear force, and using a discharge chute for perpendicular discharge, reducing die opening and closing paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the die is completely opened to prevent precision blanking from being pressed back into the material strip, then the precision blanking quality is improved, but the opening path increases and the number of press strokes is limited
Solution Approach 1:
The die cutting edge is segmented into a first cutting edge and a second cutting edge that are offset from each other. The first cutting edge makes an initial cut while the material strip is fed forward, and the second cutting edge completes the cut. This segmentation allows the die to remain partially closed during the cutting process, reducing the opening path while maintaining cutting quality.
Solution Approach 2:
The material strip is fed forward a predetermined distance before the cutting operation is completed. This preliminary feeding action creates space for the precision blanking to be discharged in the running direction of the strip without requiring the die to open completely, thus reducing the opening path while preventing the blanking from being pressed back.
2Ease of manufacture
If the precision blanking is pressed back into the material strip for discharge, then the discharge mechanism is simplified, but the cutting quality is significantly reduced
Solution Approach 1:
Instead of pressing the precision blanking back into the material strip for discharge (conventional method), the invention discharges the blanking in the running direction of the strip by feeding the strip forward during the cutting process. This inverted discharge direction maintains cutting quality while achieving effective blanking removal.
3Productivity
If the die is completely opened to allow precision blanking removal, then the blanking can be discharged, but the construction complexity increases and high speed press usage is restricted
Solution Approach 1:
The die system incorporates dynamic feeding of the material strip during the cutting operation. The strip is fed forward a predetermined distance in coordination with the cutting edges, creating a dynamic process that reduces the required opening path. This dynamic approach enables faster press cycles while maintaining simple die construction.
Data Source
AI summary
The incomplete compound die cut along the circumference of the precision blanking is performed with a specially shaped cutting edge of cutting punch (11) and/or the die plate (5) in such a way that the precision blanking (1) remains initially connected by a material bonding to at leas one partial connecting part on the material strip (2), either on the upper or lower plane at a level relative to the material strip. It is then moved together with the material strip in the running direction of the strip to a subsequent removal stage (ejector), in which the precision blanking and the material strip are separated from each other perpendicular to the running direction of the material strip towards the bottom by breaking out the connecting part without a vertical shear force component and without being pressed back, wherein the removed precision blanking (1) is discharged through a discharge chute (9) in the die plate.