Press Die Machining with Protruding Edge Tool
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Solution Overview
Problem
Traditional machining methods for press dies require multiple steps and skilled labor, leading to inefficiencies and safety concerns due to the use of different tools for pierce cutters and secondary relief-clearance areas, resulting in increased labor and time costs.
Innovation Solution
A machining method using a single tool with an edge portion protruding from the outer circumference, capable of rotating and moving axially, to perform both relative movement and plunge cutting along the profile of the pierce cutter and secondary relief-clearance area in a single step, reducing tool flexure and carving resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate tools are used for machining pierce cutter and secondary relief-clearance area, then machining precision can be maintained, but machining time increases and productivity decreases
Solution Approach 1:
The patent combines multiple separate tools (flat-end mill for pierce cutter, T-shaped tool for secondary relief-clearance area) into a single integrated tool that can perform both machining operations. The tool includes a body portion for machining the pierce cutter and a protruding portion that extends beyond the body to machine the secondary relief-clearance area, eliminating the need for tool changes and reducing machining time while maintaining precision through continuous operation.
Solution Approach 2:
The single tool is designed with multi-functionality to perform both pierce cutter machining and secondary relief-clearance area machining. The tool body and protruding portion are configured to accommodate different machining requirements, allowing one tool to replace multiple specialized tools, thereby improving productivity without sacrificing manufacturing precision.
2Ease of manufacture
If T-shaped tool is manually moved up and down by operator, then secondary relief-clearance area can be machined, but skilled labor is required and safety risks increase
Solution Approach 1:
The tool design enables the machining process to be self-sufficient without requiring manual intervention. The protruding portion automatically machines the secondary relief-clearance area as the tool is positioned by the CNC system, eliminating the need for operators to manually move the tool up and down. This reduces skill requirements and safety risks while maintaining the ability to machine complex geometries.
3Productivity
If single tool of elaborated configuration is used to machine both pierce cutter and secondary relief-clearance area, then tool length increases, but this causes tool flexure and requires multiple separate carving processes
Solution Approach 1:
The tool is designed with a dynamic configuration where the protruding portion extends beyond the body portion only when needed for machining the secondary relief-clearance area. The tool can be positioned and oriented to minimize flexure during different machining operations, allowing continuous machining without requiring excessive tool length or multiple separate processes.
Data Source
AI summary
A machining method of a press die having a pierce cutter and a secondary relief-clearance area recessed inward relative to a profile of the pierce cutter is provided. A plunge cutting tool having a tool body and at least one edge portion provided on an outer circumference of an end of the tool body is used, the edge portion being protruding from the outer circumference of the tool body and being capable of carving while rotating around an axis of the tool body and moving in an axial direction of the tool body. While rotating the plunge cutting tool with an axis of the tool body being approximately parallel to a surface of the pierce cutter, the plunge cutting tool is relatively moved along the profile of the pierce cutter. The plunge cutting tool is also relatively moved in the axial direction of the tool body along the shape of the pierce cutter and the secondary relief-clearance area in a piercing direction each time the plunge cutting tool is relatively moved by a predetermined pitch.