Sheet Metal Press Edge Processing Tool
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Solution Overview
Problem
Shearing processes in sheet metal production reduce deformability, leading to edge cracks during further processing, and existing methods for avoiding cracks are economically unsatisfactory, particularly in manufacturing three-dimensionally shaped components like wishbones.
Innovation Solution
Integration of a cutting edge processing tool within a transfer press that uses a conical and circular-cylindrical milling section, coupled to the press stroke movement via a gear, to smoothly process the cut edge without reducing press operating speed, ensuring reliable material removal and minimizing crack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shearing process is used to trim or punch sheet metal, then the cut edge is produced, but the deformability of the sheet metal is reduced locally, increasing the risk of cracks during further processing
Solution Approach 1:
The patent applies preliminary action by performing material removal at the cut edge before the forming process. The cutting edge processing tool removes material in advance to create a relief effect, preventing stress concentration during subsequent collar or flange forming operations. This preliminary material removal eliminates the root cause of crack formation while maintaining the benefits of the shearing process.
2Reliability
If the collar depth is reduced to avoid crack formation, then crack risk decreases, but insufficient collar depths are achieved, particularly in chassis components
Solution Approach 1:
The patent performs material removal at the cut edge before forming operations to create a relief effect. This preliminary action allows the forming process to proceed without stress concentration at the cut edge, enabling achievement of required collar depths without crack formation. The relief effect redistributes stresses, permitting deeper collar formation.
3Reliability
If post-processing by machine is used to smooth the cut edge, then crack formation is prevented, but the workpiece must be discharged and reintroduced, reducing productivity
Solution Approach 1:
The patent merges the cutting edge processing function with the transfer press by integrating a cutting edge processing tool that is coupled to the press stroke movement. This combination eliminates the need for separate post-processing operations and workpiece handling, maintaining high production speeds while preventing crack formation. The integrated tool performs material removal during the press cycle itself.
Solution Approach 2:
The patent ensures continuity of useful action by integrating the cutting edge processing tool with the press stroke movement through a gear coupling. The tool operates continuously during the press cycle without interrupting production, maintaining the high working speed of modern transfer presses (more than 25 strokes/min) while providing continuous crack prevention.
4Productivity
If the cutting edge processing tool is integrated and coupled to press stroke movement, then productivity is maintained, but the device complexity increases
Solution Approach 1:
The patent uses a gear as an intermediary element to couple the cutting edge processing tool to the press stroke movement. This gear mechanism translates the vertical press stroke into rotational movement of the milling tool, enabling the tool to operate at high speeds while maintaining simplicity of control. The gear coupling is a straightforward mechanical transmission that adds minimal complexity.
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
Enables the economical production of sheet metal components with formed collars or flanges without cracking, maintaining high press performance and achieving optimal surface quality by effectively removing material from the cut edge, thus increasing deformability and preventing edge cracks.
Implementation Method 1
the cutting edge processing tool (3) integrated in the press (1) to remove material on the cut edge (4) by cutting
Implementation Method 2
the gear (5), by means of which the milling tool (3) is coupled to a press lifting movement or the closing movement of the press (1)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a press (1) for forming sheet metal (2), comprising a punching tool for trimming or punching the sheet metal (2) and a forming tool for forming a cut edge (4) produced by trimming or punching. According to the invention, a rotating edge-processing tool (3) for removing material from the cut edge (4) to be formed is integrated in the press (1) between the punching tool and the forming tool, wherein the edge-processing tool (3) is coupled to a press stroke movement of the press (1) by means of a gearbox (5), and wherein the gearbox (5) converts the press stroke movement into a rotary movement and causes an increase in rotational speed.With the press according to the invention (1), single-shell body and chassis components, in particular control arms made of sheet steel, which are to have a cut edge formed into a collar or flange, can be produced economically without cracking during collar or flange formation.