Integrated Press Hardening With In-Die Fastener Setting
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Solution Overview
Problem
Existing manufacturing processes face challenges in attaching functional elements, such as nuts or bolts, to workpieces, especially those made of strong materials or with complex geometries, particularly in automotive engineering, where direct material-to-material fastening is unsuitable.
Innovation Solution
A device comprising a pressing and a setting mechanism, allowing independent operation of forming and fastening processes, with thermal conditioning and sensor feedback for optimal timing and temperature control during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If workpieces are first formed and then fed to a separate setting device for attaching functional elements, then the forming and setting processes can be performed with dedicated equipment, but the process complexity increases and productivity decreases due to multiple handling steps
Solution Approach 1:
The patent combines the forming device and setting device into a single integrated machine. The forming device includes both a forming unit for shaping the workpiece and a setting unit for attaching functional elements, eliminating the need to transfer workpieces between separate devices. This integration maintains joining quality through precise positioning while significantly improving productivity by eliminating handling steps and enabling simultaneous operation of both functions.
2Productivity
If the pressing device and setting device are coupled together, then productivity improves by eliminating workpiece handling, but the operation flexibility decreases due to coordinated movement constraints
Solution Approach 1:
The patent implements independent control systems for the forming device and setting device within the integrated machine. The forming device can operate independently to shape workpieces, while the setting device can operate independently to attach functional elements. This dynamic independence allows each device to be controlled separately based on specific process requirements, maintaining full operational flexibility while benefiting from the integrated design that eliminates workpiece handling between separate machines.
3Strength
If functional elements are attached to press-hardened workpieces made of strong materials, then the structural strength is maintained, but the difficulty of attachment increases due to material hardness
Solution Approach 1:
The patent employs a setting device with controlled applying force capability that can attach functional elements to press-hardened workpieces made of strong materials like boron-alloyed steel. The device controls the magnitude and distribution of force during the attachment process, enabling successful fastening to hardened surfaces without compromising the material's structural strength. This parameter control allows the attachment process to accommodate the high hardness of press-hardened materials while maintaining their mechanical properties.
Data Source
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AI summary
The present invention relates to a device for machining a workpiece, comprising at least one pressing device with a first tool half and a second tool half, which are movable toward one another, in particular for forming and/or press-hardening the workpiece, and at least one setting device for fastening at least one functional element in a setting movement at a setting point on the workpiece, wherein the setting device is arranged on the first tool half or the second tool half. The setting device can be operated independently of the pressing device.