Profiled Article Forming with Opposing Die Blocks
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Solution Overview
Problem
Current methods for forming deformable materials into desired profiles, such as roll forming and chain-die forming, suffer from issues like redundant deformation, high residual stresses, complex tooling design alignment difficulties, and material wastage, particularly when producing irregular profiles.
Innovation Solution
A method and apparatus using a series of complementary and opposing body forming die blocks with locating elements to form deformable materials into irregular profiles, allowing for independent action on each blank to achieve the desired profile in one or multiple passes, eliminating the need for a blank-holder and reducing material wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If roll forming is used to form uniform profiles, then the desired profile can be achieved, but redundant deformation occurs resulting in high residual stresses and product defects
Solution Approach 1:
The forming process is divided into multiple sequential roll sets, each responsible for a specific portion of the profile formation. This segmentation allows for controlled deformation at each stage rather than concentrated deformation, reducing redundant strain and residual stresses while maintaining profile accuracy.
Solution Approach 2:
The process performs preliminary deformation actions in early roll sets before final profile formation. This preliminary action gradually pre-shapes the strip, distributing the deformation workload and preventing concentrated stress buildup that would occur with single-stage forming.
2Manufacturing precision
If roll forming is used for complex profiles, then the desired profile can be achieved, but the distance between first and last roll sets increases requiring substantial space
Solution Approach 1:
The roll sets are arranged in a compact dynamic configuration where rolls can be positioned and adjusted to minimize the overall length of the forming assembly. The system uses multiple passes through fewer roll sets rather than many roll sets in sequence, reducing the stationary object length while maintaining complex profile formation capability.
3Manufacturing precision
If multiple roll sets are used for forming, then profile accuracy can be improved, but initial alignment becomes significantly difficult
Solution Approach 1:
Multiple forming functions are merged into fewer roll sets that perform multiple operations in sequence. This consolidation reduces the number of alignment interfaces between roll sets, making initial alignment and subsequent maintenance significantly easier while preserving profile accuracy through the combined forming action.
4Manufacturing precision
If stamping is used to form irregular profiles, then the desired irregular profile can be achieved, but material wastage occurs due to earring that needs trimming
Solution Approach 1:
The traditional stamping mechanical system that causes earring is replaced with a roll forming system that uses progressive deformation through multiple roll sets. This substitution eliminates the sudden forming action that creates earring, allowing irregular profiles to be formed without material wastage from trimming.
5Manufacturing precision
If stamping is used for profile formation, then the desired form can be produced, but the process is discontinuous requiring a blank-holder
Solution Approach 1:
The discontinuous stamping process is replaced with continuous roll forming where the strip passes through multiple roll sets in an uninterrupted flow. This continuous action eliminates the need for blank-holders and stopping/starting operations, simplifying the device while maintaining profile formation precision.
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 reduces residual stresses, simplifies the structure, and improves the surface finish of the final product by using whole body forming die blocks with minimal clearance, enabling efficient production of irregular profiles with reduced material waste and alignment complexities.
Implementation Method 1
forming deformable materials into a desired profile
Implementation Method 2
at least one body forming die block is employed to form at least part of the profiled article
Data Source
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AI summary
The present invention provides an apparatus (40) for forming a profiled article (46) comprising: a forming path (41) through which a blank of deformable material to be formed into the profiled article passes; a pair of complementary and opposing body forming die members (45, 45') adapted to travel along the forming path (41); and a drive (44, 44') that facilitates travel of the body forming die members (45, 45') along the forming path (41), wherein the pair of body forming die members (45, 45') is adapted to act on the blank of deformable material independently to form a desired profile on the blank. Locating elements (75) that locate the blanks may be provided. A method of forming material is also provided. Further, there is provided a length of deformable material for use with the apparatus.