Punch-Die Assembly for Single-Stroke Flared Steel Openings
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Solution Overview
Problem
Conventional machinery for forming flared openings in steel workpieces, particularly for commercial forming steel with thicknesses between 1 mm and 3 mm, is large, heavy, and not mobile due to the need for robust clamping and multiple stations, leading to deformation and mobility issues.
Innovation Solution
A punch and die assembly with a punching element having multiple evenly spaced peaks and troughs, and a flaring element that tapers inwardly, allowing for a single-stroke formation of flared openings in commercial forming steel sheeting, using a punch and die assembly with specific dimensions and angles to minimize deformation and facilitate clean slug detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional punching operations use robust clamping and multi-station tooling to form flared openings, then manufacturing precision and structural integrity are improved, but device complexity and equipment weight increase significantly
Solution Approach 1:
The patent combines punching and flaring operations into a single integrated punch assembly. The punch includes a cylindrical portion for punching and a frustoconical flaring portion that forms the flare during the same stroke, eliminating the need for separate multi-station tooling and reducing equipment complexity while maintaining manufacturing precision
Solution Approach 2:
The punch assembly serves multiple functions: it punches through the steel sheeting to create openings and simultaneously forms flared rims on the openings. This multi-functional design replaces complex multi-station tooling with a single versatile tool that performs both operations in one stroke
2Manufacturing precision
If conventional equipment uses large clamping forces and robust dies to prevent material deformation, then manufacturing precision is improved, but the equipment becomes too heavy for mobile application
Solution Approach 1:
By combining punching and flaring in one stroke, the material remains clamped throughout the entire process. The flaring portion of the punch forms the flare while the material is still supported by the die, preventing deformation without requiring excessive clamping force or heavy equipment
Solution Approach 2:
The punch penetrates the material completely before the flaring portion begins to form the flare. This sequence ensures the opening is fully created and the material is properly positioned before flaring begins, allowing precise control with lighter equipment
3Manufacturing precision
If radial clearance between punch and die is reduced to 5-8% of material thickness for precise punching, then punching precision is improved, but the equipment requires larger size to accommodate the clearance
Solution Approach 1:
The integration of flaring into the punching operation changes the clearance requirements. The die clearance is optimized for the combined operation, allowing precise punching while the flaring portion of the punch creates the flare within the same stroke, reducing the overall equipment size needed
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 efficient, single-stroke formation of flared openings in commercial forming steel without significant deformation, allowing for mobile machinery capable of forming beams with flared rims, maintaining structural integrity, and reducing equipment size and weight.
Implementation Method 1
The punching element having a base portion and a working portion that extends from a face of the base portion, the working portion defining a working edge with more than two substantially evenly spaced peaks and troughs for forming an opening in the steel sheeting
Implementation Method 2
a flaring element that defines an arcuate flaring surface that is tapered inwardly along a direction of the working stroke
Data Source
AI summary
A punch and die assembly for a forming assembly for forming flared openings in commercial forming steel sheeting, includes a punch. The punch has a punching element having a base portion and a working portion that extends from a face of the base portion, the working portion defining a working edge with more than two substantially evenly spaced peaks and troughs for forming an opening in the steel sheeting during a working stroke. A flaring element is mountable on the base portion of the punching element, a side of the flaring element defining an arcuate flaring surface that tapers inwardly in the direction of the working stroke. A die supports the steel sheeting, the die having a die opening with a flared die face for facing the flaring surface of the flaring element such that the opening in the steel sheeting is flared by the flaring surface of the flaring element and the die face in the working stroke.