Punch-Die Surface Texturing for Higher Workpiece Yield Strength

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Solution Overview

Problem

Conventional methods for improving yield strength of workpieces, such as heat treatment and laser surface texturing, are energy-intensive and costly, and often compromise ductility, while mechanical surface texturing methods are expensive due to the use of precision instruments.

Innovation Solution

A method and apparatus using a punch and die assembly to form surface protrusions on workpieces through plastic deformation, which increases yield strength by at least 10% without requiring expensive equipment, by imprinting a template mesh onto the workpieces to create troughs and crests.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If heat treatment is used to improve yield strength, then strength increases, but ductility declines and energy consumption increases

Engineering Contradiction:

Improveyield strengthVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The patent replaces thermal energy-based heat treatment with mechanical energy-based surface texturing. Instead of heating the workpiece to high temperatures and controlling cooling rates, the invention uses a punch and die assembly to mechanically deform the surface, creating micro-protrusions that enhance strength through strain hardening and size effects, thereby eliminating the high energy consumption associated with thermal processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies surface texturing only to the outer surface of the workpiece rather than treating the entire bulk material. The punch and die create localized micro-protrusions on the surface, concentrating the mechanical treatment where it is most effective for strength enhancement while minimizing overall energy input and preserving ductility in the bulk material

Inventive Principle:

Principle #3Local quality

2Strength

If laser surface texturing is used to create micron sized features, then yield strength improves, but manufacturing cost increases due to expensive precision instruments

Engineering Contradiction:

Improveyield strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces expensive, precision laser engraving equipment with a simple, cost-effective punch and die assembly. The punch and die can be made from relatively inexpensive materials and can be easily replaced or modified, eliminating the need for costly laser systems while achieving the same surface texturing effect through mechanical deformation

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses the punch and die assembly to mechanically replicate the surface texturing effect that would otherwise require complex laser systems. The punch face is designed with the desired micro-pattern, and each press operation copies this pattern onto the workpiece surface, achieving consistent micron-sized features through a simple mechanical copying process

Inventive Principle:

Principle #26Copying

3Strength

If conventional surface texturing methods are used, then yield strength improves, but the process becomes expensive and time-consuming

Engineering Contradiction:

Improveyield strengthVSAvoidprocessing time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent enables continuous surface texturing by integrating the punch and die assembly into existing press operations. The surface texturing is performed in-line during the forming process, eliminating separate post-processing steps and maintaining continuous production flow, thereby improving productivity while enhancing strength

Inventive Principle:

Principle #20Continuity of useful action

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

The method effectively enhances yield strength by at least 10% while being time-efficient and economical, eliminating the need for costly equipment and minimizing energy consumption.

Implementation Method 1

a plurality of surface protrusions is formed by plastic deformation on the one or more workpieces, to improve yield strength of the one or more workpieces

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

cold working (e.g. cold rolling, drawing, extrusions below recrystallization temperature of the workpiece), which exploits strain hardening phenomenon. These processes induce strain hardening on workpiece, and improve the yield strength

Methodology Applied

Scientific EffectStrain hardening:

Data Source

PatentUS11821052B2Method for improving yield strength of a workpiece, an apparatus and a workpiece thereof

Publication Date: 2023.11.21 TATA STEEL LTD

AI summary

The present disclosure discloses a method for improving yield strength of one or more workpieces. The method includes positioning the one or more workpieces in a punch and die assembly and operating the punch and die assembly such that, a plurality of surface protrusions are formed on the one or more workpieces. The plurality of surface protrusions are formed by plastic deformation on the one or more workpieces, to improve yield strength of the one or more workpieces. The present disclosure also provides an apparatus to improve yield strength of the one or more workpieces. The present disclosure is configured to improve yield strength of the one or more workpieces, without altering its mechanical characteristics.