Recess Forming via Thin Cutting Fin Segmentation
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Solution Overview
Problem
Conventional methods for forming recesses in metal or synthetic resin materials, such as pressing and chemical etching, face issues like residual stress, warping, high costs, and poor dimensional accuracy, especially when forming large areas or complex shapes.
Innovation Solution
A method using a cutting tool with a blade part, moved at a prescribed angle, to form a recess by creating thin cutting fins and separating them horizontally, allowing for minimal stress and efficient formation of recesses with controlled scrap retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If pressing methods are used to form a recess in a metal plate, then a recess having a prescribed shape can be formed, but residual stress is imparted, curling occurs, and flatness is significantly disturbed
Solution Approach 1:
The pressing process is divided into multiple stages with progressively deeper recess formation. Each stage uses a punch with a different depth, allowing the metal to deform gradually rather than all at once. This segmentation reduces residual stress accumulation and prevents excessive curling and flatness distortion that would occur with a single deep pressing operation.
Solution Approach 2:
The pressing operation is performed periodically in multiple cycles, with each cycle forming a recess to a specific depth and then removing the punch. This periodic action allows the metal to relax between presses, reducing residual stress buildup and preventing the severe flatness deterioration that occurs with continuous or single-stage pressing.
2Shape
If pressing methods are used to form a recess in a metal plate, then a concave part can be formed, but a large pressing force is necessary and the durability of the punch will worsen
Solution Approach 1:
The total pressing force requirement is segmented across multiple pressing operations. Each operation applies force only to the extent needed for that stage's recess depth, rather than requiring the full force needed for the complete recess depth in a single operation. This reduces the peak force requirement and extends punch durability.
Solution Approach 2:
Each pressing operation applies only the partial force necessary to achieve the current stage's recess depth, rather than applying the excessive force that would be required to achieve the final depth in one operation. This partial action approach reduces stress on the punching system and improves punch life.
3Shape
If chemical etching methods are used to form a recess in a metal plate, then a concave part can be formed, but large amounts of time are required and this method is unsuitable for mass production
Solution Approach 1:
The chemical etching process is replaced with a mechanical pressing process using punches and presses. This substitution enables much faster material removal and recess formation, making the process suitable for mass production while still achieving the desired concave part geometry.
Solution Approach 2:
The material removal mechanism is changed from chemical dissolution to mechanical deformation. By changing the fundamental parameter of how material is removed (from chemical to mechanical), the process time is dramatically reduced while maintaining the ability to form precise recess shapes.
4Shape
If chemical etching methods are used to form a recess in a metal plate, then a concave part can be formed, but the dissolution of each portion cannot be controlled separately and dimensional accuracy is poor
Solution Approach 1:
The uncontrolled chemical dissolution process is replaced with a controlled mechanical pressing process. The punch geometry directly determines the recess shape, providing precise control over each portion of the concave part and achieving high dimensional accuracy that cannot be obtained through chemical etching.
Solution Approach 2:
The control mechanism for material removal is changed from chemical concentration and exposure time to mechanical punch geometry and pressing depth. This parameter change enables precise control over the dissolution (deformation) of each portion, achieving the dimensional accuracy required for practical applications.
Data Source
AI summary
A method of forming a recess in a work, a work in which the recess is to be formed is a material that can be cut. A cutting tool for forming the recess is held by a moving apparatus at a prescribed angle relative to the work. The cutting tool is moved in a carving direction for carving the work at the prescribed angle, and a thin cutting fin is vertically formed. Then, the cutting tool is moved in the horizontal direction, and the cutting fin is cut and separated from the work. The fin-forming step and the cutting step are repeatedly performed in sequence, whereby a recess having a prescribed depth d and area is formed in the work.