Reprocessed Die Cross-Section Adjustment
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Solution Overview
Problem
Regrinding of dies results in an enlarged die cutting edge cross-section due to the relief angle, leading to an unduly wide cutting gap and inferior processing quality, limiting the useful life of punching tool sets and requiring premature replacement.
Innovation Solution
A method to reassign a punch or workpiece thickness to a reprocessed die based on changes in the cutting edge cross-section, utilizing a control unit and adjusting device to position the die and punch relative to each other, allowing for continued high-quality processing despite regrinding, and extending the life of dies by reassigning them to different punches or workpiece thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If regrinding is performed to restore the cutting edge of the die, then the die can be reused, but the die cutting edge cross-section is enlarged leading to an unduly wide cutting gap and inferior processing quality
Solution Approach 1:
The patent applies parameter changes by modifying the assignment parameters of the die (punch diameter assignment and/or workpiece thickness assignment) based on the measured cutting edge cross-section after regrinding. Instead of discarding the die when the cutting edge cross-section changes, the system adjusts the assignment parameters to accommodate the new dimensions, thereby maintaining processing quality while extending the die's useful life.
2Manufacturing precision
If the die cutting edge cross-section is kept within strict limits to maintain high-quality processing, then processing quality is preserved, but the die must be scrapped after minimal regrinding
Solution Approach 1:
The patent implements dynamics by making the die assignment flexible rather than fixed. The assignment parameters (punch diameter and workpiece thickness) are dynamically adjusted based on the actual cutting edge cross-section measurements. This dynamic reassignment allows the die to continue being used with modified parameters rather than being scrapped when original parameters can no longer be maintained.
Solution Approach 2:
The system changes the operational parameters of the die assignment based on its worn state. By measuring the cutting edge cross-section and recalculating appropriate punch diameter and workpiece thickness assignments, the patent transforms a static assignment system into an adaptive one that extends die utilization while maintaining acceptable processing quality.
3Reliability
If a large relief angle is provided on the die to ensure reliable material ejection and punch return, then process reliability is improved, but the die cutting edge cross-section enlarges more rapidly during regrinding
Solution Approach 1:
The patent compensates for the accelerated cross-section enlargement caused by large relief angles by implementing parameter changes in the die assignment. The system measures the actual cutting edge dimensions and adjusts the assigned punch diameter and workpiece thickness accordingly, allowing dies with large relief angles to be fully utilized without premature scrapping.
Data Source
AI summary
A method includes removing material from a die and thereby changing a location of a cutting edge of the die in a punch entry direction and changing a cutting edge cross-section of the die; and assigning a punch and/or a workpiece thickness to the die based, at least in part, on the change in the cutting edge cross-section of the die.