Expandable-Core Ring Wall Piercing for Fast Multi-Hole Stamping
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Solution Overview
Problem
Existing methods for producing sheet metal rings with holes in the side wall are inefficient as they require sequential punching of each hole, which is time-consuming and prone to distortion and burr formation.
Innovation Solution
A slew-actuated stamping station that uses an expandable core and multiple punches to simultaneously form multiple holes in the radial wall of a ring-shaped part in a single operation, with the expandable core applying radially outward pressure to secure and shape the part, preventing distortion and burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential punching is used to create holes in sheet metal rings, then each hole can be formed individually, but the production time is excessive and distortion and burr formation occur
Solution Approach 1:
The die is segmented into multiple punching elements (first punch, second punch, third punch, fourth punch) arranged around the expandable core, allowing simultaneous formation of multiple holes in different radial walls of the ring-shaped workpiece during a single operation cycle
Solution Approach 2:
Multiple punching operations that were previously performed sequentially are merged into a single simultaneous operation, where all punches operate at the same time to create multiple holes in one stamping cycle, dramatically reducing production time
2Productivity
If multiple punches are used to simultaneously form multiple holes, then production time is reduced, but the device complexity increases
Solution Approach 1:
The expandable core serves multiple functions: it supports the ring-shaped workpiece during punching, provides radial outward pressure to prevent distortion and burr formation, and maintains geometric accuracy. This multi-functional component reduces the need for additional specialized devices
Solution Approach 2:
The expandable core transitions from a compressed state (during workpiece loading) to an expanded state (during punching operation), dynamically adjusting its volume and pressure application. This dynamic behavior allows the same component to accommodate workpiece insertion while providing the necessary counter-pressure during forming
3Device complexity
If sequential punching is used, then the equipment structure is simpler, but the production efficiency is low
Solution Approach 1:
The expandable core is pre-positioned within the die cavity before the punching operation begins, and the punches are pre-aligned around the core. This preliminary preparation ensures that when the punching operation starts, all components are ready for immediate simultaneous action, maximizing production efficiency
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 method allows for the efficient and precise formation of multiple holes in a single operation, reducing production time and minimizing distortion and burr formation, while ensuring accurate hole placement and maintaining the desired shape of the radial wall.
Implementation Method 1
an expandable core (120) that, when expanded, applies radially outward pressure (122) to a radially inward facing surface (196) of the radial wall (192)
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A slew-actuated stamping station includes an expandable core configured to apply radially outward pressure to a radially inward facing surface of a radial wall, and at least one slew-actuated punch for piercing, along a radially inward direction, a respective hole in the radial wall. A method for piercing a radial wall includes simultaneously (a) applying radially outward pressure against a radially inward facing surface of the radial wall, and (b) driving a slew to actuate at least one punch to pierce, along direction opposite the radially outward pressure, at least one hole in the radial wall. A method for forming an object, having a radial wall with holes, includes forming a ring with a radial wall, and piercing at least one hole in the radial wall with at least one slew-actuated punch.