Segmented Binder Fixture for Incremental Forming Scrap Reduction

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Solution Overview

Problem

Incremental forming machines face inefficiencies due to the need for a full blank to fill the binder, resulting in excessive scrap and reduced productivity, as each part requires a new blank setup, limiting the ability to form small or multiple parts accurately and quickly.

Innovation Solution

A fixture assembly with a divisible binder opening and clamp support segments allows for multiple smaller blanks to be secured within a single setup, using connecting members and reinforcement rods to support the clamping mechanism, enabling the formation of different sized parts on various blanks without reloading the machine.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If a full blank is used to fill the binder for incremental forming, then the binder is properly supported during forming, but excessive scrap is produced and productivity is reduced due to requiring a new blank for each part

Engineering Contradiction:

ImprovescrapVSAvoidproductivity

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The binder is divided into multiple segments or zones, allowing different blanks of varying sizes to be positioned in different segments. This segmentation enables efficient use of blank material by matching blank size to part size, reducing scrap while maintaining productivity through multi-part forming capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The binder is designed to serve multiple functions simultaneously - it can hold and form multiple different blanks in a single setup. This multi-functionality allows the binder to process various part sizes and configurations without requiring reloading, thereby reducing both scrap and setup time

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If a new blank is loaded for each part in the binder, then each part can be formed with proper support, but time is lost due to repeated loading and setup

Engineering Contradiction:

Improvedimensional accuracyVSAvoidsetup time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Multiple blanks are pre-positioned and secured in the binder during a single setup operation. This preliminary action of arranging all blanks beforehand eliminates the need for repeated loading and positioning operations, saving time while maintaining dimensional accuracy through proper initial support

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the binder opening is used as a single large area, then large parts can be formed, but small parts result in excessive scrap and reduced efficiency

Engineering Contradiction:

Improvepart size flexibilityVSAvoidscrap

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The binder opening is segmented into multiple zones that can accommodate blanks of different sizes. This segmentation provides adaptability for forming various part sizes while minimizing scrap by matching blank dimensions to actual part requirements in each segment

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9038999B2Fixture assembly for forming prototype parts on an incremental forming machine

Publication Date: 2015.05.26 FORD GLOBAL TECH LLC

AI summary

An incremental forming machine binder is provided that has a blank holding opening that may be subdivided into smaller blank holding openings. The opening is subdivided by one or more clamping modules that are connected by connecting modules to each other and the frame. Clamps are attached to the clamping modules to clamp blanks in the blank holding openings. Multiple blanks may be secured to the binder for incremental forming.