Segmented Draw Die with Ultrasonic Vibration Isolation
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Solution Overview
Problem
Aluminum is less formable and more prone to scratching than steel in conventional forming processes, leading to higher reject rates and increased capital and energy costs in deep drawing operations, with challenges in controlling lubricant application and removal.
Innovation Solution
A segmented draw die system with ultrasonic vibration capability, where specific die segments are isolated to apply localized friction reduction through ultrasonic vibrations, reducing the energy required for vibration and minimizing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional forming press is used for aluminum deep drawing, then manufacturing process is simple, but formability is poor and scratching occurs
Solution Approach 1:
The patent applies ultrasonic vibration to the draw die during deep drawing operations. The vibration reduces friction between the aluminum sheet and die surface, improving formability and reducing scratching while maintaining a simple single-stage press configuration.
Solution Approach 2:
The draw die is divided into multiple segments that can be independently controlled. This allows selective application of ultrasonic vibration to specific areas where friction reduction is most needed, improving overall formability without requiring multiple press stages.
2Reliability
If lubricants are employed to reduce friction, then deep drawing capability is improved, but lubricant control and removal becomes challenging
Solution Approach 1:
The patent uses ultrasonic vibration of the draw die to reduce friction between the aluminum sheet and die surface. This eliminates the need for lubricants while maintaining deep drawing capability, avoiding all associated lubricant control and removal issues.
Solution Approach 2:
The patent replaces the chemical lubrication system with a mechanical vibration system. The ultrasonic vibrations create a lubricating effect through reduced friction without requiring any lubricant material, thus eliminating lubricant control complexity.
3Reliability
If multiple press stages are used to form deep drawn parts, then manufacturing capability is improved, but capital costs and energy consumption increase
Solution Approach 1:
The patent applies ultrasonic vibration to enable deep drawing in a single press stage. This achieves the same manufacturing capability as multiple stages would provide, but with significantly reduced energy consumption and without requiring additional press equipment.
Solution Approach 2:
The segmented die design allows targeted application of ultrasonic vibration to critical areas, enabling complex deep drawn shapes to be formed in one stage rather than requiring multiple sequential pressing operations.
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
Facilitates efficient and cost-effective production of deep drawn parts by reducing friction and preventing defects like fracturing and surface wear, while minimizing lubricant usage and energy consumption.
Implementation Method 1
applying ultrasonic vibrations to drilling and machining processes is known. For example, ultrasonic vibrations applied to a tool on a machining device provide a lubricating effect
Data Source
AI summary
A draw die for use in a draw stage configured to process a work piece in a forming operation is provided. The draw die includes a first segment, a second segment positioned adjacent to the first segment, and an isolation material positioned between the first segment and the second segment and configured to substantially isolate the second segment from ultrasonic vibrations of the first segment.