Sequential Press Punch Bending for Corrugated Shape Control
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Solution Overview
Problem
Conventional bending processes for corrugated products often result in material breaking or shape distortion, particularly when dealing with materials of high aspect ratio or high Young's modulus, due to inadequate control over the pulling force and external forces applied during the bending process.
Innovation Solution
A bending process and machine design that involves opposing die units with sequential movement and controlled clearance to manage the pulling force, preventing shape distortions like bowing or breaking, and allowing for the formation of corrugated shapes with a higher aspect ratio by adjusting the stroke and engagement of cam members with press punches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple press punches are simultaneously pushed down to form corrugated shapes, then productivity is improved, but material breaking and shape distortion occur due to uncontrolled pulling forces
Solution Approach 1:
The patent divides the simultaneous press work into multiple sequential stages. Multiple press punches are operated in sequence rather than simultaneously, with each punch completing its stroke before the next begins. This segmentation controls the pulling force on the material at any given time, preventing material breaking while maintaining high productivity through continuous operation.
Solution Approach 2:
The patent employs dynamic control of the press punches through cam mechanisms that provide sequential activation. The cam members are positioned at different locations along the moving direction, creating a dynamic sequence where press punches are activated one after another. This dynamic approach allows the system to maintain high productivity while controlling material deformation forces.
2Manufacturing precision
If the stroke of press punches is increased to form higher aspect ratio corrugated shapes, then manufacturing precision is improved, but material breaking occurs due to excessive external forces
Solution Approach 1:
The patent positions cam members at different locations along the moving direction to create a preliminary sequence of press punch activation. The first press punch begins its stroke before subsequent punches are activated, allowing the material to be gradually deformed in controlled stages. This preliminary action enables the formation of high aspect ratio corrugated shapes without applying excessive force that would cause material breaking.
Solution Approach 2:
The patent changes the temporal parameter of press punch activation by introducing time delays between successive punches through cam positioning. This parameter change allows the material to undergo gradual deformation, achieving high aspect ratio precision while maintaining material strength by avoiding sudden excessive forces.
3Productivity
If press work is carried out at higher speed to increase productivity, then productivity is improved, but shape distortion occurs due to inadequate control over pulling forces
Solution Approach 1:
The patent maintains continuous press work operation where multiple press punches work in sequence without interruption. While the overall process speed is high, each individual press punch operates at a controlled rate with proper timing. This continuous sequential action ensures both high productivity and shape accuracy by preventing material restoration that would occur with intermittent operation.
Solution Approach 2:
The patent implements a feedback mechanism through the cam sequencing system where the position and timing of each press punch is predetermined based on the material's deformation characteristics. The cam members are positioned to create optimal time intervals between punches, providing implicit feedback control that maintains shape accuracy while achieving high processing speeds.
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
The solution effectively prevents material breaking and shape distortion, enabling the production of corrugated products with improved stability and accuracy, even for materials with high aspect ratios, by controlling the pulling force and distributing external forces evenly during the bending process.
Implementation Method 1
a movable cam is moved in a direction along the line of the press punches, so that each of the press punches is sequentially pushed down in a predetermined stroke
Implementation Method 2
The corrugated shape of the material M is likely to restore to its original flat shape to some extent by its elasticity, when the material M is processed by the press work at the first press work point
Data Source
AI summary
Multiple movable die portions (press punches) are respectively opposing to multiple fixed die portions (block members). Each of the press punches is sequentially pushed down with a predetermined time difference to the corresponding block member to continuously carry out press work to a material inserted into a press-work area between the press punches and the block members. A clearance is formed between a forward end of the press punch and a forward end of the block member at a position shortly before a press-work operating position in order to control a pulling force of the material, so that a shape distortion can be avoided.