Shaping Tool Contour Cooling Grooves
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Solution Overview
Problem
Existing shaping tools for cooling and shaping sheet steel components are expensive, complex to manufacture, and have limited cooling capacity, leading to inefficient cooling and thermal stresses in both the tool and the workpiece.
Innovation Solution
The shaping tool is composed of multiple shell-like parts with a contoured shaping surface shell and milled cooling grooves on the rear side, allowing for effective coolant distribution that follows the contour of the workpiece, increasing cooling capacity and reducing thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional drilling methods are used to create cooling conduits, then the cooling capacity is limited, but the manufacturing complexity and cost increase
Solution Approach 1:
The shaping tool half is divided into a shaping surface shell and a support form as separate segments. The cooling conduits are created by milling grooves into the shaping surface shell, which is then screwed to the support form. This segmentation allows the cooling channels to be easily manufactured in the shell portion without complex drilling operations through the entire tool assembly.
Solution Approach 2:
Instead of creating cooling conduits by drilling through the shaping tool half in the traditional manner, the invention mills grooves into the rear side of the shaping surface shell, creating cooling channels that follow the contour of the shaping surface. This dimensional approach allows the cooling conduits to be formed on the surface rather than through the bulk material, simplifying manufacturing.
2Area of stationary object
If traditional drilling methods are used to create cooling conduits, then the manufacturing process is simpler in theory, but the cooling area achieved is not very large
Solution Approach 1:
The cooling grooves are milled into the rear side of the shaping surface shell in the region where cooling is most needed, following the contour of the shaping surface. This local concentration of cooling capacity allows the cooling area to be maximized in the critical regions without requiring complex drilling through the entire tool half.
Solution Approach 2:
The cooling conduits are formed as grooves on the surface of the shaping surface shell rather than as through-drills, allowing the cooling area to extend across the entire shaping surface contour. This surface-based approach dramatically increases the achievable cooling area compared to traditional drilling methods.
3Temperature
If cooling conduits are drilled through the shaping tool half, then cooling can be provided, but thermal stresses occur in the tool and workpiece
Solution Approach 1:
The cooling grooves are strategically milled into the rear side of the shaping surface shell to follow the contour and provide localized cooling where thermal stresses are most likely to occur. This targeted approach allows for more uniform temperature distribution and reduced thermal gradients, minimizing thermal stresses in both the tool and workpiece.
Solution Approach 2:
By forming cooling grooves on the surface of the shaping surface shell rather than drilling through the tool half, the cooling is applied more uniformly across the shaping surface. This reduces thermal gradients and prevents the concentrated thermal stresses that occur with traditional drilling methods.
4Reliability
If multiple bores and connecting conduits are drilled to create cooling channels, then cooling can be achieved, but the manufacturing cost and time increase
Solution Approach 1:
The cooling system is segmented into the shaping surface shell with milled grooves and the support form with through-bores. The grooves can be milled into the shell in a single operation, and the shell is then screwed to the support form. This segmentation eliminates the need for multiple sequential drilling and connecting operations, significantly reducing manufacturing time.
Solution Approach 2:
The cooling conduits are formed by milling grooves into the shaping surface shell rather than by drilling through the material. This surface-based formation method is much faster and requires fewer manufacturing steps compared to traditional drilling and connecting conduit methods, reducing overall manufacturing time while maintaining effective cooling function.
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 design enables efficient cooling with reduced manufacturing complexity and cost, achieving uniform cooling and faster cycle times with fewer thermal stresses, allowing for stable processing temperatures and reduced energy expenses.
Implementation Method 1
the rear side has cooling grooves milled into it... which are acted on through the support form by means of coolant, in particular water
Implementation Method 2
coolant, in particular water... distributes this water into the inlet conduits and therefore into the cooling conduits
Data Source
AI summary
The invention relates to a shaping tool which is used to shape a workpiece, in particular, a sheet steel component, comprising at least two shaping tool halves. Contoured regions are provided in the region of the shaping tool halves in order to give the workpiece a corresponding contour, at least in sections. Each shaping tool half has a shaping surface shell which is oriented towards the workpiece and a support shaping half. The shaping surface shell is arranged on the support shaping half and comprises a shaping surface, which is oriented towards the workpiece, and a rear side which is oriented away from the workpiece. The support shaping half comprises a contoured area which essentially corresponds to the contour of the workpiece which is to be produced and the contoured area is surrounded by a flange area. Grooves are provided in the contoured area in the region of the rear side of the shaping surface shell. The support shaping half comprises receiving surfaces which receive the support shaping half in a positive fit and the receiving surfaces and the grooves form cooling channels. The support shaping half comprises supply channels and discharge channels such that a coolant can be guided through the channels.