Shaping Tool Allowance Element for Sharp Sheet-Metal Edges
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Solution Overview
Problem
Existing methods for producing sharp-edged sheet-metal part edges with small radii in motor vehicle outer skin parts are inefficient due to high energy requirements, difficulty in reproducing consistent edge profiles across adjacent parts, and material thinning issues during deep-drawing processes.
Innovation Solution
A shaping tool with a first and second shaping component that can be moved from an open to a shaping position, featuring a shaping surface with an allowance element that projects beyond the base surface regions, allowing the part to be pressed into a negative mold with a small pressing region, reducing process forces and ensuring precise edge formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional deep-drawing shaping is used to produce sheet-metal part edges, then the basic shaping function is achieved, but the edge radius cannot be sufficiently small and consistent reproduction across adjacent parts is difficult
Solution Approach 1:
The shaping tool is divided into two separate shaping components instead of using a conventional single punch-die system. This segmentation allows each component to be optimized independently for creating consistent small radii edges, with the first component forming the initial shape and the second component refining the edge radius to precise specifications.
Solution Approach 2:
The shaping components feature locally optimized surface geometries with specific radius profiles at the contact regions. The shaping surfaces are designed with precise local curvature characteristics that directly determine the edge radius, allowing consistent reproduction of small radii across multiple parts while maintaining overall shaping efficiency.
2Manufacturing precision
If electromagnetic post-shaping is used to create sharp-edged sheet-metal part edges, then the edge sharpness is improved, but the energy consumption becomes excessively high
Solution Approach 1:
The patent replaces electromagnetic post-shaping processes with a purely mechanical two-component shaping system. The mechanical shaping components directly form the sharp edges through controlled plastic deformation during the main shaping operation, eliminating the need for subsequent high-energy electromagnetic processing while achieving the same edge sharpness.
3Manufacturing precision
If multistage shaping with preshaping and final forming is used, then the edge profile is improved, but the production time increases significantly
Solution Approach 1:
The patent merges the preshaping and final forming operations into a single integrated shaping action using two shaping components that work simultaneously. The first shaping component creates the initial edge geometry while the second component forms the final precise edge radius in one coordinated operation, eliminating the sequential time-consuming steps of separate preshaping and finishing operations.
4Ease of manufacture
If conventional shaping with large contact area between part and tools is used, then the basic forming is achieved, but material thinning increases and tool wear accelerates
Solution Approach 1:
The shaping components are designed with localized contact regions that concentrate the forming action only where edge shaping is required. The contact area is minimized to the specific region needed for edge formation, preventing excessive material thinning in other areas of the part and reducing overall tool wear by limiting the area subjected to high contact pressures.
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 enables efficient and reproducible creation of sharp edges with small radii, reducing wear on the shaping tool, extending its service life, and ensuring consistent edge profiles across multiple parts, while minimizing energy consumption and material thinning.
Implementation Method 1
the part, which can be supported on both shaping components during the movement in the pressing region, is pressed into a negative mold, which is formed in the second shaping component, of the edge to be produced
Data Source
AI summary
A shaping tool and a method are provided for producing an edge on a part. A first and a second shaping component are moveable from an open position into a shaping position, as a result of which, in a pressing region of the shaping tool, the part, which can be supported on both shaping components while it is moved in the pressing region, can be pressed into a negative mold, formed in the second shaping component, for the edge that is to be produced. A shaping surface of the first shaping component in the pressing region has an allowance element which projects over base surface regions of the shaping surface adjacent to the allowance element, as a result of which the part can be distanced from the second shaping component at least in the shaping position in a sub-region adjacent to the pressing region.