Shear Beveling with Serrations in Single Die Operation
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Solution Overview
Problem
Conventional manufacturing methods require separate steps for creating a beveled edge and serrations, increasing cost and time.
Innovation Solution
A die set with a first and second die piece, where the first die piece moves relative to the second, shearing and serrating the part in a single operation to form both the beveled edge and serrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate beveling and serrating steps are used, then manufacturing precision is improved, but productivity is reduced
Solution Approach 1:
The patent combines the beveling and serrating operations into a single die set that performs both functions simultaneously. The first die piece creates the beveled edge while the second die piece with projections forms the serrations in one continuous motion, eliminating the need for separate manufacturing steps and thereby improving productivity without sacrificing precision
Solution Approach 2:
The die set is designed as a multi-functional tool where the first die piece performs beveling and the second die piece performs serrating. This universal tool replaces what would traditionally require multiple specialized tools or sequential operations, achieving both bevel and serration formation in a single operation
2Manufacturing precision
If separate beveling and serrating steps are used, then manufacturing precision is improved, but device complexity is reduced
Solution Approach 1:
While the die set does combine multiple functions, the merging is achieved through a relatively simple configuration: a first die piece for beveling and a second die piece with projections for serrating. This integrated approach actually reduces overall system complexity by eliminating the need for multiple separate tools, setups, and handling steps that would be required in conventional separate 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
Enables the simultaneous creation of a high-quality beveled edge with serrations in a single operation, reducing manufacturing time and cost while minimizing cracking and burr formation.
Implementation Method 1
moving the first die piece relative to the second die piece. The movement results in both shearing a portion of the part to create the beveled edge
Implementation Method 2
serrating the beveled edge to create the serration
Data Source
Figure 1~2
Figure 3~4a
Figure 4b~4c
AI summary
A method of manufacturing a part having a beveled edge with a serration formed in the beveled edge. The method includes positioning a part (200) between a first die piece (14) and a second die piece (22); and moving the first die piece (14) relative to the second die piece (22). The movement results in both shearing a portion of the part (200) to create the beveled edge, and serrating the beveled edge to create the serration.