High-Speed Shear Cutting Tool Wear Reduction via Segmented Ejection
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Solution Overview
Problem
High-speed shear cutting methods (HGSS) face significant wear due to adhesion and abrasion issues when creating passages, leading to a shorter service life of tools, as the fracture line scatters and causes high adhesive forces between the punch and passage wall, limiting the efficiency and longevity of the cutting process.
Innovation Solution
The method separates the generation of passages and ejection of slugs by using a stamp with dimensions matching the passage for initial fracture and then employing an ejector with smaller dimensions to remove the slug, avoiding contact with the passage wall and reducing wear, allowing simultaneous or independent operation with the punch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stamp with dimensions matching the passage is used for high-speed shear cutting to create passages, then the passage generation is efficient and fast, but the adhesive forces between the punch and passage wall cause high wear and short tool service life
Solution Approach 1:
The process is divided into two separate steps: first the stamp creates the passage through high-speed shear cutting, then the ejector removes the slug. This segmentation allows the stamp to focus on cutting efficiency while the ejector handles slug removal without contacting the passage wall, thus resolving the contradiction between productivity and tool service life.
Solution Approach 2:
An ejector is introduced as an intermediary tool to perform the slug ejection function. The ejector with smaller dimensions can pass through the created passage and push out the slug without the lateral contact that causes wear on the main stamp, thereby protecting the stamp while maintaining process efficiency.
2Ease of operation
If the stamp continues its full lifting movement after fracture completion, then the slug is completely ejected, but the prolonged contact between the punch and passage wall accelerates wear due to adhesion
Solution Approach 1:
The lifting movement is segmented into two phases: the stamp performs the initial fracture and partial slug ejection, then retracts while the ejector completes the slug removal. This segmentation eliminates the need for prolonged stamp-passage wall contact, reducing wear while ensuring complete slug ejection.
Solution Approach 2:
The ejector is designed to work independently after the stamp creates the passage. The ejector's smaller dimensions allow it to navigate through the passage and perform slug ejection without lateral contact, making the system self-sufficient in slug removal without requiring the main stamp to maintain contact.
3Reliability
If an ejector with smaller dimensions than the stamp is used to push out the slug, then wear on the stamp is reduced, but the device complexity increases
Solution Approach 1:
The ejector is designed with multi-functionality: it serves as both the slug ejection tool and can be integrated into the existing tool structure. By making the ejector a universal component that can be incorporated into the stamp assembly, the increase in device complexity is minimized while achieving the goal of reduced stamp wear.
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 approach significantly increases the service life of tools by minimizing wear and enabling efficient creation of passages with reduced power requirements and faster processing times, applicable to both flat and curved surfaces, including sliding blocks.
Implementation Method 1
The fracture line or fracture surface resulting from the HGSS by exploiting the adiabatic material condition
Implementation Method 2
with the force being applied to an active part via the ram
Implementation Method 3
the slug still in the passage is driven out of the passage by means of an ejector
Data Source
Figure 1~4
Figure 5
Figure 6~9
AI summary
The invention relates to a method for creating through-passages in a metal body by means of high-speed impact cutting (HSIC) with a closed cutting line, characterized in that a punch (11) having a first dimension (D) corresponding to the through-passages is introduced down to an insertion depth at which the break passes through the entire metal body in the direction of action of the punch (11), forming a slug (13), and then the stroke movement is stopped and the punch (11) is withdrawn again, and in that in a subsequent step the slug (13), which is still located in the through-passage, is driven out of the through-passage by means of an ejector, which has a smaller second dimension than the punch (11).