Sheared Component Punch with Retracting Surface
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing shearing methods for manufacturing components from high-tension or ultra-high-tension steel struggle with sudden tool cutting edge deficiencies, leading to increased burr formation and reduced productivity, especially when the workpiece's Vicker's hardness exceeds 0.3 times that of the tool.
Innovation Solution
A manufacturing method and device that employ a punch and die with specifically designed cutting edges and retracting surfaces, where the retracting surfaces have curvatures or chamfers within defined ranges to minimize friction and prevent sudden cutting edge deficiencies, and optional surface treatments like hot-dip galvanizing are applied to reduce burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional shearing methods are used on high-tension steel, then processing cost is low, but sudden cutting edge deficiency occurs leading to increased burr formation and reduced productivity
Solution Approach 1:
The patent changes the geometric parameters of the cutting edge by introducing a retracting surface with specific curvature radius (R1) that satisfies 0.01mm ≤ R1 ≤ 0.05mm. This parameter modification allows the cutting edge to gradually retract during shearing, preventing sudden deficiency and reducing burr formation while maintaining cost-effectiveness
Solution Approach 2:
The patent applies curvature to the cutting edge by designing a retracting surface with a specific radius of curvature (R1) between 0.01mm and 0.05mm. This curved geometry enables gradual material separation and prevents sudden cutting edge failure, thereby improving productivity without increasing processing costs
2Duration of action of stationary object
If coating treatment is applied to tool surface, then tool service life is improved by reducing friction, but sudden cutting edge deficiency caused by impact cannot be prevented
Solution Approach 1:
The patent modifies the geometric parameters of the cutting edge by adding a retracting surface with curvature radius R1 (0.01mm ≤ R1 ≤ 0.05mm). This geometric change provides mechanical protection against impact-induced deficiency, complementing coating treatments to enhance both tool service life and cutting edge stability
Solution Approach 2:
The retracting surface acts as a pre-designed protective feature that cushions against impact forces before they can cause sudden cutting edge deficiency. This beforehand cushioning mechanism works in conjunction with coating treatments to prevent reliability failures while maintaining extended tool service life
3Reliability
If cutting edge is rounded or chamfered, then shock absorption is improved, but burr formation in mild steel cannot be prevented
Solution Approach 1:
The patent precisely controls the curvature radius parameter (R1) of the retracting surface within the narrow range of 0.01mm to 0.05mm. This precise parameter control provides sufficient shock absorption for high-tension steel while maintaining sharp enough geometry to prevent excessive burr formation in mild steel applications
Solution Approach 2:
The retracting surface with specific curvature is applied locally at the cutting edge region where shock absorption is needed, while maintaining the overall sharp geometry of the tool. This localized quality modification enables shock absorption without compromising the cutting precision required to minimize burr formation
Data Source
AI summary
In a manufacturing method of sheared components, the shearing including a process of fixing a workpiece to a die, and a process of punching the workpiece by bringing a punch and the die relatively close to each other, is performed a plurality of times, and when a shearing sequence is started, the shearing is performed by using a punch including a first cutting edge having a first tip end surface which opposes the workpiece, and a first retracting surface which retracts from the first tip end surface considering an approaching direction to the die as a standard; and a die including a second cutting edge having a second tip end surface which opposes the workpiece, and a second retracting surface which retracts from the second tip end surface considering an approaching direction to the punch as a standard.