Shearing Method Using Recycled Punch and Die for High-Strength Materials
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Solution Overview
Problem
Existing shearing methods face challenges in achieving excellent surface perpendicularity and surface properties of sheared edges while minimizing tool wear and damage, particularly when processing high-strength materials.
Innovation Solution
The method involves reutilizing punched out materials as punches and worked materials as dies in subsequent shearing steps, reducing the clearance between the punch and die to enhance surface quality and productivity, and incorporating mechanisms like electromagnets or suction parts for precise positioning and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional shearing methods with clearance between punch and die are used, then tool wear and damage occur when processing high-strength materials, but surface perpendicularity and surface properties of sheared edges deteriorate
Solution Approach 1:
The invention changes the clearance parameter from a fixed value to a dynamically adjustable parameter. By controlling the clearance between punch and die to be within a specific range (0.01-0.05mm) or even making it negative (interference fit), the method optimizes both tool durability and surface quality for high-strength materials
Solution Approach 2:
The invention introduces dynamic control of the clearance parameter during the shearing process. The clearance is not fixed but can be adjusted based on material properties, tool wear, and processing requirements, allowing optimization of both tool life and surface quality throughout the process
2Reliability
If punching and shearing are performed as separate processes, then tool wear is reduced, but productivity decreases due to multiple steps
Solution Approach 1:
The invention merges punching and shearing operations into a single integrated process. By designing the punch and die with specific geometric relationships and controlling the clearance, both punching and shearing functions are achieved in one operation, improving productivity while managing tool wear through optimized parameter control
3Manufacturing precision
If multiple shearing steps are used to improve surface quality, then surface perpendicularity and surface properties improve, but productivity decreases and manufacturing costs increase
Solution Approach 1:
The invention performs preliminary optimization of the shearing parameters (clearance control, punch and die geometry design) before the actual shearing process. By pre-setting the clearance within optimal ranges and designing appropriate tool geometries, excellent surface quality is achieved in a single pass, eliminating the need for multiple corrective steps
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 results in sheared edges with improved surface perpendicularity, fatigue strength, and hydrogen embrittlement resistance, while reducing tool wear and damage, and enabling efficient processing of high-strength materials with enhanced productivity.
Implementation Method 1
incorporating mechanisms like electromagnets or suction parts for precise positioning and retention
Implementation Method 2
incorporating mechanisms like electromagnets or suction parts for precise positioning and retention
Data Source
AI summary
Provided is a shearing method which can produce a worked material having a sheared edge excellent in surface perpendicularity and surface properties with a good productivity while suppressing tool wear and damage. The method comprises a first shearing step of placing a first blank having first and second surfaces on a first die so that said second surface is arranged on said first die side, and shearing said first blank from said first surface toward said second surface in a sheet thickness direction of said first blank by a first punch arranged at said first surface side to obtain a first punched out material and first worked material; and a second shearing step of placing a second blank and (x) using said first punched out material as a second punch, (y) using said first worked material as a second die, or both thereof.