Sheet Blank Forming at Solution Heat Temperature for Tight Radii

Solution Overview

Problem

Existing forming processes face long cycle times, non-optimal forming temperatures, and springback issues, which hinder the production of high-strength alloys with precise wall thickness and small radii, making them inefficient and costly.

Innovation Solution

The method involves forming metal blanks at the solution heat treatment temperature, using a blankholder to control material flow into the cavity, and combining temperature and roughness profiles to achieve precise wall thickness, along with gas or mechanical forming under controlled pressure to minimize cycle time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the workpiece is cooled down to forming temperature before forming, then the material strength is improved, but the cycle time increases and springback occurs

Engineering Contradiction:

Improvematerial strengthVSAvoidcycle time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The workpiece is heated to the solution heat treatment temperature range and held there during the forming process, preparing the material in advance to maintain optimal forming temperature throughout forming, eliminating the need for subsequent heating and reducing cycle time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The forming process is performed continuously at the solution heat treatment temperature range without interrupting the thermal state, maintaining material ductility throughout the entire forming operation and eliminating cooling time

Inventive Principle:

Principle #20Continuity of useful action

2Strength

If the workpiece is cooled down to forming temperature before forming, then the material strength is improved, but springback effect occurs impairing tolerance keeping

Engineering Contradiction:

Improvematerial strengthVSAvoidtolerance keeping

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The workpiece is heated to the solution heat treatment temperature range and held there during the forming process, preparing the material in advance to maintain optimal forming temperature throughout forming, eliminating the need for subsequent heating and reducing cycle time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The forming temperature is changed from conventional cold or warm forming temperatures to the solution heat treatment temperature range, fundamentally altering the material's mechanical properties to eliminate springback while maintaining strength

Inventive Principle:

Principle #35Parameter changes

3Speed

If fast cooling is applied during forming, then the forming speed is improved, but the degree of forming is limited and tight radii cannot be reproduced

Engineering Contradiction:

Improveforming speedVSAvoiddegree of forming

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The workpiece is heated to the solution heat treatment temperature range and held there during the forming process, preparing the material in advance to maintain optimal forming temperature throughout forming, eliminating the need for subsequent heating and reducing cycle time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The forming temperature is changed from conventional cold or warm forming temperatures to the solution heat treatment temperature range, fundamentally altering the material's mechanical properties to eliminate springback while maintaining strength

Inventive Principle:

Principle #35Parameter changes

4Temperature

If superplastic forming is used with fixed clamping, then the material can be formed at superplastic temperature, but the wall thickness becomes undefined and random

Engineering Contradiction:

Improvesuperplastic temperatureVSAvoidwall thickness

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The blankholder force is dynamically adjusted during the forming process, transitioning from high clamping force to allow material flow to controlled pressure to define final wall thickness, enabling precise wall thickness control while maintaining superplastic forming benefits

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The blankholder force parameter is changed from constant fixed clamping to dynamically variable pressure, allowing the system to adapt during forming to achieve both superplastic temperature benefits and precise wall thickness definition

Inventive Principle:

Principle #35Parameter changes

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 allows for cycle times of less than a minute, enabling the formation of complex components with high-strength materials and small radii, significantly reducing production time and improving tolerance retention.

Implementation Method 1

forming takes place in the range of the solution heat treatment temperature of the material of the flat metal blank to be formed

Methodology Applied

Scientific EffectSolution heat treatment: Heat Treatment

Implementation Method 2

with material of the flat metal blank being actively pushed into the cavity

Methodology Applied

Scientific EffectGas pressure: Pressure Increase

Data Source

PatentUS20250018453A1Method for forming a sheet blank as a workpiece in a forming tool

Publication Date: 2025.01.16 HODFORMING GMBH

AI summary

A method is provided for forming a flat metal blank as a workpiece in a forming die.