Sheet Metal Fold Radius Control via Pre-Profiling
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Solution Overview
Problem
Existing methods for producing folds in sheet metal elements are limited by the material thickness, as the outer radius of the fold is determined by the thickness, making it difficult to predetermine the fold radius independently of the sheet metal thickness.
Innovation Solution
A method involving pre-profiling the sheet metal element with a depression and a projection along the desired folding line, followed by bending, allowing for the predetermined outer radius of the fold to be achieved, which reduces the contact pressure required during bending and enables a smaller outer radius than conventional methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional press brake bending is used without pre-profiling, then the bending process is simpler, but the outer radius of the fold is determined by material thickness and cannot be predetermined independently
Solution Approach 1:
The sheet metal element is pre-profiled before bending to create a depression on one side and a projection on the other side along the desired folding line. This preliminary action defines the outer radius of the fold in advance, allowing the projection to serve as a template for the final fold geometry. The pre-profiling step enables precise control of the outer radius independent of material thickness.
2Manufacturing precision
If pre-profiling is performed to create depression and projection, then the outer radius of the fold can be predetermined independently of material thickness, but the device complexity increases
Solution Approach 1:
The sheet metal element is pre-profiled before bending to create a depression on one side and a projection on the other side along the desired folding line. This preliminary action defines the outer radius of the fold in advance, allowing the projection to serve as a template for the final fold geometry. The pre-profiling step enables precise control of the outer radius independent of material thickness.
3Force
If conventional bending is used without pre-profiling, then the manufacturing process is simpler, but higher contact pressure is required to achieve small outer radii
Solution Approach 1:
The sheet metal element is pre-profiled before bending to create a depression on one side and a projection on the other side along the desired folding line. This preliminary action defines the outer radius of the fold in advance, allowing the projection to serve as a template for the final fold geometry. The pre-profiling step enables precise control of the outer radius independent of material thickness.
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 production of folds with a small outer radius, enhancing visual design, facilitating chamfer definition, and allowing for easier assembly of worktop elements by reducing the radius of folds, thus improving the design and assembly process.
Implementation Method 1
The embossing roller is pressed against the sheet metal element with a contact pressure to produce the depression and the opposite projection
Implementation Method 2
bending the sheet metal element at the fold line along which the depression and the projection extend to produce the fold
Data Source
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AI summary
The aim of the invention is to provide a method for producing a fold on a sheet metal element (100) whereby the outer radius (RA) of the fold can be predetermined substantially independently of the material thickness of the sheet metal element (100). For this purpose, the inventive method comprises the following steps: preprofiling the sheet metal element (100) in such a manner as to produce, on a first face (104) of the sheet metal element (100), a recess (106) which extends along a desired fold line, and, on a second face of the sheet metal element, a projection (110) which also extends along the desired fold line and is opposite the recess; and bending the sheet metal element (100) on the fold line along which the recess (106) and the projection (110) extend, thereby producing the fold.