Sheet Metal Sizing via Time-Staggered Calibration
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Solution Overview
Problem
Existing methods for producing sheet metal components, especially large or heavily stepped parts with high strength and thick walls, face challenges such as high press force requirements, tool life reduction, and optical defects like ripples due to upsetting processes, which limit dimensional accuracy and rigidity.
Innovation Solution
The method involves calibrating different areas of the preformed component at different times using a tool with partially relieved tool parts, allowing for partial or complete overlap in calibration steps, and introducing excess material to create locally thickened areas for stiffening without the need for additional shaping steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the preformed component is compressed in certain sections during calibration, then dimensional accuracy and rigidity are improved, but press force requirements increase
Solution Approach 1:
The calibration process is divided into multiple sequential steps where different areas of the preformed component are calibrated at different times. The tool has multiple tool parts that can be partially relieved of pressure, allowing the component to be compressed in certain sections while other sections remain unsupported. This segmentation of the calibration process enables high dimensional accuracy in specific critical areas without requiring excessive overall press force.
Solution Approach 2:
The tool parts are configured to be dynamically adjustable with partial relief of pressure capabilities. This allows the compression force to be applied selectively to different areas of the component during different calibration steps, rather than applying uniform force across the entire component. The dynamic adjustment of tool part pressure enables precise control over where and how much compression is applied.
2Strength
If excess material is introduced into the preformed component, then locally thickened areas for stiffening are created, but material waste increases
Solution Approach 1:
Excess material is introduced selectively into specific areas of the preformed component where local thickening is desired for stiffening and reinforcement. Rather than adding material uniformly across the entire component, the excess material is placed only in critical areas that require enhanced rigidity. This localized approach achieves the necessary structural strength while minimizing overall material waste.
Solution Approach 2:
The excess material is introduced during the preforming stage before the calibration process begins. This preliminary introduction of excess material allows it to be subsequently compressed and formed into the final thickened areas during calibration, rather than requiring additional material addition steps later. The excess material is strategically positioned in advance to become the locally thickened areas needed for stiffening.
3Force
If different areas are calibrated at different times, then press force requirements are reduced, but production time increases
Solution Approach 1:
The calibration process is segmented into multiple steps with different tool parts calibrating different areas of the component at different times. This segmentation allows the press force to be applied sequentially to different sections rather than simultaneously to the entire component, reducing the peak force requirements. The tool parts are designed to be partially relieved of pressure between calibration steps, enabling this sequential approach.
Solution Approach 2:
The calibration of different areas is performed in a periodic sequence rather than all at once. The tool parts are periodically applied to different sections of the component, with periods of partial pressure relief between applications. This periodic calibration action reduces the instantaneous force requirements while systematically working through all areas that need calibration.
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 enables the production of components with high dimensional accuracy and rigidity while reducing press force requirements and avoiding complex tooling and trimming, expanding the range of manufacturable components and minimizing scrap and costs.
Implementation Method 1
the preformed component is compressed at least in certain sections
Data Source
Figure 1a~1c
Figure 2~3
AI summary
The invention relates to methods and tools for producing sheet metal components. The method comprises: preforming a workpiece into a preformed component (2, 3), wherein, at least in some regions, excess material (4) is introduced into the preformed component (2, 3); and sizing the preformed component (2, 3) to an at least partially finished component (2', 3') using the excess material (4), wherein the preformed component (2, 3) is upset at least in sections. According to one aspect of the invention, the object of achieving components with high dimensional accuracy, stiffness and/or hardness with little complexity in terms of process engineering is achieved by sizing different regions (2a, 2b, 2c) of the preformed component (2, 3) in a time-staggered manner, or by creating one or more locally thickened regions (5) during sizing.