Sequential Sheet Shaping With Reverse-Side Annealing
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Solution Overview
Problem
Existing sequential shaping methods face challenges in ensuring a laser light transmission path for integral rod-form tools, leading to incomplete residual stress removal and reduced productivity due to slow movement speeds, which compromises shape-retention properties of shaped articles.
Innovation Solution
A sequential shaping method and apparatus that heats the metal sheet from the reverse side during shaping, using a rod-form tool and a separate heating device to anneal plastically deformed regions, allowing for efficient residual stress removal and enhanced shape-retention properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rod-form tool and laser irradiator move integrally to heat and shape the metal sheet simultaneously, then the metal sheet can be heated and plastically deformed, but it is difficult to ensure a laser light transmission path and the front side heating causes residual stress removal issues
Solution Approach 1:
Instead of heating the metal sheet from the front side (conventional method), the patent heats from the reverse side. This inversion allows the laser irradiator to be positioned on the opposite side of the rod-form tool, ensuring an unobstructed laser light transmission path while effectively heating the metal sheet for residual stress removal during shaping
Solution Approach 2:
The patent separates the heating function from the shaping function by using independent devices: a rod-form tool for shaping and a separate laser irradiator for heating. This segmentation allows each device to operate optimally without interfering with the other, particularly enabling the laser to transmit light without obstruction while the rod-form tool performs plastic deformation
2Reliability
If the rod-form tool movement speed is reduced to sufficiently carry out heating, then residual stress can be removed, but productivity is greatly reduced
Solution Approach 1:
The laser irradiator performs preliminary heating of the metal sheet before the rod-form tool arrives at the heating zone. This preliminary action ensures that the metal sheet is pre-heated to the appropriate temperature for residual stress removal, allowing the rod-form tool to move at higher speeds without compromising the heating effectiveness
Solution Approach 2:
The laser irradiator continuously heats the metal sheet as the rod-form tool moves along the shaping path. This continuous heating action ensures that the metal sheet maintains the appropriate temperature throughout the shaping process, enabling residual stress removal to occur effectively at higher tool movement speeds without interruption
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
The method effectively removes residual stress and enhances shape-retention properties by heating the metal sheet from the reverse side, ensuring efficient shaping without obstructing the rod-form tool's movement and maintaining article integrity.
Implementation Method 1
the local movement region is heated for a fixed time from a reverse side... portions that are plastically deformed by a rod-form tool are annealed by heating a metal sheet from a reverse-surface side
Implementation Method 2
the metal sheet is heated by being irradiated with laser light at the front side of the rod-form tool
Data Source
AI summary
A sequential shaping method is used to shape a metal sheet into a three-dimensional form by pressing and moving a rod-form tool against the metal sheet. In the method, a path along which the rod-form tool moves on the metal sheet is divided into a plurality of local movement regions based on a preset movement path of the rod-form tool; In the method, an entirety of each of the local movement regions is heated from a reverse side, the metal sheet using the rod-form tool, and after shaping the local movement regions, the local movement regions are heated continuously for a fixed time at a temperature at which the metal sheet can be annealed. Then the metal sheet is shaped while sequentially heating an entirety of a subsequent one of the local movement regions following a preceding local movement region.