Spacer Member Controls Panel Punch for Shell Depth
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Solution Overview
Problem
In shell manufacturing, the thermal expansion of tooling assemblies causes variations in shell unit depth, leading to impractical adjustments in press ram settings, affecting production efficiency and shell dimensions, which can result in reduced material in the curl and adverse seaming effects.
Innovation Solution
A tooling assembly with a die center and panel punch, where a spacer member is used to control the movement of the panel punch and prevent engagement with the die core ring, maintaining consistent shell depth across strokes and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the press ram is adjusted to compensate for thermal expansion, then shell unit depth can be maintained at specification, but production efficiency is reduced due to frequent adjustments
Solution Approach 1:
The press shutheight is preliminarily adjusted to provide shell unit depth at the low limit of specification before thermal expansion occurs. This preliminary setting anticipates the thermal growth and pre-compensates for it, eliminating the need for mid-production adjustments.
Solution Approach 2:
The press shutheight parameter is changed to account for thermal expansion effects. By adjusting this parameter to a specific value that compensates for expected thermal growth, the system maintains shell dimensions within specification without requiring operational interventions.
2Manufacturing precision
If the press shutheight is adjusted to account for thermal expansion, then shell unit depth remains within specification, but other processes such as conveying and bagging are negatively affected
Solution Approach 1:
Instead of adjusting press ram position, the press shutheight parameter is modified. This parameter change maintains shell unit depth within specification while avoiding the operational complications that would arise from ram position adjustments, thereby preserving ease of manufacture for downstream processes.
3Weight of moving object
If reduced gauge metal sheet is used to reduce metal content, then shell weight is reduced, but shell dimensions must be precisely centered within specifications to prevent rupture
Solution Approach 1:
The tooling assembly self-adjusts to maintain consistent shell unit depth through the spacer member mechanism. The spacer member automatically compensates for thermal expansion effects, allowing the system to self-regulate and produce shells with precise dimensions centered within specifications, which is critical when using reduced gauge metal.
4Device complexity
If the die core ring is allowed to expand freely with thermal growth, then tooling assembly is simple, but shell unit depth becomes deeper than specification
Solution Approach 1:
The spacer member acts as an intermediary element between the die core ring and panel punch. It mediates the thermal expansion of the die core ring by providing a fixed reference distance, thereby preventing excessive shell unit depth while maintaining relatively simple tooling assembly structure.
5Manufacturing precision
If the panel punch engages the die core ring to provide specified shell unit depth, then shell depth control is achieved, but thermal expansion causes the shell unit depth to become too deep
Solution Approach 1:
The spacer member provides a preliminary constraint on the panel punch movement, preventing it from engaging the die core ring beyond the specified penetration distance. This preliminary anti-action counteracts the thermal expansion effect before it can cause excessive shell unit depth.
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 solution ensures shells are manufactured with uniform unit depth, maintaining dimensional stability and improving production efficiency by preventing excessive material thinning and enhancing seaming quality.
Implementation Method 1
the heat in the die set causes the tooling to grow which, in turn, causes the shell unit depth to be too deep
Data Source
AI summary
The invention generally relates to an apparatus for forming a shell. The apparatus has a die center and a panel punch located in opposed relation to the die center. A panel punch piston is coupled to the panel punch. The panel punch piston has an upper end and a spacer member is disposed concentrically around an outside surface of the panel punch piston at or proximate to the upper end of the panel punch piston. The upper end of the spacer member is in contact with a lower end of the panel punch and the spacer member is located proximate to a peripheral surface of the lower end of the panel punch. A method for manufacturing a shell is additionally provided as well.