Splitting Non-Circular Metal Plates With Adjustable Punch Clamping
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Solution Overview
Problem
Existing methods for splitting the end parts of metal plates or rods with non-circular or non-disk-like shapes, such as rectangular or elliptical shapes, lack the ability to adjust the length of the split portion freely and produce smooth, even surfaces, limiting their application in manufacturing and bonding processes.
Innovation Solution
A method involving repeated press-splitting using a slitting or cleaving punch, where the clamping device is moved to adjust the position of the metal plate or rod between each splitting operation, allowing for free adjustment of the split length and ensuring smooth surfaces, by employing a tapering cutting edge and progressive transfer techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotating slitting roller or cleaving roller is pressed against a circular metal material to split it, then dimensional accuracy and reliability are improved, but the method cannot be applied to metal plates or rods with non-circular cross-sections (rectangular, elliptical, polygonal shapes)
Solution Approach 1:
The patent divides the splitting process into multiple sequential pressing operations using a punch and die system. Instead of a single rotating roller action, the method segments the splitting into discrete steps where the punch is pressed against the workpiece in a controlled manner, enabling application to various cross-sectional shapes while maintaining precision.
Solution Approach 2:
The patent inverts the conventional approach by instead of rotating the workpiece against a roller, pressing a punch against the workpiece in a controlled linear motion. This inversion of the splitting mechanism allows precise control over the splitting process for non-circular shapes while maintaining dimensional accuracy.
2Ease of manufacture
If conventional welding, fusing, or gluing methods are used to join metal parts, then manufacturing is simpler, but bonding strength and reliability are reduced
Solution Approach 1:
The patent converts the potential harm of complex manufacturing processes into benefit by demonstrating that while the splitting process is more complex than simple welding, it eliminates the inherent weaknesses of bonding methods. The controlled splitting creates superior joints with enhanced reliability and strength, transforming process complexity into product quality advantage.
3Ease of operation
If the clamping device position is fixed during pressing operations, then the operation is simpler, but the length of incision in the split portion cannot be freely adjusted
Solution Approach 1:
The patent introduces dynamic positioning capability to the clamping device, allowing it to be moved to different positions along the workpiece for each pressing operation. This dynamic adjustment enables flexible control over the length of incision while maintaining ease of operation through systematic repositioning rather than complex adjustments.
Solution Approach 2:
The patent utilizes parameter changes by systematically varying the position of the clamping device and the pressing depth in each operation. By changing these parameters in a controlled sequence, the method achieves free adjustment of split length while maintaining operational simplicity through standardized adjustment procedures.
4Productivity
If pressing operations are performed in a single step, then productivity is higher, but the split face is not smooth and even
Solution Approach 1:
The patent employs periodic pressing operations where the punch is pressed and retracted in controlled cycles. This periodic action allows the split face to be progressively formed and smoothed through multiple passes, achieving even surfaces while maintaining productivity through efficient cycle timing and systematic progression.
Solution Approach 2:
The patent applies preliminary pressing operations that create initial splits followed by subsequent refining presses. These preliminary actions prepare the workpiece for final smoothing operations, ensuring both productivity through staged processing and manufacturing precision through progressive refinement of the split face.
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 method enables the efficient splitting of metal parts with non-circular cross-sections, reducing manufacturing costs and improving bonding strength, particularly in three-layer build-ups, while enhancing the reliability and durability of the metal parts produced.
Implementation Method 1
advancing the splitting by pressing the slitting punch or the cleaving punch against a cleft of the split
Implementation Method 2
on both sides in the case of the splitting punch or on one side in the case of the cleaving punch, a cutting edge is given a tapering shape
Data Source
AI summary
Provided are a method for splitting longitudinally an end part of a metal plate or a metal rod having a rectangular, polygonal, or elliptical shape, in which the length of incision in the split portion can be freely adjusted and smooth split face can be formed; a metal part manufactured by such method; and a method for bonding such metal part. The present invention is characterized by the process comprising the steps of securing a metal plate by pinching both sides thereof with a clamping device, or securing a metal rod by pinching at least two opposite-facing portions on the periphery thereof with a clamping device; splitting longitudinally by slitting or cleaving the metal plate, or the metal rod, by pressing a slitting punch or a cleaving punch against the face of one end of the metal plate, or the metal rod; and advancing the splitting further by repeating the same operation of pressing the same punch stated above against the cleft of the splitting; and is characterized further in that, in each time of the press-splitting operation, the position of the clamping device on at least one side is moved in advance of the next pressing by a stroke corresponding to the distance from one end of the metal plate, or the metal rod, to the distal end of a split-desired portion.