Progressive Stamping Pilot Hole Positioning Under Plastic Flow
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Solution Overview
Problem
In progressive stamping methods, pilot holes formed in the strip material are often displaced due to plastic flow, leading to positioning issues during subsequent stamping operations. This results in wasted material, increased production costs, and larger die sizes.
Innovation Solution
The method involves determining the displacement of pilot holes caused by stamping and adjusting the shape or position of pilot pins to ensure they remain in contact with the inner edge of the pilot holes, even after displacement. This is achieved by shaping the pilot holes and adjusting the pilot pin positions based on pre-stamping displacement tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pilot holes are formed in predetermined sites of the strip material other than processing sites, then positioning of the strip material can be achieved, but the areas to form pilot holes must be ensured and material is wasted without being processed into final product
Solution Approach 1:
The invention merges the pilot hole formation with the actual processing operations. The same punch that forms the pilot hole is used to form the final product features, eliminating the need for separate pilot hole formation and preventing material waste at pilot hole locations.
Solution Approach 2:
The punch serves multiple functions: it first forms the pilot hole for positioning, then continues to form the final product features. This multi-functionality eliminates the need for dedicated pilot hole punches and reduces material waste.
2Manufacturing precision
If a great number of pilot holes and large areas are required for forming pilot holes, then positioning can be maintained, but production yield decreases and manufacturing costs increase
Solution Approach 1:
By combining pilot hole formation with product feature formation, the invention eliminates unnecessary material removal and increases the proportion of material that becomes final product, thereby improving production yield.
3Manufacturing precision
If punches are formed on the die at each step to form pilot holes, then positioning can be achieved, but the size of the die increases
Solution Approach 1:
The same punch is used for both positioning (pilot hole formation) and product feature formation, eliminating the need for additional dedicated pilot hole punches and reducing die size and complexity.
4Manufacturing precision
If punches to form pilot holes are added to the die, then positioning can be maintained, but load caused by these punches increases energy loss
Solution Approach 1:
The invention combines pilot hole formation with product feature formation in a single punching operation, eliminating redundant punching actions and reducing energy consumption.
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 allows for accurate positioning of the strip material throughout the stamping process using only the initial pilot hole, reducing material waste, lowering production costs, and minimizing die size and energy loss.
Implementation Method 1
the position of the pilot hole may be displaced with respect to the pilot pin due to plastic flow in materials composing the strip material
Data Source
AI summary
A manufacturing method of a plate member, in which a strip material can be positioned with respect to a die all through stamping operations using a pilot hole formed in an initial phase of the stamping operations. The plate member is manufactured by a press machine in which a progressive stamping die having a plurality of stations is placed. The manufacturing method comprises: forming an oval pilot hole 14 in an uncoiled strip 13; and stamping the uncoiled strip 13 by a plurality of operations while bringing a pilot pin 17 into contact with an inner edge of the pilot hole 14 at the operation before the pilot hole 14 is displaced, and at the operation after the pilot hole 14 is displaced.