Stamping Tool Corrugating and Burr Compression Sequence
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing stamped disks face issues with rollover during fine blanking, leading to inaccurate shape and dimensional defects, and require additional processing stages for burr compression and corrugation, increasing complexity and costs.
Innovation Solution
A tool with a two-stage process where the outer and inner contours of a disk blank are cut in a first step, followed by a corrugating and embossing stage that fixes the contours before burr compression, using an upper and lower die part with embossing surfaces and shoulders to secure the disk blank, allowing for accurate corrugation prior to burr compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If corrugating and burr compression are performed in separate stages, then shape and dimensional accuracy of outer teeth is improved, but device complexity and production costs increase
Solution Approach 1:
The patent combines corrugating and burr compression operations into a single integrated stamping stage. The upper die includes both corrugating elements and embossing elements that compress burrs simultaneously during one stroke, eliminating the need for separate processing stages while maintaining production efficiency
Solution Approach 2:
The patent performs burr compression as a preliminary action during the stamping stage before the workpiece is transferred to the next stage. By compressing burrs early in the process while the workpiece is still in the stamping device, the patent prevents contour distortion that would occur if burrs were compressed after transfer, thereby improving shape and dimensional accuracy
2Productivity
If burr compression is performed before corrugating, then production efficiency is improved, but shape accuracy of outer teeth deteriorates due to contour displacement
Solution Approach 1:
The patent merges burr compression and corrugating operations into the same stamping stage, allowing both operations to occur simultaneously during one stroke. This eliminates the need for sequential processing and prevents contour displacement that would occur during workpiece transfer between stages
Solution Approach 2:
The patent performs burr compression as a preliminary action during the stamping operation itself, before the workpiece is transferred to the corrugating stage. The embossing elements compress burrs while the workpiece is held firmly in position, preventing any contour displacement and ensuring shape accuracy is maintained
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 enhances the shape and dimensional accuracy of the outer teeth of the disks while reducing production costs by separating the corrugating step from burr compression, ensuring precise contour maintenance and reducing reworking complexity.
Implementation Method 1
The burrs on the disk that developed during fine blanking are compressed
Implementation Method 2
The disk blank is provided with a corrugated profile in a second method step by forming on an upper die part and a lower die part
Data Source
AI summary
An upper die part includes an embossing bell, a stripper ring, and an inner shape embossing element. The stripper ring has an embossing surface with a corrugated profile on the embossing surface. A lower die part includes an embossing anvil having a corrugated profile on its embossing surface. The embossing bell and the inner shape embossing element each are provided with an embossing shoulder, which are disposed, with respect to the corrugated profile of the stripper ring, in the stroke direction in such a way that the shoulders can seize the burrs only alter the corrugating step. The corrugating step takes place prior to burr compression. The outer and inner contours of the disk are not able to change positions, but are able to change shapes on the burr side after the corrugating step.