Tapered Pilot Assembly for Faster Metal Die Setup
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Solution Overview
Problem
Current metal forming dies are labor-intensive and costly to design, manufacture, and modify due to the custom nature of their components, requiring precise machining and long lead times for setup in a stamping press.
Innovation Solution
A multi-station metal forming die with a pilot assembly featuring a pilot with a cylindrical shoulder portion, tapered transition, and fastener relief, allowing for secure mounting to a die member using a shaped washer and fastener, enabling easier installation and reduced machining complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-designed and handcrafted pilot components are used in metal forming dies, then the precision and reliability of part location is improved, but the manufacturing cost and lead time increase significantly
Solution Approach 1:
The pilot assembly is divided into separate modular components: the pilot body, the fastener, and the washer. This segmentation allows each component to be manufactured independently using standard processes, eliminating the need for complex custom machining while maintaining precise assembly through designed interfaces and tolerances.
Solution Approach 2:
The pilot assembly design incorporates universal features that can be applied across multiple die configurations. The standardized pilot body with consistent dimensions and the generic fastener-washer combination create a universal solution that can be used in various metal forming applications, reducing the need for custom-designed pilots for each specific die.
2Manufacturing precision
If custom-designed and handcrafted pilot components are used in metal forming dies, then the precision and reliability of part location is improved, but the manufacturing cost increases
Solution Approach 1:
The pilot assembly is divided into separate modular components: the pilot body, the fastener, and the washer. This segmentation allows each component to be manufactured independently using standard processes, eliminating the need for complex custom machining while maintaining precise assembly through designed interfaces and tolerances.
Solution Approach 2:
The pilot assembly uses simple, easily manufactured components that can be produced at low cost. The pilot body is a basic cylindrical form, and the fastener and washer are standard hardware items, all of which can be manufactured economically and replaced if needed without significant expense.
3Manufacturing precision
If precisely machined holes and recesses are required in the die set for mounting components, then the mounting precision is improved, but the labor intensity and complexity increase
Solution Approach 1:
The pilot assembly is divided into separate modular components: the pilot body, the fastener, and the washer. This segmentation allows each component to be manufactured independently using standard processes, eliminating the need for complex custom machining while maintaining precise assembly through designed interfaces and tolerances.
Solution Approach 2:
The pilot body includes pre-formed features such as the cylindrical shape, shoulders, and counterbore that are created during standard manufacturing processes. These preliminary actions prepare the component for easy installation with minimal additional machining required in the die set, reducing both complexity and labor intensity.
Data Source
AI summary
A pilot assembly having a shaped portion and a shaped fastener relief for attachment to a die. The pilot assembly includes a fastener with a shaped washer that engages the shaped fastener relief to permit installation and removal of the pilot from the die. The shaped portion of the pilot assembly helps to locate and center the stock down the pilot assembly toward the die.