Two-Stage Multi-Layer Blanking for Complex Motor Laminations
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Solution Overview
Problem
The existing multi-layer blanking process is limited in terms of complexity of metal parts that can be manufactured and is inefficient due to the need to remove scrap material and metal parts sequentially, which slows down the production speed.
Innovation Solution
The process is divided into two stages: the first stage cuts holes in the layered basic material without a counter punch, allowing scrap to be discarded through the blanking die, and the second stage cuts the metal parts using a counter punch, enabling easier removal of both scrap and metal parts after opening the blanking device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a counter punch is applied in multi-layer blanking to ensure surface quality and shape accuracy, then manufacturing precision is improved, but device complexity and operation complexity increase due to the need to remove both scrap and metal parts sequentially
Solution Approach 1:
The blanking process is divided into two separate stages: a first blanking stage without a counter punch for simple parts, and a second blanking stage with a counter punch for complex parts requiring high precision. This segmentation allows each stage to be optimized independently, reducing overall device complexity while maintaining manufacturing precision when needed.
Solution Approach 2:
The first blanking stage performs preliminary cutting of simple contours and holes without a counter punch, removing scrap material through the blanking die. This preliminary action simplifies the subsequent second stage, where only the final precision cutting with counter punch is needed, reducing the complexity of the complete blanking device.
2Manufacturing precision
If scrap material is held between blanking die and blank holder after blanking stroke, then manufacturing precision is maintained, but productivity decreases due to sequential removal of scrap and metal parts
Solution Approach 1:
The scrap material is extracted and removed through the blanking die cavity during the first blanking stage, before the metal parts need to be removed. This extraction of scrap material during the punching action itself, rather than holding it for subsequent removal, eliminates the sequential removal step and maintains high productivity.
Solution Approach 2:
The removal of scrap material is performed as a preliminary action during the first blanking stage, before the second blanking stage processes the metal parts. This preliminary removal of scrap eliminates the need for sequential removal operations, maintaining both manufacturing precision and productivity.
3Manufacturing precision
If minimum separation is required between two cutting lines to ensure adequate strength and rigidity of blanking die, then manufacturing precision is maintained, but adaptability decreases for complex metal part designs
Solution Approach 1:
The blanking process is segmented into two stages with different capabilities: the first stage handles simple cutting operations with greater design freedom, while the second stage handles precision operations. This segmentation allows complex metal parts to be manufactured without being constrained by minimum separation requirements between cutting lines, as the first stage can create initial features that the second stage then refines with precision.
Solution Approach 2:
The blanking device operates dynamically by switching between two modes: a first mode without counter punch for operations requiring close cutting lines, and a second mode with counter punch for precision operations. This dynamic operation allows the system to adapt to complex part designs that would be impossible with a single fixed mode, maintaining shape accuracy while increasing versatility.
Data Source
Figure 1A~1F
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Figure 6~8
AI summary
The present disclosure concerns a process for the blanking of metal parts (1 ) from a - layered basic material (51 ) composed of a number of mutually stacked individual layers (50) placed and clamped between a blanking die (80) and a blank holder (70) of a blanking device (100), wherein a blanking punch (31; 32) of the blanking device (100) is moved relative to the blanking die (80) to cut and separate the metal parts (1) from the basic material (51). According to the present disclosure, such multi-layer blanking process is carried out in two successive stages (I, II), whereof a first stage (I) entails the punching of holes (3) by a first blanking punch (31) without applying a counter punch and whereof a second stage (II) entails the blanking of the metal parts (1) by a second blanking punch (32) while being supported by a counter punch (40).