Universal Die Forming for Joggle Configurations

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Solution Overview

Problem

The aircraft industry faces inefficiencies in forming unique joggle configurations for metal parts, requiring numerous custom-made die pairs and multiple hydraulic press systems, which is time-consuming and costly.

Innovation Solution

A die-forming apparatus and method that allows for the formation of joggles in bendable workpieces by securing them to adjacent working areas and displacing one area relative to another, enabling equal angular and linear displacement across multiple sections without the need for unique tooling, using a single set of workpiece dies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional custom-machined die pairs are used for each unique joggle configuration, then manufacturing precision is improved, but device complexity and loss of time increase significantly

Engineering Contradiction:

Improvejoggle configuration precisionVSAvoidnumber of die pairs required

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A single universal die pair with adjustable positioning mechanisms can form multiple unique joggle configurations through programmable displacement control, eliminating the need for custom-machined dies for each configuration while maintaining precision through digital positioning and control systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The die pair incorporates movable and adjustable components that allow dynamic repositioning and reconfiguration for different joggle formations, replacing static custom-machined dies with adaptive tooling that can be repositioned programmatically for each unique configuration

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If custom-machined die pairs are manufactured for each unique joggle configuration, then manufacturing precision is improved, but loss of time increases due to several hours of custom manufacturing per configuration

Engineering Contradiction:

Improvejoggle configuration precisionVSAvoiddie manufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system pre-programs displacement paths and die positions for multiple joggle configurations, allowing rapid switching between configurations without time-consuming custom manufacturing, as the universal die pair is pre-configured with adjustable mechanisms and control software

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If multiple hydraulic die press systems are used to handle different die widths, then adaptability is improved, but device complexity and loss of time increase

Engineering Contradiction:

Improvedie width handling capabilityVSAvoidnumber of die press systems required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single hydraulic die press system incorporates adjustable die platform positioning mechanisms that can accommodate different die widths and configurations, eliminating the need for multiple dedicated press systems through programmable repositioning and adjustable tooling fixtures

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The die press system features movable die platforms with adjustable positions along the workpiece, allowing dynamic reconfiguration for different die widths and joggle locations without requiring multiple fixed press systems

Inventive Principle:

Principle #15Dynamics

4Manufacturing precision

If conventional die forming methods are used, then manufacturing precision is maintained, but productivity decreases due to time-consuming operations

Engineering Contradiction:

Improvejoggle formation precisionVSAvoidjoggle formation speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system pre-programs displacement paths, velocities, and positions for multiple joggle configurations, allowing rapid sequential formation of joggles without time-consuming setup or custom die manufacturing between operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The die platform incorporates programmable motion control that can dynamically adjust displacement velocity and position for each joggle formation, enabling rapid precision forming through automated control rather than manual conventional methods

Inventive Principle:

Principle #15Dynamics

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 significantly reduces time and material costs by allowing a range of joggle configurations to be formed quickly, often in under an hour, compared to conventional methods that take several hours, and eliminates the need for custom-manufactured dies.

Implementation Method 1

displacing the movable die platform relative to the fixed die platform to induce a bend in the workpiece

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS8006530B2Apparatus and methods for material fabrication

Publication Date: 2011.08.30 L3HARRIS TECH INTEGRATED SYST LP

AI summary

Apparatus and methods for fabricating materials by die-forming that may be implemented to form a joggle in a bendable workpiece by securing the workpiece to each of at least two respective adjacent working areas, and then by displacing at least one of the at least two working areas relative to an adjacent working area in order to induce the joggle within the workpiece.