Universal Radius Forming System Using Urethane Pads
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Solution Overview
Problem
Conventional radius bending systems for sheet metal forming require expensive and time-consuming machining of matching steel punches and dies for each radius size, and existing urethane pad systems are prone to cracking and have limited size range and height compatibility with press brakes.
Innovation Solution
A universal radius forming system using a pair of cooperating urethane pads, where a larger bottom pad fits within a bottom die retainer and a heavier durometer top pad sits on it, with optional reinforcement rods, allowing for flexible deflection and increased forming pressure to bend various radii and thicknesses of metals without re-machining, and featuring a pressure pad for wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional steel punches and dies are used for each radius size, then manufacturing precision is improved, but device complexity and cost increase due to requiring multiple specialized tools
Solution Approach 1:
The patent applies universality by designing a single bottom die with a V-shaped groove that can accommodate multiple punches of different radii. Instead of requiring a dedicated die for each radius size, the V-groove geometry allows different punches to be used with the same bottom die, reducing the total number of tools needed while maintaining precision for various bend radii.
Solution Approach 2:
The patent segments the forming system into interchangeable components: a standardized bottom die and multiple removable punches with different radii. This segmentation allows the system to handle multiple radius sizes without requiring complete tool sets, as each punch can be independently selected and replaced based on the specific bending requirement.
2Manufacturing precision
If steel punches and dies are re-machined to account for spring back, then manufacturing precision is improved, but loss of time and productivity decrease
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-configuring the V-groove geometry in the bottom die to compensate for spring back. The die geometry is designed in advance with specific angles and dimensions that account for the expected elastic recovery of the material, allowing the final bend radius to be achieved without requiring re-machining after testing.
Solution Approach 2:
The patent changes the geometric parameters of the bottom die V-groove to compensate for spring back effects. By adjusting the groove angle, depth, and shape parameters, the system achieves the desired final bend radius after elastic recovery, eliminating the need for time-consuming re-machining operations.
3Ease of manufacture
If urethane pads are used for radius forming, then ease of manufacture and adaptability are improved, but reliability decreases due to cracking and limited size range
Solution Approach 1:
The patent applies composite materials by combining urethane pads with a supportive framework or reinforcement structure. This composite construction maintains the ease of manufacture and adaptability of urethane while adding structural integrity to prevent cracking and extend the usable size range, thereby improving overall reliability.
Solution Approach 2:
The patent applies local quality by reinforcing specific areas of the urethane pad where stress concentrations occur. Instead of making the entire pad uniformly thick or rigid, localized reinforcement is applied to critical regions to prevent cracking while maintaining the flexible, adaptable nature of the urethane material in other areas.
4Adaptability or versatility
If existing urethane pad systems are used, then adaptability is improved, but device complexity increases due to height constraints and setup requirements
Solution Approach 1:
The patent applies dynamics by designing the urethane pad system with adjustable and movable components. The pad thickness, position, and configuration can be dynamically adjusted to accommodate different radius sizes and press brake height constraints, reducing setup complexity while maintaining versatility across a wide range of forming applications.
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
Enables efficient bending of multiple radii and thicknesses with the same bottom die, reducing the need for re-machining and minimizing material damage, while providing wear resistance and compatibility with standard press brake heights, thus lowering costs and improving process efficiency.
Implementation Method 1
a bottom die comprising a urethane pad having a top surface, a bottom surface, and a deflection space between the top surface and the bottom surface
Implementation Method 2
The pads are coupled to one another on one of the sides of the bottom pad
Data Source
AI summary
A universal radius metal forming system wherein a bottom die elastomer is used on a sheet metal bending machine or press brake. The bottom die includes a forming pad used in combination with a wear pad to form virtually any radius in any type of metal. The forming pad includes a bottom cavity that is sized according to the volumetric relationship with the press punch. The wear pad is designed and coupled to the forming pad according to the gauge and shape of the metal being bent.