Variable-Clearance Plate Shearing for Better Stretch-Flangeability
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Solution Overview
Problem
Shearing processes inherently cause work-hardening on metal components, leading to reduced stretch-flangeability and potential cracking during subsequent flanging operations, despite existing techniques to mitigate this issue.
Innovation Solution
A shearing method and equipment that apply a shear force with an initial clearance between blades orthogonal to the workpiece's thickness direction, increasing the clearance based on the workpiece's deformation during cutting to distribute work-hardening more evenly and reduce its impact on the end face.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed clearance is used between blades during shearing, then the shearing process is simple and efficient, but work-hardening concentrates on the end face reducing stretch-flangeability
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a fixed clearance system to a dynamic clearance adjustment mechanism. The clearance between the upper and lower blades is no longer constant but changes during the shearing process based on the deformation state of the workpiece. This allows the system to adapt the clearance dynamically to distribute work-hardening more evenly throughout the material volume rather than concentrating it on the end face, thereby improving stretch-flangeability while maintaining process efficiency.
Solution Approach 2:
The patent implements parameter changes by varying the clearance parameter during the shearing process. Initially, a smaller clearance is used to start the shearing action, and then the clearance is increased as the deformation progresses. This parameter change strategy allows better control over the plastic deformation process and work-hardening distribution, enabling improved surface quality and subsequent formability without significantly complicating the overall shearing operation.
2Reliability
If clearance is increased to distribute work-hardening, then stretch-flangeability improves, but the shearing process becomes more complex
Solution Approach 1:
The patent employs feedback control by monitoring the deformation state of the workpiece during shearing and using this information to adjust the clearance between blades. The system incorporates sensors or detection mechanisms that provide real-time feedback on the deformation progress, which then triggers appropriate clearance adjustments. This feedback loop ensures that the clearance is optimized to distribute work-hardening evenly, improving end face quality and reliability while keeping the control system manageable through intelligent automation.
3Manufacturing precision
If multiple shearing machines with different clearances are used, then work-hardening distribution is optimized, but equipment complexity and cost increase
Solution Approach 1:
The patent applies the merging principle by integrating multiple clearance adjustment capabilities into a single shearing machine. Instead of using separate shearing machines each with fixed different clearances, the invention combines the functions of multiple machines into one by equipping a single machine with an adjustable clearance mechanism that can provide different clearance values during different stages of the shearing process. This reduces equipment complexity and cost while achieving the same work-hardening distribution optimization that would otherwise require multiple machines.
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
The method effectively reduces the influence of work-hardening on the end face of cut components, improving stretch-flangeability and processability by dispersing work-hardening across a wider region, thereby enhancing the quality of the sheared surface.
Implementation Method 1
A shearing method for applying a shear force on a plate-shaped workpiece in a thickness direction to cut the workpiece
Implementation Method 2
the component is plastically deformed between the upper blade and the lower blade to be eventually cut
Implementation Method 3
a part affected by work-hardening (work-hardened part) caused by the plastic deformation during the shearing remains on an end face of the component after being cut
Data Source
AI summary
A shearing method of a plate-shaped workpiece for applying a shear force in a thickness direction of the plate-shaped workpiece includes: a step for starting applying the shear force on the workpiece with a clearance between action points in a surface direction orthogonal to the thickness direction of the workpiece; a step for applying the shear force after the start of applying the shear force until a fractured surface is created in the workpiece; and a step for increasing the clearance depending on a deformation of the workpiece in the thickness direction after starting applying the shear force until the fractured surface is created in the workpiece.