Variable Blade Clearance Shearing for Low Work-Hardened Edges
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Solution Overview
Problem
Existing shearing methods result in work-hardening on the end face of components, which can lead to cracking during subsequent flanging operations, despite techniques to improve stretch-flangeability.
Innovation Solution
A shearing method that applies a shear force with an initial clearance between blades orthogonal to the workpiece thickness, gradually increasing the clearance as the shear force is applied, using a movable upper blade and a lower blade with a clearance adjuster to control the distance between them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed clearance is used between upper and lower blades during shearing, then the shearing process is simple and fast, but work-hardening occurs on the end face of the component
Solution Approach 1:
The patent applies a dynamic clearance adjustment mechanism where the clearance between upper and lower blades is continuously varied during the shearing process. The clearance is smallest at the initial stage to minimize work-hardening, and gradually increases as the shearing progresses. This dynamic adjustment resolves the contradiction by enabling both high productivity (through optimized clearance variation) and reduced work-hardening (through initially small clearance).
Solution Approach 2:
The patent changes the clearance parameter during the shearing process rather than maintaining a fixed value. The clearance is controlled to vary according to the deformation state of the workpiece, with specific clearance values corresponding to different stages of shearing. This parameter change strategy allows the system to achieve both high productivity and reduced work-hardening by optimizing clearance at each stage.
2Object-affected harmful factors
If clearance is increased to reduce work-hardening, then stretch-flangeability improves, but the shearing process becomes more complex
Solution Approach 1:
The patent employs a self-service mechanism where the clearance adjustment is automatically coupled to the shearing process itself. The clearance varies in response to the deformation state of the workpiece during shearing, eliminating the need for separate complex control systems. This self-adjusting mechanism reduces device complexity while achieving the goal of minimizing work-hardening influence.
Solution Approach 2:
The dynamic clearance adjustment is integrated into the shearing mechanism itself, where the clearance naturally varies during the shearing stroke. This dynamic integration avoids adding separate complex control systems, thereby improving stretch-flangeability through reduced work-hardening while keeping the device complexity manageable.
3Device complexity
If a single shearing machine with fixed clearance is used, then the equipment is simple, but the end face properties of the component are poor
Solution Approach 1:
The patent transforms a static fixed-clearance shearing machine into a dynamic system where the clearance automatically varies during operation. This single machine with dynamic clearance control achieves end face quality comparable to or better than multiple fixed-clearance machines, thereby improving manufacturing precision without significantly increasing equipment complexity.
Solution Approach 2:
The patent implements parameter changes (clearance variation) within a single shearing machine to achieve high end face quality. By controlling the clearance to vary during the shearing process, the machine produces components with excellent end face properties, avoiding the need for complex multi-machine setups while maintaining simplicity.
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
Reduces the influence of work-hardening on the end face of the sheared component, improving properties like stretch-flangeability and hole expandability.
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.