WO2009038998A2 - Technologie de l'usinage à étages - Google Patents

Technologie de l'usinage à étages Download PDF

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Publication number
WO2009038998A2
WO2009038998A2 PCT/US2008/075692 US2008075692W WO2009038998A2 WO 2009038998 A2 WO2009038998 A2 WO 2009038998A2 US 2008075692 W US2008075692 W US 2008075692W WO 2009038998 A2 WO2009038998 A2 WO 2009038998A2
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WO
WIPO (PCT)
Prior art keywords
die
tool
locating
bend
bearing
Prior art date
Application number
PCT/US2008/075692
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English (en)
Other versions
WO2009038998A3 (fr
Inventor
Bryan L. Rogers
Thomas S. Duppong
Mike J. Mcnertney
William J. Klein
Original Assignee
Wilson Tool International Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wilson Tool International Inc. filed Critical Wilson Tool International Inc.
Publication of WO2009038998A2 publication Critical patent/WO2009038998A2/fr
Publication of WO2009038998A3 publication Critical patent/WO2009038998A3/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/02—Bending sheet metal along straight lines, e.g. to form simple curves on press brakes without making use of clamping means
    • B21D5/0209—Tools therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/02—Die constructions enabling assembly of the die parts in different ways

Definitions

  • the present invention relates generally to tooling for industrial presses. Specifically, this invention relates to tooling for press brakes, methods of fabricating sheet metal and other workpieces, and tooling setups for press brakes.
  • Press brakes are particularly useful. Press brake tooling can play a significant role in minimizing setup, reducing WIP, increasing throughput, and minimizing waste — the goals of lean manufacturing.
  • Press brake tools In the area of press brake tooling, a closer look reveals room for improvement. Press brake tools, in fact, can play a very significant role in minimizing setup time, reducing work-in-progress (WIP), increasing throughput, and minimizing waste.
  • WIP work-in-progress
  • staged press brake tooling that can make small runs cost-effective, e.g., by simplifying complex bending sequences and allowing each part to be handled only once.
  • Staged bending is the execution of multiple bends in a single press brake setup. In staged bending, all the bends on a single part can be made in succession, using a single setup.
  • staged, quick-change tooling It would be desirable to provide staged, quick-change tooling. Further, it would be desirable to provide staged European-style press brake tooling, preferably based on common theoretical sharp dimensions, being quick-change tooling, or both. Finally, it would be desirable to provide a staged, quick-change die with a plurality of different forming recesses.
  • Figure 1 is a perspective view of a press brake setup in accordance with certain embodiments of the invention.
  • Figure 2 is a side end view of a press brake setup in accordance with certain embodiments of the invention.
  • Figure 3 is a perspective view of a press brake setup in accordance with certain embodiments of the invention, where the tools on the upper and lower beams are shown in open position.
  • Figure 4 is a perspective view of the press brake setup of Figure 3, where the tools are shown in closed position.
  • Figure 5A is a broken-away detail view of the tip of a press brake tool in accordance with certain embodiments of the invention.
  • Figure 5B is a broken-away detail view of the tip of another press brake tool in accordance with other embodiments of the invention.
  • Figure 6 is a side end view of a press brake setup in accordance with certain embodiments of the invention.
  • Figure 7 is a side end view of a die mounted on a rail in accordance with certain embodiments of the invention.
  • Figure 8 is a side end view of a die in accordance with certain embodiments of the invention.
  • Figure 9 is a side view of the die of Figure 8, with the die rotated 90° from the position shown in Figure 8.
  • Figure 10 is a perspective view of a die mounted on a rail in accordance with certain embodiments of the invention.
  • Figure 11 is a perspective view of the rail-mounted die of Figure 10, with the die being rotated 90° from the position shown in Figure 10 such that a ridge of the rail is received in a second locating channel of the die.
  • Figure 12 is a side end view of a die mounted on a rail in accordance with certain embodiments of the invention.
  • Figure 13 is a side end view of the rail-mounted die of Figure 12, with the die being rotated 90° from the position shown in Figure 12 such that a ridge of the rail is received in a second locating channel of the die.
  • Figure 14 is a perspective view of a rail on which multiple dies are mounted in accordance with certain embodiments of the invention.
  • Staged bending is the execution of different types of bends on a workpiece using a single press brake setup.
  • a plurality of (optionally all of the) different bends on a single part can be made in succession, using a single setup.
  • the bending process may require a 30-degree bend with hem, an offset bend, a 60-degree bend, and four 90- degree bends.
  • an operator would set up the 30- degree bend with a 30-degree hemming punch and die and perform the bend on all of the parts, handling each part one at a time. Then, the operator would either remove the 30-degree hemming punch and die or reposition them so the top and bottom tool would not collide. Next, the operator would set up an offset punch and a corresponding die and make the offset bend on all of the parts, again handling each part another time.
  • the operator would either remove the offset punch and die or reposition them so the top and bottom tool would not collide.
  • the operator would set up a 60-degree punch and die and make this bend on all of the parts, handling the parts for the third time.
  • the operator would have to either remove or reposition the 60-degree punch and die so the top and bottom tool would not collide.
  • the operator would set up a 90-degree punch and die and complete the four 90- degree bends, handling the parts for the fourth time.
  • This conventional manufacturing method requires the operator to complete four separate setups and create or load four separate programs.
  • staged bending the operator would set up the 30-degree hemming punch and die, the offset punch and die, the 60-degree punch and die, and the 90-degree punch and die all at the same time, creating or loading only one program. These tools would be set up in progressive order. On the same blank, the operator would complete the 30-degree hemming, the offset bending, the 60-degree bending, and the four 90-degree bending operations, thus achieving a completed component. The part would only need to be handled and set up once.
  • the present invention provides several advantageous staged tooling technologies. These technologies allow a press brake to be equipped with multiple pairs of tools, of which at least one pair (e.g., at least one mateable punch and die set) is adapted to create a different bend than at least one other pair. Even though the present setup has different tool pairs with different angles, different radii, etc., the tools do not collide. In some embodiments, all the tools (e.g., punches and dies) of a common height series (e.g., all the tools in a desired combination) have the same "shut height" 700 (without material between the mateable tools). Reference is made to Figure 6.
  • FIG. 1 it can be seen that in some embodiments, different tool pairs on a single press are adapted to create different bends.
  • at least one of the upper tools 100 has a tip configuration (e.g., shape) different from that of another upper tool. More will be said of this later.
  • a plurality of (preferably a majority of, perhaps optimally all of) the tool pairs on the press brake PB are adapted to come together (or "mate") at the same time.
  • the upper and the lower tools preferably have the same shut height 700 (or at least substantially the same shut height).
  • the punches For setups where punches are on the upper beam and dies are on the lower beam, the punches preferably contact (e.g., bottom out in) corresponding dies at the same time (i.e., when the upper and lower beams are brought together — by moving the upper beam toward the lower beam, by moving the lower beam toward the upper beam, or both).
  • One group of embodiments provides a staged press brake system including a press brake PB having upper 125 and lower 145 beams.
  • the system (or "setup") includes a plurality of upper press brake tools 100 mounted in respective tool holders TH on the upper beam 125.
  • each of these tools 100 has a tang TG, and the tangs are received in respective tool holders.
  • At least one of the upper tools 100 has a tip configuration different from that of another upper tool.
  • Figures 1-4 and 6 show exemplary embodiments of this nature.
  • the tip configurations of such tools can have different angles, different radii, etc.
  • the tip of one tool has two converging surfaces CV separated by a certain angle, while the tip of another tool in the same combination (e.g., in the same setup) has two converging surfaces CV separated by a different angle.
  • These angles can optionally be different by at least one degree, at least 2 degrees, at least 5 degrees, at least 10 degrees, at least 25 degrees, or more.
  • the tip of one tool can have a first radius, while the tip of another tool has a different radius.
  • These radii can optionally be different by at least .001 inch, at least .002 inch, at least .01 inch, or more.
  • the setup includes at least three pairs of mateable tools.
  • These embodiments can include a first punch and die pair adapted to make a first bend, a second punch and die pair adapted to make a second bend, and a third punch and die pair adapted to make a third bend.
  • the first, second, and third bends are all different types of bends. These can be any desired bend types. As just one possibility, these bends can be three different bends selected from the group consisting of a 30-degree bend, an offset bend, a 60-degree bend, a 90-degree bend, and a hemming bend.
  • the tool combination can also include one or more flattening punches, if desired. Many other possibilities will be apparent to skilled artisans given the present teaching as a guide.
  • each such load-bearing shoulder LB contacts (e.g., has an upwardly facing surface SS that contacts) a downwardly facing force-transmitting surface LD of a tool holder TH.
  • the tool 100 can optionally have a second shoulder on the other side of the tang, but in the present embodiments the second shoulder is not a load bearing shoulder (i.e., it does not receive a downward pressing force from the tool holder, rather it is spaced downwardly from the bottom end of the adjacent clamp CL on the tool holder TH).
  • the top end TE of the tang TG is spaced downwardly from the tool holder's confronting downwardly facing surface DF.
  • the illustrated tang TG configuration involves a safety recess formed in one side of the tang.
  • the safety recess can optionally receive a lip of a pivotable clamp of a tool holder.
  • the safety recess is a slot formed in the side of the tang. The slot has a downwardly facing shoulder adapted to engage, as a safety measure, an upwardly facing shoulder of the lip on a clamp CL.
  • Other tang and clamp configurations can be used in the present setup, as either an alternative to, or in combination with, the illustrated tang and clamp configurations.
  • each upper tool 100 has a downwardly facing tip TP comprising two downwardly converging surfaces CV.
  • two planes CVP lying respectively on planar portions of the two converging surfaces CV intersect at a tool theoretical sharp location IP.
  • the tool theoretical sharp location may be located beyond the tip of a given tool (see Figure 5A), or it may be at the end of the tool's tip (see Figure 5B).
  • Many different tip configurations can be used.
  • a variety of useful European-style punches are shown in the Wilson Tool publication entitled “European Style Press Brake Tooling” (February 2006), the salient teachings of which are incorporated herein by reference. The tools shown in this publication are commercially available from Wilson Tool (White Bear Lake, Minnesota, U.S.A.).
  • a common vertical distance 99 separates the tool theoretical sharp location IP and the upwardly facing surface SS of the load- bearing shoulder LB for a plurality of (preferably a majority of, perhaps optimally all of) the tools 100 in the combination (when the upper and lower tools are in closed positions, as shown in Figure 6).
  • the term "common” here means the distance is the same or substantially the same for the tools in question.
  • this distance 99 is the "punch staged height.”
  • the tooling setup includes at least one large-radius bending tool.
  • the large-radius bending tool and its corresponding die preferably are configured to have the same shut height (or substantially the same shut height) as the other tools on the press brake.
  • the same is true of any flattening tools that may be included in the tooling setup.
  • any variance in the actual shut heights preferably is less than 0.010 inch.
  • the present setup also includes a plurality of press brake dies 10, 10'.
  • each die 10, 10' is mounted on a rail 20 carried by the lower beam.
  • the rail 20 can optionally be mounted on a die holder 30 secured to the lower beam.
  • the present staged setup does not require any special shims or risers.
  • the bottom of each die preferably sits directly on the rail, and the bottom of the rail preferably sits directly on the die holder.
  • each die 10, 10' preferably has a bearing face 15FB, 15SB with a bearing base 15FBB, 15SBB and a locating recess (e.g., channel) 15FL, 15SL in which a locating ridge 25 of the rail 20 is received.
  • each bearing base is defined by two flush, planar surfaces separated by a single locating recess.
  • Each illustrated die has only one locating recess in the/each bearing face, although this is not strictly required.
  • each illustrated locating recess has a cross section (taken perpendicular to the die's longitudinal axis LA) that is rectangular, although other configurations can be used.
  • each die 10, 10' also has a workpiece- contact face 15FC, 15SC with an upwardly open forming recess 15FR, 15SR.
  • each forming recess 15FR, 15SR is bounded by two downwardly convergent surfaces CS.
  • a shared vertical distance 300 separates the die theoretical sharp location FTS, STS and the bearing base 15FB, 15SB (a base surface 15FBB, 15SBB thereof) for a plurality of, a majority of, or all of the dies 10, 10' in the present setup.
  • the term "shared” here means the distance is the same or substantially the same for the dies in question.
  • the dies 10', the rail 20, and the die holder 30 are configured such that the "closed height" 900 for each operatively positioned tool pair is the same (or substantially the same).
  • the die staged height 1700 preferably is the same or substantially the same for a plurality of the dies, a majority of the dies, or all of the dies.
  • the tool holders TH on the upper beam have a centerline 500 that extends vertically downwardly and passes through all of the following: (a) the downwardly facing force-transmitting surface LD of each tool holder, (b) the upwardly facing load-bearing shoulder LB (and its upwardly facing surface SS) of each tool, (c) the tool theoretical sharp location IP of each tool, and (d) the operative die theoretical sharp location FTS, STS of each die.
  • operative die theoretical sharp location refers to the theoretical sharp location of the forming recess that is operatively positioned (the operative forming recess will typically be upwardly facing, i.e., facing the upper beam). This is perhaps best understood by referring to Figure 7, which illustrates a staged 2-V die.
  • the operative locating recess 15FL, 15SL of each die 10, 10' is not directly aligned with the machine's centerline 500. Rather, the operative locating recesses (e.g., channels) of the illustrated dies are spaced from this centerline.
  • the (or each) locating recess 15FL, 15SL on each die has a width 800, 810, and a plurality of (preferably a majority of, or all of) the dies have a common die locating dimension DLD. This is perhaps best appreciated by referring to Figures 7 and 8.
  • the "die locating dimension” is defined as the distance between the centeriine 500 of the press brake PB and a midpoint of the width 800, 810 of the operative locating recess 15FL, 15SL.
  • the term "operative locating recess” refers to the locating recess that is operatively positioned (the operative locating recess will typically receive the ridge 25 of the rail 20).
  • the tools e.g., punches
  • dies when mated all have a common shut height 700.
  • the "shut height” is defined as the vertical distance between the operative bearing face 15FB, 15SB (a base surface 15FBB, 15SBB thereof) and the upwardly facing load-bearing shoulder LB (an upwardly facing load-bearing surface SS thereof) of a closed tool and die pair.
  • At least one mateable tool and die pair is adapted to create a first bend
  • at least one other mateable tool and die pair is adapted to create a second bend.
  • the first and second bends are different. (It is to be appreciated that the terms “first bend,” “second bend,” and the like do not require those bends to be made in any particular sequence. For example, the "first bend” could be made in a workpiece after the "second bend” has been made in the workpiece.)
  • the first or second bend is a 90-degree bend.
  • the first and second bends are two different bends selected from the group consisting of a 90-degree bend, a 60- degree bend, and a 30-degree bend.
  • the first bend can optionally be a 90-degree bend, while the second bend is a 30-degree bend. This is merely one example, however. Some embodiments involve a first mateable tool and die pair adapted to create a first bend, a second mateable tool and die pair adapted to create a second bend, and a third mateable tool and die pair adapted to create a third bend. Again, the first, second, and third bends are all different. For instance, the first bend can optionally be a 90-degree bend, while the second bend is a 60- degree bend, and the third bend is a 30-degree bend. This particular example, however, is not required.
  • each bending station includes at least one mateable punch and die set.
  • Figures 3 and 4 show one exemplary setup having three bending stations.
  • each bending station includes a mateable punch and die pair.
  • Each of these bending stations is adapted to make a different bend than the other two stations.
  • At least one of the dies 10, 10' has a working height WH different from that of another die 10, 10'.
  • the working height WH of a die 10, 10' is defined as the distance between its operative bearing face 15FB, 15SB (a base surface 15FBB, 15SBB thereof) and its operative workpiece-contact face 15FC, 15SC.
  • at least one of the dies 10, 10' has a working height WH that is greater than that of another die by at least 1/32 inch, by at least 1/16 inch, by at least 1/4 inch, or more.
  • the setup includes at least one die (or a plurality of dies) having a forming recess with a radiused bottom.
  • planar portions of two convergent surfaces CS are connected by a radiused valley section RVS.
  • RVS radiused valley section
  • Each of these forming recesses would have a greater depth if the two convergent surfaces CS converged at constant angles over their whole length until reaching a vertex at the die theoretical sharp location FTS, STS rather than being connected by a radiused valley section RVS.
  • each forming recess 15FR, 15SR comes to a sharp vertex, rather than terminating at a radiused valley section.
  • the present embodiments can include dies with any combination of sharp Vs, rounded Vs, etc.
  • a plurality of the tool holders TH on the press brake PB have pivotable clamps CL. This is perhaps best seen in Figures 1 , 2, and 6.
  • Useful European style tool holders are described in U.S. Patent No. 6,003,360, the salient teachings of which are incorporated herein by reference.
  • each clamp CL is pivotable about a horizontal axis.
  • the tool holder TH has a downwardly extending support plate 114.
  • This support plate 114 has a downwardly facing shoulder that is adapted to engage the upwardly facing load-bearing shoulder LB of a tool (e.g., a punch).
  • This downwardly facing shoulder defines the surface LD.
  • the tool holder TH has pivotable clamps CL spaced from both sides of the support plate 114. This, however, is not required.
  • the tool holders TH (or at least some of them) have seating mechanisms that, in response to clamping movement of the tool holders, move upwardly facing shoulders LB of the tools 100 into contact with respective downwardly facing force-transmitting surfaces LD of the tool holders.
  • Useful seating mechanisms of this nature are described in U.S. patent applications 11/178,977 and 11/230,742, the salient teachings of which are incorporated herein by reference.
  • staged press brake system e.g., a setup
  • PB press brake PB
  • the tooling combination is adapted for use on a press brake with upper and lower beams.
  • the tooling combination includes a plurality of press brake tools (e.g., punches) 100 and a plurality of press brake dies 10, 10'.
  • the tools 100 are upper tools adapted to be mounted in respective tool holders on the upper beam 125.
  • each tool 100 has a tang TG, and the tangs are adapted for receipt in respective tool holders TH.
  • at least one of the tools 100 has a tip configuration different from that of another tool of the combination. This was explained above in connection with the setup embodiments.
  • each tool 100 there is a load-bearing shoulder LB on only one side of the tang TG of each tool 100.
  • each such shoulder LB e.g., a surface SS thereof
  • each tool 100 has a tip TP comprising two converging surfaces CV, and two planes CVP lying respectively on planar portions of these two converging surfaces intersect at a tool theoretical sharp location IP.
  • a common distance 99 separates the tool theoretical sharp location IP and the load- bearing shoulder LB (surface SS thereof) for all (or at least a plurality of) the tools 100 in the tooling combination.
  • each one preferably is adapted to be mounted on a rail 20.
  • the die rail 20 is mounted on a die holder 30, which is supported by the press brake's lower beam 145.
  • each die 10, 10' has a bearing face 15FB, 15SB with a bearing base 15FBB, 15SBB and a locating recess (e.g., channel) 15FL, 15SL.
  • Each locating recess is adapted to receive a locating ridge 25 of the rail 20.
  • each die 10, 10' preferably has a workpiece-contact face 15FC, 15SC with a forming recess 15FR, 15SR, which in some cases is bounded by two convergent surfaces CS.
  • two planes P lying respectively on planar portions of such two convergent surfaces CS intersect at a die theoretical sharp location FTS, STS.
  • a shared distance 300 separates the die theoretical sharp location FTS, STS and the bearing face 15FB, 15SB (a base surface 15FBB, 15SBB thereof) for all the dies 10, 10' (or at least a plurality of the dies) in the present tooling combination.
  • each workpiece-contact face 15FC, 15SC has a single forming recess.
  • two flush, planar surfaces are separated by each forming recess.
  • the tools and dies when held in a closed (i.e., mated) position, preferably all have a common shut height 700. It is possible, though, for the tooling combination to include some tools that have a smaller shut height than that of the staged tools in the combination. In such cases, the staged tools can be used to perform staged bending, without actually using the shorter tools (the shorter tools would not collide). In some of the tooling combination embodiments, at least one of the dies
  • the tooling combination includes at least one die having a forming recess with a radiused bottom.
  • planar portions of two convergent surfaces CS can be connected by a radiused valley section RVS.
  • Each such forming recess 15FR, 15SR would have a greater depth if the two convergent surfaces CS converged at constant angles over their whole length until reaching a vertex at the die theoretical sharp location FTS, STS, rather than being connected by a radiused valley section.
  • one or more of the forming recesses can alternatively have two convergent surfaces CS that come to a sharp vertex.
  • at least one mateable tool and die pair is adapted to create a first bend
  • at least one other mateable tool and die pair is adapted to create a second bend. As already explained, the first and second bends are different.
  • the first and second bends can optionally be two different bends selected from the group consisting of a 90-degree bend, a 60- degree bend, a 30-degree bend, an offset bend, and a hemming bend. However, this is by no means required.
  • the tooling combination includes a first mateable tool and die pair adapted to create a first bend, a second mateable tool and die pair adapted to create a second bend, and a third mateable tool and die pair adapted to create a third bend.
  • first, second, and third bends are all different types of bends.
  • the present tooling combination can include two mateable tool pairs, three mateable tool pairs, or more mateable tool pairs. Many variants of this nature will be apparent to skilled artisans given the present teaching as a guide.
  • the tooling combination includes at least one tool with a seating mechanism.
  • the seating mechanism here is adapted to seat the load-bearing shoulder LB of the tool 100 against a downwardly facing force- transmitting surface LD of a tool holder TH in response to a clamping movement of the tool holder.
  • Tools with useful seating mechanisms are described in U.S. patent application No. 11/451 ,148, the salient teachings of which are incorporated herein by reference.
  • one or more (optionally each) of the tool holders comprises a pivotable clamp CL. This is best seen in Figures 1 , 2, and 6.
  • the invention also provides fabrication methods involving a press brake with upper and lower beams.
  • the method involves providing a plurality of press brake tools.
  • Each tool has a tang, and at least one of the tools has a tip configuration different from that of another tool.
  • at least one tool (optionally each tool) has a tip comprising two converging surfaces CV, and two planes lying respectively on planar portions of these two converging surfaces intersect at a tool theoretical sharp location.
  • a common distance 99 separates the tool theoretical sharp location and the load-bearing shoulder (surface SS thereof) for a plurality of, a majority of, or all of the tools 100.
  • the present method also involves providing a plurality of press brake dies.
  • Each die 10, 10' has a bearing face 15FB, 15SB with a bearing base 15FBB, 15SBB and a locating recess (e.g., channel) 15FL, 15Sl.
  • Each die 10, 10' also has a workpiece-contact face 15FC, 15SC with a forming recess 15FR, 15SR, which in some cases is bounded by two convergent surfaces CS.
  • two planes P lying respectively on planar portions of such two convergent surfaces intersect at a die theoretical sharp location FTS, STS.
  • a shared distance 300 separates the die theoretical sharp location FTS, STS and the bearing base 15FB, 15SB (a base surface 15FBB, 15SBB thereof) for a plurality of, a majority of, or all of the dies 10, 10'.
  • an arrangement of tools 100 and dies 10, 10' is provided on the press brake PB by: (i) mounting the tools 100 in respective tool holders TH of the upper beam 125, e.g., such that the load-bearing shoulders LB of the tools confront downwardly facing force-transmitting surfaces LD of respective tool holders, and (ii) mounting each die 10, 10' on a rail 20 carried by the lower beam 145 such that the locating recess 15FL, 15SL of each die receives a locating ridge 25 of the rail.
  • a workpiece is positioned between the upper tool and the die of a first mateable tool set, and a first bend is made in the workpiece WP by bringing the upper 125 and lower 145 beams of the press brake PB together so as to deform the workpiece between the upper tool and die of the first mateable tool set. Then, without changing the arrangement of tools and dies on the press brake (i.e., without changing the setup), the workpiece is positioned between the upper tool and die of a second mateable tool set, and a second bend is formed in the workpiece WP by bringing the upper 125 and lower 45 beams together so as to bend the workpiece between the upper tool and die of the second mateable tool set.
  • the first and second bends here are two different types of bends.
  • the method further includes using a third tool set to make a third bend in the workpiece WP.
  • the first, second, and third bends are all different types of bends.
  • the first bend can be a 90-degree bend
  • the second bend can be a 60-degree bend
  • the third bend can be a 30-degree bend.
  • Many other bend combinations can be used, depending upon the particular part being fabricated.
  • the die 10 has multiple forming recesses, e.g., multiple Vs. Reference is made to Figures 7-14.
  • the die 10 has two Vs, and the Vs are on two respective faces of the die. Preferably, these two faces are perpendicular (or at least generally or substantially perpendicular) to each other. This, however, may not be the case with all die configurations.
  • V can refer to a V-shaped recess with a sharp vertex, a V- shaped recess with a radiused bottom, etc.
  • One exemplary manner in which the die can be manufactured is by milling the tool from a tool steel billet.
  • the billet for example, can be milled to a near net shape.
  • the tool can be ground on all working surfaces.
  • the part can either be milled or cut with a saw to lengths.
  • the tool can optionally be heat treated to a desired heat-treat specification.
  • the die (in accordance with one manufacturing method) is then ready for sale. Skilled artisans will be familiar with other manufacturing methods that can be used.
  • the illustrated die 10 has a first bearing face 15FB and a first workpiece-contact face 15FC.
  • the first bearing face 15FB and the first workpiece-contact face 15FC are on opposed (i.e., opposite) sides of the die 10.
  • these two faces 15FB, 15FC are parallel (or at least generally or substantially parallel) to each other.
  • the illustrated die 10 has a generally square cross section (in a plane perpendicular to the longitudinal axis LA of the die). This, however, is not required.
  • the die can alternatively have a generally rectangular cross section.
  • the cross section can have various other polygonal shapes.
  • the die can alternatively have a more irregular cross-section.
  • the first bearing face 15FB includes a first bearing base 15FBB and a first locating recess (e.g., channel) 15FL.
  • the first bearing base 15FBB comprises two wall sections separated by the first locating recess 15FL. These two wall sections are shown as being flush, planar wall sections, although this is not strictly required.
  • the present die 10 is a quick-change die, which can be mounted on a rail 20 (see Figures 7 and 10-14).
  • the illustrated die 10 can be mounted by placing the first bearing base 15FBB on the rail 20 such that a ridge 25 of the rail is received in the die's first locating recess 15FL.
  • the illustrated ridge 25 is elongated in the longitudinal direction, and it has a rectangular cross section (in a plane perpendicular to the longitudinal axis LA).
  • the ridge 25 projects upwardly from the two surfaces (shown as being flush, planar surfaces) that are separated by the ridge.
  • the first locating recess (e.g., channel) 15FL has a rectangular cross section (taken in a plane perpendicular to the die's longitudinal axis). However, this is not strictly required.
  • the first workpiece-contact face 15FC has therein formed a first forming recess 15FR.
  • this forming recess 15FR is V- shaped or generally V-shaped.
  • this recess can be provided in a variety of different shapes, depending upon the particular bend desired.
  • the first forming recess 15FR is bounded by two converging surfaces CS, preferably such that two planes P lying respectively on planar portions of the two converging surfaces CS intersect at a first theoretical sharp location FTS.
  • the first forming recess 15FR terminates in a radiused valley section RVS.
  • the first theoretical sharp location FTS is spaced from (so as to be closer to the first bearing base 15FB than is) the bottom of the radiused valley section RVS.
  • the first forming recess 15FR terminates in a sharp vertex at the first theoretical sharp location FTS.
  • first theoretical sharp distance is defined as the distance between the first bearing base 15FB (the base surface 15FBB thereof) and the first theoretical sharp location FTS.
  • the die 10 has a second bearing face 15SB and a second workpiece-contact face 15SC. These two faces 15SB, 15SC are on opposed sides of the die. In the illustrated embodiments, these two faces 15SB, 15SC are parallel (or at least generally or substantially parallel) to each other.
  • the second bearing face 15SB includes a second bearing base 15SBB and a second locating recess (e.g., channel) 15SL.
  • the second bearing base 15SBB comprises two wall sections separated by the second locating recess 15SL. These two wall sections are shown as being flush, planar wall sections. However, this is not strictly required.
  • the second workpiece-contact face 15SC has therein formed a second forming recess 15SR.
  • the recess 15SR is generally V-shaped and is bounded by two convergent surfaces CS.
  • two planes P lying respectively on planar portions of these two convergent surfaces CS intersect at a second theoretical sharp location STS.
  • second theoretical-sharp distance STSD is defined herein as the distance between the second bearing base 15SB (the base surface 15SBB thereof) and the second theoretical sharp location STS. This is shown in Figure 9.
  • the first 15FR and second 15SR forming recesses have different sizes (e.g., different widths).
  • the die 10 can have two Vs of different size.
  • the first forming recess 15FR is larger (e.g., wider and/or deeper) than the second forming recess 15SR.
  • the situation can be reversed. That is, the second forming recess can be larger than the first forming recess.
  • the first forming recess 15FR has a first width
  • the second forming recess 15SR has a second width
  • the first and second widths are different
  • the die 10 is dimensioned such that the first FTSD and second STSD theoretical-sharp distances are the same (or at least substantially the same).
  • the configurations of the forming recesses 15FR, 15SR can be varied to accommodate the particular bends desired. As noted above, one or both of the Vs may come to a sharp bottom, such that the V terminates at the theoretical sharp location. In Figure 7, the first forming recess 15FR comes to a sharp bottom, as does the second forming recess 15SR. In Figures 8 and 9, both forming recesses 15FR, 15SR have radiused bottoms. In Figures 10-14, the first forming recess 15FR comes to a sharp bottom, while the second forming recess 15SR terminates at a radiused bottom section. Variations of this nature will be apparent to skilled artisans given the present disclosure as a guide.
  • the die 10 has a first centerline FCL defined by an axis that is perpendicular to the first bearing base 15FBB and passes through the first theoretical sharp location FTS.
  • a first centerline FCL defined by an axis that is perpendicular to the first bearing base 15FBB and passes through the first theoretical sharp location FTS.
  • the first locating recess 15FL is not directly aligned with the first forming recess 15FR, such that the first locating recess 15FL is spaced from the first centerline FCL. This is shown in Figure 8.
  • the die 10 can have a second centerline SCL defined by an axis that is perpendicular to the second bearing base 15SBB and passes through the second theoretical sharp location STS.
  • the second locating recess 15SL preferably is not directly aligned with the second forming recess 15SR, such that the second locating recess is spaced from the second centerline SCL. This is shown in Figure 9.
  • the width 810 of the first locating recess 15FL can optionally be the same (or substantially the same) as the width 800 of the second locating recess SCL. Additionally or alternatively, the two locating recesses 15FL, 15SL can optionally have the same depth. These features, though, are not strictly required.
  • the "first die-locating dimension” is defined as the distance between the first centerline FCL and a midpoint of the width 810 of the first locating recess 15FL.
  • the “second die-locating dimension” is defined as the distance between the second centerline SCL and a midpoint of the width 800 of the second locating recess 15SL.
  • the first and second-die locating dimensions are the same or substantially the same.
  • the die has first and second working heights that are different.
  • the "first working height” is defined as the distance between the first bearing base 15FBB and the first workpiece-contact face 15FC.
  • the “second working height” is defined as the distance between the second bearing base 15SBB and the second workpiece-contact face 15SC.
  • the present die is a staged, multiple forming recess (e.g., multiple-V) die.
  • Some embodiments involve the converging surfaces CS connected by a radiused valley section RVS, such that the first forming recess 15FR would have a greater depth if its two converging surfaces converged at constant angles over their whole length until reaching a vertex at the first theoretical sharp location FTS, rather than being connected by a radiused valley section RVS.
  • the planar portions of the two convergent surfaces CS can optionally be connected by a radiused valley section RVS, such that the second forming recess SFR would have a greater depth if its two convergent surfaces converged at constant angles over their whole length until reaching a vertex at the second theoretical sharp location STS, rather than being connected by a radiused valley section.
  • the die 10 has a length, and the first 15FL and second 15SL locating recesses (e.g., channels) extend entirely along the die's length. This is best seen in Figures 10, 11 , and 14. Additionally or alternatively, the first 15FR and second 15SR forming recesses can extend entirely along the die's length.
  • first 15FL and second 15SL locating recesses e.g., channels
  • the two locating recesses 15FL, 15SL are formed in two faces of the die that are perpendicular (or at least generally or substantially perpendicular) to each other. This, however, is not required in all embodiments.
  • the first locating recess 15FL, the second locating recess 15SL, the first forming recess 15FR, and the second forming recess 15SR all extend in directions that are parallel or substantially parallel. This is shown in Figures 10, 11 and 14.
  • all the locating recesses 15FL, 15SL and forming recesses 15FR, 15SR are elongated in a direction parallel or substantially parallel to the die's longitudinal axis LA.
  • first 15FL and second 15SL locating recesses are both rectangular channels.
  • first 15FL and second 15SL locating recesses can advantageously have substantially the same width, substantially the same depth, and substantially the same length. These features, though, are not always required.
  • die 10 has six faces: the first bearing face 15FB, the first workpiece-contact face 15FC, the second bearing face 15SB, the second workpiece-contact face 15SC, and two end faces. Reference is made to Figure 10. In other embodiments, the die can have more faces.
  • each punch or die is provided with a Nitrex treatment (optionally over the entire tool) for both hardness and as a rust preventative. It is to be appreciated, though, that such treatments are not strictly required.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Braking Arrangements (AREA)

Abstract

Cette invention concerne des combinaisons d'usinage de presses plieuses à étages. Dans certains modes de réalisation, l'invention concerne une configuration de presses plieuses à étages. Dans d'autres modes de réalisation, l'invention concerne une matrice de presse plieuse à étages qui forme des creux multiples et se remplace rapidement.
PCT/US2008/075692 2007-09-19 2008-09-09 Technologie de l'usinage à étages WO2009038998A2 (fr)

Applications Claiming Priority (2)

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US11/857,825 US20090071223A1 (en) 2007-09-19 2007-09-19 Staged Tooling Technology
US11/857,825 2007-09-19

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WO2009038998A2 true WO2009038998A2 (fr) 2009-03-26
WO2009038998A3 WO2009038998A3 (fr) 2009-05-07

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WO2009038998A3 (fr) 2009-05-07

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