Reducing waste in metal stamping processes and systems therefor

Patent metadata

Field	Value
Publication number	US-9409222-B2
Application number	US-201113581662-A
Country	US
Kind code	B2
Filing date	Feb 25, 2011
Priority date	Mar 1, 2010
Publication date	Aug 9, 2016
Grant date	Aug 9, 2016

Abstract

Disclosed herein is a sheet metal stamping device and methods for reducing the size of a blank required for producing a stamped part therefrom than is conventionally possible. The device utilizes an intermediate clamp section with projections having clamping formations located thereon which complement clamping formations located on a first die section. The intermediate clamp section projections allow for the use of a smaller blank size as less addendum material is required to secure the blank during the stamping process. The blank is secured using the intermediate clamp section and the first die section prior to the second die section engaging the blank to stamp the part. In some embodiments, retention beads resultant from the clamping process may remain in the stamped part, that being inside a trim line. Furthermore, in some embodiments, a blank shifter may be provided to locate the blank between the die sections prior to clamping. In other embodiments, more than one complementary pair of clamping formations may be provided. Furthermore, in some embodiments a trim line cutter may be provided.

First claim

The invention claimed is:

1. A stamping device for stamping a metal blank, comprising:
a first die section and a second die section, the first and second die sections operable for movement along a travel path relative to each other between a retracted position and a stamping position;
the first and second die sections including complementary first and second surface portions with respective first and second work piece-forming regions located thereon, the first die section including a pair of opposed first die section boundaries and the first work-piece forming region being located in a central inner region of the first die section and spaced from the opposed first die section boundaries;
die sections being configured to receive a metal blank therebetween, the metal blank having opposed edges to be inwardly spaced from the corresponding first die section boundaries, the first and second work-piece forming regions being arranged for shaping a work piece from the metal blank in the stamping position;
an intermediate clamp section located intermediate the first and second die sections;
the first die section including a plurality of opposed first clamping formations, and the intermediate clamp section including a plurality of opposed inwardly offset second clamping formations, for clamping the blank in a clamping position;
the intermediate clamp section including at least a pair of clamp modules on opposite sides of the travel path, each clamp module having an inner peripheral region with at least one projection extending inwardly therefrom and transverse to the travel path, wherein at least one of the plurality of opposed inwardly offset second clamping formations is formed on each projection, and is inwardly offset relative to the corresponding clamping nodule, in order to clamp the metal blank in the clamping position;
the second die section having cut-out regions transverse to the travel path, each cut-out region for receiving a corresponding projection;
the first die section being movable relative to the second die section from the retracted position to the clamping position before reaching the stamping position, so as to clamp the metal blank between the first clamping formations and the corresponding inwardly offset second clamping formations;
the intermediate clamp section being operable for travel with the first die section, relative to the second die section, to the stamping position so as to nest with the second die section with each projection resident in a corresponding cut-out region.

2. A device as defined in claim 1 , the second surface portion having at least one support portion slidably extending therethrough for supporting the metal blank prior to clamping.

3. A device as defined in claim 2 , the at least one supporting portion being movable relative to the second die section, wherein the second die section is operable for travel to the stamping position so as to disengage the metal blank and the supporting portion.

4. A device as defined in claim 1 , the projections being oriented so as not to extend into the second work piece-forming region.

5. A device as defined in claim 4 , the clamping formations being shaped to form retention beads on a peripheral scrap region in the blank which is spaced from the work piece.

6. A device as defined in claim 1 , the projections being oriented so as to extend into the second work piece-forming region.

7. A device as defined in claim 6 , the clamping formations being continuous with the work piece-forming regions, so as to form one or more clamping retention beads inside a trim line, thereby to remain in a final stamped part.

8. A device as defined in claim 1 , the first die section and the intermediate clamp section further comprising at least respective third and fourth clamping formations for clamping blanks of different lengths.

9. A device as defined in claim 8 , the intermediate clamp section further comprising a blank shifting member operable for aligning the blank for clamping with the first and second clamping formations and/or the third and fourth clamping formations.

10. A device as defined in claim 9 , the blank shifting member including an actuated member for aligning and maintaining the blank in a desired clamping position.

11. A device as defined in claim 1 , the intermediate clamp section including a trim line cutter.

12. A device as defined in claim 10 , the actuated member including a hydraulic cylinder with a piston carrying an effector operatively coupled to the intermediate clamp section; the piston operable for aligning and maintaining the blank in the desired clamping position.

13. A method for reducing the required length of a blank to produce a stamped part therefrom, the method comprising the steps of:
a) providing a first die section, a second die section, and an intermediate die section, the first die section including a pair of opposed first section boundaries;
b) providing a metal blank with a reduced length in relation to a corresponding length of the first die section, and with opposed edges inwardly spaced from the opposed first die section boundaries;
c) placing the metal blank between the first and second die sections with the first and second die sections in a retracted position;
the first and second die sections being operable for movement along a travel path relative each other between the retracted position and a stamping position;
the first and second die sections including complementary first and second surface portions with respective first and second work piece-forming regions located thereon, the first work-piece forming region being located in a central inner region of the first die section and spaced from the opposed first die section boundaries;
the first and second work piece-forming regions being arranged for shaping a work piece from the metal blank;
the intermediate clamp section including at least a pair of clamp modules on opposite sides of the travel path, each clamp module including an inner peripheral region with at least one projection extending inwardly therefrom and transverse to the travel path, the second die section having cut-out regions transverse to the travel path, each cut-out region for receiving a corresponding projection;
the first die section including a plurality of opposed first clamping formations, and the intermediate clamp section including a plurality of opposed inwardly offset second clamping formations, wherein at least one of the inwardly offset second clamping formations is located on each projection and inwardly offset relative to the corresponding clamp module, for clamping the blank;
d) aligning the metal blank with the first clamping formations and the inwardly offset second clamping formations;
e) causing the first die section to travel relative to the intermediate clamp section to engage and clamp the metal blank therebetween at a clamping position; and thereafter
f) causing the first die section and the intermediate clamp section to travel relative to the second die section, with each projection being received in a corresponding cut-out region on the second work piece-forming region, so as to communicate with the first work piece forming region in a stamping position, so as to form a stamped part;
g) causing the first and second die sections and the intermediate clamp section to move to a retracted position; and
h) removing the stamped part from between the first and second die sections.

14. A method as defined in claim 13 , further comprising utilizing respective third and fourth clamping formations on the first die section and the intermediate clamp section at least for clamping blan

Assignees

• Moore William R
• Glenn Kevin P
• Honda Motor Co Ltd

Inventors

• Moore William R
• Glenn Kevin P

Classifications

• B21D22/06 Primary

  having relatively-movable die parts · CPC title

• B21D24/04

  Blank holders; Mounting means therefor · CPC title

• B21D22/22

  with devices for holding the edge of the blanks (B21D22/24 - B21D22/30 take precedence; shaping over a die without external former B21D11/02) · CPC title