U.S. patent application number 11/857825 was filed with the patent office on 2009-03-19 for staged tooling technology.
Invention is credited to Thomas S. Duppong, William J. Klein, Mike J. McNertney, Bryan L. Rogers.
Application Number | 20090071223 11/857825 |
Document ID | / |
Family ID | 40428032 |
Filed Date | 2009-03-19 |
United States Patent
Application |
20090071223 |
Kind Code |
A1 |
Rogers; Bryan L. ; et
al. |
March 19, 2009 |
Staged Tooling Technology
Abstract
The invention involves staged press brake tooling combinations.
In some embodiments, the invention provides a staged press brake
setup. In other embodiments, the invention provides a staged
quick-change multiple forming recess press brake die.
Inventors: |
Rogers; Bryan L.; (Forest
Lake, MN) ; Duppong; Thomas S.; (Lake Elmo, MN)
; McNertney; Mike J.; (Hugo, MN) ; Klein; William
J.; (Stillwater, MN) |
Correspondence
Address: |
INTELLECTUAL PROPERTY GROUP;FREDRIKSON & BYRON, P.A.
200 SOUTH SIXTH STREET, SUITE 4000
MINNEAPOLIS
MN
55402
US
|
Family ID: |
40428032 |
Appl. No.: |
11/857825 |
Filed: |
September 19, 2007 |
Current U.S.
Class: |
72/481.1 |
Current CPC
Class: |
B21D 37/02 20130101;
B21D 5/0209 20130101 |
Class at
Publication: |
72/481.1 |
International
Class: |
B21D 37/04 20060101
B21D037/04 |
Claims
1. A staged quick-change multiple forming recess die for a press
brake, the die having a first bearing face and a first
workpiece-contact face, the first bearing face and the first
workpiece-contact face being on opposed sides of the die, the first
bearing face including a first bearing base and a first locating
recess, the first workpiece-contact face having therein formed a
first forming recess bounded by two converging surfaces, wherein
two planes lying respectively on planar portions of said two
converging surfaces intersect at a first theoretical sharp
location, wherein a first theoretical-sharp distance is defined as
the distance between the first bearing base and the first
theoretical sharp location, the die having a second bearing face
and a second workpiece-contact face, the second bearing face and
the second workpiece-contact face being on opposed sides of the
die, the second bearing face including a second bearing base and a
second locating recess, the second workpiece-contact face having
therein formed a second forming recess bounded by two convergent
surfaces, wherein two planes lying respectively on planar portions
of said two convergent surfaces intersect at a second theoretical
sharp location, wherein a second theoretical-sharp distance is
defined as the distance between the second bearing base and the
second theoretical sharp location, the first forming recess having
a first size, the second forming recess having a second size,
wherein said first and second sizes are different and yet the first
and second theoretical-sharp distances are substantially the
same.
2. The die of claim 1 wherein the die has a first centerline
defined by an axis that is perpendicular to the first bearing base
and passes through the first theoretical sharp location, wherein
the first locating recess is not directly aligned with the first
forming recess, such that the first locating recess is spaced from
the first centerline.
3. The die of claim 2 wherein the die has a second centerline
defined by an axis that is perpendicular to the second bearing base
and passes through the second theoretical sharp location, wherein
the second locating recess is not directly aligned with the second
forming recess, such that the second locating recess is spaced from
the second centerline.
4. The die of claim 3 wherein the die has first and second
die-locating dimensions that are substantially the same, the first
locating recess having a width, the first die-locating dimension
being defined as the distance between the first centerline and a
midpoint of the width of the first locating recess, the second
locating recess having a width, the second die-locating dimension
being defined as the distance between the second centerline and a
midpoint of the width of the second locating recess.
5. The die of claim 4 wherein the first locating recess is an
elongated channel extending longitudinally along the die's first
bearing face, and the second locating recess is an elongated
channel extending longitudinally along the die's second bearing
face.
6. The die of claim 1 wherein the die has first and second working
heights that are different, the first working height being defined
as the distance between the first bearing base and the first
workpiece-contact face, the second working height being defined as
the distance between the second bearing base and the second
workpiece-contact face.
7. The die of claim 1 wherein the first and second
workpiece-contact faces are substantially perpendicular to each
other.
8. The die of claim 7 wherein the first and second bearing faces
are substantially perpendicular to each other.
9. The die of claim 1 wherein the first forming recess is at least
generally V-shaped.
10. The die of claim 9 wherein the second forming recess is at
least generally V-shaped.
11. The die of claim 1 wherein said first size is a width of the
first forming recess, said second size is a width of the second
forming recess, wherein these two widths are different and yet the
first and second theoretical-sharp distances are the same.
12. The die of claim 1 wherein the planar portions of said two
converging surfaces are connected by a radiused valley section,
such that the first forming recess 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 rather than being connected by a radiused valley
section.
13. The die of claim 12 wherein the planar portions of said two
convergent surfaces are connected by a radiused valley section,
such that the second forming recess 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 rather than being connected by a radiused valley
section.
14. The die of claim 1 wherein the die has a length, and the first
and second locating recesses extend entirely along the die's
length.
15. The die of claim 14 wherein the first and second forming
recesses extend entirely along the die's length.
16. The die of claim 1 wherein the first locating recess, the
second locating recess, the first forming recess, and the second
forming recess all extend in directions that are substantially
parallel.
17. The die of claim 1 wherein the first and second locating
recesses have substantially the same width, substantially the same
depth, and substantially the same length.
18. The die of claim 17 wherein the first and second locating
recesses are both rectangular channels.
19. The die of claim 1 wherein the die has six faces: the first
bearing face, the first workpiece-contact face, the second bearing
face, the second workpiece-contact face, and two end faces.
20. A staged quick-change two-V press brake die, the die having
first and second bending Vs formed respectively in first and second
workpiece-contact faces of the die, said first and second
workpiece-contact faces being at least generally perpendicular to
each other, the first bending V having a first theoretical sharp
location, the second bending V having a second theoretical sharp
location, the die having first and second bearing faces, the first
bearing face having formed therein a first elongated locating
channel, the second bearing face having formed therein a second
elongated locating channel, the first bearing face being at least
generally parallel to the first workpiece-contact face, the second
bearing face being at least generally parallel to the second
workpiece-contact face, wherein a first theoretical-sharp distance
is defined as the distance between the first bearing face and the
first theoretical sharp location, and a second theoretical-sharp
distance is defined as the distance between the second bearing face
and the second theoretical sharp location, wherein the first and
second bending Vs have different widths and yet the die is
configured such that the first and second theoretical-sharp
distances are substantially the same.
21. A staged quick-change press brake system including a press
brake with upper and lower beams, the system comprising: a
plurality of press brake tools mounted in respective tool holders
on the upper beam, each tool having a tang, the tangs being
received in respective tool holders, at least one of the tools
having a tip configuration different from that of another tool of
said plurality, wherein there is an upwardly facing load-bearing
shoulder on only one side of the tang of each tool, each such
upwardly facing shoulder contacting a downwardly facing
force-transmitting surface of a tool holder, each tool having a
downwardly facing tip comprising two downwardly converging
surfaces, wherein two planes lying respectively on planar portions
of said two converging surfaces intersect at a tool theoretical
sharp location, wherein a common vertical distance separates the
tool theoretical sharp location and the upwardly facing
load-bearing shoulder for all the tools of said plurality, and a
plurality of press brake dies, each mounted on a rail carried by
the lower beam, each die having a bearing face with a bearing base
and a locating recess in which a locating ridge of the rail is
received, each die having a workpiece-contact face with an upwardly
open forming recess bounded by two downwardly convergent surfaces,
wherein two planes lying respectively on planar portions of said
two convergent surfaces intersect at a die theoretical sharp
location, wherein a shared vertical distance separates the die
theoretical sharp location and the bearing base for all the dies of
said plurality.
22. The press brake system of claim 21 wherein the tool holders on
the upper beam of the press brake have a centerline that extends
vertically downwardly and passes through all of the following: (a)
said downwardly facing force-transmitting surface of each tool
holder, (b) said upwardly facing load-bearing shoulder of each
tool, (c) the tool theoretical sharp location of each tool, and (d)
the die theoretical sharp location of each die.
23. The press brake system of claim 22 wherein the locating recess
of each die is not directly aligned with said centerline, such that
the locating recesses of the dies are spaced from said
centerline.
24. The press brake system of claim 22 wherein the locating recess
in each die has a width, and the dies all have a common die
locating dimension, the die locating dimension being defined as the
distance between said centerline and a midpoint of said width.
25. The press brake system of claim 21 wherein the tools and dies
when mated all have a common shut height, the shut height being
defined as the vertical distance between the bearing base and the
upwardly facing load-bearing shoulder of a mated tool and die
pair.
26. The press brake system of claim 21 wherein at least one
mateable tool and die pair is adapted to create a first bend, and
at least one other mateable tool and die pair is adapted to create
a second bend, the first and second bends being different, and
wherein said tools are punches.
27. The press brake system of claim 26 wherein the first and second
bends are 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.
28. The press brake system of claim 27 wherein the first or second
bend is a 90-degree bend.
29. The press brake system of claim 21 wherein a first mateable
tool and die pair is adapted to create a first bend, a second
mateable tool and die pair is adapted to create a second bend, and
a third mateable tool and die pair is adapted to create a third
bend, the first, second, and third bends all being different.
30. The press brake system of claim 21 wherein at least one of the
dies has a working height different from that of another die of
said plurality, the working height of a die being defined as the
distance between its bearing base and its workpiece-contact
face.
31. The press brake system of claim 30 wherein at least one of the
dies has a working height at least 1/16 inch greater than that of
another die of said plurality.
32. The press brake system of claim 30 wherein, on at least one of
the dies, the planar portions of said two convergent surfaces are
connected by a radiused valley section, such that the forming
recess would have a greater depth if its two convergent surfaces
converged at constant angles over their whole length until reaching
a vertex at the die theoretical sharp location rather than being
connected by a radiused valley section.
33. The press brake system of claim 21 wherein at least a plurality
of the tools are punches with tangs each having a safety recess
formed in one side.
34. The press brake system of claim 21 wherein the tool holders
have seating mechanisms that, in response to clamping movements of
the tool holders, move said upwardly facing shoulders of the tools
into contact with the respective downwardly facing
force-transmitting surfaces of the tool holders.
35. A tooling combination for a press brake having upper and lower
beams, the combination comprising: a plurality of press brake tools
adapted to be mounted in respective tool holders on the upper beam,
each tool having a tang, the tangs being adapted for receipt in
respective tool holders, at least one of the tools having a tip
configuration different from that of another tool of said
plurality, wherein there is a load-bearing shoulder on only one
side of the tang of each tool, each such shoulder being adapted to
contact a downwardly facing force-transmitting surface of a tool
holder when the tools are operatively mounted in respective tool
holders, each tool having a tip comprising two converging surfaces,
wherein two planes lying respectively on planar portions of said
two converging surfaces intersect at a tool theoretical sharp
location, wherein a common distance separates the tool theoretical
sharp location and the load-bearing shoulder for all the tools of
said plurality, and a plurality of press brake dies, each adapted
to be mounted on a rail carried by the lower beam, each die having
a bearing face with a bearing base and a locating recess adapted to
receive a locating ridge of the rail, each die having a
workpiece-contact face with a forming recess bounded by two
convergent surfaces, wherein two planes lying respectively on
planar portions of said two convergent surfaces intersect at a die
theoretical sharp location, wherein a shared distance separates the
die theoretical sharp location and the bearing base for all the
dies of said plurality.
36. The combination of claim 35 wherein the tools and dies when
mated all have a common shut height, the shut height being defined
as the distance between the bearing base and the load-bearing
shoulder of a mated tool and die pair.
37. The combination of claim 35 wherein at least one of the dies
has a working height different from that of another die of said
plurality, the working height of a die being defined as the
distance between its bearing base and its workpiece-contact
face.
38. The combination of claim 37 wherein at least one of the dies
has a working height at least 1/16 inch greater than that of
another die of said plurality.
39. The combination of claim 35 wherein, on at least one of the
dies, the planar portions of said two convergent surfaces are
connected by a radiused valley section, such that the forming
recess would have a greater depth if its two convergent surfaces
converged at constant angles over their whole length until reaching
a vertex at the die theoretical sharp location rather than being
connected by a radiused valley section.
40. The combination of claim 35 wherein at least one mateable tool
and die pair is adapted to create a first bend, and at least one
other mateable tool and die pair is adapted to create a second
bend, the first and second bends being different, and wherein said
tools are punches.
41. The combination of claim 40 wherein the first and second bends
are 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.
42. The combination of claim 35 wherein a first mateable tool and
die pair is adapted to create a first bend, a second mateable tool
and die pair is adapted to create a second bend, and a third
mateable tool and die pair is adapted to create a third bend, the
first, second, and third bends all being different.
43. The combination of claim 35 wherein at least a selected one of
the tools includes a seating mechanism, the seating mechanism being
adapted to seat the load-bearing shoulder of the selected tool
against a downwardly facing force-transmitting surface of a
selected tool holder in response to a clamping movement of the
selected tool holder.
44. The combination of claim 35 further including the press brake,
wherein each of a plurality of the tool holders comprises a
pivotable clamp.
45. A fabrication method involving a press brake with upper and
lower beams, the method comprising: providing a plurality of press
brake tools, each tool having a tang, at least one of the tools
having a tip configuration different from that of another tool of
said plurality, wherein there is a load-bearing shoulder on only
one side of the tang of each tool, each tool having a tip
comprising two converging surfaces, wherein two planes lying
respectively on planar portions of said two converging surfaces
intersect at a tool theoretical sharp location, wherein a common
distance separates the tool theoretical sharp location and the
load-bearing shoulder for all the tools of said plurality,
providing a plurality of press brake dies, each die having a
bearing face with a bearing base and a locating recess, each die
having a workpiece-contact face with a forming recess bounded by
two convergent surfaces, wherein two planes lying respectively on
planar portions of said two convergent surfaces intersect at a die
theoretical sharp location, wherein a shared distance separates the
die theoretical sharp location and the bearing base for all the
dies of said plurality, providing an arrangement of tools and dies
on the press brake by: (i) mounting the tools in respective tool
holders of the upper beam such that the load-bearing shoulders of
the tools confront downwardly facing force-transmitting surfaces of
respective tool holders, and (ii) mounting each die on a rail
carried by the lower beam such that the locating recess of each die
receives a locating ridge of the rail, positioning a workpiece
between a first mateable tool and die pair and then forming a first
bend in the workpiece by bringing the upper and lower beams of the
press brake together so as to deform the workpiece between the tool
and die of the first mateable pair, and without changing the
arrangement of tools and dies on the press brake, positioning the
workpiece between a second mateable tool and die pair and then
forming a second bend in the workpiece by bringing the upper and
lower beams of the press brake together so as to bend the workpiece
between the tool and die of the second mateable pair, wherein the
first and second bends are two different types of bends.
46. The method of claim 45 wherein the tool holders on the upper
beam have a centerline that extends vertically downwardly and
passes through all of the following: (a) said downwardly facing
force-transmitting surface of each tool holder, (b) said
load-bearing shoulder of each mounted tool, (c) the tool
theoretical sharp location of each mounted tool, and (d) the die
theoretical sharp location of each mounted die.
47. The method of claim 46 wherein the locating recess of each
mounted die is not directly aligned with said centerline, such that
the locating recesses of the mounted dies are spaced from said
centerline.
48. The method of claim 46 wherein the locating recess of each die
has a width, and the mounted dies all have a common die locating
dimension, the die locating dimension being defined as the distance
between said centerline and a midpoint of said width.
49. The method of claim 45 wherein the tools and dies when mated
all have a common shut height, the shut height being defined as the
distance between the bearing base and the load-bearing shoulder of
a mated tool and die pair.
50. The method of claim 45 wherein the first and second bends are
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.
51. The method of claim 50 wherein the first or second bend is a
90-degree bend.
52. The method of claim 45 wherein the method further comprises
using a third mateable tool and die pair to make a third bend in
the workpiece, the first, second, and third bends all being
different types of bends.
Description
FIELD OF THE INVENTION
[0001] 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.
BACKGROUND OF THE INVENTION
[0002] A variety of presses are used in fabricating sheet metal and
other workpieces. 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.
[0003] Most of today's original equipment manufacturers (OEMs) and
contract manufacturers have embraced the principles of lean
manufacturing. Many of the obvious offenders--the most wasteful
processes and excess inventory--have been revamped and streamlined.
But reaching the next level of lean is more challenging. It
requires manufacturers to dig deeper, carefully examining each
piece of the manufacturing puzzle for potential improvements.
[0004] 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.
[0005] As OEMs move to reduce inventory, and continue to call for
just-in-time (JIT) manufacturing, small-batch press brake runs are
increasingly common.
[0006] Smaller does not necessarily mean easier or more efficient,
though. Taking into account the setup time for multiple bends, it
can be difficult to justify the expense of complex short-run
jobs.
[0007] Thus, it would be desirable to provide 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.
[0008] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a press brake setup in
accordance with certain embodiments of the invention.
[0010] FIG. 2 is a side end view of a press brake setup in
accordance with certain embodiments of the invention.
[0011] FIG. 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.
[0012] FIG. 4 is a perspective view of the press brake setup of
FIG. 3, where the tools are shown in closed position.
[0013] FIG. 5A is a broken-away detail view of the tip of a press
brake tool in accordance with certain embodiments of the
invention.
[0014] FIG. 5B is a broken-away detail view of the tip of another
press brake tool in accordance with other embodiments of the
invention.
[0015] FIG. 6 is a side end view of a press brake setup in
accordance with certain embodiments of the invention.
[0016] FIG. 7 is a side end view of a die mounted on a rail in
accordance with certain embodiments of the invention.
[0017] FIG. 8 is a side end view of a die in accordance with
certain embodiments of the invention.
[0018] FIG. 9 is a side view of the die of FIG. 8, with the die
rotated 90.degree. from the position shown in FIG. 8.
[0019] FIG. 10 is a perspective view of a die mounted on a rail in
accordance with certain embodiments of the invention.
[0020] FIG. 11 is a perspective view of the rail-mounted die of
FIG. 10, with the die being rotated 90.degree. from the position
shown in FIG. 10 such that a ridge of the rail is received in a
second locating channel of the die.
[0021] FIG. 12 is a side end view of a die mounted on a rail in
accordance with certain embodiments of the invention.
[0022] FIG. 13 is a side end view of the rail-mounted die of FIG.
12, with the die being rotated 90.degree. from the position shown
in FIG. 12 such that a ridge of the rail is received in a second
locating channel of the die.
[0023] FIG. 14 is a perspective view of a rail on which multiple
dies are mounted in accordance with certain embodiments of the
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] The following detailed description is to be read with
reference to the drawings, in which like elements in different
drawings have like reference numerals. The drawings, which are not
necessarily to scale, depict selected embodiments and are not
intended to limit the scope of the invention. Skilled artisans will
recognize that the given examples have many useful alternatives,
which fall within the scope of the invention.
[0025] Staged bending is the execution of different types of bends
on a workpiece using a single press brake setup. In staged bending,
a plurality of (optionally all of the) different bends on a single
part can be made in succession, using a single setup.
[0026] Consider the manufacturing process for a cabinet component
(this is merely an example for purposes of discussion). The bending
process may require a 30-degree bend with hem, an offset bend, a
60-degree bend, and four 90-degree bends. Using conventional
methods, 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. Once the offset bends were complete, the operator
would either remove the offset punch and die or reposition them so
the top and bottom tool would not collide. Next, 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. When finished with
this bend, the operator would have to either remove or reposition
the 60-degree punch and die so the top and bottom tool would not
collide. Finally, 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.
[0027] In contrast, by using staged bending to bend the same part,
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.
[0028] Due to the considerable setup and programming time required
in conventional manufacturing methods, it is common to run large
batch sizes to gain the economies of scale needed to absorb the
non-value-added time (setup, teardown, and part handling). With
staged bending, much smaller production runs are feasible, because
setup, teardown, and part handling are eliminated or minimized.
This allows the fabricator to make what is needed when it is
needed, reducing both WIP and excess inventory.
[0029] 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.
[0030] 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 FIG. 6.
[0031] Turning to FIG. 1, it can be seen that in some embodiments,
different tool pairs on a single press are adapted to create
different bends. In these embodiments, 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.
[0032] In the present embodiments, 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.
Thus, for each such mateable tool pair, the upper and the lower
tools preferably have the same shut height 700 (or at least
substantially the same shut height). 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).
[0033] One group of embodiments provides a staged press brake
system including a press brake PB having upper 125 and lower 145
beams. In these embodiments, the system (or "setup") includes a
plurality of upper press brake tools 100 mounted in respective tool
holders TH on the upper beam 125. Preferably, each of these tools
100 has a tang TG, and the tangs are received in respective tool
holders.
[0034] As noted above, at least one of the upper tools 100 has a
tip configuration different from that of another upper tool. FIGS.
1-4 and 6 show exemplary embodiments of this nature. The tip
configurations of such tools can have different angles, different
radii, etc.
[0035] In some embodiments, 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. Additionally or alternatively, 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 0.001 inch, at least 0.002 inch, at least 0.01 inch, or
more.
[0036] In some embodiments, the setup includes at least three pairs
of mateable tools. These embodiments, for example, 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. Other possibilities include large-radius
bending and other acute-angle bends (such as 45-degree bending,
75-degree bending, or 85-89 degree bending, to name just a few
examples). 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.
[0037] In the embodiments shown in FIGS. 1-4 and 6, there is an
upwardly facing load-bearing shoulder LB on only one side of the
tang TG. This is perhaps best seen in FIGS. 2 and 6. Preferably,
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). In some
cases, the top end TE of the tang TG is spaced downwardly from the
tool holder's confronting downwardly facing surface DF. There are,
however, embodiments where these features are not present.
[0038] Referring to FIGS. 2 and 6, it can be seen that the
illustrated tang TG configuration involves a safety recess formed
in one side of the tang. In setups having one or more tools of this
nature, the safety recess can optionally receive a lip of a
pivotable clamp of a tool holder. In FIGS. 2 and 6, 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.
[0039] In FIGS. 1-6, each upper tool 100 has a downwardly facing
tip TP comprising two downwardly converging surfaces CV. Here, 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 FIG. 5A), or it may be at the
end of the tool's tip (see FIG. 5B).
[0040] 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, Minn., U.S.A.).
[0041] In the present embodiments, 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 FIG. 6). The term "common" here means
the distance is the same or substantially the same for the tools in
question. For embodiments where the upper tools are punches, this
distance 99 is the "punch staged height."
[0042] In some of the present embodiments, the tooling setup
includes at least one large-radius bending tool. Here, 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. Preferably, the
same is true of any flattening tools that may be included in the
tooling setup.
[0043] For embodiments where different tool pairs have at least
substantially the same shut height, any variance in the actual shut
heights preferably is less than 0.010 inch.
[0044] The present setup also includes a plurality of press brake
dies 10, 10'. Preferably, 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. Thus, the bottom of
each die preferably sits directly on the rail, and the bottom of
the rail preferably sits directly on the die holder.
[0045] As is perhaps best seen in FIGS. 7 and 8, 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. In the illustrated
embodiments, 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. Furthermore, 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.
[0046] In the present setup embodiments, each die 10, 10' also has
a workpiece-contact face 15FC, 15SC with an upwardly open forming
recess 15FR, 15SR. In the illustrated embodiments, each forming
recess 15FR, 15SR is bounded by two downwardly convergent surfaces
CS. Here, two planes P lying respectively on planar portions of the
two convergent surfaces CS intersect at a die theoretical sharp
location FTS, STS. Preferably, 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.
[0047] In FIG. 6, it can be appreciated that 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). Similarly, in the present setup
embodiments, 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. Reference is made to FIG. 7.
[0048] In some of the present embodiments (see FIG. 6), 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. For embodiments
involving a die with multiple forming recesses 15FR, 15SR, the term
"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 FIG. 7, which illustrates a staged
2-V die.
[0049] In embodiments like those of FIG. 6, 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. In some embodiments of this nature, 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 FIGS. 7 and 8. For purposes of the present
disclosure, the "die locating dimension" is defined as the distance
between the centerline 500 of the press brake PB and a midpoint of
the width 800, 810 of the operative locating recess 15FL, 15SL. For
embodiments involving a die with multiple locating recesses, 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).
[0050] Thus, in certain embodiments, the tools (e.g., punches) and
dies when mated all have a common shut height 700. For purposes of
this disclosure, 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.
[0051] As noted above, in the present embodiments, at least one
mateable tool and die pair is adapted to create a first bend, and
at least one other mateable tool and die pair is adapted to create
a second bend. The first and second bends here 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.) In some cases, the first or second bend is a 90-degree
bend. In certain embodiments, 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.
[0052] 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.
[0053] The present setup can have virtually any number of different
bending stations. Generally, each bending station includes at least
one mateable punch and die set. FIGS. 3 and 4 show one exemplary
setup having three bending stations. Here, 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.
[0054] In some embodiments, at least one of the dies 10, 10' has a
working height WH different from that of another die 10, 10'. This
is perhaps best appreciated by referring to FIGS. 1 and 7. 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. In some cases, 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.
[0055] In certain embodiments, the setup includes at least one die
(or a plurality of dies) having a forming recess with a radiused
bottom. In some cases, planar portions of two convergent surfaces
CS are connected by a radiused valley section RVS. This is the case
with the forming recesses 15FR, 15SR shown in FIGS. 8 and 9. 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. In FIG. 7, 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.
[0056] In some of the present setup embodiments, a plurality of the
tool holders TH on the press brake PB have pivotable clamps CL.
This is perhaps best seen in FIGS. 1, 2, and 6. Useful European
style tool holders are described in U.S. Pat. No. 6,003,360, the
salient teachings of which are incorporated herein by reference.
Generally, each clamp CL is pivotable about a horizontal axis. In
FIG. 2, it can be seen that 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. In the
illustrated embodiments, the tool holder TH has pivotable clamps CL
spaced from both sides of the support plate 114. This, however, is
not required.
[0057] In one group of embodiments, 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 Ser. Nos. 11/178,977 and 11/230,742, the
salient teachings of which are incorporated herein by
reference.
[0058] Thus, some embodiments of the invention involve a staged
press brake system (e.g., a setup) that includes a press brake PB.
Other embodiments, though, simply provide a combination of staged
tools 100, 10, 10' for a press brake system. Preferably, 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'.
[0059] Commonly, the tools 100 are upper tools adapted to be
mounted in respective tool holders on the upper beam 125. As noted
above, each tool 100 has a tang TG, and the tangs are adapted for
receipt in respective tool holders TH. In the present tooling
combination, 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.
[0060] In some of the present embodiments, there is a load-bearing
shoulder LB on only one side of the tang TG of each tool 100.
Preferably, each such shoulder LB (e.g., a surface SS thereof) is
adapted to contact a downwardly facing force-transmitting surface
LD of a tool holder TH when the tools 100 are operatively mounted
in respective tool holders. In certain embodiments, each tool 100
(or at least one 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. In the present embodiments, 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.
[0061] In connection with the dies 10, 10', each one preferably is
adapted to be mounted on a rail 20. In the illustrated embodiments,
the die rail 20 is mounted on a die holder 30, which is supported
by the press brake's lower beam 145. Preferably, 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. And 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. As noted above, two planes P lying
respectively on planar portions of such two convergent surfaces CS
intersect at a die theoretical sharp location FTS, STS. As with the
setup embodiments described above, 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.
[0062] In the illustrated embodiments, each workpiece-contact face
15FC, 15SC has a single forming recess. In the figures, two flush,
planar surfaces are separated by each forming recess. These
features, however, are not required in all embodiments.
[0063] In the tooling combination embodiments, 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).
[0064] In some of the tooling combination embodiments, at least one
of the dies 10, 10' has a working height WH different from that of
another die. This is perhaps best seen in FIG. 1. In some cases, 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. This, however, is not
required.
[0065] In certain embodiments, the tooling combination includes at
least one die having a forming recess with a radiused bottom. For
example, 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. As
noted above, one or more of the forming recesses can alternatively
have two convergent surfaces CS that come to a sharp vertex.
[0066] In the present tooling combination, at least one mateable
tool and die pair is adapted to create a first bend, and 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. For example, 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.
[0067] In some embodiments, 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. Here again, the first, second, and third bends are all
different types of bends.
[0068] Thus, 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.
[0069] In one group of embodiments, 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 Ser. No. 11/451,148, the salient teachings
of which are incorporated herein by reference.
[0070] Some embodiments provide the tooling combination together
with a press brake. Setup embodiments of this nature have already
been described. As noted above, in some of these embodiments, one
or more (optionally each) of the tool holders comprises a pivotable
clamp CL. This is best seen in FIGS. 1, 2, and 6.
[0071] 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. In some of these embodiments, there is a
load-bearing shoulder on only one side of the tang of each tool.
Preferably, 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. As already
explained, 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.
[0072] 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, 15SI. 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. As noted above, two
planes P lying respectively on planar portions of such two
convergent surfaces intersect at a die theoretical sharp location
FTS, STS. Preferably, 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'.
[0073] In the present method, 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.
[0074] 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.
[0075] In some of the present embodiments, the method further
includes using a third tool set to make a third bend in the
workpiece WP. In such cases, the first, second, and third bends are
all different types of bends. As just one example, the first bend
can be a 90-degree bend, the second bend can be a 60-degree bend,
and the third bend can be a 30-degree bend. Many other bend
combinations, of course, can be used, depending upon the particular
part being fabricated.
[0076] The invention also provides a group of embodiments involving
a staged quick-change die. In some of these embodiments, the die 10
has multiple forming recesses, e.g., multiple Vs. Reference is made
to FIGS. 7-14. Here, 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.
[0077] The term "V" can refer to a V-shaped recess with a sharp
vertex, a V-shaped recess with a radiused bottom, etc.
[0078] 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. After milling, the tool
can be ground on all working surfaces. After grinding, the part can
either be milled or cut with a saw to lengths. Once the tools have
been milled, ground and cut to length, 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.
[0079] Referring to FIG. 8, the illustrated die 10 has a first
bearing face 15FB and a first workpiece-contact face 15FC. Here,
the first bearing face 15FB and the first workpiece-contact face
15FC are on opposed (i.e., opposite) sides of the die 10. In FIG.
8, these two faces 15FB, 15FC are parallel (or at least generally
or substantially parallel) to each other.
[0080] 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. For example, the die can
alternatively have a generally rectangular cross section. Or the
cross section can have various other polygonal shapes. The die can
alternatively have a more irregular cross-section.
[0081] The first bearing face 15FB includes a first bearing base
15FBB and a first locating recess (e.g., channel) 15FL. In the
illustrated embodiments, 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.
[0082] The present die 10 is a quick-change die, which can be
mounted on a rail 20 (see FIGS. 7 and 10-14). Thus, 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. In
the illustrated embodiments, 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.
[0083] Referring to FIGS. 2, 7, 12, and 13, it can be seen that
when the die is mounted on the rail, there preferably is at least
some separation, e.g., a gap 333, between the top of the rail's
ridge 25 and the confronting end surface ES of the locating recess
in which the ridge 25 is received. The lateral dimension of the
ridge 25, however, preferably fits snuggly within the width of the
locating recess.
[0084] The first workpiece-contact face 15FC has therein formed a
first forming recess 15FR. In the illustrated embodiments, this
forming recess 15FR is V-shaped or generally V-shaped. However,
this recess can be provided in a variety of different shapes,
depending upon the particular bend desired.
[0085] In FIG. 8, 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. In the
embodiment of FIG. 8, the first forming recess 15FR terminates in a
radiused valley section RVS. Thus, 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. In other cases, the first forming recess 15FR
terminates in a sharp vertex at the first theoretical sharp
location FTS. Reference is made to FIG. 7.
[0086] For purposes of the present disclosure, the term "first
theoretical sharp distance" FTSD is defined as the distance between
the first bearing base 15FB (the base surface 15FBB thereof) and
the first theoretical sharp location FTS. Reference is made to FIG.
9.
[0087] In the present embodiments, 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.
[0088] The second bearing face 15SB includes a second bearing base
15SBB and a second locating recess (e.g., channel) 15SL. In the
illustrated embodiments, 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.
[0089] The second workpiece-contact face 15SC has therein formed a
second forming recess 15SR. Here, the recess 15SR is generally
V-shaped and is bounded by two convergent surfaces CS. Preferably,
two planes P lying respectively on planar portions of these two
convergent surfaces CS intersect at a second theoretical sharp
location STS.
[0090] The term "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 FIG. 9.
[0091] In some embodiments, the first 15FR and second 15SR forming
recesses have different sizes (e.g., different widths). For
example, the die 10 can have two Vs of different size. In FIG. 7,
for example, the first forming recess 15FR is larger (e.g., wider
and/or deeper) than the second forming recess 15SR. The situation,
of course, can be reversed. That is, the second forming recess can
be larger than the first forming recess. In the present
embodiments, the first forming recess 15FR has a first width, the
second forming recess 15SR has a second width, and the first and
second widths are different, yet 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). This dimensioning
feature makes it possible to use either forming recess on the die
with a staged tooling set-up.
[0092] 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 FIG. 7, the first
forming recess 15FR comes to a sharp bottom, as does the second
forming recess 15SR. In FIGS. 8 and 9, both forming recesses 15FR,
15SR have radiused bottoms. In FIGS. 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.
[0093] In certain embodiments, 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. Reference is made to FIG. 8. Preferably, 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 FIG. 8.
[0094] Additionally or alternatively, 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. Reference is made to FIG. 9. Here again, 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
FIG. 9.
[0095] 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.
[0096] For purposes of the present disclosure, 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. Similarly, 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. In certain embodiments, the first and second-die locating
dimensions are the same or substantially the same.
[0097] In some embodiments, 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. In these embodiments, even
though the first and second working heights are different, the
first and second theoretical-sharp distances FTSD, STSD are the
same or substantially the same. Thus, the present die is a staged,
multiple forming recess (e.g., multiple-V) die.
[0098] 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. Additionally or alternatively, 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. Embodiments of this
nature have already been described.
[0099] In certain embodiments, 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 FIGS.
10, 11, and 14. Additionally or alternatively, the first 15FR and
second 15SR forming recesses can extend entirely along the die's
length.
[0100] In FIGS. 7-14, 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.
[0101] In illustrated 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 FIGS. 10, 11
and 14. Here, 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.
[0102] In FIGS. 7-14, the first 15FL and second 15SL locating
recesses are both rectangular channels. As noted above, the 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.
[0103] In the illustrated embodiments, 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 FIG. 10. In other
embodiments, the die can have more faces.
[0104] Skilled artisans will appreciate that various materials can
be used in manufacturing the present punches and dies. Following
are a few examples of materials from which the tool bodies can be
formed: (1) pre-hard tool steel, optionally with a Nitride hardened
surface or the like (the Nitrided surface can have an HRC rating of
up to 70); (2) pre-hard steel, optionally with laser hardened,
flame hardened, or induction hardened working surfaces (optionally
28-32HRC for the pre-hard material, or 45-60 HRC for the hardened
working surfaces); (3) thru-hardened tool steel, optionally with a
hardness of 50-52HRC.
[0105] In certain embodiments, 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.
[0106] While a preferred embodiment of the present invention has
been described, it should be understood that various changes,
adaptations and modifications may be made therein without departing
from the spirit of the invention and the scope of the appended
claims.
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