Punching tools

Abstract

The disclosure relates to punching tools for punching machines for punching plate-shaped materials. The punching tools have an upper tool part with an upper cutting edge and a lower tool part with a lower cutting edge that move axially with respect to each other. The upper and lower cutting edges are arranged to cut off a part of the workpiece in a punching stoke. The upper cutting edge and/or the lower cutting edge include one or more transition regions that separate the cutting edge into at least two adjacent portions. The transition regions include, in the punching direction with respect to the respective adjacent portions, a discontinuity that is adapted to cut the material cut off from the workpiece into two or more individual parts in the same punching stroke.

Claims

1. A punching tool for a punching machine for cutting off material from a plate-shaped workpiece and for reducing a linear dimension of the material cut off from the workpiece, the punching tool comprising an elongated upper tool part and an elongated lower tool part that when mounted in a punching machine are arranged to move relative to each other in a punching direction, wherein: the elongated upper tool part comprises a first upper cutting edge and the lower tool part comprises a lower cutting edge, wherein the first upper cutting edge comprises two narrow side cutting edges and two elongated side cutting edges of the elongated upper tool part to delimit an upper cutting face and the lower cutting edge comprises side edges of the elongated lower tool part to delimit a lower cutting face, wherein the first upper cutting edge and the lower cutting edge are arranged opposite to each other, respectively, so that a material is cut off from the workpiece by the respective first upper cutting edge and the lower cutting edge upon a punching stoke; the two elongated side cutting edges of the first upper cutting edge are each partitioned into two portions by a transition region comprising a discontinuity in the form of a sharp cutting tip, wherein the discontinuity of the sharp cutting tip comprises a triangular cross-section with sides having an angle that is steeper than an angle of the two portions of the elongated side cutting edges on either side of the discontinuity when viewed perpendicular to the elongated side cutting edges, and wherein a second upper cutting edge extends across the entire upper cutting face from the sharp cutting tip of one of the two elongated side cutting edges to the sharp cutting tip of the other elongated side cutting edge, and extending parallel to the two narrow side cutting edges of the upper cutting face, the second upper cutting edge is adapted to first contact the material to be cut off from the workpiece and cut an inner area of a contour of the material to be cut off from the workpiece into two parts, each part still being connected to the workpiece and at least one of the narrow side cutting edges and at least one of the elongated side cutting edges of the first upper cutting edge are adapted to thereafter cut the two parts from the workpiece and separate the cut off material into two separate parts that each have a reduced linear dimension than the entire material cut off from the workpiece, in one punching stroke; and a distance (A) between the upper cutting face and the lower cutting face in a direction parallel to the punching direction, increases linearly along both of the portions of each of the two elongated side cutting edges of the first upper cutting edge from a smallest distance (A) at the sharp cutting tip to a larger distance (A) at the two narrow side cutting edges of the upper cutting face.

2. A method for cutting off material from a workpiece and for reducing a linear dimension of the material cut off from the workpiece, the method comprising obtaining a punching tool of claim 1 and mounting the punching tool into a punching machine; inserting a workpiece into the punching machine; and performing a single punching stroke with the punching tool, whereby a part of the material to be cut off from the workpiece is cut off with the first upper cutting edge and a linear dimension of the cut off part is reduced by cutting the cut off part of the material with the at least one second upper cutting edge in the same punching stroke, wherein the material to be cut off is first cut by the at least one second upper cutting edge into at least two parts, each still being connected to the workpiece, and those two parts are then cut off from the workpiece by at least one of the narrow side cutting edges and at least one of the elongated side cutting edges of the first upper cutting edge in a continuous motion of the upper tool part in the same punching stroke.

3. The method of claim 2, wherein the punching tool comprises a transition region that further reduces the linear dimension of the cut off part of the material by deforming the cut off part of the material.

4. A punching tool for a punching machine for cutting off material from a plate-shaped workpiece and for reducing a linear dimension of the material cut off from the workpiece, the punching tool comprising an elongated upper tool part and an elongated lower tool part that when mounted in a punching machine are arranged to move relative to each other in a punching direction, wherein: the elongated upper tool part comprises a first upper cutting edge and the lower tool part comprises a lower cutting edge, wherein the first upper cutting edge comprises two narrow side cutting edges and two elongated side cutting edges of the elongated upper tool part to delimit an upper cutting face and the lower cutting edge comprises side edges of the elongated lower tool part to delimit a lower cutting face, wherein the first upper cutting edge and the lower cutting edge are arranged opposite to each other, respectively, so that a material is cut off from the workpiece by the respective first upper cutting edge and the lower cutting edge upon a punching stoke; the two elongated side cutting edges of the first upper cutting edge are each partitioned into two portions by a transition region comprising a discontinuity in the form of a sharp cutting tip, wherein the discontinuity of the sharp cutting tip comprises a triangular cross-section with sides having an angle that is steeper than an angle of the two portions of the elongated side cutting edges on either side of the discontinuity when viewed perpendicular to the elongated side cutting edges, and wherein a second upper cutting edge extends entirely across the upper cutting face from the sharp cutting tip of one of the two elongated side cutting edges to the sharp cutting tip of the other elongated side cutting edge, and extending parallel to the two narrow side cutting edges of the upper cutting face, the second upper cutting edge is adapted to first contact the material to be cut off from the workpiece and cut an inner area of a contour of the material to be cut off from the workpiece into two parts, each part still being connected to the workpiece, and at least one of the narrow side cutting edges and at least one of the elongated side cutting edges of the first upper cutting edge are adapted to thereafter cut the two parts from the workpiece and separate the cut off material into two separate parts that each have a reduced linear dimension than the entire material cut off from the workpiece, in one punching stroke; and a distance (A) between the upper cutting face and the lower cutting face in a direction parallel to the punching direction increases non-linearly along the two portions of each of the two elongated side cutting edges of the first upper cutting edge from a smallest distance (A) at the sharp cutting tip to larger distances (A) at the two narrow side cutting edges of the upper cutting face, wherein the two portions of each of the two elongated side cutting edges adjacent to the sharp cutting tip comprise a concave shape in the direction parallel to the punching direction.

5. A method for cutting off material from a workpiece and for reducing a linear dimension of the material cut off from the workpiece, the method comprising obtaining a punching tool of claim 4 and mounting the punching tool into a punching machine; inserting a workpiece into the punching machine; and performing a single punching stroke with the punching tool, whereby a part of the material to be cut off from the workpiece is cut off with the first upper cutting edge and a linear dimension of the cut off part is reduced by cutting the cut off part of the material with the at least one second upper cutting edge in the same punching stroke, wherein the material to be cut off is first cut by the at least one second upper cutting edge into at least two parts, each still being connected to the workpiece, and those two parts are then cut off from the workpiece by at least one of the narrow side cutting edges and at least one of the elongated side cutting edges of the first upper cutting edge in a continuous motion of the upper tool part in the same punching stroke.

6. The method of claim 5, wherein the punching tool comprises a transition region that further reduces the linear dimension of the cut off part of the material by deforming the cut off part of the material.

7. A punching tool for a punching machine for cutting off material from a plate-shaped workpiece and for reducing a linear dimension of the material cut off from the workpiece, the punching tool comprising an elongated upper tool part and an elongated lower tool part that when mounted in a punching machine are arranged to move relative to each other in a punching direction, wherein: the elongated upper tool part comprises a first upper cutting edge and the lower tool part comprises a lower cutting edge, wherein the first upper cutting edge comprises two narrow side cutting edges and two elongated side cutting edges of the elongated upper tool part to delimit an upper cutting face and the lower cutting edge comprises side edges of the elongated lower tool part to delimit a lower cutting face, wherein the first upper cutting edge and the lower cutting edge are arranged opposite to each other, respectively, so that a material is cut off from the workpiece by the respective first upper cutting edge and the lower cutting edge upon a punching stoke; the two elongated side cutting edges of the first upper cutting edge are each partitioned into two portions by a transition region comprising a discontinuity in the form of a sharp cutting tip, wherein the discontinuity of the sharp cutting tip comprises a triangular cross-section with sides having an angle that is steeper than an angle of the two portions of the elongated side cutting edges on either side of the discontinuity when viewed perpendicular to the elongated side cutting edges, and wherein a second upper cutting edge extends entirely across the upper cutting face from the sharp cutting tip of one of the two elongated side cutting edges to the sharp cutting tip of the other elongated side cutting edge, and extending parallel to the two narrow side cutting edges of the upper cutting face, the second upper cutting edge is adapted to first contact the material to be cut off from the workpiece and cut an inner area of a contour of the material to be cut off from the workpiece into two parts, each part still being connected to the workpiece, and at least one of the narrow side cutting edges and at least one of the elongated side cutting edges of the first upper cutting edge are adapted to thereafter cut the two parts from the workpiece and separate the cut off material into two separate parts that each have a reduced linear dimension than the entire material cut off from the workpiece, in one punching stroke; and a distance (A) between the upper cutting face and the lower cutting face in a direction parallel to the punching direction increases non-linearly along the two portions of each of the two elongated side cutting edges of the first upper cutting edge from a smallest distance (A) at the sharp cutting tip to larger distances (A) at the two narrow side cutting edges of the upper cutting face, wherein the two portions of each of the two elongated side cutting edges adjacent to the sharp cutting tip comprise a convex shape in the direction parallel to the punching direction.

8. A method for cutting off material from a workpiece and for reducing a linear dimension of the material cut off from the workpiece, the method comprising obtaining a punching tool of claim 7 and mounting the punching tool into a punching machine; inserting a workpiece into the punching machine; and performing a single punching stroke with the punching tool, whereby a part of the material to be cut off from the workpiece is cut off with the first upper cutting edge and a linear dimension of the cut off part is reduced by cutting the cut off part of the material with the at least one second upper cutting edge in the same punching stroke, wherein the material to be cut off is first cut by the at least one second upper cutting edge into at least two parts, each still being connected to the workpiece, and those two parts are then cut off from the workpiece by at least one of the narrow side cutting edges and at least one of the elongated side cutting edges of the first upper cutting edge in a continuous motion of the upper tool part in the same punching stroke.

9. The method of claim 8, wherein the punching tool comprises a transition region that further reduces the linear dimension of the cut off part of the material by deforming the cut off part of the material.

Description

DESCRIPTION OF DRAWINGS

(1) FIG. 1A shows a partial sectional side view of an upper tool part and a lower tool part during a punching stroke in which a portion of the cutting edges cuts off a portion of a material to be cut off.

(2) FIG. 1B shows a partial sectional side view of the upper tool part and the lower tool part of FIG. 1A with the divided cut off material after a completed punching stroke.

(3) FIG. 2 shows a partial sectional side view of an upper tool part and a lower tool part with divided and deformed cut off material after a completed punching stroke.

(4) FIGS. 3A, 3B, and 3C show schematic side views of an upper tool part having step-shaped transitions and having portions of the cutting edges with a respectively constant distance in a punching direction to a cutting edge of a lower tool part (not shown).

(5) FIGS. 4A and 4B show schematic side views of an upper tool part having step-shaped transitions and having portions with a respectively non-constant distance in the punching direction to the cutting edge of a lower tool part (not shown).

(6) FIGS. 5A and 5B show schematic side views of an upper tool part having kinks as transitions and having portions with a respectively non-constant distance in the punching direction to the cutting edge of a lower tool part (not shown).

(7) FIG. 6A shows a schematic side view of an upper tool part having a tip as transition and having portions having a respectively non-constant distance in the punching direction to the cutting edge of a lower tool part (not shown).

(8) FIG. 6B shows a schematic side view of an upper tool part having a tip as transition point and having portions with concave shapes.

(9) FIG. 6C shows a schematic side view of an upper tool part having a tip as transition point and having portions with convex shapes.

(10) FIG. 7A shows a schematic side view of the upper tool part having portions with step-shaped transition points and with a respectively constant distance in the punching direction to the cutting edge of the lower tool part (not shown) and with additional further cutting edges;

(11) FIG. 7B shows a schematic front view of the upper tool part of FIG. 7A.

DETAILED DESCRIPTION

(12) FIG. 1A shows a partial sectional side view of an upper tool part 1 and of a lower tool part 2 of a punching tool. The upper tool part 1 and the lower tool part 2 are shown in a state being mounted in a punching machine and they have an axis 3. The upper tool part 1 and the lower tool part 2 are movable relatively with respect to each other along the axis 3.

(13) The lower tool part 2 is accommodated in a tool holder (not shown) and the punching machine comprises a drop out orifice 10 through which cut off material can exit.

(14) FIG. 1B shows the upper tool part 1 and the lower tool part 2 of FIG. 1A after a completed punching stroke. Due to the state when the upper tool part 1 and the lower tool part 2 moved apart from each other, an upper cutting edge 6 of the upper tool part 1 and a lower cutting edge 7 of the lower tool part 2 can be seen in this illustration.

(15) The upper cutting edge 6 delimits an upper cutting face 4 and the lower cutting edge 7 delimits a lower cutting face 5. The cutting edges 6, 7 are complementary with respect to each other and they have a required clearance.

(16) The cutting faces 4, 5 are provided respectively at front sides of the upper tool part 1 and the lower tool part 2 in direction of the axis 3, i.e., in the punching direction. The upper cutting face 4 of the upper tool part 1 and the upper cutting edge 6 are partitioned in three portions 4a, 4b, and 4c along the cutting edge 6. As shown below, the upper cutting edge 6 can alternatively also be partitioned in another number of portions. However, at least two portions must be provided. Between the portions 4a, 4b, and 4c, a transition region 8 is respectively provided. The transition region 8 comprises a discontinuity along the upper cutting edge 6 in direction of the axis 3. As used herein, the term “discontinuity,” means a sudden change of the upper cutting face. Examples of a discontinuity include, e.g., a step, a kink, or a tip.

(17) Alternatively, also the lower cutting face 5 of the lower tool part 2 may comprise a transition region 8. Hereby, it is then necessary that the lower tool part 2 is provided with a spring-loaded stripper or that the punching machine is provided with an active lower tool holder enabling an axial motion of the lower tool part 2.

(18) As shown in FIG. 1B, the transition regions 8 respectively separate portions 4a and 4b, and portions 4b and 4c. At the portions 4a, 4b, and 4c, the upper cutting edge 6 and the lower cutting edge 7 have a distance A in direction of the axis 3 from each other in a respectively predetermined position of the upper tool part 1 and the lower tool part 2. In the embodiment shown in FIGS. 1A and 1B, the distance A within one of the portions 4a, 4b, and 4c is constant and it increases or decreases stepwise along the cutting edges 6, 7.

(19) In operation, a punching stroke of the upper tool part 1 is performed after a positioning of a plate-shaped workpiece 9, e.g., a piece of sheet metal. Thereby, during the punching stroke, firstly, an inner area of a contour to be punched out is stretched against its internal stress beyond its elastic limit or yield strength until the material cracks by the portion 4b with the least axial distance A between the upper cutting edge 6 and the lower cutting edge 7 and a segment 9a of a material to be cut off drops downwardly through the drop out orifice 10 (as shown in FIG. 1B).

(20) When further moving the upper tool part 1 during the punching stroke, further segments 9b, 9c of the residual material to be cut off are cut off by means of the same mechanism and drop downwardly through the drop out orifice 10 (FIG. 1B).

(21) By cutting the cut off material of the workpiece 9 into three parts, the cut off material, the entire linear dimension of which would otherwise be larger than a diameter of the drop out orifice 10, can reliably be disposed of through the drop out orifice 10 without seizing or jamming.

(22) The separation of the punching slugs during a single punching stroke along several planes, e.g., into several pieces, results basically from the velocity of the punching stroke and the resistivity of the material or raw material to be punched. In the case in which the resistivity of the material or raw material to be punched is relatively low, an emerging punching slug is partially deformed or bent before it is divided, whereby a enveloping circle (i.e., a projected length of the punching slug when the bent punching slug is projected onto a underlying plane) of the punching slug to be disposed of is smaller than the drop out orifice 10 of the punching machine. However, it is not necessary that the transition region 8 has an exact discontinuity, but slight deviations of an ideal step, an ideal tip, or an ideal kink are possible as long as the resistivity of the material or raw material to be punched in conjunction with the velocity of the punching stroke enables cutting.

(23) In FIG. 2, a partial sectional side view of the upper tool part 1 of another embodiment and of the lower tool part 2 after a completed punching stroke is shown. In this embodiment, the upper tool part 1 comprises a transition region 8 in the form of a transition point configured as a tip. The lower tool part 2 is unchanged with respect to the preceding embodiment.

(24) In operation, in this embodiment a segment is not previously punched out such as in FIGS. 1A and 1B. Here, during the punching stroke, the material is firstly stretched beyond its elasticity limit or its yield strength by the tip until it is deformed or divided and, then, the material to be cut off is cut off from the workpiece 9 by the cutting edges 6 at the portions 4a, 4b in a further motion of the upper tool part 1 in the same punching stroke, whereby it is divided into the two segments 9a, 9b. Also here, the cut off material, the entire linear dimension of which is larger than a diameter of the drop out orifice 10, is reliably disposed of through the drop out orifice 10 without seizing or jamming by cutting the cut off material into the two segments 9a and 9b.

(25) The cutting edges 6 of the portions 4a, 4b adjacent to the transition point 8 configured as a tip have a distance A in the punching direction to the second cutting edge 7, which is not constant within the portions 4a, 4b. The distance A increases in a non-linear manner and the cutting edges 6 in the portions 4a, 4b have a concave shape in this embodiment. By the non-linear change (concave shape), the segments 9a, 9b are additionally deformed so that a linear dimension, therefore, a projected length, of the cut off material is further shortened. Thereby, it is possible to avoid the need for additional transition points 8. In addition, further enlargement of the cutting edges 4, 5 is possible without increasing the risk of seizing or jamming in an orifice of the lower tool part 2 or in the drop out orifice 10.

(26) FIGS. 3 to 6 show various embodiments of transition regions 8 and arrangements of portions 4a, 4b, 4c, 4d, and 4e. The lower cutting edge 7 of the lower tool part 2 is not illustrated here, but in conjunction with these figures, the term “axial distance A” as discussed above means the axial distance from the upper cutting edge 6 to the lower cutting edge 7.

(27) FIGS. 3A to 3C, respectively, show an upper tool part 1, the upper cutting face 4 and the upper cutting edge 6, both of which are partitioned by steps (bounds) as transition points 8 into three portions 4a, 4b, and 4c (as shown in FIG. 3A) or the five portions 4a, 4b, 4c, 4d, and 4e (as shown in FIGS. 3B and 3C).

(28) In FIGS. 3A and 3B, the distance A in the punching direction of the upper cutting edge 6 in the portions 4a, 4b, 4c, 4d, and 4e increases respectively stepwise in a direction from the center along the upper cutting edge 6. Alternatively, the distances can also increase stepwise beginning from an end of the cutting edge 6.

(29) In FIG. 3C, at the portions 4a, 4b, 4c, 4d, and 4e, the distance in the punching direction of the upper cutting edge 6 of the upper tool part 1 increases or decreases stepwise along the cutting edge 6. The distance A of the cutting edge 6 of one of the portions 4a, 4b, 4c, 4d, and 4e in this embodiment is identical to the distance A of the cutting edge 6 of the next-but-one portion 4a, 4b, 4c, 4d, and 4e. In an alternative embodiment, the distance A of the cutting edge of the next-but-one portion 4a, 4b, 4c, 4d, and 4e is not identical.

(30) In FIGS. 4A and 4B, the upper cutting face 4 and the upper cutting edge 6 of the upper tool part 1 comprise the portions 4a, 4b, 4c, (FIG. 4A) or the portions 4a, 4c (FIG. 4B) where the distance A from the upper cutting edge 6 to the lower cutting edge 7 is not constant. Here, a saw tooth shape along the cutting edges is formed by the shape of the portions.

(31) Also in FIGS. 5A and 5B, the distance A in the punching direction between the upper cutting edge 6 of the upper tool part 1 and the lower cutting edge 7 within the portions 4a, 4b, 4c, and 4d is not constant. However, in these embodiments, the transition points or regions 8 are formed as discontinuations in the form of kinks.

(32) In FIG. 6A to 6C, as also in FIG. 2, the transition region 8 in the form of a transition point configured as a discontinuation of the cutting face 4 of the upper tool part 1 in the shape of the tip. The distance A in the punching direction between the upper cutting edge 6 and the lower cutting edge 7 is not constant within the several portions 4a, 4b adjacent to the tip.

(33) In FIG. 6A, beginning from the tip, the distance A in the punching direction from the upper cutting edge 6 to the lower cutting edge 7 linearly increases along the upper cutting edge 6 within the portion 4a, 4b.

(34) In FIGS. 6B and 6C, the distance A increases non-linearly and as described with respect to FIG. 2, in addition to being severed the cut off material is also deformed in the punching direction by the concave shape (FIG. 6B) or convex shape (FIG. 6C), whereby the linear dimension of the cut off part is additionally decreased.

(35) By the transition region 8 in the form of a transition point shaped as a discontinuity, mainly by a transition point 8 configured as a step, a varying rollover can occur so that a proper edge cannot be manufactured in the punching process, because the cut edge may be uneven.

(36) FIGS. 7A and 7B show a punching tool that in addition to the upper cutting edges 6 and a lower cutting edges 7 has, a further upper cutting edge 11 on the upper tool part 1, which corresponds to the lower cutting edge 7 on the lower tool part 2. The further upper cutting edge 11 is set back with respect to the upper cutting edge 6 in the axial direction and, as shown in FIG. 7B, is arranged laterally of the upper cutting edge 6 outside the upper cutting face 4 at the upper tool part 1. The lateral offset between the upper cutting edge 6 and the further upper cutting edge 11 amounts to a few tenths of a millimeter. Provided that the function of the cutting and/or the deforming of the cut off material and an even cut are enabled, the lateral offset can alternatively also be some other size.

(37) In operation, a part of the material to be cut off is severed by the upper cutting edge 6 and the lower cutting edge 7 and is cut, and separated, and as the case may be, deformed, as described with respect to FIGS. 1A to 1C, in a first step in one and the same punching stroke, whereby, however, a varying rollover can occur. When continuing the same punching stroke, in a second step, a further portion of the material to be cut off, namely remaining residual of material between a pre-punching contour and a finish-punching contour, breaks by the further upper steady cutting edge 11 and the lower cutting edge 7 and a punching edge having a continuous rollover results. The material cut off from the workpiece 9 is divided into the segments 9a, 9b, and 9c. Since a width of the remaining residual of material is only very small, these are also divided and the segments 9a, 9b, and 9c with the respective residuals of material can be disposed of through the drop off orifice 10 without the risk of seizing or jamming.

(38) The various embodiments can be combined to each other.

OTHER EMBODIMENTS

(39) A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.