Apparatus and method for stripping away/pushing out a punched grid/internally formed part and ejecting a blanked part in a precision blanking press

Abstract

In an apparatus and a method for stripping/pushing out a punched grid and for ejecting a blanked part from a die in a precision blanking press, the force of stripping/pushing out and ejection can be adjusted independent of the knife-edged ring force and the counterstay counteracting force while reducing the mass of the knife-edged ring and counterstay pistons, increasing the stripping/pushing and ejection speeds, and at the same time simplifying the hydraulic circuit.

Claims

1. A hydraulically actuated apparatus configured to cooperate, as part of a fine blanking press, with a punch die comprised of a punch, a hole punch, a die block and a knife-edged ring block comprising a knife-edged ring, the punch having an axial throughhole and an annular distal end, the hole punch being configured to be received in the throughhole at the distal end of the punch, the punch die being configured to blank the workpiece to form a blanked part from an internal part of the workpiece and a part in the form of a grid, the hydraulically actuated apparatus comprising a top and a base, a knife-edged ring-actuating cylinder disposed in the top, a knife-edged ring-actuating piston received in the cylinder disposed in the top and configured to apply a force that acts on first pins, the first pins being guided in said cylinder and configured to act on the knife-edged ring block, said knife-edged ring-actuating cylinder including a pressure chamber configured to be pressurized by a hydraulic fluid, a main cylinder disposed in the base, a main piston with a counterstay piston actuated by a pressure chamber communicating only with the counterstay piston, the counterstay piston being configured to act on second pins, the second pins being guided in said base and configured to apply a force to the clamped workpiece counter to a punching force applied to the clamped workpiece by the punch, the main cylinder comprising pressure chambers configured to be pressurized by a hydraulic fluid to actuate the main piston, said main piston being configured to make a stroke in a direction of a stroke axis and thereby to blank the workpiece to form a grid retained on the die block and an interior part of the workpiece punched out by the hole punch and retained in the punch, and a hydraulic system for supplying the pressure chambers with the hydraulic fluid, a central control system configured to adjust the fluid to a predetermined working pressure, wherein the knife-edged ring-actuating piston and cylinder and a stripping/pushing piston and cylinder are disposed in the top as a first unit and the counterstay piston and an ejecting piston are disposed as a second unit in the base, the stripping/pushing piston is configured to apply a force to strip the grid from the die block and the ejection piston is configured to apply a force to eject the punched out part of the workpiece out of the punch, the stripping/pushing piston comprises a piston rod extending through and coaxially with the knife-edged ring-actuating piston, a pusher block is formed at a distal end of the piston rod abutting a surface of a distal end of the knife-edged ring-actuating piston, the pressure chamber in the knife-edged ring-actuating cylinder operatively communicates only with the knife-edged ring-actuating piston, the stripping/pushing cylinder is situated atop the knife-edged ring-actuating cylinder, at least one respective pressure chamber situated in the stripping/pushing cylinder operatively communicates only with the stripping/pushing piston and a respective pressure chamber operatively communicates only with the ejecting piston, the pressure chamber operatively communicating with the stripping/pushing piston and the pressure chamber respectively communicating with the ejecting piston are in mutual connection by way of a first controllable hydraulic circuit of a hydraulic system, and the respective pressure chambers operatively communicating with the knife-edged ring-actuating piston and with the counterstay piston respectively are in mutual connection by way of a second controllable hydraulic circuit wherein the first and the second controllable hydraulic circuits are configured to be controlled independently of one another and wherein the main piston is provided with a channel having a first section perpendicular to and a second section parallel to the stroke axis for pressurizing the pressure chamber which communicates operatively with the counterstay piston with hydraulic fluid of redetermined pressure from the second hydraulic circuit of the hydraulic system.

2. The apparatus according to claim 1, wherein the stripping/pushing piston is dual-acting and operatively communicates with first and second respective pressure chambers therefor in the stripping/pushing cylinder.

3. The apparatus according to claim 1, wherein the stripping/pushing cylinder is sealed pressure-tight by a cover through which a hydraulic line connected to the hydraulic system is guided for pressurizing the first pressure chamber with hydraulic fluid of a predetermined pressure from the first hydraulic circuit.

4. The apparatus according to claim 1, wherein the stripping/pushing cylinder comprises a channel in a wall area thereof for pressurizing the second pressure chamber with hydraulic fluid of a predetermined pressure from the first hydraulic circuit of the hydraulic system, the channel comprising a first section parallel to the stroke axis and a second section perpendicular to the stroke axis.

5. The apparatus according to claim 1, wherein the stripping/pushing cylinder is provided with a channel for pressurizing the pressure chamber operatively connected to the knife-edged ring-actuating piston with hydraulic fluid of a predetermined pressure from the second hydraulic circuit of the hydraulic system.

6. The apparatus according to claim 1, further comprising a channel in the main piston extending perpendicular to the stroke axis, which channel communicates between the first hydraulic system and the pressure chamber which communicates with the ejecting piston for purposes of pressurization with hydraulic fluid of a predetermined pressure, whereby the ejecting piston and the counterstay piston can make a stroke movement independent of one another.

7. The apparatus according to claim 1, wherein the first hydraulic circuit comprises a high-pressure accumulator, the accumulator being configured to operate at the working pressure of the stripping/pushing piston and ejecting piston by the hydraulic system by way of a built-in valve, a first proportional valve associated with the pressure chambers operatively communicating with the stripping/pushing piston and a second proportional valve associated with the pressure chamber operatively communicating with the ejecting piston for the purposes of turning on and shutting off the pressure chambers of the stripping/pushing piston and the ejecting piston, a pressure sensor for the first proportional valve, and a pressure sensor the second for proportional valve configured to control the built-in valve.

8. The apparatus according to claim 1, wherein the second hydraulic circuit comprises at least one first built-in valve configured to connect two of the respective pressure chambers of the ring piston and the counterstay pistons and for adjusting working pressure, at least one pressure sensor for controlling the built-in valve and at least one hydraulic pump unit associated with at least one second built-in valve for adjusting flow of hydraulic fluid, at least one pressure sensor for controlling the at least one second built-in valve and at least one pressure limiting valve for limiting pressure of the hydraulic fluid and maintaining flow thereof.

9. A method of using the apparatus of claim 1 to punch out the interior part of the workpiece thereby to form the punched out part and the grid from the workpiece, strip away the punched grid from the die block, and eject the punched out part from the punch, comprising first generating a force to press the knife-edged ring into the workpiece by use of the knife-edged ring-actuating piston and the stripping/pushing piston disposed in the top of the press, said force acting on the knife-edged ring block by way of the first pins, and generating a counteracting force directed opposite to the blanking by use of the counterstay piston disposed in the base of the press, whereupon the hydraulic fluid is displaced from the pressure chamber of the knife-edged ring-actuating piston or counterstay piston at an adjustable pressure during blanking and, after blanking, pressuring the pressure chamber of the knife-edged ring-actuating piston in the press top and pressuring the pressure chamber of the counterstay piston in the press base by the hydraulic fluid from the hydraulic system, the hydraulic fluid in the hydraulic system being set to a predetermined working pressure, then using the central control system, providing a predetermined stripping/pushing force for only to the stripping/pushing piston which strips the punched grid resulting from blanking of the workpiece and then setting the pressure chamber which communicates with the ejecting piston to a predetermined ejection force which ejects the punched out part, wherein the stripping/pushing force and the force applied to the knife-edged ring as well as the ejection force and the counteracting force are generated in pressure chambers that are separate from one another, using active surfaces that are correspondingly matched to the stripping/pushing and ejecting processes, wherein the pressure chambers for the stripping/pushing force and the pressure chambers for the force applied to the knife-edged ring and counteracting forces are controlled by the central control system using the hydraulic fluid of a preset pressure in the independently controlled first and second hydraulic circuits of the hydraulic system controlled so that the knife-edged ring-actuating piston which applies the force to the knife-edged ring and the counterstay piston which applies the counteracting force lag behind the stripping/pushing piston and ejector piston during stripping and ejecting.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 a schematic representation of the precision blanking process according to the prior art,

(2) FIG. 2 a schematic representation of the stripping/pushing and ejection process in precision blanking according to the prior art,

(3) FIG. 3 a section of the top with knife-edged ring cylinder and stripping/pushing cylinder,

(4) FIG. 3 a section of the top of the press,

(5) FIG. 4 a section of the stripping/pushing cylinder with knife-edged ring cylinder,

(6) FIG. 5 a section of the stripping/pushing cylinder with a representation of the channel for the pressure chamber of the knife-edged ring cylinder,

(7) FIG. 6 a section of the base of the press with table top,

(8) FIG. 7 a section of the main piston with table top and

(9) FIG. 8 a schematic representation of the operational sequence of the method according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

(10) FIG. 1 shows the working principle of precision blanking in the manufacture of a blanked part 1 with an inner shape in a punch die 2 made up of a top part 3 and a bottom part 4. The material to be blanked 7 is clamped between the die block 5 of the bottom part 4 and the guide or knife-edge ring block 6 of the top part 3. The knife-edged ring force F.sub.R acting on the guide or knife-edged ring block 6 by way of pressure pins 8 has pressed the knife-edged ring 9, which is located in the guide or knife-edged ring block 6, into the material to be blanked 7. In the positional state shown, the punch 10, which is guided by the guide or knife-edged ring block 6, cuts into the material to be blanked 7 with punching force F.sub.S, wherein a counterstay 11 counteracts the punch 10 with counterforce F.sub.G applied to the counterstay 11 by way of pressure pin 12. The hole punch 13 is guided in the counterstay 11 and punches the inner shape into the material to be blanked 7 counter to the punching force F.sub.S of the punch 10.

(11) The pusher 14 acts as a counterstay for the hole punch 13.

(12) Shown schematically in FIG. 2 is the stripping/pushing process for the punched grid 15 and the part to be blanked 1. Prior to the beginning of blanking, the knife-edged ring 9 is pressed into the material to be blanked 7 outside of the cut line. During blanking using the punch 10, the force F.sub.R is displaced by the upwardly-moving main piston/ram of the precision blanking press and the punched grid 15 is stripped away from the punch 10 by the stripping force F.sub.RA after blanking is finished and while the die is open, and the inner shape is pushed out into the die cavity.

(13) At the beginning of blanking, the counterforce F.sub.G immediately acts against the die 10 and is exceeded by the punching force F.sub.S. When the blanking process has ended, the ejection force F.sub.GA ejects the blanked part 1 from the punch opening of the die block 5.

(14) The pressure pins 8 for the guide or knife-edged ring block 6 and the pressure pins 12 for counterstay 11 are hydraulically actuated.

(15) FIG. 3 shows the top 16 of a hydraulic precision blanking press, which is not further illustrated. A receiving space 17 for a knife-edged ring cylinder 19 designed as a core member 18 is disposed in the top 16 of the press in line with the stroke axis HU, the ring cylinder having a perforated base 20 facing the bottom side US of the top 16, a tubular neck 21 facing the top side OS of the top 16 and a flange 22 associated with the perforated base 20.

(16) A stripping/pushing cylinder 25 is placed on the tubular neck 21 at the end of the core member 18 in abutment therewithas shown in FIG. 4coaxial to the stroke axis HU, the cylinder sealing the knife-edged ring cylinder chamber 26 pressure-tight by way of bolted attachment. The stripping/pushing cylinder 26 and the core member 18 are secured at the top 16 against rotation using a groove piece 27. A cylinder chamber 28 is formed in the stripping/pushing cylinder 25, the chamber being closed in by way of a cover 29 that is bolted on pressure-tight and holds a dual-acting stripping/pushing piston 30.

(17) The stripping/pushing piston 30 subdivides the cylinder chamber 28 into a first pressure chamber 31a associated with one side of the stripping/pushing piston 30 and a second pressure chamber 31b associated with the other side of the stripping/pushing piston 30. The cover 29 has a center feed opening 32 for connecting a hydraulic line 33 of the hydraulic system 34 in order to pressurize the first pressure chamber 31a with hydraulic fluid.

(18) The second pressure chamber 31b is connected to the hydraulic system 34 for purposes of pressurization with hydraulic fluid of a predetermined pressure, said connection being made by way of a channel 36 made in the wall area 35 of the stripping/pushing cylinder 25 parallel and perpendicular to the stroke axis HU and through hydraulic line 33a (see FIG. 4).

(19) The stripping/pushing piston 30 is connected to a piston rod 37 that is passed through a knife-edged ring piston 38 that is guided in the knife-edged ring cylinder chamber 26 along the stroke axis HU, the piston rod supporting a pusher block 39 supported on the perforated base 20 of the core member 18.

(20) A pressure chamber 40 is associated with the knife-edged ring piston 38 in the knife-edged ring cylinder chamber 26, the pressure chamber being connected through hydraulic line 33b to the hydraulic system 34 by way of another channel 41 disposed in the wall area 35 of the stripping/pushing cylinder 25 (see FIG. 5).

(21) Knife-edged ring pins 43 and pressure pins 44 associated with the knife-edged ring piston 38 are guided vertically displaceably in the holes 42 of the perforated base 20 in line with the stroke axis HU. Immediately below the perforated base 20 lies a coplanar piston block 45 inside a recess 46 of the core member 18, the piston block enclosing a centrally disposed, cylindrical washer-shaped support member 47. The support member 47 has through holes 48 for the pressure pins 44, the holes disposed coaxial to the stroke axis HU. A support block 49 is located below the piston block 45 in another recess 50 that is opposite recess 46 and that is displaced outward in stepped fashion, wherein the support block 49 is disposed coplanar to the piston block 45.

(22) Through holes 51 are located in the support block 49, pressure pins 52a and 52b being guided in said holes, wherein pressure pins 52a are associated with pressure pins 44 penetrating the support member 47 and pressure pins 52b are associated with the knife-edged ring pins 43.

(23) In the blanking process, pressure pins 52a and 52b, piston block 45, pressure pins 44, knife-edged ring pins 4L pushing block 39, piston rod 37, stripping/pushing piston 30 and knife-edged ring piston 38 move synchronously upward, in other words toward top 4. The hydraulic fluid in the pressure chamber 40 of knife-edged ring piston 38 and in pressure chamber 31a of the stripping/pushing piston 30 is displaced.

(24) As soon as the main piston/ram 55 reaches the upper dead point OT, the stripping/pushing piston 30 is activated and the stripping process begins, in other words working chamber 31 a is pressurized with hydraulic fluid. Stripping/pushing piston 30 synchronously pushes the pusher block 39 and thereby all pressure pins 52a, 52b, knife-edged ring pins 43 and pressure pins 44 as well as the piston block 45 downward, in other words toward base 53. Said pressure pins push on the pressure pins in the die, which are not further shown, which strip away the punched grid from the punch and push out the internally formed part.

(25) The knife-edged ring piston 38 follows behind the stripping/pushing piston 30 in parallel therewith or with a time delay, and at a lower speed, when working chamber 40 is pressurized with hydraulic fluid.

(26) FIG. 6 shows the base 53 in a sectional representation. A main cylinder chamber 54 is formed in the base 53, the axis HA of the chamber lying on the stroke axis HU of the precision blanking press and holding the dual-acting main piston 55. The main piston 55 has a cylindrical shaft 56 comprising protruding discus-shaped working surfaces 57a and 57b that protrude out perpendicularly from the axis HA of the shaft, the surfaces subdividing the main cylinder chamber 58 into two pressure chambers 59a and 59b with minimal travel so that base 53 has a low design height. Pressure chambers 59a and 59b are each connected to the hydraulic system 34 through a channel 60a and 60b, respectively, and corresponding connections and hydraulic lines 61. The main cylinder chamber 58, and as a result pressure chamber 59a, is sealed off pressure-tight by way of a cover 62.

(27) Depending on the pressurization of pressure chambers 59a and 59b with hydraulic fluid of a predetermined pressure, the main piston makes a corresponding stroke movement between the upper dead point OT and the lower dead point UT.

(28) A counterstay cylinder chamber 63 is formed in the main piston 55, a counterstay piston 64 and an ejector piston 65 being held in said chamber, the piston rod 66 of the ejector piston passing through the middle of the counterstay piston 64 and ending in a pressure chamber 68 for piston rod 66 with pusher block 39. The counterstay piston 64 separates out a pressure chamber 69 in the cylinder chamber 63 of the main piston 55.

(29) Pressure chamber 68 for the ejector piston 65 and pressure chamber 69 for the counterstay piston 64 are connected to hydraulic line 33 of the hydraulic system 34 by way of separate channels 70a and 70b made in the shaft 56 perpendicular to axis HA through distribution recesses 71 made in shaft 56 and channels 72a and 72b in the base 53.

(30) FIG. 7 refers to the arrangement and fastening of the table top 73 at main piston 55. The bottom of table top 73 abuts shaft 56 of the main piston 55 and has a protruding cylindrical bottom area 74 whose diameter is matched to the diameter of the shaft 56 of the main piston 55.

(31) The bottom area 74 of the table top 73 is provided with holes 75 that run coaxial to the stoke axis HU. Counterstay pins 76 are guided in holes 75, the pins being supported by a piston block 78 disposed in a recess 77 above the bottom area 74, the block comprising a central cylindrical washer-shaped support member 79.

(32) The support member 79 has through holes 80 coaxial to the stroke axis HU for pressure pins 81 that are led through the holes 80 of the support member 79. A support block 82 is located above piston block 78 in a recess 83 that is opposite recess 77 and that is displaced outward in stepped fashion, wherein the support block 82 is disposed coplanar to piston block 78.

(33) Through holes 84a and 84b are made in the support block 82, wherein pressure pins 85 are guided in through holes 84a, the pins being associated with the counterstay pins 76 and the pressure pins 81 that pass through the through holes 84b through the support member 79.

(34) Pressure pins 81 and 85, piston block 78, counterstay pins 76, ejector block 39, piston rod 66, ejector piston 65 and counterstay piston 64 move synchronously downward during the blanking step. The hydraulic fluid in the pressure chamber 68 of the ejector piston 65 and in pressure chamber 69 of the counterstay piston 64 is displaced.

(35) As soon as the main piston 55 has reached the push-out switching point in upward movement when the die is opened, the ejector piston 65 is activated and the ejection of the blanked part punched into the die block begins, in other words pressure chamber 68 is pressurized with hydraulic fluid. Ejector block 39 presses all pressure pins 76, 81 and 85 as well as the piston block 78 synchronously upward. Pressure pins 81 and 85 press onto the pressure pins in the die, which are not further shown, which eject the blanked part out of the punch opening of the die block and into the internal cavity of the die.

(36) The counterstay piston 64 follows behind in parallel therewith or with a time delay, and at a lower speed, when pressure chamber 69 is pressurized with hydraulic fluid.

(37) The operational sequence of the method according to the invention is described with the help of FIG. 8 which shows excerpts of the circuit of pressure chambers 31a and 31b of the stripping/pushing piston 30 including the pressure chamber 68 of the ejector piston 65 and of the circuit of pressure chamber 40 of the knife-edged ring piston 38 including pressure chamber 69 of the counterstay piston 64 in the first hydraulic circuit 92 and the second hydraulic circuit 93.

(38) The pressure chambers 31a and 31b of the stripper/pusher piston 30 and the pressure chamber 68 of the ejector piston 65 in the first hydraulic circuit 92 are supplied by way of a common high-pressure accumulator 86 for hydraulic fluid, the accumulator being adjusted using a logical built-in valve 88 that is controlled by a central control system 87 and is connected to the hydraulic system 34 through hydraulic line 33 and adjusted to a desired pressure level matched to the stripping/pushing force F.sub.RA and ejector force F.sub.GA. The adjustment and the turning on and off of the pressure chambers 31a and 31b as well as pressure chamber 68 is done using a respective 4/3-way proportional valve 89 and 90, said valve being integrated into the respective hydraulic line 33, wherein a respective pressure sensor 91a and 91b in hydraulic line 33 is associated with each valve for purposes of controlling the 4/3-way proportional valves 89 and 90 using the central control system 87.

(39) The second hydraulic circuit 93 comprises at least one built-in valve 94 associated with the pressure chamber 40 of the knife-edged ring piston 38 and the pressure chamber 69 of the counterstay piston 64, said built-in valve adjusting the working pressure, at least one pressure sensor 95 for pressure detection in the second hydraulic circuit 93 and for sending the pressure value to the central control system 87 for controlling the built-in valve 94, and at least one hydraulic pump unit 96. Associated with the hydraulic pump unit 96 is at least one built-in valve 97 for adjusting the flow, at least one pressure limiting valve 98 for limiting the pressure of the flow stream and at least one pressure sensor 95 for pressure detection and sending the pressure value to the central control system 87 to control the built-in valve 94.

(40) Pressure chambers 31a, 31b and 68 of the first hydraulic circuit 92 and pressure chambers 40 and 69 of the second hydraulic circuit therefore represent separate control circuits which are adjusted separately based on the position of the ram by the central control system by way of the built-in valve 88 and the 4/3-way proportional valves 89 and 90 on the one hand and the built-in valve 94 and the hydraulic pump unit 96 on the other.

(41) The method according to the invention therefore makes it possible to control the stripper/pusher force F.sub.RA and the ejector force F.sub.GA independent of the knife-edged ring piston 38 and the counterstay piston 64.

(42) In another variation, the hydraulic circuit 92 can also supply the pressure chamber 90 from the accumulator 86 and the hydraulic circuit 93 can supply the pressure chamber 31a from the pump.