MACHINE AND METHOD FOR FORMING INTER-SHEET REGISTERING CONTOURS IN METAL BLANKS FOR SEPARATION

Abstract

An apparatus for making one or more registering contour features in a workpiece. At least some of the registering contour features have an outer annular rim and basin-shaped portion there within. One embodiment has: (i) one or more first tools, each tool being adapted to form the outer annular rim in one or more registering contour features; and (ii) one or more second tools for forming in cooperation with the first set of insert tools one or more of the basin-shaped portions that lie within the outer annular rims, thereby forming a set of one or more registering contour features in the workpiece so that workpieces in a stack are separated to facilitate subsequent handling by removing an uppermost workpiece from the stack.

Claims

1. An apparatus for making one or more registering contour features in a workpiece at the same location in each workpiece to enable a stack of such workpieces to be separated, each registering contour feature having an annular rim and a basin-shaped portion lying there within, the apparatus comprising: (i) an upper tool adapted to form the annular rim in one or more registering contour features; and (ii) a lower tool for forming in cooperation with the upper tool an inner basin-shaped portion that lies within the annular rim, thereby forming a set of one or more registering contour features in the workpiece, whereby the registering contour features of adjacent workpieces in a stack provide an inter-workpiece separation of intermediate sections of the workpieces that lie between the registering contour features, wherein the registering contour features are formed prior to the bottom of a press stroke and/or prior to a cutting of the workpiece to remove regions thereof that include the registering contour features.

2. The apparatus of claim 1, wherein the upper tool is a female tool.

3. The apparatus of claim 2, wherein the lower tool is a male tool.

4. The apparatus of claim 3, wherein one or more of the male tools include rounded leading ends.

5. The apparatus of claim 2, wherein the female tool includes the basin-shaped portion.

6. An apparatus for making one or more registering contour features in a workpiece at the same location in each workpiece to enable a stack of such workpieces to be separated, each registering contour feature having an annular rim and a basin-shaped portion lying there within, the apparatus comprising: (i) a lower tool adapted to form the annular rim in one or more registering contour features; and (ii) an upper tool for forming in cooperation with the lower tool the inner basin-shaped portion that lies within the annular rim, thereby forming a set of one or more registering contour features in the workpiece, whereby the registering contour features of adjacent workpieces in a stack provide an inter-workpiece separation of intermediate sections of the workpieces that lie between the registering contour features, wherein the contour features are formed prior to the bottom of a press stroke and/or prior to a cutting of the workpiece to remove regions thereof that include the registering contour features.

7. The apparatus of claim 1, wherein the workpiece comprises a material that can receive and resist a closure pressure non-destructively as the upper and lower dies converge without imparting damage to the workpiece.

8. An array of stacked workpieces, one or more workpieces in the stack having an intermediate planar portion and one or more registering contour features extending from the intermediate planar portion, one or more of the registering contour features in a first workpiece having an outer annular rim; and a basin-shaped portion that lies within the annular rim.

9. The array of claim 8, wherein the outer annular rim of the registering contour feature of the first workpiece at least partially cooperate with the outer annular rim in a registering contour feature of an adjacent workpiece.

10. The array of claim 8, wherein the basin-shaped portion in a registering contour feature of the first workpiece is spaced apart from the basin-shaped portion in a registering contour feature of an adjacent workpiece.

11. The array of claim 8, further including a space between planar portions of adjacent workpieces.

12. The array of claim 8, wherein a space lies between the outer annular rim of the registering contour feature of the first workpiece and the outer annular rim in a registering contour feature of an adjacent workpiece.

13. The array of claim 8, in which the planar section of one or more workpieces in the stack has an imaginary datum plane, a top of the rim of the outer annular rim lying above the imaginary datum plane and the basin-shaped portion has a lowermost portion that lies below the datum plane.

14. A method for making a registering contour feature in a workpiece comprising the steps of (A) providing: (i) one or more upper tools, each upper tool being adapted to form an outer annular rim in one or more registering contour features; and (ii) one or more lower tools for forming in cooperation with the upper tool a basin-shaped portion to lie within an outer annular rim, thereby forming a set of one or more registering contour features in the workpiece; (B) inserting a workpiece between the die sets; (C) closing the die sets so that they form a localized contour feature in the workpiece; (i) prior to the die being completely closed; and/or (ii) prior to any cutting of the workpiece; (D) opening the die sets; and (E) withdrawing the workpiece.

15. A method for making a registering contour feature in a workpiece comprising the steps of (A) providing: (i) one or more lower tools, each lower tool being adapted to form an outer annular rim in one or more registering contour features; and (ii) one or more upper tools for forming in cooperation with the lower tool a basin-shaped portion to lie within an outer annular rim, thereby forming a set of one or more registering contour features in the workpiece; (B) inserting a workpiece between the die sets; (C) closing the die sets so that they form a localized contour feature in the workpiece; (i) prior to the die being completely closed; and/or (ii) prior to any cutting of the workpiece. (D) opening the die sets; and (E) withdrawing the workpiece.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0015] FIG. 1 is a quartering perspective view of an apparatus including a press with a lower die and an upper die in accordance with one embodiment and practice variant.

[0016] FIG. 2 is a sectional view of the apparatus in an open position with an annular rim-shaped outer contour feature forming tool and a button-shaped inner contour feature forming tool.

[0017] FIG. 2A is an enlarged portion (A) of FIG. 2 that illustrates the annular rim-shaped outer forming tool and the button-shaped inner forming tool in more detail.

[0018] FIG. 3 illustrates the apparatus in a position where an outer annular rim and crater are formed.

[0019] FIG. 3A is a view of a workpiece;

[0020] FIG. 4 illustrates the apparatus in a position where an inner annular rim is formed, at which point in the movement or travel of the press, all forming of the localizing contour feature is complete.

[0021] FIG. 4A is a view of the resulting workpiece.

[0022] FIG. 5 illustrates the apparatus in a closed position.

[0023] FIG. 5A is a view of the resulting workpiece.

[0024] FIG. 6 is a representative top view of a registering contour feature made with the disclosed apparatus.

[0025] FIG. 7 shows sectional views of stacked workpieces and registering contour features.

[0026] FIG. 8 shows sectional views of intermediate regions between registering contour features of adjacent workpieces in partial registration with each other to enforce a spacing between the intermediate regions of adjacent workpieces.

DETAILED DESCRIPTION OF THE INVENTION

[0027] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0028] FIGS. 1-5 show an overall apparatus and exemplary parts of an embodiment of the forming apparatus. In summary, those parts include a press with lower and upper die sets;

TABLE-US-00001 Parts List ITEM NAME 1 Upper Die Set 2 Upper Cutting Tool 4 Large Forming Tool 6 Workpiece 8 Lower Die Set 9 Shim for Large Male Tool 11 Stripper 12 Small Forming Tool 13 Jam Nut 14 Shim 15 Spacer 17 Pressurized Cylinder 19 Lower Cutting Tool

[0029] FIGS. 6-8 illustrate various aspects of a contour feature arrangement 20 (top elevation view, FIG. 6) in a workpiece 6 and in stacked workpieces (FIGS. 7-8) for inter-workpiece spacing. In FIG. 7 the vertical cross sections of a nest of three workpieces 6 are shown, in which the registering contour features 30 of adjacent workpieces 6 are stacked on top of each other. A rim 34 in the registering contour feature 30 of one workpiece 6 underlies the rim of a registering contour feature in the workpiece positioned there above. Similarly, a concave, basin-shaped section 40 of one workpiece 6 underlies the corresponding concave section of a workpiece positioned there above. There is an interstitial space 46 between the rims 34 of adjacent workpieces. Optionally, other interstitial spaces 48 separate the concave sections 40 of adjacent workpieces. In a given workpiece, an inter-workpiece contact area 32 is formed between a rim 34 and the concave section 40. In a stack of two or more workpieces 6, the contact areas 32 abut.

[0030] In the cross sections of the embodiment depicted, there are two shoulders 34 that are connected by an annular rim 50 for each registering contour feature 30 and one concave, basin-shaped section 40. Other embodiments may have more rims with rounded valleys therebetween. Like the rims 50, the concave basin-shaped sections 40 are positioned so that concave sections of adjacent workpieces preferably are separated by the space 48 (FIG. 7). As a result, FIG. 8 shows exemplary gaps 36 or interstitial spaces lying between the workpieces 6 and between sets of registering contour features in a given workpiece. In practice, such gaps or interstitial spaces may be lessened or closed by the sagging of intermediate regions between registering contour features associated with stacked workpieces.

[0031] The air gaps 36 separate the workpieces 6 so that they can be removed from a stack one at a time and not adhere due to a fluid film therebetween. One set of experiments measured typical dimensions between workpieces 6 (FIGS. 7-8).

[0032] Consider the upper die 1 and the lower die 8 in an open position before one of the workpieces 6 (FIG. 2A) is loaded, i.e. inserted therebetween. An outer annular rim-forming tool 4 is supported by the upper die 1. The lower die 8 supports an inner basin-forming tool (having an optional shape like a button) 12. If desired, these tools could be placed on the opposing die or upside down so that the upper die 1 may support the button tool and the lower die 8 may support the tool that forms the annular rim.

[0033] It will be appreciated that a given die set may support multiple tools 4, 12 so that multiple registering contour features may be formed on a given workpiece or workpieces 6 by one closure (or multiple closures) of the dies. Optionally, the process may operate in more than one place of a workpiece or on more than one workpiece at a time, subject to the design of the cutting die. In practice, one closure may operate on multiple workpieces simultaneously within the die, although one workpiece at a time is preferred.

[0034] As to the inner basin-shaped section 40, in FIGS. 3-4, the upper and lower dies 1, 8 are in the stroke position. The small male insert 12 enters the large insert 4 to form a registering contour feature shape 30. The spacer or jam nut 15 is now in contact with the bottom of the stripper 11 to control how deeply to make a small basin-shaped recess that forms a part of the registering contour feature. The small insert 12 is threaded into the jam nut 13 and the spacer 15. The height of the small recess can be adjusted by adding or removing the thickness of the small shim 14. It will be appreciated that the die still has to close more to cut the material with cutting tools 2, 19 as the registering contour feature is completely formed before the workpiece is cut.

[0035] Turning now to FIG. 5, the die is at the bottom of the press stroke. The stop block contacts the upper die 1, thereby arresting its downward travel. Preferably, the workpiece 6 is now trimmed with the registering contour feature close to an edge of the workpiece. As used herein, the term edge connotes an outer peripheral edge, or an edge of an inner hole (for example, in the case of an automobile body having multiple holes cut for doors).

[0036] Desirably, registering contour features 30 of adjacent metal workpieces 6 are aligned (see, FIGS. 6-7). After workpieces 6 are stacked, adjacent workpieces are separated by sets of registering contour features 30 because contacting portions 32 of the rim portions 34 of adjacent workpieces abut. Thus, an air gap 36 is created between the workpieces and between side portions 38 of the vertically aligned sets of registering contour features 30. This facilitates material handling because lateral access to interstitial spaces is now available.

[0037] As mentioned earlier, the apparatus includes one or more sets of tools for forming the registering contour features 30. Such tools may be selected to make registering contour features 30 with a topography that includes undulations, indentations, depressions, impressions, projections and the like in the workpiece. As noted earlier, one or more sets of registering contour feature forming tools can be located on the upper or lower dies (FIGS. 1, 2, 2A) or on both.

[0038] Thus, there has been disclosed a metal processing apparatus for forming one or more sets of registering contour features 30 in a workpiece 6 that may be made of a ferrous material, or a non-ferrous material such as a carbon-reinforced section or a plastic.

[0039] In one embodiment, the registering contour features 30 may be formed by nested basin-shaped portions 40 (concave sections) that have radii of curvature (FIG. 7) such that spaces are formed between the shoulder portions 34 of the registering contour features of adjacent workpieces. Similarly, for basin-shaped portions 40. (FIG. 7).

[0040] It will be appreciated that using suitable process parameters (e.g., strain rates, temperatures, tool dimensions and pressures) the registering contour features can be pressed into the workpiece without weakening the workpieces themselves.

[0041] As noted earlier, the registering contour features can be characterized in a workpiece of a given thickness and material by a footprint having a height and diameter. The footprint can preferably be circular, oval, or elliptical. An indentation with a curved perimeter is generally desired over other geometries (e.g., a square, rectangle, a polygon) that have abrupt changes in perimetral edges. Usually, the footprint has a rim 34 (like the edge of a volcano) that lies above a crater or concave section or basin 40 (female portion), which may have another dome that rises there from.

[0042] With further references to FIGS. 7-8, an exemplary array of stacked workpieces 6 includes one or more workpieces in the stack having a planar section 44 and one or more registering contour features 30 extending from the planar portion. One or more of the registering contour features in a first workpiece has an outer annular rim 34 and an inner concave section 40 that lies within the annular rim. The outer annular rim 34 of the registering contour feature 30 of the first workpiece 6 cooperates with the outer annular rim in a registering contour feature of an adjacent workpiece. The inner concave section 40 in a registering contour feature of the first workpiece 6 cooperates with the inner concave section in a registering contour feature of an adjacent workpiece. As a result, a space 48 lies between planar portions of adjacent workpieces. Correspondingly, a space 46 may also lie between the shoulder portions 34 in a registering contour feature of the first workpiece and the shoulder portions in a registering contour feature of an adjacent workpiece.

[0043] In an alternative embodiment (see, FIG. 7) the planar section 44 of one or more workpieces in the stack has a central plane that defines an imaginary datum plane (R-R). A top of the rim 34 lies above the imaginary datum plane and the inner concave section 40 has a lowermost portion that lies below the datum plane.

[0044] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.