Tool components and related machines and methods

Abstract

In some aspects of the invention, tool components for processing of plate-like workpieces, the tool component include an end face adjoined by a tool region provided for regrinding, the tool region being configured to undergo regrinding as a result of wear; and at least one identification mark located on the tool component to indicate the amount of shortening of the tool region as a result of regrinding.

Claims

1. A tool die for processing of plate-like workpieces, the tool die comprising: an end face adjoined by a tool region provided for regrinding; and at least one identification mark located on the tool die to indicate an amount of shortening of the tool region as a result of regrinding, wherein the tool region comprises a frustoconical inclined portion formed around the end face, wherein the identification mark extends circumferentially along an outer surface of the frustoconical inclined portion in a substantially helical manner, wherein the tool die defines a smooth bore extending from the end face, the smooth bore being configured to receive a punching tool for processing a plate-like workpiece supported above the end face of the tool die, and wherein the identification mark travels from the end face in an axial direction that is perpendicular to the end face to a maximum axial length of the identification mark, wherein the identification mark terminates at a single revolution around the end face at the maximum axial length, and wherein the maximum axial length corresponds to a maximum regrinding length of 1 mm from an initial axial position of the end face in a new, non-ground state of the tool die.

2. The tool die according claim 1, further comprising a scale for determining the amount of shortening of the tool region from the identification mark.

3. The tool die according to claim 2, wherein the scale is in the form of a dial.

4. The tool die according to claim 1, wherein at least one characteristic of the identification mark changes axially with respect to the end face.

5. The tool die according to claim 4, wherein the characteristic changes gradually.

6. The tool die according to claim 4, wherein the characteristic is shape or color.

7. The tool die according to claim 1, wherein the identification mark is spaced from the end face so that it is located outside the tool region that is ground during a regrinding process.

8. The tool die according to claim 1, wherein the identification mark is spaced from the end face by a distance that corresponds to a maximum regrinding length of the tool die.

9. The tool die according to claim 1, wherein the identification mark comprises a helical line.

10. The tool die according to claim 1, wherein the end face of the tool die defines an opening from which the smooth bore extends, the opening being configured to receive the punching tool.

11. The tool die according to claim 1, wherein the amount of shortening is provided along a direction perpendicular to the end face.

12. The tool die according to claim 1, wherein the smooth bore is configured to receive a portion of the plate-like workpiece that is punched through by the punching tool.

13. The tool die according to claim 1, wherein the frustoconical inclined portion has a circular cross-sectional shape with a plurality of grooves that define a scale for determining the amount of shortening of the tool region from the identification mark.

14. The tool die according to claim 1, wherein in the new, non-ground state of the tool die, the identification mark is visible, in its entirety, within a 360 degree angle traversed by the identification mark within the single revolution, and wherein in a completely reground state of the tool die, the identification mark is completely removed such that the identification mark is not visible.

15. The tool die according to claim 14, wherein in the completely reground state of the tool die, a part of the frustoconical inclined portion remains visible.

16. The tool die according to claim 1, wherein the end face has an annular shape.

17. A machine tool for punching and/or shaping plate-like workpieces, the machine tool comprising: a punching tool; and a tool die comprising: an end face adjoined by a tool region provided for regrinding, and at least one identification mark located on the tool die to indicate an amount of shortening of the tool region as a result of regrinding, wherein the tool region comprises an inclined portion that is formed circumferentially around the end face, wherein the identification mark extends circumferentially along an outer surface of the inclined portion in a substantially helical manner, and wherein the tool die defines a smooth bore extending from the end face, the smooth bore being configured for receiving the punching tool.

Description

DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic illustration of a machine tool for processing plate-like workpieces.

(2) FIG. 2 illustrates a tool die having an identification mark in the form of a helix.

(3) FIG. 3 illustrates a tool die having several identification marks formed along an end face of the tool die that extend through the end face to different depths within the tool die.

(4) FIG. 4 illustrates a tool stamp having a hole formed along its end face to receive a plug that includes several identification marks along its length.

(5) FIG. 5 illustrates a punching stamp having an identification mark indicating the maximum regrinding length and a limit mark, and an adjustment ring.

(6) FIGS. 6a, b illustrate two end faces of shaping tools, on which identification marks that indicate the respective tool length are included.

DETAILED DESCRIPTION

(7) FIG. 1 illustrates a machine tool 1 for punching and/or shaping plate-like workpieces, such as metal sheets. The punching/shaping machine 1 has a C-shaped machine frame 2 that includes a workpiece support in the form of a workpiece table 3 that serves to support a workpiece (e.g., a metal sheet) 4. At the upper side of the workpiece table 3, a horizontal support plane 5 is formed that extends along an x-direction and a y-direction and supports the metal sheet 4 to be processed. Using a co-ordinate guide 6, the metal sheet 4, which is clamped to the coordinate guide 6 by collet chucks 7, can be moved along the support plane 5 of the workpiece table 3.

(8) At the front end of the upper member of the C-shaped machine frame 2, a tool stamp receiving member 8 is arranged in which a punching tool 9 having a punching stamp is supported. Additionally, a tool die receiving member 10 in which a tool die 11 is supported is provided at the front end of the lower member of the C-shaped machine frame 2. The punching tool 9 and the tool die 11 together form a tool unit 12 for the separating and/or shaping processing operation of the metal sheet 4.

(9) A drive unit of the punching/shaping machine 1 is formed by a stamp drive 13 and a die drive 14 that are powered by linear drives. Using the stamp drive 13, the tool stamp receiving member 8 together with the punching tool 9 that is supported thereon or secured thereto can be raised and lowered along a travel axis 15 with respect to the workpiece table 3. In a comparable manner, the tool die receiving member 10 together with the tool die 11 which is supported or secured therein can be raised and lowered along the travel axis 15 with respect to the workpiece table 3 by the die drive 14. The tool stamp receiving member 8 and the tool die receiving member 10 can further be rotationally adjusted about a tool rotation axis 16 which is identical to the travel axis 15 by means of a rotary drive which is not shown in greater detail.

(10) A linear magazine 17 with additional tool units 12 is provided on the co-ordinate guide 6. The tool units 12 located along the linear magazine 17 are each retained by a tool cartridge 18 and, depending on requirements, can be secured to the tool stamp receiving member 8 or the tool die receiving member 10 for processing the metal sheet 4.

(11) When a tool is changed and when a workpiece is processed, the drives (e.g., the stamp drive 13 and the die drive 14) of the punching/shaping machine 1 are controlled by a numerical control unit 21. The numerical control unit 21 includes a storage device 19 for storing tool data and an additional control device 20 in order to measure and control the lifting, lowering and rotational movements of both the tool stamp receiving member 8 and the tool die receiving member 10 based on the stored data relating to the workpiece 4 and the tool 12, respectively. The storage device 19 can include information relating to the regrinding state of the tool die 11 and also to the multiple tool stamps 9 positioned in respective tool cartridges 18. The information can be provided by a machine operator based on the regrinding state established during the preliminary set-up operation.

(12) In order to obtain information relating to the regrinding state of the tool die 11 in a simple manner, and without subsequent measurement, the tool die can be constructed to have an identification mark. For example, as shown in FIG. 2, the substantially cylindrical tool die 11 has an end face 22 with a circular opening 23 for the engagement of a punching tool (e.g., a punching stamp). Along the end face 22 of the tool die 11, a radially substantially continuous, frustoconical inclined portion 24 (e.g., an inclined ramp or chamfer) is formed having an identification mark 25 in the form of a helical line with a substantially constant pitch. The inclined portion 24 also includes a scale 26 in the form of a dial with twelve grooves that extend outward radially.

(13) The helical identification mark 25 extends outward along the inclined portion 24 relative to the end face 22 to a distance that is positioned away from the end face that corresponds to the maximum regrinding amount (e.g., about 1 mm axially from the end face 22). The pitch of the helical line 25 is selected in such a manner that, during a revolution of 360 to and from a wedge-like groove 27 that extends in an axial direction, the identification mark 25 travels a distance of 1 mm in the axial direction perpendicular to the end face 22.

(14) When the tool die 11 is reground, it is ground flat at the end face 22 and an angular portion of the identification mark 25 associated with the respective regrinding length is eliminated. When the tool die 11 is new (i.e., having a regrinding length of 0 mm), the line 25 can be seen over its entire 360 range. In the completely reground state, the helical identification mark 25 is completely removed. In a region of the regrinding length between 0 mm<x<1 mm, an angular range of (y) of the identification mark 25 can be seen. The relationship of x/1 mm=z/360 can be used to determine the regrinding amount, where the angular range z represents the angular range of the portion of the identification mark 25 that can no longer be seen. The portion of the identification mark 25 that can no longer be seen (z) can be determined relatively simply by inspecting the portion of the identification mark 25 that can be seen (y), as described below, by using the following equation z=360y. There is a linear relationship between the regrinding amount and the angular range of the identification mark that can no longer be seen, thereby enabling simple identification by an operator to determine the amount of material removed due to regrinding.

(15) In the manner described above, the regrinding length is determined from the angular range of the identification mark 25 that is removed during regrinding, which can be assessed visually. If, as described above, a scale 26 is used that corresponds to reading a clock (e.g., using scale marks positioned like the 5-minute intervals of a clock so that the scale marks are spaced 30 from each other), the regrinding amount of the die on the scale 26 can be read in increments (e.g., 1 mm30/360=0.08 mm increments). The reading precision can be increased further if the scale 26 is subdivided into smaller ranges.

(16) Once the regrinding length is established, it is possible to compensate for the regrinding length, by placing one or more compensation shims below the tool die 11 whose combined thicknesses correspond to the regrinding length read on the scale 26. It is also possible to adapt the scale 26 to the minimum thickness of the compensation shims. For example, in some cases, the maximum regrinding length is 1 mm and the thicknesses of the compensation shims increase in increments of 0.1 mm. In such cases, the scale 26 can have ten increments that are each separated by 36 so that as the regrinding length is reduced by 0.1 mm properly sized compensation shims can be used to compensate for the regrinding.

(17) It is additionally possible to include an identification mark to the inclined portion 24 in the form of an inscription (e.g., a dimension), from which the regrinding amount can be read. It is also possible to omit the scale 26 completely if, there is a reference formed on the tool die 11 using the axial groove 27, from which the removed angular range of the identification mark 25 can be determined. The identification mark 25 does not have to be continuous. For example, in some embodiments, the identification mark 25 includes multiple marks that are also arranged in a helical manner, one or more marks being arranged in each of the circumferential regions of the inclined portion 24 separated by the radial grooves 26, respectively.

(18) Another possibility for determining the current regrinding length of a tool die 11 is illustrated in FIG. 3. The tool die 11 shown has an identification mark with ten recesses 28a-j in the form of indentations that extend through the end face 22 and into the portion of the tool die 11 underlying the end face 22 to varying depths. In the illustrated example, the recesses 28a-j include ten shallow indentations that have depths varying from 0.1 mm to 1 mm. By counting the number of recesses 28a-j that remain after regrinding, it is possible to determine the current regrinding state of the tool die 11. For example, if only seven of the recesses 28a-j are visible, the regrinding amount is 0.3 mm. The recesses 28a-j can also be constructed in the form of shoulders or pockets. In addition to forming multiple indentations having different depths, it is also possible to form a stepped hole for displaying the regrinding length in the end face 22. For example, the stepped hole can have multiple steps that each correspond to a particular distance, and therefore, the number of visible steps in the hole represent a measurement for the regrinding length. Using the techniques described above, the regrinding length of the tool die 11 can typically be identified without requiring additional measurements. The regrinding length can then be compensated for (e.g., by using compensation discs) so that the required height of the tool die 11 (e.g., 30 mm) can be achieved.

(19) Referring to FIG. 4, a similar method can also be used to determine the regrinding length of a tool stamp 9 in the form of a punching stamp. The tool stamp 9 includes a punching/cutting portion 30 on which a region of the punching stamp 9 provided for regrinding is formed. A hole 31 is formed along the end face 22 of the punching/cutting portion 30. A plug 32 (shown in FIG. 4 in a part-section) is pressed into the hole 31 and extends through the punching/cutting portion 30. The plug 32 can be formed of several portions (e.g., multiple discs) 32a-e of different colors and/or thicknesses. The sequence of the different colors corresponds to a coding of the regrinding length. During a regrinding operation, the plug 32 is also partially removed (i.e., ground away), whereby the color of the plug 32 which can be seen at the end face 22 as soon as the thickness of a respective portion 32a-e has been removed changes. The current regrinding length can consequently be determined using the visible color of the plug 32 at the end face 22 of the punching/cutting portion 30. A corresponding identification mark in the form of a plug can also be applied to a tool die 11 by forming a hole in the tool die 11 and inserting the plug.

(20) FIG. 5 illustrates another possibility for displaying the regrinding state of a punching stamp 9. The punching stamp 9 includes identification marks that not only indicated the regrinding length of the punching stamp 9, but also the thickness of workpieces 4 that can be processed using the punching stamp 9. Along a punching/cutting portion 30 of the punching stamp 9, which has not yet been reground, an identification mark in the form of a limit mark 35 is applied with a spacing A from the end face 22. The spacing A corresponds to a position where an upper edge of a thickest workpiece 4 to be processed using the punching stamp 9 would be when the punching stamp 9 is at the maximum insertion depth, taking into account the maximum regrinding length L.

(21) For example, the spacing A from the end face 22 to the limit mark 35 for an unused punching stamp 9 is determined by the following equation:
spacing A=regrinding length L (e.g., 6.5 mm)+maximum sheet thickness (e.g., 8.0 mm)+insertion depth (e.g., 1.0 mm)=(e.g., 15.5 mm).

(22) A typical value for the spacing A is therefore about 15.5 mm. When such a spacing A is used between the limit mark 35 and the end face 22, it helps to ensure that the limit mark 35 does not contact the workpiece 4 during workpiece processing so that it is protected from wear. Multiple additional marks can be included to provide a scale 37 in order to simplify the determination of the spacing A between the end face 22 and the limit mark 35 as the punching stamp 9 is reground. The multiple marks of the scale 37 are separated by a distance (e.g., 0.1 mm) so that distance from the limit mark 35 to the end face 22 can be determined in order to estimate the maximum sheet thickness that can be processed using a particular tool. In some cases, wear of the mark 36 and the scale 37 can occur due to friction of the punching cutting portion 30 rubbing on the workpiece 4.

(23) If the punching stamp 9 illustrated in FIG. 5 is reground, the punching stamp 9 can typically be used with little to no limitations in most sheet thicknesses up to a sheet thickness that corresponds to the remaining spacing A of the limit mark. As subsequent regrinding of the punching stamp 9 is performed, the thickness of a sheet that can still be processed using the same punching stamp 9 consequently decreases.

(24) The following table can be used to estimate the maximum acceptable sheet thicknesses that can be processed based on spacing A of a punching stamp.

(25) TABLE-US-00001 TABLE 1 Spacing A between end face and mark: Acceptable sheet thicknesses A is approximately 15.5 mm Maximum sheet thickness of 8 mm (using a new stamp) A > 10 mm (stamp has Maximum sheet thickness of 8 mm been reground) 10 mm > A > 5 mm Maximum sheet thickness is approximately spacing A - 2 mm. A < 5 mm Maximum sheet thickness is approximately 3 mm. (stamp is used or spent)

(26) For a user that would like easily determine whether the punching stamp 9 can be used for a desired application, the estimation provided in Table 1 is typically sufficient. For tool selection, the marking and scale 37 is typically sufficiently precise for most applications. The actual length of a punching stamp 9 may also be stored in a tool management system.

(27) For example, if a punching stamp 9 is intended to process a sheet thickness of 3 mm, a presetter typically selects only those punching stamps 9 in which the mark has at least 5 mm spacing remaining with respect to the end face 22 so that the punching stamp 9 will be able to adequately penetrate the entire thickness of the sheet. For a task with a sheet thickness of 8 mm, the presetter typically selects a punching stamp 9 with a minimum spacing A of approximately 10 mm. An additional mark 36 can be included to provide additional information, such as that a maximum regrinding length L (e.g., of about 6.5 mm) has been used.

(28) If a differentiation is to be made between new and reground tool components, it is possible to apply an identification mark to the end face 22, typically in the form of lettering that designates the new state of the tool component. It is also possible to provide a mark along the end face 22 of the punching stamp 9 that is identified with a color (e.g., black). The mark can be a discrete mark or alternatively it can be applied over the entire end face 22. Due to the relatively flat regrinding process, the mark is removed from the end face 22 so that the regrinding state can be identified. A similar mark can also be applied to tool dies or other tool components to denote a new tool component.

(29) In addition to designating the purely new state, the end-face identification mark can also contain information relating to a feature, characteristic, and/or property of the tool component. Examples of such features, characteristics, or properties include a total length and/or thickness of the tool component or the shape or machine group on which the tool component is intended to be used. The identification mark can be in the form of text and/or symbols in which a specific feature of the tool component is encoded or indicated.

(30) Examples of identification marks 38a, 38b at the end face 22 of two shaping tools 39a, 39b are shown in FIGS. 6a, b. The identification marks 38a, 38b each have numbers that indicate the tool length (in mm) and a symbol (L) that indicates the type of information being presented (e.g., L for length). Since the shaping tools 39a, 39b are not yet reground, the information relating to the tool length is retained, as long as it is not removed due to wear caused by friction with the workpiece. With shaping tools 39a, 39b or with other tool components that are typically not reground (e.g., punching needles), it is also possible to provide additional identification marks to indicate specific features (e.g., length, shape, or associated equipment information) at a location other than the end face 22. The end-face identification mark can also be provided on tool stamps which are constructed as inserts for a turret tool, since these are typically also reground. Typical maximum regrinding lengths for such inserts are about 0.5 mm.

(31) The identification marks 38a, 38b can be applied to the components by any of various types of machining processes (e.g., by laser inscription). In some cases, the marks 38a, 38b are formed in an operating step together with additional inscriptions. It is also alternatively possible to include manual identifications. By including various identifications it is possible to omit additional machining processing operations or the application of additional inscription elements (e.g., signs, adhesive labels, or tags). Additionally, tool components that have already been manufactured can typically be retrofit to include an identification mark in the form of an inscription in a relatively simple manner.

(32) The information read from the tool components described above (e.g., the regrinding length) can be input into the machine tool 1 (shown in FIG. 1) by a machine operator at an operator console of the machine tool 1 and stored in the storage device 19 so that this information is available during processing using the machine tool 1.

(33) 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.