使用一对旋转体的高速冲孔系统的发展【中文3800字】
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上传时间：2018-04-12
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- 关 键 词：
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使用
一对
旋转体
高速
冲孔
系统
发展
中文
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使用一对旋转体的高速冲孔系统的发展【中文3800字】,使用,一对,旋转体,高速,冲孔,系统,发展,中文
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JOURNALOFMATERIALSPROCESSINGTECHNOLOGY155156200411571163THEDEVELOPMENTOFHISPEEDPUNCHINGSYSTEMUSINGACOUPLEOFROTATINGBODIESKSHIMIZU,STAYATECHNICALRESEARCHLABORATORY,TOYOKOHANCOLTD,JAPANABSTRACTPUNCHEDSTEELSHEETSMETALSHEETSORFOILSASTHINAS01MMAREUSEDINTHEFIELDOFFILTERANDVARIOUSPRECISIONINSTRUMENTSRAPIDANDACCURATETECHNIQUESFORPUNCHINGTHINSHEETARETHEREFORENEEDEDTHETRADITIONALPUNCHINGMETHODEMPLOYSTHEUPDOWNPRESSINGACTIONOFAPUNCHORADIEONASTRIPMETALTHEEFFICIENCYOFTHISMETHODISDETERMINEDBYTHESPEEDOFTHEACTIONTOPUNCHASEQUENCEOFTINYHOLEJUSTAFEWMILLIMETERSAPART,THEFEEDSPEEDOFASTRIPOFAMETALTOTHEPUNCHINGMACHINECANNOTEXCEED2M/MINWEHAVETHEREFOREDEVELOPEDANEWTECHNIQUESUCHASTHEFEEDINGSPEEDCANBEUPTO100M/MINHERE,THENEWPUNCHINGMECHANISMANDTOOLCONFIGURATION,THESEQUENTIALPUNCHINGSYSTEM,THEQUALITYOFTHEPUNCHEDMETALANDTHEPATTERNTOBEPUNCHEDAREDISCUSSED2004PUBLISHEDBYELSEVIERBVKEYWORDSHISPEEDPUNCHINGROTATINGBODIESTHINMETALSHEETRECTANGULARHOLE1INTRODUCTIONPUNCHEDSTEELSHEETSMETALSHEETSORFOILSASTHINAS01MMAREUSEDINTHEFIELDOFFILTERANDVARIOUSPRECISIONINSTRUMENTSRAPIDANDACCURATETECHNIQUESFORPUNCHINGTHINSHEETARETHEREFORENEEDEDASTHEPUNCHINGTECHNIQUES,THEREHAVEBEENDRILLING,ELECTRICDISCHARGE,LASERBEAMORELECTRONBEAMMACHINING,ANDPRESSING,WHOSEFEATURESAREMULTIFACETEDFORTHEPRODUCINGEFFICIENCYINTHECASEOFTINYHOLEPUNCHING,THEPRESSTECHNIQUEMAYBETHEBESTCHOICEHOWEVER,THEEFFICIENCYOFTHEPRESSTECHNIQUEDEPENDSONTHEPUNCHINGSPEEDTOBEDETERMINEDBYTHENUMBEROFSTROKESOFTHEPRESSSO,INTHECASEWHERE1MMSIZEHOLESARETOBEPUNCHEDINPITCHESOFSOMEMILLIMETERS,THEMAXIMUMFEEDSPEEDOFTHESHEETTOBEPUNCHEDWILLFALLINTHERANGEOF003005M/SIFAPUNCHINGMETHODBYUSINGROTATINGBODIESBECOMESPRACTICAL,AVERYHIGHPUNCHINGEFFICIENCYCANBEEXPECTEDSTUDIESONTHEPUNCHINGTECHNIQUESUSINGROTATINGBODIESHADBEENREPORTEDBYSUKEGAWA1THEMETHODREPORTEDBYSUKEGAWAWASPROPOSEDWITHTHEAIMOFATTAININGAHIGHSPEEDPUNCHINGWITHIMPROVEDPRODUCTIONEFFICIENCYANDPRECISIONOFCUTTINGPROFILESINTHEREPORTEDMETHOD,HOWEVER,WHENTHECLEARANCEBETWEENTHEMALEANDCORRESPONDINGAUTHOREMAILADDRESSU3885TOYOKOHANCOJPKSHIMIZUFEMALETOOLSISAPPROPRIATELYSETFORATHICKNESSOFTHESHEETTOBEPUNCHED,THEMALEANDFEMALETOOLSMAYINTERFEREWITHEACHOTHER,ANDFROMTHATREASON,THECLEARANCEBETWEENTHETOOLSNEEDTOEXTENDSUFFICIENTLYASARESULT,SUKEGAWACONCLUDEDTHATTHEMETHODISGOODFORAPPLICATIONSWHERETHEPRECISIONISNOTAMATTEROFSERIOUSCONCERN,SUCHASPUNCHINGINTHEFURNITURE,CONSTRUCTIONMATERIALS,ANDSOFORTHTOPREVENTTHETOOLSFROMINTERFERENCEWITHEACHOTHER,USEOFARUBBERSHEETFORTHEFEMALETOOLWASALSOBEENPROPOSED,INWHICHCASE,HOWEVER,THEMASSPRODUCTIONREMAINEDTOBEADIFFICULTYBECAUSEOFTHELIFECYCLETHEAUTHORSHAVEDEVELOPEDANEWPUNCHINGTECHNIQUE24BYUSINGROTATINGBODIES,SUCHTHATISFREEFROMCONCERNSOFTHEINTERFERENCEBETWEENTHEMALEANDFEMALETOOLS,ANDALSOSUPERIORINTHEDISCHARGEOFSTAMPEDOUTCHIPSARISINGFROMPUNCHING,ASITHADBEENAPROBLEMINTHECASEOFPUNCHINGASEQUENCEOFTINYHOLES,THATIS,INSHORT,OURNEWPUNCHINGTECHNIQUEENABLESASUPERIORPRODUCTIONEFFICIENCYASWELLASANIMPROVEDLIFECYCLEOFTHEPUNCHTHEDEVELOPEDNEWPUNCHINGTECHNIQUECANMAKEITPOSSIBLETOPUNCHATSPEEDSOFUPTO3M/S200M/MINFIG1SHOWSASCHEMATICCOMPARISONOFTHEDEVELOPEDNEWTECHNIQUEWITHTHETRADITIONALTECHNIQUETHISREPORTDESCRIBESTHEEXPERIMENTRESULTSOFTHEPUNCHINGOFMETALSHEETSFOILDONEBYTHENEWTECHNIQUEASFORTHEPUNCHINGPERFORMANCE,DEFORMATIONCAUSEDAROUNDPUNCHEDHOLES,SHEARINGCONDITIONS,ANDPRECISIONOFHOLESIZESWEREEXAMINED09240136/SEEFRONTMATTER2004PUBLISHEDBYELSEVIERBVDOI101016/JJMATPROTEC2004042331158KSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY155156200411571163FIG3ASCHEMATICVIEWOFPUNCHINGMECHANISMFIG1COMPARISONOFPUNCHINGSPEEDS2DEVELOPEDNEWPUNCHINGTECHNIQUEPREVIOUSSTUDIES1,HAVEREPORTEDTHATMETHODSUSINGROTATINGBODIESREQUIREMALEANDFEMALETOOLSTHATALLOWAPPROPRIATECLEARANCEFORTHETHICKNESSOFTHESHEETTOBEPUNCHEDTHETWOTOOLSMAYINTERFEREORDESYCHRONISEASTHEDRIVINGGEARSBACKLASHORIFTHETOOLSTHEMSELVESLACKACCURACYINTERFERENCEBECOMESCRITICAL,ESPECIALLYWHENTHEMETALSHEETISVERYTHINOURDEVELOPEDTECHNIQUEISSHOWNINFIG2WHERETHEFEMALETOOLHASAROUNDBLADEANDTHEMALETOOLHASMSHAPEDBOSSESTHEREISANALTERNATINGSETTINGBETWEENTHETWOTOOLSINTERFERENCEBETWEENTHEMCANNOTOCCURBECAUSETHECLEARANCEBETWEENTHEFRONTANDBACKEDGEOFTHEMALETOOLANDTHEFEMALETOOLINTHEDIRECTIONOFROTATIONBECOMESINFINITEINTHISCONFIGURATIONAPPROPRIATECLEARANCEISDESIGNATEDFORTHETHICKNESSOFTHESHEETBETWEENTHESIDEEDGEOFTHEMALETOOLANDTHEFEMALETOOLTHEPUNCHINGITSELFISDONEBYSHEARINGALTHOUGHTHESIDEEDGEOFTHEMALETOOLDOESMAKECONTACTWITHTHEFEMALETOOL,THEREISNOINTERFERENCEANOTHERADVANTAGETOTHISTECHNIQUECOMPAREDWITHTHETRADITIONALUPDOWNPRESSTECHNIQUEISTHEEASEWITHWHICHSTAMPEDOUTCHIPSAREDISCHARGEDASCHEMATICVIEWOFTHEDEVELOPEDPUNCHINGMECHANISMISSHOWNINFIG3PUNCHINGPROCEEDSINTHEDESIGNATEDORDER13MALETOOLSWITHMSHAPEDBOSSESARESHOWNINTHEUPPERSIDETHEFRONTEDGEOFTHEMSHAPEDBOSSFIRSTPUNCHESTHEMETALSHEETBYROTATION,FOLLOWEDBYTHEBACKEDGESIMILARLYROTATED,THESIDEEDGEOFTHEMSHAPEDBOSSANDTHEROUNDBLADEOFTHEFEMALETOOLPUNCHESBOTHSIDESOFARECTANGULARHOLEINTHEDIRECTIONOFROTATIONBYSHEARING,WHICHCOMPLETESTHEPUNCH3EXPERIMENTSTOEXAMINETHEPUNCHINGCHARACTERISTICS,EXPERIMENTSWERECONDUCTEDONROLLINGSTEELSHEETFOILCUTSHEETSANDCOILWITHATHICKNESSOF60MTHESIZEOFMSHAPEDBOSSESOFTHEMALETOOLUSEDINTHEEXPERIMENTSIS1MMWIDEAND15MMLONG,HAVINGA45ANGLEOFTHETOOLSBLADEEDGESOMETOOLSUSEDINTHEEXPERIMENTSHAVEEDGEANGLESOF30AND60PUNCHINGWASDONEATTHEPUNCHINGSPEEDSOF016067M/S1040M/MINFORCOILAND33M/S10200M/MINFORCUTSHEETSASCHEMATICVIEWOFTHESEQUENTIALPUNCHINGSYSTEMEMPLOYEDINTHEEXPERIMENTSISSHOWNINFIG4THESYSTEMCOMPRISESSUCHPROCESSESASUNCOILING,TENSIONING,PUNCHING,MASHING,ANDFIG2CONFIGURATIONOFTHEPUNCHINGPARTKSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1551562004115711631159FIG4SCHEMATICVIEWOFSEQUENTIALPUNCHINGSYSTEMRECOILINGINOURPUNCHINGEXPERIMENTS,STUDIESWEREDONEONTHEEFFECTSOFTOOLSHAPESONTHEDEFORMATIONCAUSEDAROUNDHOLESTHEEFFECTSOFPUNCHINGSPEEDSONTHEDEFORMATIONCAUSEDAROUNDHOLESTHEEFFECTSOFPUNCHINGSPEEDSONTHEPRECISIONOFHOLESIZESANDHOLEPITCHESTHEMECHANICALPROPERTIESOFPUNCHEDSHEETS4RESULTSANDDISCUSSION41EXTERIOROFPUNCHEDITEMSFIG5SHOWSANEXTERIORVIEWOFTHEPARTPUNCHEDBYTHEMALETOOLHAVINGA45ANGLEOFBLADEEDGE,WHICHSECTIONALVIEWINTHEPERIPHERALDIRECTIONISSYMMETRICWITHRESPECTTOTHEROOTOFTHEBLADEMATERIALSPUNCHEDARESTEELSHEETWITHATHICKNESSOF60MHEREINAFTERTHESAMEMATERIALUSEDASOTHERWISESTATEDINTHISREPORTSHOWNINFIG5AISANENLARGEDVIEWOFTHEPARTPUNCHED,ANDFIG5BISANOVERALLVIEWOFPUNCHEDSHEETAFTERRESULTINGDEFORMATIONISNEGATEDBYAMASHROLLFOLLOWINGTHEPUNCHINGPROCESSINFIG5A,THESHEETDEFORMEDINTHEUPWARDDIRECTIONATTHEFORWARDSTRAIGHTSIDEOFAHOLECANBESEENTHISISPRESUMABLYCAUSEDBYTHEMALETOOLWHENITISSTRIPPEDOFFFROMTHEHOLEAFTERPUNCHING,ASARESULTOFRAISINGTHESHEETATTHEFORWARDSTRAIGHTSIDEOFTHEHOLETHEAMOUNTOFSUCHDEFORMATIONDEPENDSONTHESHAPEOFTHEMALETOOL,THEDEPTHOFOVERLAPOFTHEMALEANDFEMALETOOLS,THEMATERIALTOBEPUNCHED,ANDTHEPUNCHINGSPEEDTHEDEFORMATION,HOWEVER,CANBEFLATTENED,ASSHOWNINFIG5B,THROUGHAMASHINGPROCESSAFTERPUNCHING42DEFORMATIONAROUNDHOLES421EFFECTOFMALETOOLCONFIGURATIONFIG6INDICATESTHEEDGEANGLESOFTHEMALETOOLBLADE30,45AND60,WHICHCANHAVEANEFFECTONTHEDEFORMATIONAROUNDHOLESATTHEINITIALSTAGEOFPUNCHING,ASWELLASOBSERVATIONSBYLASERMICROSCOPEOFTHEEFFECTSOFTHELEVELOFOVERLAPOFTHEMALEANDFEMALETOOLSONTHEDEFORMATIONADASHEDLINEINTHISFIGURESHOWSAPERIPHERYOFTHEMSHAPEDBOSSOFTHEMALETOOL,AND,ASSHOWN,ITCANBESEENTHATTHESMALLERTHEBLADEEDGEANGLEIS,THESMALLERDEFORMATIONISRESULTEDFROMPUNCHINGFIG7ILLUSTRATESTHATTHEDEEPERTHEOVERLAPOFTHEMALEANDFEMALETOOLSISANDTHESMALLERTHETOOLBLADEEDGEANGLEIS,THEMORETHESHEETDEFORMATIONFIG5CONFIGURATIONOFMALETOOLANDHOLEPATTERN1160KSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY155156200411571163FIG6DEFORMATIONSAROUNDHOLESATINITIALSTAGEOFPUNCHINGFIG7EFFECTSOFTOOLSOVERLAPANDEDGEANGLEONSHEETDEFORMATIONAROUNDTHEHOLEISDEVELOPED,WHICHISNOTINAGREEMENTWITHTHEPREVIOUSRESULTINFIG6RELATIVETOTHEEFFECTOFTHEBLADEEDGEANGLEHENCE,ITISPRESUMEDTHATTHEDEFORMATIONINFIG7ISRESULTEDFROMSUCHANACTIONOFTHEMALETOOLOFRAISINGTHESHEETATTHEFORWARDSTRAIGHTSIDEOFARECTANGULARHOLEWHENITISSEPARATEDFROMTHEHOLEAFTERPUNCHINGTHERESULTSINFIGS6AND7AREFROMTHEMALETOOLWITHITSAXIALSECTIONBEINGSYMMETRICINTHEPERIPHERALDIRECTIONTHESERESULTSFOLLOWTHATTHESMALLERTHETOOLBLADEEDGEANGLEIS,ANDTHESMALLERTHEDEPTHOFTHEBLADEFROMEDGETOROOTIS,THEMORETHEDEFORMATIONAROUNDTHEHOLECANBERESULTEDANEXTERIORVIEWAROUNDTHEHOLEPUNCHED,SHOWNINFIG8,ISAFTERDUECONSIDERATIONISTAKENINTOTHEEDGEANGLEANDDEPTHOFTHEBLADEASINFIG8,THEDEFORKSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1551562004115711631161FIG8EFFECTOFMALETOOLSHAPEONSHEETDEFORMATIONAROUNDHOLEMATIONENCIRCLEDWITHANELLIPTICALDASHEDLINEHASBEENNEGATED422EFFECTOFPUNCHINGSPEEDSTHEEFFECTOFPUNCHINGSPEEDSONTHESHEETDEFORMATIONAROUNDHOLESISILLUSTRATEDINFIG9ITINDICATESSUCHATRENDTHATTHEDEFORMATIONISDECREASEDASTHEPUNCHINGSPEEDISINCREASEDTHISISPRESUMABLYDUETOTHEINERTIAAPPLIEDINTHESHEET,WHICHMAYBECONTRADICTORYTOSUCHINFERENCETHATASTHESHEARRATEISINCREASED,THEWORKHARDENINGBECOMESDOWN,RESULTINGINBRITTLENESS5ANDSOBLUEBRITTLENESS6BASEDONTHESERESULTS,BYEMPLOYINGSTILLHIGHERSPEEDS,REDUCTIONOFTHEDEFORMATIONAMOUNTISEXPECTED43PRECISIONOFHOLESIZESANDHOLEPITCHESTHEDEVELOPEDNEWTECHNIQUEISSUCHTHATTHEMETALSHEETSARETOBEPUNCHEDBYTHEMALETOOLANDTHEFEMALETOOLROTATINGATTHESAMESPEEDUNDERASPECIFIEDTENSION,WHERETHESIZEOFPUNCHEDHOLESISDETERMINEDBYTHESIZEOFBOSSESANDTHEPITCHOFHOLESISDETERMINEDBYTHEDISTANCEBETWEENBOSSESTHEMETALSHEETTOBEPUNCHEDISTOBEFITINTHEBOSSESTOBETRANSFERREDATTHESAMESPEEDASTHEPERIPHFIG9EFFECTOFPUNCHINGSPEEDSONSHEETDEFORMATIONERALSPEEDOFTHEBOSSESTHEREFORE,SINCETHESPEEDOFTHEMETALSHEETANDTHEPERIPHERALSPEEDOFTHEBOSSESARETHEORETICALLYTHESAME,THEDISTANCEOFPITCHESISDETERMINEDBYTHESIZEOFTHEMALETHEN,THESIZEOFTHEHOLESBECOMESPOSSIBLYALITTLEGREATERTHANTHESIZEOFBOSSESINTERMSOFPERIPHERY,ASITCANBEAFFECTEDBYTHEDEPTHOFOVERLAPOFTHEMALEANDFEMALETOOLSANDTHETENSIONTOBEAPPLIEDINTHETRADITIONALUPDOWNPRESSTECHNIQUE,THESIZEOFHOLESISDETERMINEDBYTHESIZEOFAPUNCHORADIE,ANDTHEMATERIALISFEDINTERMITTENTLYBYAFEEDER,SOTHATTHEPRECISIONOFPITCHESDEPENDSONTHEFEEDERDEPENDENCEOFTHEPRECISIONOFHOLESIZESBOSSSIZE10MMWIDTHAND15MMLENGTHONTHEPUNCHINGSPEEDSISSHOWNINFIG10,ANDDEPENDENCEOFTHEPRECISIONOFPITCHESBOSSPITCH155MMCROSSWAYSAND240MMLONGITUDINALLYONTHEPUNCHINGSPEEDSISSHOWNINFIG11ASFORTHEPRECISIONOFHOLESIZES,OUROBSERVATIONSTHROUGHEXPERIMENTSINDICATEAPPROXIMATELYA01MMVARIATION,OFWHICHPRESUMABLEFACTORSMAYBEINCONSISTENTPERIPHERALSPEEDSBETWEENTHEMALEANDFEMALETOOLS,ORTHEIRTENSIONINGBALANCETHEN,FORTHEPRECISIONOFHOLEPITCHES,SHOWNINFIG11,OUROBSERVATIONSINDICATENOVARIATIONSATALLITMEANSTHAT,ASABOVEMENTIONED,THESIZEOFTOOLSDICTATESTHEDISTANCEOFPITCHES,ANDTHEREFOREAHIGHPRECISIONOFHOLEPITCHESCANBEOBTAINEDEVENBYPUNCHINGFIG10EFFECTOFPUNCHINGSPEEDSONPRECISIONOFHOLESIZES1162KSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY155156200411571163FIG11EFFECTOFPUNCHINGSPEEDSONPRECISIONOFHOLEPITCHESFIG14VARIATIONSOFHOLEPATTERNFIG12EXTERIORVIEWOFCOILPUNCHEDBYPRODUCTIONSYSTEMATHIGHSPEEDSFIG12SHOWSANEXTERIORVIEWOFPRODUCTPUNCHEDINTHEPRODUCTIONLINEPRODUCTAFTERTHEPROCESSOFMASHINGHASAPREFERABLEEXTERIORWITHAFLATSMOOTHCONFIGURATION44MECHANICALPROPERTIESOFPUNCHEDMETALSHEETSTHETENSILESTRENGTHOFSTEELSHEETWITHATHICKNESSOF60M,ONWHICHRECTANGULARHOLESHOLESIZE10MMWIDTHAND15MMLENGTHAREPUNCHEDHOLEPITCHES155MMCROSSWAYSAND240LONGITUDINALLYOPENINGRATIO40,ISGIVENINFIG13THEHOLEPATTERNSINTHEPUNCHEDMETALSHEETSSUBJECTEDTOEXPERIMENTSPROVIDEHIGHTENSILESTRENGTHSINTHEDIRECTIONOFSHEETFEEDING,HAVINGADIRECTIONALITYTHISCANBEPRESUMEDORJUSTIFIEDFROMTHEHOLEPATTERNSORBYSTRESSANALYSESASWELLHERE,ITFOLLOWSTHATSUCHFIG13MECHANICALPROPERTIESOFPUNCHEDSHEETADIRECTIONALITYINTHEMECHANICALPROPERTIESISADJUSTABLEBYSELECTINGHOLEPATTERNSAPPROPRIATELYTHEDEVELOPEDNEWTECHNIQUEMAKESITPOSSIBLETOMODIFYTHEBASICHOLEPATTERNEASILY,SOMEOFWHICHARESHOWNINFIG14INTHEFIGURE,THEPATTERNSHOWNATTHETOPISABASICPATTERNWITHTHESIDESOFTHEMALEANDFEMALETOOLS,ANDTHEPATTERNSSHOWNBELOWAREVARIATIONSOFTHEPATTERN,WHERE1PARTOFTHEMALETOOLCONFIGURATIONISMODIFIED2LOCATIONOFAKEYSEATINGWAYFORTHEFEMALETOOLISCHANGEDOR3ATHICKNESSOFTHESPACERISCHANGEDOTHERMOREPATTERNSMAYBEOBTAINEDWITHOUTANYSPECIALSKILLSREQUIREDOR,AHIGHPRECISIONOFHOLEPOSITIONINGFROMTHESHEETEDGECANBEACHIEVEDBYPROVIDINGASLITBLADEATTHEBOTHENDSOFPUNCHINGINTHEAXIALDIRECTION5CONCLUSIONSFORTHEDEVELOPEDNEWPUNCHINGTECHNIQUE,RESULTSCANBESUMMARIZEDASFOLLOWS1PUNCHINGBYTHENEWTECHNIQUEISPRACTICALATSEVERALTENTIMESHIGHERSPEEDSTHANTHETRADITIONALTECHNIQUE2PUNCHINGOFTINYRECTANGULARHOLES,SIZED10MMBY15MM,CANBEACHIEVEDSTABLYATSPEEDSOFUPTO067M/S40M/MINCOILAND3M/S200M/MINCUTSHEETS,WITHNODIFFICULTIESOFDISCHARGINGSTAMPEDOUTCHIPS3DEFORMATIONISCAUSEDAROUNDTHEPUNCHEDHOLESINTHESHEETDURINGTHEPROCESSOFPUNCHING,THEAMOUNTOFWHICHDEPENDSONTHESHAPEOFPUNCHINGTOOLS,ORPUNCHINGSPEEDSBUTAPREFERABLEEXTERIOROFSUCHASHEETKSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1551562004115711631163CANBEOBTAINEDBYEMPLOYINGAMASHINGPROCESSAFTERPUNCHING4THEPRECISIONOFHOLESIZESANDPITCHESISGOODEVENINTHEPUNCHINGATHIGHSPEEDSBECAUSEITISDETERMINEDBYTHESIZEOFPUNCHINGTOOLS,WHICHMEANSTHATTHENEWTECHNIQUEREQUIRESNOFEEDER5VARIATIONSOFPUNCHINGPATTERNAREEASYTOOBTAINBYTHENEWTECHNIQUE,ANDSOAPPLICATIONSTOVARIOUSFIELDSAREEXPECTEDREFERENCES1MSUKEGAWA,PRESSWORKING61196853782KSHIMIZU,JAPANESEPATENTPUBLICATIONNO20001078203KSHIMIZU,WO01/17710A14STAYA,KSHIMIZU,HNAKASIMA,YOHASHI,IAOKI,INPROCEEDINGSOFTHESPRINGCONFERENCEOFJSTP,TOKYO,2001,PP1611625MMURAKAWA,JJSTP2730019861321396NYANAGIHARA,HSAITO,TNAKAGAWA,JJSTP23252198271JOURNALOFMATERIALSPROCESSINGTECHNOLOGY155156200411571163THEDEVELOPMENTOFHISPEEDPUNCHINGSYSTEMUSINGACOUPLEOFROTATINGBODIESKSHIMIZU,STAYATECHNICALRESEARCHLABORATORY,TOYOKOHANCOLTD,JAPANABSTRACTPUNCHEDSTEELSHEETSMETALSHEETSORFOILSASTHINAS01MMAREUSEDINTHEFIELDOFFILTERANDVARIOUSPRECISIONINSTRUMENTSRAPIDANDACCURATETECHNIQUESFORPUNCHINGTHINSHEETARETHEREFORENEEDEDTHETRADITIONALPUNCHINGMETHODEMPLOYSTHEUPDOWNPRESSINGACTIONOFAPUNCHORADIEONASTRIPMETALTHEEFFICIENCYOFTHISMETHODISDETERMINEDBYTHESPEEDOFTHEACTIONTOPUNCHASEQUENCEOFTINYHOLEJUSTAFEWMILLIMETERSAPART,THEFEEDSPEEDOFASTRIPOFAMETALTOTHEPUNCHINGMACHINECANNOTEXCEED2M/MINWEHAVETHEREFOREDEVELOPEDANEWTECHNIQUESUCHASTHEFEEDINGSPEEDCANBEUPTO100M/MINHERE,THENEWPUNCHINGMECHANISMANDTOOLCONFIGURATION,THESEQUENTIALPUNCHINGSYSTEM,THEQUALITYOFTHEPUNCHEDMETALANDTHEPATTERNTOBEPUNCHEDAREDISCUSSED2004PUBLISHEDBYELSEVIERBVKEYWORDSHISPEEDPUNCHINGROTATINGBODIESTHINMETALSHEETRECTANGULARHOLE1INTRODUCTIONPUNCHEDSTEELSHEETSMETALSHEETSORFOILSASTHINAS01MMAREUSEDINTHEFIELDOFFILTERANDVARIOUSPRECISIONINSTRUMENTSRAPIDANDACCURATETECHNIQUESFORPUNCHINGTHINSHEETARETHEREFORENEEDEDASTHEPUNCHINGTECHNIQUES,THEREHAVEBEENDRILLING,ELECTRICDISCHARGE,LASERBEAMORELECTRONBEAMMACHINING,ANDPRESSING,WHOSEFEATURESAREMULTIFACETEDFORTHEPRODUCINGEFFICIENCYINTHECASEOFTINYHOLEPUNCHING,THEPRESSTECHNIQUEMAYBETHEBESTCHOICEHOWEVER,THEEFFICIENCYOFTHEPRESSTECHNIQUEDEPENDSONTHEPUNCHINGSPEEDTOBEDETERMINEDBYTHENUMBEROFSTROKESOFTHEPRESSSO,INTHECASEWHERE1MMSIZEHOLESARETOBEPUNCHEDINPITCHESOFSOMEMILLIMETERS,THEMAXIMUMFEEDSPEEDOFTHESHEETTOBEPUNCHEDWILLFALLINTHERANGEOF003005M/SIFAPUNCHINGMETHODBYUSINGROTATINGBODIESBECOMESPRACTICAL,AVERYHIGHPUNCHINGEFFICIENCYCANBEEXPECTEDSTUDIESONTHEPUNCHINGTECHNIQUESUSINGROTATINGBODIESHADBEENREPORTEDBYSUKEGAWA1THEMETHODREPORTEDBYSUKEGAWAWASPROPOSEDWITHTHEAIMOFATTAININGAHIGHSPEE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ONFIG6INDICATESTHEEDGEANGLESOFTHEMALETOOLBLADE30,45AND60,WHICHCANHAVEANEFFECTONTHEDEFORMATIONAROUNDHOLESATTHEINITIALSTAGEOFPUNCHING,ASWELLASOBSERVATIONSBYLASERMICROSCOPEOFTHEEFFECTSOFTHELEVELOFOVERLAPOFTHEMALEANDFEMALETOOLSONTHEDEFORMATIONADASHEDLINEINTHISFIGURESHOWSAPERIPHERYOFTHEMSHAPEDBOSSOFTHEMALETOOL,AND,ASSHOWN,ITCANBESEENTHATTHESMALLERTHEBLADEEDGEANGLEIS,THESMALLERDEFORMATIONISRESULTEDFROMPUNCHINGFIG7ILLUSTRATESTHATTHEDEEPERTHEOVERLAPOFTHEMALEANDFEMALETOOLSISANDTHESMALLERTHETOOLBLADEEDGEANGLEIS,THEMORETHESHEETDEFORMATIONFIG5CONFIGURATIONOFMALETOOLANDHOLEPATTERN1160KSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY155156200411571163FIG6DEFORMATIONSAROUNDHOLESATINITIALSTAGEOFPUNCHINGFIG7EFFECTSOFTOOLSOVERLAPANDEDGEANGLEONSHEETDEFORMATIONAROUNDTHEHOLEISDEVELOPED,WHICHISNOTINAGREEMENTWITHTHEPREVIOUSRESULTINFIG6RELATIVETOTHEEFFECTOFTHEBLADEEDGEANGLEHENCE,ITISPRESUMEDTHATTHEDEFORMATIONINFIG7ISRESULTEDFROMSUCHANACTIONOFTHEMALETOOLOFRAISINGTHESHEETATTHEFORWARDSTRAIGHTSIDEOFARECTANGULARHOLEWHENITISSEPARATEDFROMTHEHOLEAFTERPUNCHINGTHERESULTSINFIGS6AND7AREFROMTHEMALETOOLWITHITSAXIALSECTIONBEINGSYMMETRICINTHEPERIPHERALDIRECTIONTHESERESULTSFOLLOWTHATTHESMALLERTHETOOLBLADEEDGEANGLEIS,ANDTHESMALLERTHEDEPTHOFTHEBLADEFROMEDGETOROOTIS,THEMORETHEDEFORMATIONAROUNDTHEHOLECANBERESULTEDANEXTERIORVIEWAROUNDTHEHOLEPUNCHED,SHOWNINFIG8,ISAFTERDUECONSIDERATIONISTAKENINTOTHEEDGEANGLEANDDEPTHOFTHEBLADEASINFIG8,THEDEFORKSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1551562004115711631161FIG8EFFECTOFMALETOOLSHAPEONSHEETDEFORMATIONAROUNDHOLEMATIONENCIRCLEDWITHANELLIPTICALDASHEDLINEHASBEENNEGATED422EFFECTOFPUNCHINGSPEEDSTHEEFFECTOFPUNCHINGSPEEDSONTHESHEETDEFORMATIONAROUNDHOLESISILLUSTRATEDINFIG9ITINDICATESSUCHATRENDTHATTHEDEFORMATIONISDECREASEDASTHEPUNCHINGSPEEDISINCREASEDTHISISPRESUMABLYDUETOTHEINERTIAAPPLIEDINTHESHEET,WHICHMAYBECONTRADICTORYTOSUCHINFERENCETHATASTHESHEARRATEISINCREASED,THEWORKHARDENINGBECOMESDOWN,RESULTINGINBRITTLENESS5ANDSOBLUEBRITTLENESS6BASEDONTHESERESULTS,BYEMPLOYINGSTILLHIGHERSPEEDS,REDUCTIONOFTHEDEFORMATIONAMOUNTISEXPECTED43PRECISIONOFHOLESIZESANDHOLEPITCHESTHEDEVELOPEDNEWTECHNIQUEISSUCHTHATTHEMETALSHEETSARETOBEPUNCHEDBYTHEMALETOOLANDTHEFEMALETOOLROTATINGATTHESAMESPEEDUNDERASPECIFIEDTENSION,WHERETHESIZEOFPUNCHEDHOLESISDETERMINEDBYTHESIZEOFBOSSESANDTHEPITCHOFHOLESISDETERMINEDBYTHEDISTANCEBETWEENBOSSESTHEMETALSHEETTOBEPUNCHEDISTOBEFITINTHEBOSSESTOBETRANSFERREDATTHESAMESPEEDASTHEPERIPHFIG9EFFECTOFPUNCHINGSPEEDSONSHEETDEFORMATIONERALSPEEDOFTHEBOSSESTHEREFORE,SINCETHESPEEDOFTHEMETALSHEETANDTHEPERIPHERALSPEEDOFTHEBOSSESARETHEORETICALLYTHESAME,THEDISTANCEOFPITCHESISDETERMINEDBYTHESIZEOFTHEMALETHEN,THESIZEOFTHEHOLESBECOMESPOSSIBLYALITTLEGREATERTHANTHESIZEOFBOSSESINTERMSOFPERIPHERY,ASITCANBEAFFECTEDBYTHEDEPTHOFOVERLAPOFTHEMALEANDFEMALETOOLSANDTHETENSIONTOBEAPPLIEDINTHETRADITIONALUPDOWNPRESSTECHNIQUE,THESIZEOFHOLESISDETERMINEDBYTHESIZEOFAPUNCHORADIE,ANDTHEMATERIALISFEDINTERMITTENTLYBYAFEEDER,SOTHATTHEPRECISIONOFPITCHESDEPENDSONTHEFEEDERDEPENDENCEOFTHEPRECISIONOFHOLESIZESBOSSSIZE10MMWIDTHAND15MMLENGTHONTHEPUNCHINGSPEEDSISSHOWNINFIG10,ANDDEPENDENCEOFTHEPRECISIONOFPITCHESBOSSPITCH155MMCROSSWAYSAND240MMLONGITUDINALLYONTHEPUNCHINGSPEEDSISSHOWNINFIG11ASFORTHEPRECISIONOFHOLESIZES,OUROBSERVATIONSTHROUGHEXPERIMENTSINDICATEAPPROXIMATELYA01MMVARIATION,OFWHICHPRESUMABLEFACTORSMAYBEINCONSISTENTPERIPHERALSPEEDSBETWEENTHEMALEANDFEMALETOOLS,ORTHEIRTENSIONINGBALANCETHEN,FORTHEPRECISIONOFHOLEPITCHES,SHOWNINFIG11,OUROBSERVATIONSINDICATENOVARIATIONSATALLITMEANSTHAT,ASABOVEMENTIONED,THESIZEOFTOOLSDICTATESTHEDISTANCEOFPITCHES,ANDTHEREFOREAHIGHPRECISIONOFHOLEPITCHESCANBEOBTAINEDEVENBYPUNCHINGFIG10EFFECTOFPUNCHINGSPEEDSONPRECISIONOFHOLESIZES1162KSHIMIZU,STAYA/JOURNALOFMATERIALSPROCESSINGTECHN
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