DRAW DIE SHOES

Abstract

An apparatus for stamping sheet metal is disclosed. The apparatus has a lower bolster having a number of air pins disposed at predetermined locations. A first die set having first and second die shoes and a stamping ring and cap are disposed on the lower bolster. The first and second die shoes are matable to form a stamped component. The second die shoe is coupled to the lower bolster so that at least one air pin is operable to apply force to the ring. The system further has third and fourth die shoes which are used to form a second stamped component. The third and fourth die shoes further have a second stamping ring and second cap. The system is such that the third and fourth die shoes can be inserted into the press after the first and second die shoes have been removed. It is not necessary to remove the air pins disposed in the lower bolster to change the die shoes.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to metal stamping systems and, more particularly, to a method and system for locating die location pins with incorporated through air pins.

BACKGROUND OF THE INVENTION

[0002] Metal stamping systems traditionally consist of shearing and forming assemblies. These assemblies are formed by an upper adapter and lower shoe. Sheet material to be formed is placed between the lower shoe and the upper adapter. The forming assembly is then brought together by use of a press to form the stamped metal component.

[0003] Referring generally to FIG. 1 which represents a prior art stamping system, disposed on the lower shoe is a ring which traps and holds the sheet stock between the upper adapter and lower shoe. Incorporated through the lower shoe and into the ring are a series of air pins which apply forces from air shocks to the ring to hold the stamped component into place. Additionally, a series of guide pins are located in a lower shoe, which support and control the movement of the ring. Traditionally, the locations of the guide pins and air pins are custom and dictated by the stamped component geometry. When a new component is to be produced in the stamping machine, the old tooling must be removed from the stamping machine. As the location of the guide pins and air pins are traditionally custom, each tool change requires a significant additional amount of time caused by the relocation of these components within the lower bolster. As such, it would be desirable to have a metal stamping system, which has a configuration, that will allow for the changing of die shoes in a minimal amount of time.

SUMMARY OF THE INVENTION

[0004] The invention includes an apparatus for stamping sheet metal components having a lower bolster supporting a plurality of air pins. The air pins are located on the bolster in a predetermined configuration. The apparatus further has a lower shoe having a cap and a ring disposed about the cap. A plurality of air pins are disposed through the lower shoe and into the ring. An upper adapter is configured to mate with the lower shoe to deform a piece of metal. The apparatus further has a second set of die components in the form of a second lower shoe and a second upper adapter. The second lower shoe is configured to accept a second ring and cap. The second lower shoe is configured to be accepted into the lower bolster without removal of the air pins.

[0005] The clamping apparatus may further include a plurality of guide pins disposed through the lower bolster and shoe to align the ring. The air pins may be encapsulated within the guide pins to prevent interference between the air pins and certain portions of the die mechanism.

[0006] Further, the stamping mechanism may have a riser disposed beneath the cap. The riser may define a plurality of spaces formed so as to prevent interference between the air pins and the riser.

[0007] The invention further includes an apparatus for forming sheet metal which includes a die assembly having first and second die shoes. The first die shoe is adapted to slidably fit within the forming assembly. The forming assembly is disposed within a lower bolster. The lower bolster has a plurality of air pins disposed on a first surface in a predetermined pattern. The second and third die shoes being operable to be accepted by the air pins upon removal of the first and second die shoes.

[0008] The invention further includes a method of replacing a first stamping tool set with a second stamping tool set when the first tool set and second tool set form substantially different components.

[0009] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0011] FIG. 1 side cross sectional view of a prior air system;

[0012] FIG. 2 is side cross sectional view of the stamping apparatus according to one embodiment of the present invention;

[0013] FIG. 3 is an exploded perspective view of an embodiment of the present invention;

[0014] FIG. 4 is a perspective lower view of the lower shoe according to the teachings of the present invention;

[0015] FIG. 5 represents a top view of the lower shoe shown in FIG. 4 according to the teachings of the present invention; and

[0016] FIG. 6 is a cross sectional side view of the lower shoe according to a second embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0018] Referring to the figures and, more particularly, to the FIGS. 2-4 which represent components of the systems for forming sheet metal according to the first embodiment of the invention. Depicted are a lower shoe 10, upper adapter 12, which are used to form sheet metal 14. The lower shoe 10 has a ring 16 and a cap 18. The cap 18 is disposed over a riser 20. Further shown is a lower bolster 28, which supports lower shoe 10 having a plurality of trusses 30, which support the lower bolster 28. Disposed within the lower bolster 28 is a plurality of air pins 32.

[0019] The ring or holding mechanism 16 is configured to surround the cap 18 to hold the sheet metal 14 into place within the die. The air pins 32 are configured to be slidably accepted through the lower shoe 10 to apply forces from air springs (not shown) to the ring 16 to entrap the sheet metal 14. Further shown are a plurality of guide pins 34 which function to allow proper orientation of the ring 16 with respect to the cap 18 and lower shoe 10. The air pins 32 are shown distributed at regular intervals throughout the lower shoe.

[0020] As can be seen, the guide pins 34 are configured to slidably receive the air pins 32, at locations where the air pins 32 are not going to be transmitting forces to the ring 16. The use of the guide pins 34 which accept the air pins 32 allows for the system to accommodate for air pins 32. This makes it possible to create a stamping system which does not require the movement of the air pins 32. In other locations 36, the air pins are shown such that they engage the lower surface 38 of the ring 16.

[0021] Further shown are a plurality of cavities 40 defined in the riser 20. The cavities 40 allow for movement of the air pins 32 without importing forces from the air pins 32 into the cap 18. This also allows for fast changes to the tooling setup without removal or reconfiguration of the air pins 32.

[0022] The use of a multiple tool set having lower shoes which are configured to interface with a fixed configuration of air pins 32 allows for very quick tool changeover without the pulling or adding of air pins 32. The stamping system of the present invention utilizes a single lower bolster 28 having air pins 32 with a fixed configuration, for example, and array of fixed spaced pins. The array of air pins 32 are used for each of the multiple tool sets.

[0023] FIG. 3 represents a partial top view of the lower shoe of FIG. 2. As can be seen, an array of air pins 32 are disposed within the surface 42 of the lower bolster 28. Also shown is the guide pin 34 which slidably accepts the air pin 32 through a through bore 62. Should component design dictate, a guide pin can be placed over any of the air pins 32 to change distribution of forces to the ring 16.

[0024] FIGS. 3 and 4 represent a lower perspective view of the lower shoe 10 of the first embodiment of the present invention. Disposed within the first surface 44 of the lower shoe 10 is an array of 50 mm holes 48. The holes 48 slidably accept the air pins (not shown). Further shown are four guide pins 34. The guide pins 34 define through bores 50 which slidably accept the air pins 32. The guide pins 34 function to control the movement of the ring 16. Additionally defined within the top surface 100 of the lower shoe 10 is built-in die locators 52. Fastened to the top surface 100 of the lower shoe 10 is the cap 18. Defined within the top surface of the cap 18 is a plurality of recesses 54. Each recess 54 gives a place to position the head of a standard fastener (not shown) which is used to couple the cap 18 to the lower shoe 20, 10. Additionally shown are other features such as the variable safety pad and stop block area 56.

[0025] As can be seen, lower shoe 10 is defined into four quadrants A-D. Each quadrant A-D defines regions with increased thicknesses, which can accept a press fit guide pin 34 to slidably support ring 16. Regions not defined by quadrants A-D are of lower thickness to reduce weight and material costs.

[0026] Additionally shown is the underside 57 of cap 18. Defined on the underside 57 of cap 18 is a plurality of recesses 58 which function to allow air pins 32 to not interact with the cap 18. Optionally, a spacer (not shown) can be positioned between the cap 18 and the lower shoe 10. Preferably, the space would have recesses 58 defined therein to prevent interaction with the air pins 32.

[0027] The apparatus for stamping sheet metal according to the teachings of the present invention utililizes single a lower bolster 28 having a plurality of air pins 32 disposed in predetermined locations. A pair of die sets, each configured to produce components have substantially different shapes, are matable to the lower bolster 28 without changing the location of the air pins 32. A first die set has a first upper adapter 12 and a first lower die shoe 10, a ring 16, and a cap 18. The first upper adapter 12 and first die shoe 10 are matable to form a first stamped component, while the said first lower die shoe 10 is matable with the air pins 32 so that at least one air pin 32 is operable to apply forces to the ring 16. In situations where another component must be produced, a second die set having a second upper adapter 12′ and second lower die shoe 10′, a second stamping ring 16′, a second cap 18′ is coupled to the lower bolster 28′. The second lower die shoe 10′ is matable with said air pins 32 such that at least one air pin 32 is operable to apply forces to said second stamping ring 16′. It is important that the lower shoes 10 and 10′ and rings 16 and 16′from each die set be configured so that no air pins 32 must be removed in order for an operator to change die sets.

[0028] FIGS. 5 and 6 represent side views of a second embodiment of the present invention. Shown is an alternate guide pin assembly 60 for use with a die set, which defines a first air pin accepting bore 62. Additionally, the guide pin 58 defines a second threaded bore 64 which is capable of accepting a threaded bolt 66. The threaded bolt 66 functions to hold a retainer cap 68. The retainer cap 68 is an additional safety feature to assist in the retention of the die ring 16 to the lower shoe 10.

[0029] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims

1. An apparatus for stamping sheet metal comprising: a lower bolster having a plurality of air pins disposed in predetermined locations; a first die set having a first upper adapter and a first die shoe, a ring, and a cap, said first upper adapter and first die shoe matable to form a first stamped component, said first die shoe being matable with said air pin so that at least one air pin is operable to apply forces to said ring; and a second die set having a second upper adapter and second die shoe, a second stamping ring, a second cap, said second upper adapter die shoe being matable to form a second stamped component having a shape substantially different than the shape of said first die component, said second die shoe being matable with said air pins such that at least one air pin is operable to apply forces to said second stamping ring.

2. The system of claim 1 comprising at least one guide pin disposed partially within a bore defined in said first die shoe, said guide pin being slidably accepted within first stamping ring, and wherein said guide pin defines a bore configured to accept one of said air pins.

3. The system of claim 1 comprising a spacer disposed between said first shoe and said cap.

4. The system of claim 3 wherein said spacer defines a plurality of compartments operable to accept at least one air pin and prevent interference between said air pin and said spacer.

5. The apparatus of claim 1 wherein said guide pin comprises a locking cap.

6. The apparatus of claim 1 wherein said plurality of air pins are spaced apart from each other at about regular intervals.

7. The apparatus of claim 1 wherein said second die shoe is configured to be matable within said lower bolster without removing any air pins.

8. An apparatus for stamping sheet metal comprising: a lower bolster having a plurality of air pins disposed in predetermined locations; a first die set having a first die shoe and holding mechanism, said first die shoe being matable with said air pins so that at least one air pin is operable to apply forces to said holding mechanism; a second die set having a second die shoe and a second holding mechanism being matable with said air pins such that at least one air pin is operable to apply forces to said second holding mechanism; and a press capable of forcing said first shoe and said second shoe together.

9. The system of claim 8 further comprising at least one guide pin coupled to said second shoe, said guide pin being coupled to said first holding mechanism.

10. The system according to claim 9 wherein said guide pin defines a bore configured to accept one of said air pins.

11. The system according to claim 8 wherein said air pin is coupled to an air spring.

12. The system according to claim 8 wherein said plurality of air pins are spaced apart from each other at about regular intervals.

13. The apparatus of claim 8 wherein said second die shoe is configured to be matable with said bolster without removing any air pins.

14. An apparatus for stamping sheet metal comprising: a lower bolster having a plurality of air pins disposed in predetermined locations; and a first die set having a first die shoe and a holding mechanism, said first die shoe being matable with said air pin so that at least one air pin is operable to apply forces to said holding mechanism, said first die show further having at least one guide pin, said guide pin defining a bore operable to accept at least one air pin.

15. The apparatus of claim 14 further comprising a second die set having a second die shoe and second holding member, said second die shoe further comprising a second guide pin operable to slidably accept said air pin.

16. The apparatus for stamping sheet metal according to claim 14 wherein said first die set comprises a first upper adapter, said first upper adapter and first die shoe being matable to form a first stamped component, and wherein said second die set comprises a second upper adapter, said second upper adapter and second die shoe being matable to form a second stamped component having a shape substantially different than the shape of said first die component.

17. The apparatus for stamping sheet metal according to claim 14 wherein said first holding mechanism is a ring.

18. The apparatus of claim 14 wherein said guide pin comprises a locking cap.

19. The apparatus of claim 14 wherein said plurality of air pins are spaced apart from each other at about regular intervals.

20. The apparatus of claim 14 wherein said first lower shoe defines a plurality of quadrants, at least one quadrant having a thickness greater than another quadrant.

21. The apparatus according to claim 14 wherein at least one air pin is coupled to an air spring.