1. Field of the Invention
The present invention relates to a die trim assembly with a recess adapted to retain slugs in a stamping process. More specifically, the present invention describes an improved stamping die trim assembly that retains a slug within the die trim insert after it has been blanked. The present invention comprises a recess that can be added to new die trim inserts, or is retrofitted to die trim inserts in existing stamping dies. The recess improves stamping process and increases overall production for metal workers in various industries.
Stamping is a form of metalworking that uses a punch and a die to perforate holes or shapes in a part, or blanks out a part using punches. The waste portion that is stamped from the material is the slug. When stamping materials with a punch and a die, loose slugs can be tilted or pulled up and into the working area of a stamping die. This can cause the in-feeding material to jam, which can cause damage to the parts being made. Additionally, a slug that is pulled into the working area of the stamping die can damage or break the die tooling, which is expensive to repair or replace.
The present invention relates to a new and improved die trim assembly with a recess adapted to retain loose slugs during a stamping process. The recess preferably vertically aligned on the die insert. In one embodiment, the recess is created via a vertical conical extrusion, such that the top part of the recess is level with the top surface of the die trim section, and the depth of the recess into trim insert wall remains the same vertically along the interior wall of the die insert. In another embodiment, the recess is created via an angled conical extrusion, such that the top part of the recess remains level with the top surface of the die trim section and the bottom part of the recess is tapered inward into the slug cavity, becoming shallower. In yet another embodiment, the recess is created via an angled cylindrical extrusion. In this embodiment, the top part of the recess still remains level with the top surface of the die trim section, and the bottom part of the recess is tapered inward into the slug cavity, becoming shallower to a lesser depth into the trim wall. In all of the embodiments, the bottom of the recess creates a wedging action to hold a slug, which secures the slug in a die insert when stamping materials with a trim punch and a die. This counteracts the tendency for a trim punch to pull the slug upwards out of the die insert, which reduces damages to stamped parts and the die trim assembly.
The present invention can be added to new or existing die trim inserts by wire electric discharge machining (EDM) or conventional grinding or other suitable methods. The recess in the die trim inserts helps retain slugs, which reduces maintenance costs and expenses while increasing efficiency in production, benefiting manufacturing companies that use dies to stamp material or use any process that creates a slug using trim punches and die trim inserts.
2. Description of the Prior Art
Devices have been disclosed in the prior art that relate to die trim assembly parts to retain slugs. These include devices that have been patented and published in patent application publications. These devices generally relate to die trim assembly parts to retain slugs. However, the prior art fails to provide a device that can be easily added to both new and existing stamping dies that is similar to the present invention, which provides a cost-effective solution to improving the stamping process. The following is a list of devices deemed most relevant to the present disclosure, which are herein described for the purposes of highlighting and differentiating the unique aspects of the present invention, and further highlighting the drawbacks existing in the prior art.
These prior art devices have several known drawbacks. For example, U.S. Pat. No. 4,821,615 to Bakermans and Owzar discloses a slug retainer for the die trim assembly of a stamping and forming machine. This device comprises a slug receiving cavity that receives a slug. After slugs are punched from a material, they are pushed through one or two slug passageways in the die trim assembly. The slug receiving cavity communicates with the die trim assembly so that the slugs are continuously produced and stacked into the slug receiving cavity. Unlike the present invention, this device is needs to be affixed to a portion of the die trim assembly. As such, this device is limited to being anchored onto a new die trim assembly. Additionally, slugs can still be pulled into the working area before entering the slug receiving cavity, damaging the die trim assembly. The present invention is capable of retaining slugs immediately after it is punched from a material. Thus, this invention is not ideal as it cannot be retrofitted to existing die assemblies and problematic in securing loose slugs.
Similarly, U.S. Pat. No. 4,974,479 to Bakermans, Deimler, and Reavis discloses a system for controlling slugs in a stamping and forming machine. This device discloses a slug stripper that strips away any slugs that adhere to the end of the punch and slug supporting bars. One end of the slug stripper is mounted to the surface of the die trim section and the other end extends over the die opening. Because one end of the slug stripper extends over the die opening, it could potentially be snapped off or jammed into the die insert in case of malfunction. Unlike the present invention, the slug stripper needs to be mounted, most likely to a new die trim assembly, and maintained in the surface of the die trim assembly, which could be costly. Additionally, the slug stripper may wear down after repeated use, failing to retain slugs. In addition, the slug stripper can push loose slugs into the working area or loose slugs can adhere to the slug stripper, causing further damage to the entire assembly.
U.S. Pat. No. 5,035,163 to Bakermans discloses a punch and die combination for trimming the edges of strip material. The Bakermans device comprises multiple die opening with upstream and downstream shearing edges and multiple punches that punch out trapezoidal-shaped slugs. Unlike the present invention, the Bakermans device requires multiple die openings, where the loose slugs are stacked in the second die opening. While the second die opening may retain loose slugs, the purpose and design of the Bakermans device diverges in intent and design from the present invention, which discloses a recess for a single die opening adapted to secure loose slugs. The Bakermans device is also limited in the fact that the slugs are much more likely to adhere to the working area because the slugs are pushed through multiple die opening for edge trimming.
U.S. Pat. No. 6,997,363 to Vossen discloses a device for removing break-off components from a sheet of material. The Vossen utilizes a clamping tool to hold a waste portion of a metal after it is broken off. Alternatively, the Vossen device requires a high friction surface to hold waste portions when the clamping tool is not used. However, the invention described in Vossen requires additional parts for use with existing die assemblies and fails to address the issues of counteracting the tendency of the slugs to be withdrawn with the punch. The present invention addresses the issue by retaining loose slugs in a die insert by wedging a slug into a die insert interior without the need or expense to create additional apparatus to hold the slug.
U.S. Pat. No. 5,136,907 to Bakermans, Dubbs, and Holbrook discloses a punch and die trim assembly that pushes the slug into a die trim section opening. The slug is moved laterally across the face of the punch by the rib, and the slug moves against the surface of the opening as it is pushed into the die opening and moves downwardly relative to the inclined rib. This is disadvantageous because the punch and the die insert must be aligned to prevent the punch from shearing the rib, which can damage the punch and the rib. This device also fails to address the issues of the slug adhering to the face of the punch while it is moved against the surface of the opening, and further does not address the ability to remove any loose slugs that adhere to the face of the punch. The present invention does not require moving the slugs laterally across any surface. The slugs are simply pushed into the die insert after it is punched. Additionally, the prior art discloses tapered die insert walls, which reduces the life of the die insert because the opening may be enlarged over use. This increases clearance of the apparatus, which can lead to burrs.
The present invention is adapted to retain slugs that is not limited by the structure of the die trim assembly being installed thereinto. The present invention provides flexibility with regard to the size and shape of the recess and where the recess can be added. Multiple recesses can be added, depending on the size of the loose slugs and the type of material used for stamping. The present invention will greatly assist metal workers using stamping machines or die trim assemblies by retaining and securing loose slugs during a stamping process. It is therefore submitted that the present invention substantially diverges in design elements from the prior art and consequently it is clear that there is a need in the art for an improvement to slug retainer devices. In this regard, the instant invention substantially fulfills these needs.
In view of the foregoing disadvantages inherent in the known types of slug retainer devices now present in the prior art, the present invention provides a die trim assembly with a recess adapted to retain slugs in a stamping process, wherein the same can be utilized for providing convenience for the user for improving efficiency with regard to the production of stamped materials.
It is therefore an object of the present invention to provide a new and improved die trim assembly with a recess adapted to retain slugs that has all of the advantages of the prior art and none of the disadvantages.
Another object of the present invention is to provide a new and improved die trim assembly with a recess in the die trim insert wall to create a small geometrical offshoot of the slug that is progressively pinched as it is pushed into the die, causing the slug to wedge thereagainst and counteract the tendency of the slug to be withdrawn with the trim punch, either by vacuum, electrostatic attraction, or the like.
Yet another object of the present invention is to provide a new and improved die trim assembly with a recess in the die trim insert wall that is created via a vertical conical extrusion such that the top of the recess has a larger radius than the narrower end of the recess which has a smaller radius, wherein the top of the recess is level with the top surface of the die trim section and the bottom of the recess extends down into the slug cavity while the depth of the recess into the die trim insert wall remains the same from the top to the bottom of the recess.
Yet another object of the present invention is to provide a new and improved die trim assembly with a recess in the die trim insert wall that is created via an angled conical extrusion such that the top of the recess is level with the top surface of the die trim section, the lower tapered end of the recess is less deep along the die trim profile wall, and the radius of the top of the recess is larger than the radius of the bottom of the recess.
Yet another object of the present invention is to provide a new and improved die trim assembly with a recess in the die trim insert wall that is created via an angled cylindrical extrusion such that the extrusion is deeper at the top surface and tapers into the cavity while the depth of the recess becomes shallower toward the bottom of the die trim profile opening.
Yet another object of the present invention to provide a new and improved die trim assembly with a recess that ensures that the slug produced during a stamping operation will be retained in the die, thereby preventing loose slugs from causing the in-feeding material to jam.
Yet another object of the present invention is to provide a series of recesses to new or existing die trim inserts, which are specifically designed to create a pinching action on the slug, by using conventional grinding or by wire EDM, or other suitable methods.
A final object of the present invention is to provide a new and improved die trim assembly with a recess to prevent the loose slugs from damaging the die tooling, which is expensive to repair or replace.
Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.
Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the die trim assembly with a recess adapted to retain slugs in a stamping process. For the purposes of presenting a brief and clear description of the present invention, the preferred embodiment will be discussed as used for die trim section assembly with a recess. The figures are intended for representative purposes only and should not be considered to be limiting in any respect.
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The recess 24 can be added to an existing die trim profile opening 22 and does not require new parts. The recess 24 may be added to the die trim profile wall 21 using one of various methods, depending upon the embodiment of the recess 24. One of the preferred cutting methods is wire or conventional EDM, which is used to add or retrofit a semi-conical embodiment of the recess 24 into a new or existing die trim profile opening 22. For a semi-cylindrical embodiment, conventional grinding method, wire EDM, or other suitable method may be used.
The recess 24 is preferably positioned vertically so that the top part of the recess 24 is level with the top surface of the die trim insert 20 and the bottom is below the depth that the trim punch enters the die trim profile opening 22. The bottom end of the recess 24 creates a pinching action and compresses a slug when the slug is pushed down with a trim punch into the die trim profile opening 22 during a stamping process. As a result, the slug is wedged against the die trim profile wall 21 and secured into place. The horizontal depth of recess 24 disposed on the die trim profile wall 21 depends upon the slug size and thickness, the composition of the stamped material, cutting clearance between trim punch and trim profile opening 22, and trim profile opening 22 design. The vertical length of the recess 24 depends upon amount of land in the die trim insert 20 and the distance that the trim punch travels into the trim profile opening 22.
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The size and depth of the recess 24 depends on the size of the slug, the cutting clearance, the stamping material, and the trim punch depth into the die trim insert. For instance, a large slug stamped from a thick stamping material would require a larger recess compared to a recess for a smaller slug stamped from a thin stamping material. Furthermore, the vertical depth of the recess is preferably equal to or greater than the depth with which the slug will travel into the die trim profile opening 22. Thus, the vertical depth of the recess may be substantially equal to or more than the distance that the trim punch travels into the die insert opening 22. Additionally, more than one recess may be added to a die trim profile wall 21. The stamping material typically comprises of metal, but the present invention is not limited only to metal, and the present invention can be used when perforating holes and shapes in other materials.
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It is therefore submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, creation of recess, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 61/813,033 filed on Apr. 17, 2013, entitled “Saige Slug Retention Features.” The above identified patent application is herein incorporated by reference in its entirety to provide continuity of disclosure.
Number | Name | Date | Kind |
---|---|---|---|
2404793 | Dickerman | Jul 1946 | A |
2604167 | Oliver | Jul 1952 | A |
4543865 | Kramski | Oct 1985 | A |
4821615 | Bakermans et al. | Apr 1989 | A |
4947720 | Howe | Aug 1990 | A |
4974479 | Bakermans et al. | Dec 1990 | A |
5035163 | Bakermans | Jul 1991 | A |
5136907 | Bakermans et al. | Aug 1992 | A |
6397715 | Roberts | Jun 2002 | B1 |
6997363 | Vossen | Feb 2006 | B1 |
Number | Date | Country | |
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61813033 | Apr 2013 | US |