Showing papers on "Stamping published in 1998"

Shaped multilayer metal foil shield structures and method of making

Abstract: A forge/swage formed three dimensional multilayer metal foil shield having areas therein where the layers are in a spaced apart relationship, areas therein where the layers are tensioned or stretched, and areas therein where the layers are compressed and interlocked together by folding, rolling, wrinkling, curling, coiling, crimping and the like. The multilayer metal foil shield is formed by forge/swage shaping in an appropriate mold apparatus a preform of a stack of metal foil layers having gaps between the layers. The gaps are provided by embossments in the layers or by spacers between the layers. The forge formed multilayer metal foil shields have utility as heat shields and acoustic shields, particularly on vehicles. The forge formed multilayer metal foil shields are mounted on automobile underbody areas, such as the bottom of the floor pan of the passenger compartment, to provide heat and sound insulation. Other automotive uses include fire wall, exhaust tunnel, motor mount and exhaust down pipe. The three dimensional shields include multilayer metal sheet formed structures. Intermediate beaded or rolled edge multilayer metal preforms are made for transport to the final three dimensional stamping operation.

Printing apparatus with inflatable means for advancing a substrate towards the stamping surface

Abstract: A micro-contact printing apparatus includes a pressure chamber with a micro-contact printing stamp, a vacuum chuck, elastomeric membrane and mechanical stops attached to the vacuum chuck and positioned within the chamber. An extractor pin is attached to the chamber and accessible externally. The micro-contact printing stamp includes a flexible layer made from an elastomer with a stamping surface and attached to a support structure. A method for micro-contact printing a substrate surface includes advancing the substrate surface toward the stamping surface and contacting mechanical stops with support structure before the substrate surface physically contacts the stamping surface. Springs of members adjust the position of the substrate surface to be parallel with the stamping surface. The membrane is inflated to physically contact the substrate surface with the stamping surface, in such a manner that complete adhesion of the stamping surface to the substrate surface is achieved. The extractor pin is used to disengage the substrate surface from the stamping surface at the chamber pressure used in micro-contact printing, so that distortion of the printing pattern is minimized.

Modifying image data

Abstract: An image data modifying system has devices for image storage, display, processing and manual control. The storage device is arranged to store many modifying textures in the form of stamps having fewer pixels than a full image frame. The processing device constructs a new texture stamp by scaling a first stamping texture, expanding a second stamping texture without scaling and combining the scaled texture with the expanded texture. In this way, the effect of scaling artefacts is significantly reduced.

On stamp forming of curved and flexible geometry components from continuous glass fiber/polypropylene composites

Abstract: A thermoforming technique known as stamp forming has been used to transform a pre-consolidated unidirectional glass fiber reinforced polypropylene (GF/PP) flat panel into a more complex geometry. To achieve this, firstly, two-dimensional half-tube composite parts were formed, mainly to optimize the processing conditions such as stamping temperature, forming velocity and mold geometry. The two-dimensional mold was kept at room temperature, whereas the composite panel to be formed was raised to a certain preheating temperature. The preconsolidated GF/PP panel, heated by contact heating in an external heater above the melting temperature of PP matrix, was then formed in the cold metal mold. Typical cycle times (including preheating and stamping) were in the range of 3–4 min. Secondly, a novel rod-bed mold was designed to manufacture three-dimensional parts using the same forming technique. Both halves of the mold were made of several tiny round metal rods in a metal frame. This rod-bed mold allowed to duplicate any solid contour by pushing it slightly on to the spring loaded rods. The final position of these rods could be fixed by forcing the side plates of the metal frame together. As an example, a saddle shaped, three-dimensional contour could be fairly well reproduced by stamp forming GF/PP composites with this rod-bed mold. The latter can have enormous potential in the manufacturing of medical devices such as adjustable prostheses or splints where only a limited number of parts with complex geometry have to be formed.

Method for manufacturing low work function surfaces

Abstract: Methods for fabricating nano-structured surfaces having geometries in which the passage of elementary particles through a potential barrier is enhanced are described. The methods use combinations of electron beam lithography, lift-off, and rolling, imprinting or stamping processes.

Overmolding of actuator E-block by thixotropic or semisolid forging

Abstract: An actuator E-block for a rotary data storage device has a number of solid flat arms and flat coil yokes. The arms and yokes are formed from a metal, metal-reinforced metal matrix composites (MMC), ceramic-reinforced MMCs, glasses, ceramics or ceramic composites having a low density metal matrix surrounding reinforcing particles of low density and high specific stiffness. The arms and yokes may be formed as inserts by inexpensive processes such as stamping, blanking or laser scribing. The arm and yoke inserts are placed in a mold and then overmolded with a metal or metal matrix composite E-block body using a thixotropic or semisolid forming process. After molding, these materials and processes form a cost effective, lightweight E-block with a near net shape and enhanced damping and stiffness.

Development of a new laser cladding process for manufacturing cutting and stamping dies

Abstract: An integrated powder delivery system is described, which can provide a highly stable, continuous, and accurate powder feeding rate, and deliver the alloy powders coaxially into the laser-generated molten pool to form high-quality cladding tracks. By combining such a powder feeding system and computer-aided design/computer aided machining system, complex, three-dimensional geometric patterns were deposited on AISI 1045 steel plate or roller via laser cladding for manufacturing cutting and stamping dies, and laminated metal matrix composites. The microstructures of cladding layers, interface, and heat-affected zone were characterized, and the microhardness of a transverse section of single cladding tracks was also measured. © 1998 Chapman & Hall

Verfahren und Vorrichtung zur Herstellung eines Kokskohlekuchens zur Verkokung in einer Ofenkammer

Abstract: The aim of the invention is to provide a method and a stamping device which is affiliated with said method. Using known economical stamping techniques, the stamping device permits coke coal cakes which are produced in an edgewise manner to be inserted into a coking furnace in a manner suited for positioning i.e. in a flat-lying manner. To this end, a coke coal cake (1) having a small cake height and a large cake base surface is stamped inside a stamp die in an edgewise arrangement while using known techniques. Afterwards, the coke coal cake (1) remains in the stamp die and is placed in a position by a tipping and holding device (3) which is placed on the stamp die and which is suited for carrying out functions. In said position, the coke coal cake (1) which has not yet been removed from the die is inserted into the furnace chamber, is removed from the die therein, and is placed on the furnace base. This is especially achieved by using an inventive stamping device which is characterized in that a tipping and holding device (3) is connected to the stamp die of a stamping machine. A setting base (2) is arranged in the tipping and holding device such that the base is both a part of the stamp die and a part of the setting base.

Study of dynamic explicit analysis in sheet metal forming processes using faster punch velocity and mass scaling scheme

Abstract: A finite element formulation using dynamic explicit time integration scheme is developed for numerical analysis of autobody panel stamping processes. The lumping scheme is employed for the diagonal mass matrix and linearizing dynamic formulation. A contact scheme is developed by combining the skew boundary condition and direct trial and error method. To investigate the effects of punch velocity, various values of punch velocity are used for numerical analysis. The mass scaling scheme is introduced for economic analysis. To investigate the effects of mass scaling, various mass scalings are used. Computations are performed for analysis of complicated autobody panel stamping processes including the formation of an oilpan and a fuel tank.

Draw stamping die for stamping body panels for motor vehicles

Abstract: A method and apparatus for forming an exterior body panel for a motor vehicle. The method comprises mounting a sheet of metal material (16) in a die assembly, clamping first peripheral portion of the sheet of metal material between clamping surfaces of the die assembly (18), moving the clamping surfaces relative to a central die structure so as to deform the sheet metal over the central die structure, clamping second peripheral portion of the sheet of metal material between a die pad of the die assembly and the central die structure after the sheet metal is deformed over the central die structure, moving the clamping surfaces relative to the central die structure to stretch the sheet metal over the central die structure after the second peripheral portion of the sheet of metal material are clamped, and stamping the sheet of metal material between the central structure and an opposing die surface after the sheet metal has been stretched over the die structure so as to provide the sheet metal with a desired configuration.

Innovative Laser-Aided Manufacturing of Patterned Stamping and Cutting Dies: Processing Parameters

Abstract: We have systematically investigated the process parameters of laser cladding CPM 10V on AISI 1045 steel substrates. Based on experimental results, we have made reasonable approximations and assumptions, developed a simple but realistic process model, relating the maximum clad thickness and various process parameters, for on-line production. The predicted results of this model are in good agreement with the experimental results. A 2.5 kW continuous-wave: CO 2 laser, a coaxial powder feeding system, and a CAD/CAM system were used for laser cladding experiments. The microstructure of cladding layer, interface and heat-affected zone are characterized by using optical microscopy. Microhardness measurements of laser cladding samples under different treatment conditions are also carried out.

The development of an integrated process model for liquid composite moulding

Abstract: In recent years, confidence in liquid composite moulding (LCM) has been enhanced by the development of a number of process models, including simulations of both the injection phase and the preform manufacturing process However, these have traditionally been developed as separate entities, with little thought given to the interaction between reinforcement deformation and resin flow In fact the impregnation characteristics of the preform are highly influenced by local variations in fibre orientation and volume fraction For preforms produced by forming or stamping of reinforcement fabrics, such variations can be predicted using a fabric deformation or `drape' simulation This paper describes the development of an integrated process model, based on a combination of a kinematic fabric drape model with a control volume/finite element flow simulation The two codes are linked by a semi-empirical reinforcement permeability model, which allows the preform flow characteristics to be predicted from the fibre architecture A number of examples are included to highlight the significant effects of fabric deformation on the flow pattern and pressure distribution during LCM

Method for producing a transponder coil

Abstract: A method of producing a transponder (20) comprising the following steps: demarcating the various turns (8) of a coil in a sheet (1), including a dielectric substrate covered by at least one conducting layer (2), by stamping said conducting layer with a stamping die (5) having sharp-edged surfaces (6) for contact with the superficial conducting layer (2; 2"'), connecting at least one electronic component (25) to the turns (8), and mounting at least one protective sheet (22; 27) covering the coil and the electronic component (25). To facilitate the stamping and to obtain clean incisions, the conducting layer is covered, before stamping, with a synthetic film. To prevent short circuits over the incisions, the incisions are preferably filled in with an adhesive, varnish or lacquer.

Form with integratable, removable card

Abstract: The form is built with multiple layers in the area of the card (K). Outside the specific form material, there is usually a glue layer (22) and a support layer (21), and there is a stamp for stamping the card. All the layers in the form are the same size. The method for manufacturing the form has the application of pre-packaged multi-layer material as raw material. These layers are all built to the same size as all the other layers. The method may be through the use of endless multi-layered materials. The endless multi-layered materials generate the stamped card and in themselves have a pressurized run-through.

An analysis of drawbead restraining force in the stamping process

Abstract: A theoretical model based on the virtual work principle was proposed to calculate the restraining force produced by the drawbead located on a stamping die surface. In the theoretical model the deformation of the sheet metal drawn over the groove shoulder or bead is assumed to be subjected to bending, sliding and unbending processes, and only the sliding process is responsible for the frictional force. The governing equations derived from the theoretical model were solved by a numerical procedure. In order to validate the proposed model, the finite element simulations were also performed to calculate the drawbead restraining forces for various steels. The simulated results together with the experimental data obtained from the published literature were compared with the predicted values calculated by using the numerical procedure. The good agreement between the simulated results, experimental data and the calculated values justifies the proposed theoretical model.

Noise-cut LC filter for power converter with overlapping aligned coil patterns

Abstract: A noise-cut filter having distributed inductances and distributed capacitances is provided wherein conductive spiral coil patterns are formed on the opposite surfaces of a dielectric sheet, such that the spiral coil patterns are aligned with each other in a direction perpendicular to the plane of the dielectric sheet, and a main circuit pattern is constructed by bonding a main circuit conductor to the spiral coil pattern formed on one of the opposite surfaces of the dielectric sheet The main circuit conductor is formed by stamping with a punch press so that the conductor has a cross sectional area large enough to allow the passage of current of a main circuit, and has substantially the same shape as the spiral coil pattern Further, a grounding wire is bonded to the spiral coil pattern formed on the other surface of the dielectric sheet, so that the grounding wire leads the current involving noises which flows from the main circuit pattern into the spiral coil pattern via the dielectric sheet, to a ground terminal

Copper alloy for electric and electronic parts

Abstract: PROBLEM TO BE SOLVED: To furthermore improve the stamping workability (the reduction of the wear of a stamping die and the burrs and sagging in a copper alloy subjected to punching) of a Cu-Ni-Si series alloy while satisfactorily maintaining its strength, electric conductivity, stress relaxation resistance and plating properties. SOLUTION: This invension is composed of a copper alloy having a compsn. contg., by weight, 0.1 to 4.0% Ni, 0.01 to 1.0% Si, 0.01 to 5.0% Zn and 0.0001 to 0.005% S, furthermore contg. one or >= two kinds of elements selected from the group of 0.00003 to 0.003% Se, 0.00003 to 0.003% Te, 0.00003 to 0.003% Sb and 0.00003 to 0.003% Bi by 0.00003 to 0.005% in total, and the balance Cu with inevitable impurities.

Pedal arm assembly

Abstract: An improved vehicle pedal arm assembly made from a one or two-piece stamping of relatively thin gauge material. The preferred pedal arm assembly preferably includes an integral pedal pad. The opposite end of the stamping is formed or spread so that it is equal in width to the arms mating bracket. This arrangement allows for the assembly to pivot without a tubular hub, or spacer.

Sheet metal housing for an HID luminaire

Abstract: A sheet metal housing for an HID luminaire which comprises a two piece, fold-up sheet metal housing which provides exceptional strength with minimal usage of materials to support a very heavy ballast therein. The sheet metal housing is suitable for a low cost highbay luminaire with high watt ballasts for Metal Halide and High Pressure Sodium, Mercury Vapor (HID) light sources. The sheet metal housing provides reflector adjustability for different size lamps and light centers. A top sheet metal stamping defines a central ballast shelf on which a ballast is mounted, and first and second ends of the top stamping are bent 90° on opposite sides of the central ballast shelf. The first and second ends of the top stamping are further bent back 180° upon themselves to form a double wall. The first and second ends of the top stamping are further bent 90° to project towards each other. The very ends of the first and second ends of the top stamping are further bent and interconnected to form a three wall top hanging system, and to form a top sheet metal housing. First and second ends of a bottom sheet metal stamping are bent 90° about a central section to form a bottom sheet metal housing.

Production of e.g. multilayer metal plastic laminate forming lead frame, includes stamping processes raising contact surfaces and adhesive dams, advancing miniaturization by replacement of ball grid arrays

Abstract: A metal foil (1) is formed by stamping and/or deep drawing of at least one metal contact surface (3, 4). The metal foil is laminated with plastic film (2), holding the contact surface profile closely. In a similar alternative, the plastic film is first laminated to the metal foil before stamping. More films and foils may be included. An Independent claim is also included for the metal/plastic laminate and corresponding lead- or support frame made as described. Preferred features: The metal contact surface is re-stamped. Following lamination, the metal contact surface has a profile height (h) of 20-50 microns . There is at least one depression (7) in the foil, to make contact with components. There is a further depression (5) at the edge of the contact surface and/or at least one more (6) in the region where lamination will later take place.

Copper alloy for electrical and electronic part

Abstract: PROBLEM TO BE SOLVED: To provide a Cu-Mg-Zn alloy for electrical and electronic parts, excel lent in stamping characteristic (minimal in burr and sagging as well as in wear of a stamping die). SOLUTION: This alloy has a composition consisting of, by weight, 0.01-2.0% Mg, 0.01-10.0% Zn, 0.00001-0.005%, in total, of one or >=2 elements selected from the group consisting of 0.00001-0.000% Se, 0.00001-0.003% Te, 0.00001-0.003% Sb, and 0.00001-0.003% Bi, 0.00001-0.003% S, and the balance Cu with inevitable impurities.

Contactless smart card has core sheet stamped out

Abstract: A smart card includes electronic component(s) and a base sheet (10). A core sheet (1) is joined to the base sheet. The core sheet has one or more regions (2) stamped out to accommodate the component(s), including e.g. an antenna coil. The component is embedded with a filler in the stamped-out region. The filler is initially in fluid form. Also claimed is the method of making the smart card. The processes include core sheet stamping with attachment of the base sheet, followed by filler and component introduction. Excess filler is removed and the core and base sheets are united under pressure and heat. Simultaneously or thereafter, the filler sets.

Counter plate and cutting die for die-cutting machine

Abstract: A counter plate is provided as a receiving surface opposed to a cutting die to be installed in a die cutting machine for stamping a sheet material into a predetermined shape and making ruled lines thereon, wherein the cutting die has rulings and cutting blades and the counter plate has edge bearing portions formed on portions corresponding to the cutting blades and hollows corresponding to the rulings, and a process for manufacturing the cutting die and counter plate comprising hardening selected portions thereof using laser beam irradiation.

Process for the production of a stamping foil

Abstract: In a process for the production of a stamping foil such as a hot stamping foil having a decorative layer provided on a carrier film only in a region-wise manner, corresponding to a desired patterning of the substrate, negative regions of the decorative layer, which do not remain on the carrier film, are removed from the carrier film of the stamping foil by being pulled off by means of a recipient foil.

Tell us about your punch, we'll tell you about your electrical steel magnetic properties

Abstract: During the building process of an electrical machine, stamping operations induce stresses in electrical steels so that it affects their magnetic properties. This detrimental effect is hereafter quantified for different grades of electrical steels with attention to size effects and stamping tool configurations.