Tooling assemblies and systems

Press tool assemblies involve separable holder and tip portions. Self-seating structure is incorporated in these assemblies, and can stem from one or both of the separable portions of the assemblies. In use, the self-seating structure facilitates proper positioning and seating of the separable portions in relation to each other, and in some cases, can be used in operatively coupling the portions together. Advantages relating to assembly and disassembly of the tool assemblies, as well as improved structural properties result as a consequence of using the self-seating structure.

FIELD OF INVENTION

The present invention relates generally to industrial presses. More particularly, this invention relates to tooling assemblies for such presses.

BACKGROUND

A variety of industrial presses are known in the art. One such press is the press brake. Press brakes are commonly used to bend or otherwise deform sheet-like workpieces, such as sheet metal workpieces. A conventional press brake has an upper beam and a lower beam, at least one of which is movable toward and away from the other. Typically, the upper beam is movable vertically while the lower beam is fixed in a stationary position. It is common for tooling (e.g., a male forming punch and a female forming die) to be separately mounted on the press brake upper and lower beams. For example, in some cases, the punch is to be mounted on the press upper beam, while the female forming die is to be mounted on the press lower beam.

Typically, the punch has a workpiece-deforming surface (or “tip”). To that end, if the punch is mounted on an upper beam of a press brake, its tip is generally oriented downward. The configuration of the tip is dictated by the shape to which one desires to deform a workpiece. In contrast, the die typically has a recess, bounded by one or more workpiece-deforming surfaces, that is aligned with the punch tip. In cases where the punch is mounted on the press brake upper beam, the die in turn is mounted on the lower beam of a press brake, with its recess generally oriented upward. The configuration of the recess corresponds to the configuration of the punch's tip. Thus, when the beams are brought together, a workpiece positioned between them is pressed by the punch into the die to give the workpiece a desired deformation (e.g., a desired bend).

In order to accurately deform a workpiece, it is necessary for the tooling (e.g., punch and die) to be securely mounted to the press. As described above, for a press brake, this generally involves mounting a select punch and a select die on opposing beams of the press brake. In so doing, the punch and die are generally mounted by forcibly clamping each with corresponding holders of such beams. To that end, each punch generally has a first end region adapted to be clamped by the holder, and a second end that forms the tip or working (e.g., bending/deforming) portion thereof. Likewise, each die generally has a first region adapted to be clamped by the holder, and a second region that forms the recess or working portion thereof.

Press tooling designs continue to evolve. For example, some punches and dies have been designed to include separable portions, thereby involving assemblies (i.e., tooling assemblies) instead of single integral bodies. Regarding punch assemblies, the separable portions generally involve a punch tip holder and a punch tip, with these portions configured to be coupled or decoupled as desired. Likewise, die assemblies involve separable die body and die insert portions that can be similarly coupled and decoupled. Such punch and die assembly designs are advantageous, as they enable the punch tips and die inserts to be removed and replaced or sharpened after they wear down. Unfortunately, these designs also tend to have aspects that are less than ideal.

For example, the methods employed in coupling/decoupling the punch tip to/from the corresponding tip holder can be demanding. In particular, the punch tip is often coupled to the tip holder by aligning openings provided along longitudinal extents of their bodies, and then securing fasteners in the aligned openings. However, properly aligning the punch tip and tip holder for coupling there between can be a laborious process, particularly given the sizes and/or weights of conventional punches. Additionally, in many cases, the coupling process requires performing a reference stroke to seat the tip against the holder prior to operatively coupling the tip and holder together. Further, having to tighten/loosen fasteners in the process can be time consuming, difficult to do, or both.

With further reference to the above-described punch assemblies, they have also been found to exhibit reduced integrity and show increased wear over time, as compared to their single integral-body counterparts. For example, when used in pressing operations, a conventional punch assembly formed by conjoining separate holder and tip portions exhibits a diminished structural integrity as compared to an integral-body punch. In addition, pressing operations tend to exert greater stresses on adjoining surfaces of the conjoined portions, thereby causing increased wear in these areas over time.

Further, in some cases, punch assemblies have been found deficient in uniformly distributing pressing force. For example, in some designs, the holder interfaces with the tip at an angle, causing some areas of the holder to encounter greater pressing force than others. This can lead to less than optimum force distribution and transfer to the tip during a deforming/bending process, and the efficiency of the process may consequently be reduced. In addition, increased wear can be found in the areas encountering the greater forces, which impart greater stresses. The above issues often are aggravated when using larger tip sizes.

It should be appreciated that many of the above-described aspects are found to exist with conventional die assemblies as well.

SUMMARY OF INVENTION

In certain embodiments, the invention provides a tool assembly configured for being mounted on a tool holder of a press. The tool assembly comprises separable portions. The separable portions include a holder and a tip. The tool assembly includes self-seating structure configured to position and seat a first of the holder and the tip in relation to a second of the holder and the tip. The self-seating structure includes a linking member having first and second end regions. The first end region forms a rigid attachment to a first of the holder and tip. The second end region protrudes from the first of the holder and tip and is adapted for engagement by a second of the holder and tip such that a mount surface of the first of the holder and tip is positioned and seated against a corresponding surface of the second of the holder and tip without further adjustment of the first of the holder and tip being required.

In other certain embodiments, the invention provides a tool assembly configured for being mounted on a tool holder of a press. The tool assembly comprises separable portions. The separable portions include a holder and a tip. The tool assembly includes self-seating structure configured to position and seat the tip in relation to the holder. The self-seating structure comprises a linking member having first and second end regions. The first end region forms a rigid attachment to the tip portion. The second end region protrudes from the tip portion and is adapted for engagement with the holder such that a mount surface of the tip is positioned and seated against a corresponding surface of the holder. The holder receives a coupling member adjustably engaged with the linking member so as to operatively couple the holder and the tip. The coupling member is adjustable in relation to a segment of the linking member.

In further certain embodiments, the invention provides a method of providing a tool assembly for use on a tool holder of a press having a pressing axis. The method comprises the steps of attaching self-seating structure to a tip of the tool assembly; engaging the self-seating structure with a holder of the tool assembly, wherein such engagement of the self-seating structure results in a mount surface of the tip being positioned and seated against a corresponding surface of the holder without further adjustment of the tip; and operatively coupling the tip to the holder by engaging the self-seating structure with a coupling member of the holder.

Optionally, the linking member is not equipped with (e.g., is devoid of) hardware, such as springs, retaining bars, nuts, and the like.

Optionally, during the seating of the tool assembly, the coupling member (or at least a portion of it) moves (e.g., axially) relative to the linking member in a direction crosswise (e.g., perpendicular) to the pressing axis of the tool assembly.

Optionally, the linking member is not integral to the tip body, but is selectively attachable to and removable from the tip.

Optionally, when the tool assembly is operatively assembled, a first end region of the linking member is removably anchored to the tip, while a second end region of the linking member is held securely on the holder by virtue of the coupling member bearing against (e.g., so as to form a rigid connection with) the linking member.

DETAILED DESCRIPTION

The following detailed description should be read with reference to the drawings, in which like elements in different drawings are numbered identically. The drawings depict selected embodiments and are not intended to limit the scope of the invention. It will be understood that embodiments shown in the drawings and described below are merely for illustrative purposes, and are not intended to limit the scope of the invention as defined in the claims.

As described above, tooling designs (e.g., punches and dies) for industrial presses (such as press brakes) continue to evolve. One known design involves punches and dies being provided as assemblies, each involving separable holder and working-end portions—namely punch tip holders and punch tips with regard to punches, and die bodies and die inserts with regard to dies. The punch tips can be removed from the tip holders so that the tips can be sharpened or replaced as desired, and the die inserts can similarly be removed from the die bodies. However, these assembly designs also have aspects that are less than ideal. For example, assembly/disassembly of the separable portions can often involve laborious and time-consuming processes, and unlike their integral body counterparts, the assemblies may have reduced structural integrity and may exhibit increased wear over time.

Despite these limitations, punch and die assemblies have continued to gain in popularity because of their overall efficiency with regard to reuse or replacement of their working-end portions. In addition, these assembly designs have been modified over the years, with the separable portions being formed of different materials. Using different materials for the separable portions has enabled manufacturing costs to be reduced. For example, while the punch tips and die inserts typically necessitate hardened materials, the punch holders or die bodies have been modified so as to be formed of less costly material(s). Thus, despite the less than ideal aspects of the punch and die assemblies commercialized to date, demand continues to grow for these assemblies.

One way in which the present invention improves upon the conventional design of tooling assemblies is by providing an improved manner of assembling the separable portions. In certain embodiments of the invention, as further detailed below, self-seating structure is incorporated in the assemblies. The self-seating structure can take a variety of forms, and can stem from one or more of the separable portions of the assemblies. In use, the self-seating structure preferably facilitates proper positioning and seating of the separable portions in relation to each other, e.g., without further requiring a reference stroke of the press (e.g., without having to press the punch forcibly against the die to seat the tools). (By “seating,” “seated,” or “seat,” it is meant that the mount surface(s) of the tip are secured (e.g., firmly) against the corresponding mount surface(s) of the holder.) Consequently, the self-seating structure eases the process of adjoining the portions, while ensuring that the portions are properly positioned and seated in the process, thereby limiting the number of steps required in coupling the portions.

Applicants have found that when the self-seating structure is also used as a means of operatively coupling the portions together, the design can be particularly advantageous. For example, in using the structure to seat the portions and couple them together in the seated position, a particularly reliable tool assembly can be attained. Consequently, the resulting tool assembly, as compared to conventional tool assemblies, is found to exhibit greater structural integrity and reduced wear in the areas of the seated portions.

Additionally, the self-seating structure of the invention involves no corresponding hardware being associated therewith. To that end, when using punch assemblies with rounded punch tips, as the radii of these tips varies, the self-seating structure needs to be correspondingly changed out to effectively couple the tip to the holder. In such cases, if the self-seating structure had corresponding hardware associated therewith, such hardware would further need to be changed out, adding time and expense to the coupling process. This is not the case with the self-seating structure of the invention, as it is devoid of any separate hardware (e.g., springs, retaining bars, nuts, etc.). More will be said of this later.

Further, the seated surfaces of the conjoined portions can be optionally oriented so that uniform distribution of pressing force through the tool assembly is achieved. For example, the self-seating structure can be configured to have a particular orientation relative to a pressing axis of the press, and, when used to seat surfaces of the separable portions, the structure can function to orient the seated surfaces in relation to the pressing axis so as to promote uniform force distribution. In some cases, these surfaces are oriented to be generally perpendicular to the pressing axis of the press. As such, the pressing force, when delivered, is uniformly distributed across the interface of the seated mounting surfaces. For example, with regard to punch assemblies, the above configuration leads to a more uniform and efficient use of the deforming/bending force from the press, regardless of size of the punch tip. In addition, in uniformly distributing this force, the punch assembly is generally found to exhibit reduced wear over its seated mounting surfaces. These and other advantages of the embodied designs are further described below.

FIGS. 1A,1B, and1C (at times collectively referenced herein asFIG. 1) illustrate front, cross-sectional, and exploded assembly views, respectively, of a punch assembly100in accordance with certain embodiments of the invention. While some tool assemblies embodied herein are shown involving punch assemblies (as inFIG. 1), it should be appreciated that such embodiments are just as applicable to die assemblies, e.g., as exemplified inFIGS. 3A,3B, and3C and described below. In addition, it should be appreciated that the embodied tool assemblies can be American Style, European Style, Wila Style, or any other tooling style that would benefit from having the features of this invention. Further, while being described herein regarding their applicability to a press brake, the tool assemblies are just as applicable to other machines having like functioning, such as folding machines, robotic bending cells, and the like.

Returning to the figures, most notablyFIG. 1C, the punch assembly100includes two primary portions, a punch tip holder102and a punch tip104, that are configured to be conjoined (i.e., attached to each other) and separated as desired. However, in embodiments involving die assemblies, e.g., as exemplified inFIGS. 3A,3B, and3C, the two primary portions correspondingly involve a die body and a die insert. It should be appreciated that when referring to a tool assembly and its tip and holder portions herein, the “tip” can be either a punch tip or a die insert. Likewise, the “holder” can correspondingly be either a punch tip holder or a die body.

In certain embodiments, the punch tip holder102is used with (and may be provided in combination with) hardened, tool steel punch tips. Such tool steel often has hardness in the range of 20 HRc to 80 HRc. However, the holder102can be used with a variety of tool tips formed of any material, such as other equivalent hardened material(s) or composite material(s), either known in the art (including those currently in less widespread use) or those not yet developed. Alternatively, in some cases, the holder102can be adapted for use with tool tips of non-hardened materials that are still applicable for their intended bending/deformation functionality.

In some cases, the punch tip holder102has a safety key106. Perhaps as best shown inFIG. 1B, a shank108of the holder102can optionally have such a safety key106.FIG. 2illustrates a side view of an exemplary set-up of the punch assembly100, mounted and aligned with a corresponding die assembly in a manner that is commonly provided in a press brake. With reference toFIG. 2, the safety key106is adapted for engaging a safety recess (or safety groove)202and/or moving into alignment with a safety shelf, defined by a press tool holder200. When provided, the safety key106can be retractable or non-retractable. Safety keys of both types are described in U.S. Pat. No. 6,467,327 and U.S. Pat. No. 7,021,116, the entire contents of each of which are incorporated herein by reference. However, it should be appreciated that, while not shown, embodiments can involve the punch tip holder102having no safety key.

With reference toFIG. 1B, in the case of a retractable safety key, the key106is mounted on the punch tip holder102so as to be moveable between an extended position and a retracted position. In more detail, the key106preferably comprises a rigid engagement portion110that is moveable relative to (e.g., generally toward and away from) the shank108of the tip holder102. In some cases, as shown, the safety key106is part of an assembly (e.g., mounted inside and/or on the punch tip holder102) having at least one spring member112resiliently biasing (directly or via one or more link members and/or other bodies) the safety key106toward its extended position. Further, in some cases, as shown, the assembly includes a push button114, which when depressed inwardly moves the engagement portion110and the spring member112in similar fashion, thereby moving the safety key106to its retracted position so as to enable the tip holder102to be removable downwardly from the press tool holder.

The tip104can be for a male forming punch. However, as alluded to above, it should be appreciated that such tip104could just as well be an insert for a female forming die (i.e., a die insert), e.g., as exemplified inFIGS. 3A,3B, and3C. Likewise, the holder102can be a punch tip holder or a die body. This is true of all embodiments disclosed herein. Typically, the punch tip104has generally opposed first and second end regions116and118. Preferably, the first end region116of the tip104defines a workpiece-deforming surface configured for making a desired deformation (e.g., a bend) in a workpiece when the surface is forced against the workpiece (e.g., when the tip104is forced against a piece of sheet metal or the like, and/or when a workpiece is forced against the tip104). The second end region118of the punch tip104has one or more surfaces configured for mating with corresponding surface(s) of the punch tip holder102. In certain embodiments, the second end region118defines a planar mounting surface150configured to be carried directly against a planar mounting surface152defined by the punch tip holder102, with such surfaces150,152shown inFIG. 1C. More will be said of this later.

As described above, self-seating structure is incorporated in the tool assembly design. One or more of the separable portions (e.g., punch tip holder102or punch tip104) can include such self-seating structure. In such cases, the structure can be coupled to (e.g., operatively coupled to) or integrally formed with a first of the separable portions (e.g., the punch tip104). As such, the structure (e.g., a linking member thereof) can be configured to form a rigid attachment with, and also to define a segment that protrudes from, the first separable portion. The protruding segment can be configured to mate with a second of the separable portions (e.g., the punch tip holder102) so as to properly position and seat the first portion in relation to the second portion.

It should be appreciated that there are a variety of configurations for the self-seating structure. As described above, the self-seating structure can be used to position and seat the punch tip104in relation to the punch tip holder102, and in some cases, the structure can also be used in coupling the tip104and holder102together. For example, in certain embodiments, the self-seating structure includes a linking member120. With reference toFIG. 1C, in certain embodiments, the linking member120is a shaft, rod, pin, or an otherwise elongated member (such as the illustrated pull stud), and includes first and second end regions122and124. In some cases, the linking member is elongated such that, when the tool assembly is mounted operably on a press, the linking member has its central axis generally parallel to a pressing axis of the press. In certain embodiments, the first end region122includes a threaded part. When provided, the threaded part of the first end region122enables the linking member120to be rigidly (e.g., threadingly) attached to one of the separable portions102or104(e.g., to the punch tip104), with the second end region124protruding from that portion so as to be engageable with (e.g., via a coupling member136mounted on) the other portion (e.g., on the punch tip holder102).

In certain embodiments, the first and second end regions122,124of the linking member120are configured to be received within corresponding apertures (e.g., bores) of the separable portions. For example, the illustrated punch tip104defines a threaded aperture (e.g., bore)126adapted to receive a threaded part of the first end region122, while the punch tip holder102defines a mount aperture (optionally a smooth, non-threaded bore)128adapted to receive the second end region124. Consequently, the second end region124is configured to be selectively adjoined to or removed from the holder aperture128, and as such the holder102. It should be appreciated that the holder aperture128preferably is defined so as to form a snug fit with (e.g., limiting lateral movement of) the linking member's second end region122. This can provide good positioning and seating of the punch tip104on the punch tip holder102without requiring a subsequent reference stroke of the press for seating purposes. In certain embodiments, as shown, the aperture128has space129between a leading end of the linking member's second end region122and the illustrated blind end131of the mount aperture128. As should be appreciated, this can also be the case with the other tool holders exemplified in FIGS.3and7-12. Such space129can permit the linking member's second end region to be further pulled within the aperture128via camming engagement with a coupling member of the holder. More will be said of this later.

While threaded coupling is exemplified for providing rigid attachment between the first end region122of the linking member120and the punch tip104, other means of coupling could just as well be used. Further, while only a single linking member120is shown inFIG. 1, it should be appreciated that for greater extents (i.e., longer lengths) of the punch assembly100, a plurality of linking members120can be spaced along the length of the punch tip104. This concept is exemplified inFIGS. 4 and 5, and is also applicable to longer lengths of a die assembly. More will be said of this later.

In some cases, the punch assembly100can include further self-seating structure. For example, in certain embodiments, such further structure can include one or more rails (or sidewalls)130. The rails130, in certain embodiments, can protrude from an end132of the punch tip holder102and be adapted to mate with the punch tip104. As shown, the rails130are integral with the punch tip holder102, but this is not required. In certain embodiments, each of the rails130is configured to mate with one or more outer (e.g., side) surfaces of the punch tip104. For example, with reference toFIG. 1B, each of the rails130is configured to mate with opposing outer surfaces134of the punch tip104. Thus, the punch tip holder102can have (e.g., define) a mount channel, optionally an elongated rectangular (or generally rectangular) channel into which a mounting end region118of the punch tip104is configured to be mounted snuggly. The rails130can advantageously define sidewalls of the mount channel. In using the rails130in combination with a linking member120, the punch assembly100is provided with a two-fold means of positioning and seating the punch tip104with the punch tip holder102.

Upon positioning and seating the punch tip104on the punch tip holder102via the self-seating structure, a coupling means can optionally be provided to secure the tip104to the holder102. As briefly described above, in certain embodiments, the self-seating structure can be used in such coupling. It should be appreciated that the coupling means can take a variety of forms. For example, the coupling means can involve a coupling member136, which can optionally be a fastener (or fastener assembly). In certain embodiments, the coupling member136is a set screw that the punch tip holder104is adapted to receive (e.g., carry). As shown, in certain embodiments, the coupling member136is received in a threaded opening (or bore)138of the punch tip holder102, with the opening (or bore)138generally oriented so as to intersect (i.e., open into) the aperture (or bore)128in the holder102. In certain embodiments, the aperture (or bore)128extends in a direction at least substantially parallel to a pressing axis PA of the assembly100(shown inFIG. 1B). As such, movement of the coupling member136toward or away from the linking member120(i.e., the second end region124thereof) can be in a direction crosswise to the assembly's pressing axis PA. In certain embodiments, the movement of the coupling member136toward or away from the linking member120is axial. Further, in certain embodiments as shown, the crosswise direction is at least substantially perpendicular to the assembly's pressing axis PA. It should be appreciated that the above description is correspondingly applicable to the die assembly300ofFIGS. 3A,3B, and3C, with pressing axis PA of the assembly300being shown inFIG. 3B.

With reference to the enlarged section ofFIG. 1B, when the second end region124of the linking member120is inserted into the corresponding aperture (or bore)128of the holder102, the coupling member136contacts such second end region124as the coupling member is advanced in the threaded opening138, thereby locking the linking member120in place and securing the punch tip104in its seated position to the punch tip holder102. To that end, in the case where the coupling member136is provided on the holder102(in the opening138), at least a portion of the member136can be movable selectively toward or away from a segment (i.e., second end region124) of the linking member120at such time as that segment is received in the mount aperture (or bore)128of the holder102. In turn and as further detailed below, movement of the coupling member136toward the linking member120can cause the coupling member portion to bear against said linking member segment so as to seat the tip104on the holder102. As shown, the linking member120can optionally have a shoulder121, that, when operatively mounted to the tip104, is carried against a mount surface150of the tip104. As shown, this can also be the case, with linking members used is the tool assemblies of FIGS.3and7-12. Here, the mount surface150of the tip104can optionally contact both the shoulder121of the linking member120and mount surface152of the tip holder102. Further, movement of the coupling member136away from said linking member segment can allow the linking member120to be released from the mount aperture (or bore)136of the holder102. It should be appreciated that the above description is correspondingly applicable to the die assembly300ofFIGS. 3A,3B, and3C.

In certain embodiments, as perhaps best shown from the enlarged section ofFIG. 1BandFIG. 1C, the second end region124of the linking member120has a female detent (e.g., an indentation, recess, narrow neck region, and/or channel)140formed on or around a portion thereof and optionally bounded on one side by a head141of the linking member120. The female detent140provides a seat for the coupling member136to extend into when advanced in the opening138, providing a secure coupling. As further shown, in certain embodiments, the detent140has ramped (or “angled”) outer surfaces142to mate with a correspondingly-configured outer surface144at the leading end region146of the coupling member136. In this case, the geometrical engagement of the coupling member's leading end region146and the linking member's female detent140enables a tighter coupling. In particular, as the coupling member136is advanced in the illustrated threaded opening138, the coupling member's angled surface144engages (e.g., makes contact with) the angled outer surfaces142of the detent140. In further advancing the coupling member136within the threaded opening138, the coupling member's leading end region146moves further into the detent140. Consequently, the coupling member's angled surface144cams with the detent's angled surfaces142, and in the process pulls the linking member's second end region124into its final, operatively mounted position within the holder aperture128. Such pulling (and in this case, raising, e.g., for when the assembly100is mounted on an upper beam of a press, with a representation of such provided inFIG. 2) of the linking member120within the holder aperture128provides a tight coupling between punch tip104and punch tip holder102, eliminating or limiting any gaps or tolerances between the adjoined surfaces of the tip104and holder102, thereby providing a tightly-bound assembly without the need to perform a prior reference stroke of the press (for seating purposes). In other embodiments (not shown), the coupling means (e.g., the fastener136), when provided, simply bears forcibly against the side of a linking member that has no female detent. Or, other types of female detents can be used. Further, while the illustrated coupling means can be an externally threaded set screw, various other coupling means can be used. For example, a body can be spring biased (or otherwise forced) into engagement with the linking member.

As briefly described above, by incorporating self-seating structure (e.g., a linking member120) in tool assembly designs to position and seat, and/or to couple, the tip holder and tip portions, the design can ease the assembly process and also have a favorable impact on the performance and durability of the tool assembly. For example, as described above, in using the structure to initially seat the portions and then couple them together in the seated position, a tightly-bound tool assembly is attained. Consequently, the resulting tool assembly, in comparison to conventional tool assemblies, exhibits enhanced structural properties. For example, in coupling the linking member120in its operative position with the punch tip holder102, unwanted gaps between the tip104and holder102are eliminated or limited in the resulting punch assembly100. Thus, when operatively assembled, the engaged mating surfaces of the punch tip and punch tip holder preferably are maintained in stable, direct contact with one another at all times during pressing operations. Consequently, the assembly100can exhibit greater structural integrity and reduced wear in areas of the seated portions.

Further, in certain embodiments with reference toFIG. 1C, the self-seating structure (the linking member120, and optionally, the rails130) are configured such that mating mount surfaces150and152of the tip104and tip holder102, respectively, are maintained in a particular orientation with respect to the pressing axis of the press. In certain embodiments, the linking member120protrudes from the punch tip104in a direction (e.g., along an axis) parallel (or substantially parallel) to the pressing axis of the press. As such, in certain embodiments, the mating surfaces150,152, once seated (i.e., carried directly against each other in their operative position), are perpendicular (or substantially perpendicular) to the pressing axis. InFIG. 2, the illustrated pressing axis A is generally vertical, although this is not strictly required. As such, the corresponding vertically-oriented pressing force, when delivered to the punch assembly100, is uniformly distributed across the entire interface area of the seated surfaces150,152. This leads to a more uniform and effective use of the deforming/bending force from the press, regardless of size of the punch tip. In addition, in uniformly distributing this force, the punch assembly100may produce less wear proximate to the seated surfaces150,152in comparison to what is typically exhibited in using conventional punch assemblies.

As alluded to above, embodiments of the invention are just as applicable to die assemblies, and this is exemplified inFIGS. 3A,3B, and3C (at times collectively referenced herein asFIG. 3), which illustrate front, cross-sectional, and exploded assembly views, respectively, of a die assembly300. Similar to the punch assembly100ofFIG. 1, the die assembly300includes two primary portions configured to be conjoined and separated as desired, but in this case, the portions involve a die body302and a die insert304.

In certain embodiments, the die body302, similar to the punch tip holder102described above, is used with (and may be provided in combination with) hardened, tool steel die inserts. However, the die body302can be used with a variety of die inserts formed of any material, such as other equivalent hardened material(s) or composite material(s), either known in the art (including those currently in less widespread use) or those not yet developed. Alternatively, in some cases, the body302can be adapted for use with inserts of other hard or non-hardened materials that are applicable for their intended bending/deformation functionality. For example, in certain embodiments, the die insert304can be formed of a hard steel of a polymer/composite material (e.g., via molding, casting, or extruding), with the material being more beneficial in applications in which mark-free bending is warranted, e.g., such as involving polished or painted materials.

As shown, the die insert304has generally opposed first and second end regions316and318. Preferably, the first end region316of the insert304defines a recess (or “channel”)306, bounded by one or more workpiece-deforming surfaces. The first end region316of the insert304, when used in a press, is aligned with a corresponding punch and generally supports a workpiece thereon. During a pressing operation, a desired deformation (e.g., a bend) is created in the workpiece when the punch is forced against the workpiece (e.g., when the punch tip is forced against a piece of sheet metal or the like, and/or when a workpiece is forced against the tip), with the workpiece being bent according to a shape of the insert recess306. The second end318of the illustrated die insert304has one or more surfaces configured for mating with corresponding surface(s) of the die body302. In certain embodiments, the second end318defines a planar mounting surface350configured to be carried directly against a planar mounting surface352defined by the die body302, with such surfaces350,352shown inFIG. 3C.

Similar to the punch assembly100ofFIG. 1, self-seating structure is incorporated in the design of the die assembly300, with this structure sharing many of the same attributes and functionality described above with regard to the punch assembly100. For example, as shown, the self-seating structure includes a linking member120. As already described, the linking member120can include first and second end regions122and124, with the first end region122optionally including a threaded part. When provided, as shown, the threaded part of the first end region122enables the linking member120to be rigidly (e.g., threadingly) attached to one of the separable portions302or304(e.g., to the die insert304), with the second end region124protruding from that portion so as to be engageable with (e.g., via a coupling member136mounted on) the other portion (e.g., on the die body302).

In certain embodiments, the first and second end regions122,124of the linking member120are configured to be received within corresponding apertures (e.g., bores) of the separable portions. For example, the illustrated die insert304defines a threaded aperture (e.g., bore)326adapted to receive a threaded part of the first end region122, while the die body302defines an aperture (optionally a smooth, non-threaded)328adapted to receive the second end region124. Consequently, the second end region124is configured to be selectively adjoined to or removed from the body aperture328, and as such the body302. It should be appreciated that the die body aperture328preferably is defined so as to form a snug fit with (e.g., limiting lateral movement of) the linking member's second end region122, resulting in good positioning and seating of the die insert304on the die body302.

In some cases, as shown, the die assembly300includes further self-seating structure, such as one or more rails (or sidewalls)330. Such rails330, in certain embodiments, can protrude from an end region332of the die body302and be adapted to mate with the die insert304. As shown, the rails330are integral with the die body302, but this is not required. In certain embodiments, each of the rails330is configured to mate with one or more outer (e.g., side) surfaces of the die insert304. For example, with reference toFIG. 1B, each of the rails130is configured to mate with opposing outer (e.g., side) surfaces334of the die insert304. Thus, similar to the punch tip holder102, the die body302can have (e.g., define) a mount channel, optionally an elongated rectangular (or generally rectangular) channel, into which a mounting end region318of the die insert304is configured to be mounted snuggly. The rails330can advantageously define sidewalls of the mount channel. In using the rails330in combination with a linking member120, the die assembly300can be provided with a two-fold means of positioning and seating the die insert304on the die body302.

Upon positioning and seating the die insert304on the die body302via the self-seating structure, a coupling means (e.g., a coupling member) can optionally be provided to secure the insert304to the body302, e.g., similar to that already described with respect to the punch assembly100. To that end, in certain embodiments, the self-seating structure can be used in such coupling, with a coupling means involving the same type of coupling member136, such as a fastener or fastener assembly, optionally involving a set screw, as described above. As such, in certain embodiments, the coupling member136is received in a threaded opening (or bore)338of the die body302, with the opening (or bore)338generally oriented so as to intersect (i.e., open into) the aperture (or bore)328in the body302. As such, with reference to the enlarged section ofFIG. 3B, when the second end region124of the linking member120is inserted into the corresponding aperture (or bore)328of the body302, the coupling member136contacts such second end region124as the coupling member is advanced in the threaded opening338, thereby locking the linking member120in place and securing the die insert304in its seated position on the die body302.

As should be appreciated from the drawings, perhaps as best shown from the enlarged section ofFIG. 3BandFIG. 3C, the second end region124of the linking member120, in certain embodiments, has a female detent140as described above with regard to embodiments concerning the punch assembly100. To that end, the female detent140provides a seat for the coupling member136to extend into when advanced in the opening338, providing a secure coupling. As also described above, in certain embodiments, the detent140has ramped (or “angled”) outer edges142to mate with a correspondingly-configured outer surface144at the leading end region146of the coupling member136. As such, the geometrical engagement of the coupling member's leading end region146and the linking member's female detent140enables a tighter coupling via pulling of the linking member second end region124(as much as possible) into its final, operative mounted position within the die body aperture328. Such pulling (and in this case, lowering, e.g., for when the assembly300is mounted on a lower beam of a press, with a representation of such provided inFIG. 2) of the linking member120within the aperture328provides a tight coupling between die insert304and die body302, eliminating or limiting any gaps or tolerances between the adjoined surfaces of the insert304and body302, thereby providing a tightly-bound assembly without the need to perform a prior reference stroke of the press (for seating purposes). As described above, in other embodiments (not shown), the coupling means (e.g., the fastener136), when provided, simply bears forcibly against the side of a linking member that has no female detent. Or, other types of female detents can be used. Further, while the illustrated coupling means can be an externally threaded set screw, various other coupling means can be used. For example, a body can be spring biased (or otherwise forced) into engagement with the linking member.

Similar to that described above with regard to the punch assembly100, by incorporating self-seating structure (e.g., a linking member120) in die assembly designs to position and seat, and/or to couple, the die body and insert portions, the design can ease the assembly process and also have a favorable impact on the performance and durability of the die assembly. For example, as described above, a tightly-bound die assembly is attained, which in comparison to conventional die assemblies, exhibits enhanced structural properties. For example, in coupling the linking member120in its operative position with the die body302, unwanted gaps between the insert304and body302are eliminated or limited in the resulting die assembly300. Thus, when operatively assembled, the engaged mating surfaces of the die body and insert portions preferably are maintained in stable, direct contact with one another at all times during pressing operations. Consequently, the assembly300can exhibit greater structural integrity and reduced wear in areas of the seated portions.

Further, in certain embodiments with reference toFIG. 3C, the self-seating structure (the linking member120, and optionally, the rails330) are configured such that mating surfaces350and352of the die insert304and die body302, respectively, are maintained in a particular orientation with respect to the pressing axis of the press. In certain embodiments, the linking member120protrudes from the die insert304in a direction (e.g., along an axis) parallel (or substantially parallel) to the pressing axis of the press. As such, in certain embodiments, the mating surfaces350,352, once seated (i.e., carried directly against each other in their operative position), are perpendicular (or substantially perpendicular) to the pressing axis, which is commonly vertical in pressing configurations (as illustrated inFIG. 2). Such orientation of the die assembly300is particularly useful in pressing operations in which the die assembly (and workpiece thereon) is forced toward and against a stationary punch. In such cases, the corresponding vertically-oriented pressing force, when delivered to the die assembly300, is uniformly distributed across the entire interface area of the seated surfaces350,352. This leads to a more uniform and effective use of the deforming/bending force from the press, regardless of size of the die insert. In addition, in uniformly distributing this force, the die assembly300may produce less wear proximate to the seated surfaces350,352in comparison to what is typically exhibited in using conventional die assemblies.

In summary, the invention provides embodiments wherein self-seating structure is provided in a tool assembly (punch or die assemblies), which allows for separable portions of the assembly to be effectively positioned and seated in relation to each other, thereby simplifying their assembly and ensuring proper positioning and seating of the portions during assembly. The above description also provides an example where the self-seating structure (e.g., a linking member120) is used in operatively coupling the separable portions, whereby the resultant assembly is tightly bound so as to enhance its structural integrity and reduce wear, particularly at the adjoined surfaces of the portions. Further, by configuring the self-seating structure (the linking member120, and optionally, the rails130or330) to seat corresponding surfaces of the separable portions so that the surfaces are uniformly perpendicular to the pressing axis, a more uniform transfer of pressing force can result between the portions, further enabling less wear there between.

As alluded to above, while only a single linking member120is shown inFIG. 1, greater extents (i.e., longer lengths) of the punch assembly100generally involve a plurality of linking members120appropriately spaced along the length of the punch tip104. This concept is exemplified inFIGS. 4 and 5, and is further applicable to longer lengths of die assemblies as well. In particular, while showing a different style than punch tip104, the punch tip404ofFIG. 4includes a plurality of spaced-apart linking members120(not shown) as demonstrated by the spaced apertures (or bores)438along a side surface406of its adjoined punch tip holder402. As described above, these apertures (or bores)438can be configured to receive coupling means (e.g., coupling members), each for respectively retaining a linking member120(not shown) extending into the holder402from the punch tip404.

It should be appreciated that various configurations of the punch tip holder402can be used. In certain embodiments, as shown inFIG. 4, the holder402can involve a single, integral body. Alternatively, in certain embodiments, the punch tip holder can be segmented, with its segments being spaced or conjoined. For example, as shown inFIG. 5, the holder502involves a plurality of spaced-apart punch tip holder segments502′, each configured to be operatively coupled to a punch tip504. An aperture538is exemplarily shown in each segment502′. As described above, these apertures538can each be configured to receive coupling means for respectively retaining a linking member120(not shown) for coupling the segment502′ to the punch tip504(similar to the design already described). It should be appreciated that other coupling designs can be alternatively used.

Referring back toFIGS. 1 and 3, sections of a punch assembly and a die assembly are illustrated, respectively. It is known that press tooling (e.g., for press brakes) is generally manufactured in standard lengths, e.g., 500 mm, 835 mm,36″, etc. For longer tooling lengths, it should be appreciated that the self-seating structure, when involving linking members120as exemplified above, may advantageously include a plurality of such bodies120appropriately coupled and spaced along the length of the tool assembly, with apertures (e.g., bores) correspondingly positioned along the length of the punch tip holder102. However, instead of being limited to standard tooling lengths, in certain embodiments, the tooling assembly100can be configured to be modular so as to form any desired length. It should be appreciated that the length of the punch tip104(generally in the range from 1′ to 20′) makes it preferable to use a single integral body, so as not to compromise its deforming/bending function. However, in certain embodiments, the punch tip holder102is formed of sections, with such sections aligned to form the length needed to accommodate the extent of the punch tip104. This may likewise be the case with the die assembly.

An example of a segmented tooling holder, modular in design, is illustrated inFIG. 6. Differing fromFIGS. 4 and 5,FIG. 6illustrates a die body602; however, similar toFIGS. 4 and 5, its design is applicable to both punch and die assemblies. The die body602is formed of a plurality of aligned sections604, as opposed to the die body302illustrated inFIGS. 3A,3B, and3C. While the die body602ofFIG. 6is shown as having four sections604to accommodate the extent of a die insert (not shown, but generally having similar extent to die bars606shown), it should be appreciated that the length of the die body602can be adjusted as needed by adding/removing one or more sections604to/from the assembly600and/or using sections604of varying lengths. The sections604, once provided, can be adjoined in any of a variety of ways. For example, while not shown, each of the sections604can include a fastener and an aperture on opposing ends thereof (e.g., such as a fastener like the linking member120and its corresponding apertures described above). As such, in certain embodiments, each of the opposing ends of the sections604can include a fastener and an aperture, respectively, wherein the aperture of one section604is configured to accept the fastener of an adjoining section304, and so on, in forming the tool holder assembly600to its desired length. Many other means can alternatively be used to secure together such multiple sections604.

As noted above, other means can be used in coupling the linking member120, and thereby the separable portions of the punch or die assemblies100,300together. While the above-described embodiments exemplify the coupling member136as a set screw, other fasteners or fastening designs can alternately be used. Additionally, the coupling means can involve mechanisms that secure the linking member without requiring use of a tool. As such, joining and coupling the linking member (and thereby, the punch tip) with the holder can performed via a tool-less (or “tool-free”) operation, and in some embodiments, by a single motion, tool-free operation. Furthermore, in certain embodiments, the coupling means can involve mechanisms that have releasing functionality in addition to their securing functionality such that assembly and disassembly processes can both be performed via a tool-less operation, and in certain embodiments, via a single motion, tool-free operation.

FIGS. 7 and 8illustrate front cross-sectional and exploded assembly views of punch assemblies having coupling designs involving other exemplary fasteners in accordance with certain embodiments of the invention, whileFIGS. 9-11illustrate front cross-sectional and exploded assembly views of punch assemblies having coupling designs involving exemplary securing and release mechanisms. The punch assemblies ofFIGS. 7-11involve punch assemblies700,800,900,1000, and1100, respectively. However, as described above, embodiments of the invention are equally applicable to die assemblies. While varying in style from the punch assembly100ofFIG. 1, the punch assemblies700,800,900,1000, and1100generally share the same functional characteristics. In particular, the punch assemblies700,800,900,1000, and1100have punch tip holders702,802,902,1002, and1102, respectively, that can be conjoined or separated as desired with respect to punch tips704,804,904,1004, and1104, respectively.

Also similar to punch assembly100, each of the punch assemblies700,800,900,1000, and1100incorporates self-seating structure involving a linking member for positioning and seating the punch tips on their corresponding holders. In many respects, these linking members share the same attributes of the linking member120already described. To that end, in certain embodiments, each of the linking members ofFIGS. 7,8,9,10, and11has a first end region (or portion) to enable coupling with a tip and a second end region (or portion) to enable coupling with a holder. Further, similar to the punch assembly100ofFIG. 1and the die assembly300ofFIG. 3, in certain embodiments, the second end region includes a female detent, and engagement between an edge (or a surface) of the coupling means and an edge (or a surface) bounding the female detent retains a mount surface of the tip directly against a corresponding surface of the holder.

FIGS. 7A and 7B(at times collectively referenced herein asFIG. 7) andFIGS. 8A and 8B(at times collectively referenced herein asFIG. 8) illustrate coupling means involving exemplary coupling members (e.g., fasteners)736and836, which respective punch tip holders702and802are adapted to receive (e.g., carry). As shown, in certain embodiments, the coupling members736and836are received in threaded openings (e.g., threaded bores)738and838respectively, of the holders702and802. In such cases, the openings (or bores)738and838are generally oriented to intersect (i.e., open into) punch tip holder apertures (e.g. bores)728and828, respectively.

The coupling member736ofFIG. 7involves a different type of set screw. In certain embodiments, as shown, the coupling member736has a leading end760defining a recess762that generally extends inward. As perhaps best shown in the enlarged view ofFIG. 7A, the shape of the recess762is defined by its inner surfaces764. Here, the recess762is shaped generally like a cone; however, the recess762can be defined as other shapes. The illustrated linking member720defines a female detent740at its second end region724, and also has a ball-shaped head742at the leading end of such region724. When the coupling member736is partially backed out in its corresponding opening738, the coupling member's leading end760is in turn backed outward from the aperture728for the linking member720, so as to permit the head742of the linking member720to be fully advanced in the aperture728. Conversely, when the coupling member736is tightened, its leading end760is advanced into the aperture728, wherein the linking member head742is received within the coupling member recess764, with the head's (and the linking member's) position being retained through contact between the inner surfaces764of the recess762and outer surfaces744of the linking member's head742.

In certain embodiments, as perhaps best seen in the enlarged view ofFIG. 7A, the inner surfaces764of the recess762are ramped (or “angled”) to mate with correspondingly-configured outer surfaces744of the head742. In this case, the geometrical engagement of the coupling member's leading end760and the linking member's head742enables a tighter coupling. In particular, as the coupling member736is advanced in the illustrated threaded opening738, the angled inner surfaces766defining the coupling member recess762engages the corresponding outer surfaces744of the linking member head742. In further advancing the coupling member736in the opening738, the head742of the linking member720advances further into the recess762. Consequently, the inner angled surfaces764of the coupling member736cam with the outer surfaces744of the head742, and in the process, further pulls the linking member's second end region724into its final, operatively-mounted position within the holder aperture728. Such pulling (and in this case, raising) of the linking member720with the holder aperture728provides a tight coupling between punch tip704and punch tip holder702, thereby providing a tightly-bound assembly without the need to perform a prior reference stroke of the press (for seating purposes).

The fastener836ofFIG. 8involves a coupling member836comprising a camming-type screw. In certain embodiments, as shown, the camming-type screw fastener836defines an opening870extending generally perpendicular through a leading end of the fastener836. The linking member820is similar in structure to that described above with respect to linking member720, having a ball-shaped head842at the leading end of its second end region824. In one orientation of the camming screw, the opening870permits the head842of the linking member820to move axially relative to the camming screw. However, when the camming screw is rotated out of that orientation (as shown), an edge (or surface)872bounding the opening870bears against (and cams with) the head842. In certain embodiments, as perhaps best shown in the enlarged view ofFIG. 8A, the edge872is ball shaped to mate with the ball-shaped fastener head842. As such, when the camming screw is rotated so as to retain the linking member820(as described above), the camming between the ball-shaped edge (or surface)872and the head842results in a pulling of the linking member's second end region824into its final, operatively-mounted position within the aperture828. Such pulling of the linking member820within the aperture828provides a tight coupling between punch tip804and punch tip holder802, thereby forming a tightly-bound assembly without the need to perform a prior reference stroke of the press (for seating purposes).

LikeFIGS. 7 and 8,FIGS. 9A and 9B(at times collectively referenced herein asFIG. 9) illustrate a coupling means involving an exemplary coupling member936that the punch tip holder902is adapted to receive. As shown, in certain embodiments, the coupling member936comprises a screw received in a threaded opening (e.g., threaded bore)980of the holder902. However, unlike the designs ofFIGS. 7 and 8(as well as the designs ofFIGS. 1 and 3, which also exemplify screw coupling means), the screw is part of an assembly that projects into the punch tip holder aperture (e.g. bore)928for receiving the second end region924of the linking member920. In certain embodiments, as shown, the fastener assembly includes a catch member970, which is oriented to extend into aperture (bore)928. As shown, in certain embodiments, the catch member970has a generally “L-shaped” configuration, e.g., so as to have opposing end regions perpendicular to each other. A first end region972of the illustrated catch member970is coupled to the illustrated screw936; however, the catch member970can alternately be integrally formed with the screw. While an exemplary coupling is shown involving an eyelet976(defined in the catch member970) through which the screw936extends, many other coupling mechanisms can be used.

As shown, the first end region972of the catch member970extends from the screw936along a channel978of the holder902. The channel978, in addition to fluidly communicating with (e.g., being open to) the opening980for the screw936, communicates with a further opening (e.g., bore)938configured to receive the second end region974of the catch member970and to intersect (open into) the aperture (e.g., bore)928that receives the linking member920. The linking member920can be similar in structure to that described above with respect to linking member720, i.e., defining a female detent940at its second end region924and having a ball-shaped head942at the leading end of such region924. The second end region974of the catch member970, in certain embodiments, has a leading end960having spaced-apart legs962that define a generally v-shaped or u-shaped recess964there between.

As shown, the screw936is used as a driver of the catch member970. When the illustrated screw936is partially backed outward in its corresponding opening980, the second end region974of the catch member970can in turn be partially backed outward from the aperture928for the linking member920, so as to permit the head942of the linking member920to pass between the legs962and through the recess964. In turn, when the fastener936is tightened, the catch member970is anchored against the holder902such that the catch member's legs962are positioned in a lock position within the aperture928and extend into the detent940, thereby retaining the head942in its operative position. In certain embodiments, as perhaps best shown in the enlarged view ofFIG. 9A, the surfaces (e.g., camming surfaces)982of the legs962that engage the head942ramp (e.g., are angled) upward from their ends so as to cam with a corresponding outer surface984of the linking member head942. As such, when the fastener936is tightened so as to mate the second end region974through the aperture928, the camming action between the ramped leg surfaces982and the head outer surfaces984results in a pulling of the linking member to its operative position. Such pulling of the linking member920within the aperture928provides a tight coupling between punch tip904and punch tip holder902, thereby forming a tightly-bound assembly without the need to perform a prior reference stroke of the press (for seating purposes).

As described above,FIGS. 10A and 10B(at times collectively referenced herein asFIG. 10) andFIGS. 11A and 11B(at times collectively referred herein asFIG. 11) illustrate coupling designs involving exemplary securing and release mechanisms. In certain embodiments, whether by mechanical, electrical, magnetic, hydraulic, and/or pneumatic means, such coupling design can involve an actuator to selectively trigger either securing or releasing of the linking member (and thereby, the corresponding punch tips1004or1104) with respect to the punch tip holder1002or1102, respectively.

As shown, the coupling means ofFIGS. 10 and 11are in some ways similar to the design ofFIG. 9. For example, the same type of catch member970(as detailed above) and linking member920are provided. As such, these elements have the same reference numbers inFIGS. 10 and 11as they do inFIG. 9. Thus, in certain embodiments, when the second end region974of the catch member970is advanced, camming between the ramped leg surfaces982of the catch member970and the outer surface(s)984of the linking member head942results in a pulling of the linking member to its operative position. Such pulling of the linking member920within the holder aperture provides a tight coupling between punch tips1004and1104and punch tip holders1002and1102in the designs ofFIGS. 10 and 11, respectively (and without having to perform a reference stroke of the press for seating purposes in either case).

Further, like the design ofFIG. 9, the punch tip holders1002,1102are provided with similarly-configured channels1078,1178and openings1038,1138to respectively receive the first and second end regions972,974of the catch member970. Moreover, fastener members1016,1118ofFIGS. 10 and 11serve as drivers of the catch member970, and particularly, the second end region974of the catch member970. However, instead of threadingly advancing and backing out the fastener members to secure and release the linking member920, the assemblies of FIGS.10and11involve button and solenoid assemblies that are actuated to move the fastener members1016,1118, thereby triggering the release and securing operations, as described below.

One distinct aspect of the coupling designs ofFIGS. 10 and 11is the trigger for actuating movement of the catch member970. Looking to the punch assembly1000ofFIG. 10A, the actuator involves a button assembly. To that end, in certain embodiments, the assembly includes a mechanically-operated button1012, a spring1014, and a fastener member1016. The assembly1010, as shown, extends through an opening (e.g., bore)1080of the tip holder1002. In constructing the assembly1010, the fastener member1016is coupled to the first end region972of the catch member970(optionally via an eyelet976as exemplified above) and then advanced through the opening1080so as receive the spring1014and have its leading end1018coupled to a back end1020of the button1012. In certain embodiments, as shown, the button back end1020can have a threaded aperture (e.g., bore)1022to threadably receive the leading end1018of the fastener member1016; however, other manners of coupling can alternately be used.

In certain embodiments, when the button1012is actuated (e.g., by depressing the button1012), the coupling means is brought to an “open state” (not shown), in which the linking member920(and thereby, the punch tip1004) is released from (if previously held by) the punch tip holder1002. The open state can also provide a period of time during which the linking member second end region924can be selectively adjoined to or removed from the punch tip holder1002. Such “open state” is not shown, however, from what was already detailed with reference toFIG. 9, the open state results when the second end region974of the catch member970is backed out from the aperture1028so as to allow free advancement and removal of the linking member920within aperture (or bore)1028. Perhaps as best shown in the enlarged view ofFIG. 10, actuation of the button1012forces the fastener member1016outward from the opening1080, which thereby also forces the catch member970to back out from the aperture1028. It should be appreciated that as actuated, the button1012is adverse to (i.e., is overcoming) a biasing force of the spring1014, e.g., due to the button1012being in a depressed position.

In certain embodiments, as shown, when the linking member970is fully advanced in the punch tip holder aperture1028during the “open state” of the coupling means, the button1012can be released (e.g., via a further depression of the button, or by simply releasing the button), whereby the coupling means is brought into a “closed state.” Thus, in contrast to the “open state,” the “closed state” involves the second end region974of the catch member970extending inwardly through the aperture1028so as to retain the linking member920in aperture (or bore)1028. Regarding the button assembly1010, in certain embodiments, a channel1024is provided in, and coaxial with, the opening1080for seating the spring1014therein. The channel1024as shown opens toward the button1012such that the spring1014can bias the button1012. Thus, the spring1014forces the button1012to extend outward from opening1080, which as a result pulls the fastening member1016inwardly with respect to the opening1080. Consequently, the catch member970is held in position, thereby securing the linking member920(and thereby, the punch tip1004) to the punch tip holder1002.

Regarding the punch assembly1000ofFIG. 10, while not shown, it should be appreciated that the button1012can be electrically powered, and in certain designs, can involve a switch. Given the design of the button assembly1010, it should be appreciated that a one-step process can be used for releasing the linking member920(and thereby, the corresponding punch tip1004) with respect to the punch tip holder1002. In certain embodiments, the one-step process involves only a single-motion process. For example, once the linking member920is secured in the aperture (e.g., bore)1028of the holder1002, by actuating the button1012(e.g., via a single-motion, one step process of depressing the button1012), the catch member970(via the fastening member1016) is automatically drawn outward from the holder aperture1028so as to unlock the linking member1020from the holder1002. A two-step process can be performed for securing the linking member920, i.e., seating the punch tip1004in relation to the punch tip holder1104(via insertion of the linking member(s)920in the corresponding aperture(s)1028), and releasing the button1012to secure the linking member(s)920(and thereby, the punch tip1004) to the punch tip holder1002. It should be appreciated that the steps of these processes can advantageously be performed without having to use secondary tools.

Thus, in certain embodiments, the coupling design of the punch assembly uses an actuator to trigger either securing or releasing of the linking member (and thereby, the punch tip) with respect to the punch tip holder. While the punch assembly1000ofFIG. 10uses a button assembly, the actuator for the punch assembly1100ofFIG. 11is a solenoid assembly. The designs of theFIGS. 10 and 11are similar, except for the addition of a solenoid1112within opening (or bore)1180for the solenoid assembly1110and the replacement of the button1012with a cap1114. As shown, in certain embodiments, the assembly1110further includes the cap1114, a spring1116, and a fastener member1118. The solenoid assembly1110, in certain embodiments, is constructed similar to the button assembly1010ofFIG. 10, except that the solenoid1112is provided, and the cap1114(replacing the button1012ofFIG. 10) is coupled to the leading end1120of the fastener member1118. As shown, in certain embodiments, the solenoid1110is seated in a channel1122(or bore region) that is coaxial with the opening1180and opens toward the spring1116and cap1114. In certain embodiments, when actuated (so as to bring the coupling means to an “open state”), the solenoid1112is configured to force the fastener member1118outward with respect to the opening1080, which thereby also forces the extension970to back out from the aperture1128, thereby releasing the linking member920(and thereby, the punch tip1104) from the punch tip holder1102. Conversely, when the solenoid is deactivated (bringing the coupling means to a “closed state”), the solenoid1112releases the fastener member1118. As a result, the spring1116biases the cap1114so as to advance partially outward from the opening1180, which pulls the fastening member1118inwardly with respect to the opening1180. Consequently, the catch member970(coupled to the fastener member1118) is locked in position, thereby securing the linking member920(and thereby, the punch tip1104) to the punch tip holder1102.

While not shown, the solenoid1112generally involves an external source for its activation, whether being pneumatic, hydraulic, or electromagnetic in design. Further, given the design of the solenoid assembly1110, it should be appreciated that a one-step process of actuating the solenoid can be used for releasing the linking member920(and thereby, the corresponding punch tip1104) with respect to the punch tip holder1102. In certain embodiments, the one-step process involves only a single-motion process. For example, in cases in which such actuation is triggered via a button or switch, the single-motion, one-step process involves depressing/flipping such button/switch to deactivate the solenoid. In contrast, a three-step process can be used for securing the linking member920(and thereby, the punch tip1104) to the punch tip holder1102. Such steps involve actuating the solenoid1120to open the aperture(s)1028of the holder1102, inserting the linking member920in the aperture(s) (e.g., bore)1028of the holder1002, and deactivating the solenoid (e.g., via depressing/flipping a button/switch) so as to secure the linking member(s)920within the aperture(s)1028of the holder1002. It should be appreciated that each step of both processes can be performed without the use of secondary tools.

While the designs ofFIGS. 10 and 11are described above with regard to “open” states of the coupling means being associated with actuating the triggering means (button1012or solenoid1112), it should be appreciated that the designs could just as well be modified to function in the alternative as well. That is, by actuating the triggering means, the coupling means can be brought into a “closed state.”

FIGS. 12A,12B, and12C (at times collectively referenced herein asFIG. 12) illustrate front, cross-sectional, and exploded assembly views, respectively, of a further punch assembly100′ in accordance with certain embodiments of the invention. In many respects, the punch assembly100′ shares the same structure and attributes already described with respect to the punch assembly100ofFIG. 1. For example, the punch assembly100′ includes a punch tip holder102′ and punch tip104′ that are configured to be adjoined (e.g., connected rigidly to each other) or separated as desired. However, the punch tip104′ is a different configuration than the punch tip104of punch assembly100. In particular, the first end116′ of the tip104′ defines a workpiece-deforming surface configured for making a different bend angle than the punch tip104of punch assembly100. As shown, this difference in the configuration of the tip end116′ enables the size of the punch tip104′ to be decreased, which in turn can affect the size and shape of the corresponding holder102′. Regardless of these differences between the punch assemblies100and100′, it should be appreciated that the self-seating structure (e.g., fastening body120, rails130′, and the mounting channel) are just as applicable in these other tooling design types.

FIG. 12is representative of a group of embodiments wherein the coupling member is configured to move selectively toward or away from the linking member in response to rotation of the coupling member.FIGS. 1,3,7,8, and12are other examples. Here, rotation of the coupling member in a first direction (e.g., clockwise) causes the coupling member to move (e.g., axially) toward the linking member, whereas rotation of the coupling member in a second direction (e.g., counterclockwise) causes the coupling member to move (e.g., axially) away from the linking member.

The rounded design of the tool tips704,804,904,1004, and1104ofFIGS. 7,8,9,10, and11, respectively, do not allow the mated tip holder surfaces to be uniformly perpendicular to the pressing axis. Accordingly, even with the use of the self-seating structure, uniform force distribution may not be entirely possible. However, even with such designs, by positioning the self seating structure (e.g., the linking member120a,120b,120c, or102d) to extend between the confronting tip holder surfaces enables fairly good distribution through the tool assemblies700,800,900,1000, and1100. In addition, by incorporating the self-seating structure, these assemblies still realize other of the favorable aspects, including simplified assembly/disassembly, enhanced structural integrity, and reduced wear.

Further, as opposed to tool assemblies having generally planar mounting surfaces, tool assemblies adapted to receive rounded tool tips (with their different sizes and radii) present other challenges which the linking members have been found to address. For example, with reference to the punch assembly1100as shown inFIG. 11A, as the radius of the punch tip1104increases, the distance1190between the center point1192of the punch tip1104and the apex1194of the punch tip holder1102increases. Consequently, the linking member920backs out of the holder aperture1128. Accordingly, the linking member920can be sized accordingly so that its detent940still intersects with the extrusion second end974. This involves a simple process of changing out the linking member920. However, if the linking member920were associated with varying coupling hardware, the hardware would also require changing out. Such hardware could invariably include springs, retaining bars, nuts, etc. However, with the linking member of the invention not having (i.e., equipped with) any corresponding hardware, the linking member serves as a more efficient (in terms of cost) and effective (in terms of ease of change out) solution.

Having now described embodiments concerning tool assembly designs with self-seating structure, further reference is made to the separable portions of these assemblies, e.g., the tool tip holder102and the tool tip104ofFIG. 1, and the materials used in forming these portions. As described above, the separable portions of such assemblies have been formed of different materials over the years. To that end, while the punch tips and die inserts (or “die plates”) preferably are formed of high-end hardened materials, such as tool-steel, other hardened materials have been substituted over the years for the punch holders and die bodies to provide a strong, yet less expensive, option. One of these substitute materials has involved aluminum. Besides the cost savings, other benefits in using aluminum for the punch holders and die bodies involve attaining a lighter design and the still being able to achieve a fairly good material hardness.

Applicants have discovered that the punch holders and/or die bodies can be formed, e.g., by molding, casting, or extruding, using a variety of non-ferrous materials, with these materials being light-weight, less costly than tool steel, and having fairly good hardness properties. For example, in certain embodiments, aluminum (or another aircraft metal) can be formed for the punch holders and die bodies so as to have tensile strength at least about 80 ksi, and perhaps more preferably, in the range of between about 80 ksi and about 100 ksi, which generally correspond to hardness values nearly reaching the lower range for tool steel. Other light-weight materials that exhibit suitable hardness properties include titanium and carbon fiber composites. In one group of embodiments, the holder of the tool assembly comprises, consists essentially of, or consists of a metal (e.g., an aircraft metal) selected from the group consisting of beryllium, titanium, magnesium, aluminum and alloys comprising one or more of these metals. Preferably, the tip (whether being a punch tip or a die insert) comprises, consists essentially of, or consists of steel. In addition, the holders and bodies, once formed, can be coated or heat treated to reduce their wear and increase their surface strength. For example, the coating process can involve any one of anodizing, induction, or nitriding treatment, each of which is known in the art. Furthermore, the punch tips and die inserts can also be coated to reduce their wear and increase their lubricity. For example, the coating process can involve any one of laser, induction, or nitriding treatment, each of which is known in the art. For particular reference, e.g., regarding nitriding, the disclosure of U.S. Pat. No. 4,790,888 is noted, the entire teachings of which are incorporated herein by reference.

With reference to the above, in certain embodiments, the punch tip holders and/or die inserts can be formed of a single integral body with regard to such materials. However, in certain embodiments, the holders and tips (e.g., along their extents aligning with a pressing axis) can involve separately portions formed together. For example, the ends of such holders and tips are often found to encounter the greatest forces and stresses. Thus, in certain embodiments, one or more of the upper or lower ends of the holders and inserts can be formed of hardened materials, while the reminder of the holders and inserts are formed of the materials exemplified above (e.g., being light-weight, less costly than tool steel, and having fairly good hardness properties). This same principle can be further applicable to the punch tips and/or die bodies. For example, in certain embodiments, the working ends of the punch tips and/or die bodies can be formed of hardened materials, with the reminder of the holders and inserts being formed of the materials exemplified above (e.g., being light-weight, less costly than tool steel, and having fairly good hardness properties).

While preferred embodiments of the present invention have been described, it is to be understood that numerous changes, adaptations, and modifications can be made to the preferred embodiments without departing from the spirit of the invention and the scope of the claims. Thus, the invention has been described in connection with specific embodiments for purposes of illustration. The scope of the invention is described in the claims, which are set forth below.