Device With Multiple Coined Areas Having Multiple Mechanical Properties

The present disclosure relates to a device with multiple coined areas having multiple mechanical properties, and systems and methods for manufacturing such a device. The device can include a central channel section with a spine and one or more legs, a flexible spring section extending from the spine at a first end of the channel section, and one or more compliant pins extending from the one or more legs at a second end of the central channel section. The device is integrally formed from a single piece of stock material having first mechanical properties and one or more of the spring section and the compliant pins are coined to produce one or more different mechanical properties.

BACKGROUND

Field of the Disclosure

The present disclosure relates to a device with multiple coined areas having multiple mechanical properties, and systems and methods for manufacturing such a device. More specifically, the present disclosure relates to manufacturing processes that include coining one or more sections of the component to produce one or more different mechanical properties.

Related Art

Various industries require components having multiple mechanical properties. This has been addressed in the past by manufacturing portions of the device separately and then subsequently attaching them together (e.g., by mechanical or chemical means) to form a single component.

SUMMARY

The present disclosure relates to a device, such as a connector, with multiple coined areas having multiple mechanical properties and systems and methods for the production thereof. The device includes a central channel section including a spine and one or more legs that curve away from the spine, a flexible spring section extending from the spine at a first end of the channel section, and one or more compliant pins extending from the one or more legs at a second end of the central channel section opposite the flexible spring section. The central channel section, the flexible spring section, and the one or more compliant pins are integrally formed and each can have different mechanical properties. The spine and the first and second legs of the central channel extend along a central axis of the device and can form a generally “C” shaped cross-sectional area and the flexible spring section can have a generally sinusoidal cross-sectional area. Additionally, the central channel section can have a first thickness and a first hardness rating, the flexible spring section can have a second thickness and a second hardness rating, and the one or more compliant pins can have a third thickness and a third hardness rating.

A system for producing the device having multiple mechanical properties is also disclosed and includes a metal stamping press and a progressive die configured to be received by the metal stamping press and to receive stock material having a first mechanical characteristic. The progressive die includes a first station having one or more piercing tools configured to pierce one or more registration holes in the stock material. A second station includes one or more first trimming tools configured to trim the compliant pins of the device from the stock material and a second trimming tool configured to trim leading and trailing edges of the spring section from the stock material. A third station includes a first coining tool configured to coin the compliant pins and impart a second mechanical property to the compliant pins. A fourth station includes a second coining tool configured to coin the spring section and impart a third mechanical property to the spring section. The system can further include a fifth station including a final trimming tool configured to trim the edges of the spring section of the device to a final shape, a cutting tool disposed between fifth and sixth stations of the progressive die configured to cut the channel section from the stock material, an eight station including a forming tool configured to form the spring section to have a generally sinusoidal cross-sectional area, a ninth station including a bending tool configured to form one or more of the legs of the channel section, and a tenth station including one or more cutting tools configured to remove web material connecting the device from the stock material, thereby separating the device from the web material.

A method for forming the device having multiple mechanical properties is also provided. The method includes loading stock material having a first mechanical property into a first station of the progressive die and punching one or more registration holes in the stock material. The material is then advanced to a second station of the progressive die for rough trimming of the compliant pins and rough trimming of a leading edge of a spring section of the device. A third station of the progressive die includes rough trimming a trailing edge of the spring section and coining the compliant pins, thereby work hardening the compliant pins and imparting a second mechanical property thereto. The material is advanced to a fourth station for final trimming of the compliant pins and coining of the spring section, thereby work hardening the spring section and imparting a third mechanical property thereto. The method can also include the steps of advancing the stock material to a fifth station and final trimming the leading edge of the spring section to a final shape, advancing the stock material to a sixth station, final trimming the trailing edge of the spring section to a final shape, and cutting a leading edge of the channel section of the device from the stock material, advancing the stock material to a seventh station and cutting a trailing edge of the channel section from the stock material, advancing the stock material to an eighth station and stamping the spring section such that the spring section has a generally sinusoidal cross-sectional area, advancing the stock material to a ninth station and bending the legs in the channel section such that the channel section has a generally “C” shaped cross-sectional area, and advancing the stock material to a tenth station and removing web material connecting the device to the stock material, thereby separating the device from the web material.

DETAILED DESCRIPTION

The present disclosure relates to a device with multiple coined areas having multiple mechanical properties, and systems and methods for manufacturing such a device. More specifically, the present disclosure relates to manufacturing processes that include coining one or more sections the component to produce one or more different mechanical properties, as discussed in detail below in connection with the figures.

FIGS. 1-6illustrate an exemplary component10according to the present disclosure having multiple mechanical properties. More specifically,FIG. 1is a perspective view of the component10,FIG. 2is a side view of the component10,FIG. 3is a top view of the component10,FIG. 4is a first cross-sectional view (taken along line D-D ofFIG. 3) of the component10,FIG. 5is a second cross-sectional view (taken along line E-E ofFIG. 3) of the component10, andFIG. 6is a third cross-sectional view (taken along line G-G ofFIG. 3) of the component10.

The component10can be of a unitary construction, integrally formed from a single piece of material (e.g., cold-rolled steel or the like), and can include a central channel section12, a spring section14at one side, and first and second compliant pins16aand16bat the other side. The channel section12can include a spine18and first and second legs20aand20bthat curve away from the spine18, forming a generally “C” shaped cross-sectional area (see, e.g.,FIG. 5) extending along the axis of the component. The spring section14can extend from the spine18of the channel section12at a first end22athereof and can be generally flexible as shown by the generally sinusoidal cross-sectional area (see, e.g.,FIG. 4). The first and second compliant pins16aand16bcan extend from the first and second legs20aand20b, respectively, at a second end22bof the channel section12. Additionally, as will be discussed in greater detail herein, the channel section12, the spring section14, and the first and second compliant pins16aand16bcan have different physical and/or mechanical properties. For example, the channel section12can have a cross-sectional thickness of 0.0040 inches and be “¼ hard” (e.g., as opposed to fully annealed steel or other metal), the spring section14can have a cross-sectional thickness of 0.0036 inches and be “½ hard,” and the first and second compliant pins16aand16bcan have a cross-sectional thickness of 0.0030 inches and be “¾ hard.” It is noted that the component10is an exemplary component that can be produced using the systems and methods of the present disclosure and those of ordinary skill in the art will understand that the systems and methods of the present disclosure can be utilized to produce other components having various shapes, sizes, and configurations.

FIGS. 7-10illustrate an exemplary system100of the present disclosure for manufacturing a component having multiple mechanical properties, for example the component10, discussed in connection withFIGS. 1-6.FIG. 7is a partial perspective view of the system100,FIG. 8is a top view of the system100,FIG. 9is a side view of the system100, andFIG. 10is a detailed view (of area H-H ofFIG. 9) of a die tool of the system100for forming the spring section14of the component10.

The system10of the present disclosure can include a plurality of metal stamping tools that are arranged within multiple stations of a progressive stamping die (not shown) that is, in turn actuated by a mechanical press. As used herein, the terms “tool” or “tools” can refer to, but are not limited to, trimming tools, coining tools, bending tools, blanking tools, piercing tools, shearing tools, and the like. As will be familiar to those of ordinary skill in the art, the press generally includes a reciprocating ram which punches against a workpiece (e.g., sheet metal) held in place by the die. The shape of the die, and the tooling therein, determines the final shape of the workpiece. A progressive die advances the workpiece through multiple stations (having various tools) to complete all necessary stamping operations and typically ends with cutting the completed part from the sheet metal stock.

FIGS. 7-10illustrate a piece of stock102(e.g., sheet metal) as it is advanced through the progressive die and formed into the component10, discussed in connection withFIGS. 1-6. The stock has a first mechanical characteristic. As shown, the die can have multiple stations, including for example, a first station104, a second station106, a third station108, a fourth station110, a fifth station112, a sixth station114, a seventh station116, an eighth station118, a ninth station120, a tenth station122, and an eleventh station124. The first station104can include first and second piercing tools126aand126bfor forming (e.g., registration) holes in the stock102, which can be used to move the stock102through the stations of the progressive die. The second station106can include rough trimming tools128aand128bfor rough trimming (e.g., establishing the general, but not final, form) the compliant pins16aand16band a rough trimming tool130for rough trimming the leading, and subsequently trailing, edges132aand132bof the spring section14. The third station108can include a coining tool134for coining (e.g., striking and reducing the thickness) the compliant pins116aand116bto impart a second mechanical characteristic to the pins. The fourth station110can include a coining tool136for coining the spring section114to impart a third mechanical characteristic to the spring section, and first and second final trimming tools138aand138bfor trimming the compliant pins116aand116bto their final shape. The fifth station112can include a final trimming tool140for trimming the leading, and subsequently trailing, edges132aand132bof the spring section14to their final shape. A cutting tool142can be disposed between the sixth station114and the seventh station116for cutting the leading, and subsequently trailing, edges144aand144bof the channel section112, thereby freeing the channel section112from the stock102. The eighth station118can include a stamping tool146for forming the spring section14(see, e.g.,FIG. 10). As best shown inFIG. 9, the ninth station120can include a bending tool148for bending the legs20aand20baway from the spine18, thereby forming the final shape of channel section12. The tenth station122can include first and second cutting tools150aand150bto remove remaining web material152aand152bconnecting the component10to the stock102, thereby separating the final component10from the stock102. The component10can exit the progressive die at the eleventh station124by way of a “drop through” in the die, or any other mechanism for final part removal.

It is noted that the system100shown and described herein is an exemplary system for manufacturing the component10and those of ordinary skill in the art will understand that the systems and methods of the present disclosure can be modified and utilized to produce other components having various shapes, sizes, and configurations, with various mechanical properties in the component.

FIG. 11is a flowchart illustrating process steps carried out by the system100, described in connection withFIGS. 7-11. In step160, a sheet of raw material (e.g., stock102) is inserted into a progressive die of a metal stamping press. The raw material can be a sheet of ¼ hard cold-rolled steel having a thickness of 0.0040 inches, however, other materials having different physical dimensions and material characteristics can be used without departing from the spirit and scope of the present disclosure.

In step162, the raw material enters the first station (e.g., station104) of the progressive die, where first and second holes are punched in the material. In step164, the material advances to the second station (e.g., station106), where a first trimming tool is used to is used to rough trim the compliant pins16aand16band a second trimming tool is used to rough trim the leading side of the spring section14. In step166, the material advances to the third station (e.g., station108), where the second trimming tool from the second station is used to rough trim the lagging side of the spring section14and a coining tool is used to coin the compliant pins16aand16b. For example, the compliant pins16aand16bcan be coined by 0.001 inches, thereby reducing their thickness to 0.003 inches. Notably, performing a coining operation on the material serves to “work harden” the coined areas, thereby altering the material properties of the material in same areas. For example, by coining the compliant pins16aand16bby 0.001 inches and thereby reducing their thickness to 0.003 inches, the hardness of the compliant pins16aand16bcan be increased from the original ¼ hard of the stock material to % hard. Those of skill in the art will understand that these are merely specific examples and varying degrees of work hardening can be performed according to the systems and methods of the present disclosure.

In step168, the material advances to the fourth station (e.g., station110), where a final trimming tool can be used to trim the compliant pins16aand16bto their final shapes and a coining tool is used to coin the spring section14. For example, the spring section14can be coined by 0.0004 inches, thereby reducing its thickness to 0.0036 inches. As discussed above, performing a coining operation on the material serves to “work harden” the coined area, thereby altering its material properties. For example, by coining the spring section14by 0.0004 inches and thereby reducing its thickness to 0.0036 inches, the hardness of the spring section14can be increased from ¼ hard to ½ hard.

In step170, the material advances to the fifth station (e.g., station112), where a final trimming tool is used to trim the leading side of the spring section14to its final dimensions. In step172, the material advances to the sixth station (e.g., station114), where the final trimming tool from the fifth station is used to trim the lagging side of the spring section14to its final dimensions and a cutting tool is used to cut the leading side of the channel section12free from the stock. In step174, the material advances to the seventh station (e.g., station116), where the cutting tool from the sixth station (e.g., cutting tool142) is used to cut the lagging side of the channel section12free from the stock.

In step174, the material advances to the eighth station (e.g., station118), where a stamping tool is used to form any desired curvature of the spring section14(see, e.g., tool146as shown and described in connection withFIG. 10). In step176, the material advances to the ninth station (e.g., station120), where a bending tool is used to form the final shape of the channel section12(see, e.g., tool148as shown and described in connection withFIG. 9). In step180, the material advances to the tenth station (e.g., station122), where any remaining web material, joining the component10to the stock material, is removed with a cutting tool, thereby separating the final component10from the stock material. The finalized component can then be removed from the progressive die.

Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit or scope thereof. It will be understood that the embodiments of the present invention described herein are merely exemplary and that a person skilled in the art may make any variations and modification without departing from the spirit and scope of the invention. All such variations and modifications, including those discussed above, are intended to be included within the scope of the invention.