Data processing: generic control systems or specific application – Specific application – apparatus or process – Product assembly or manufacturing
Reexamination Certificate
2000-10-25
2003-05-06
Picard, Leo (Department: 2125)
Data processing: generic control systems or specific application
Specific application, apparatus or process
Product assembly or manufacturing
C700S166000, C700S182000, C072S324000
Reexamination Certificate
active
06560499
ABSTRACT:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a system and method in a manufacturing operation for fabricating production stamping dies which are used for making precise die blanks wherein the operation is controlled by a computer. The system produces proposed die blanks from a customer's proposed die blank configuration. The proposed die blanks are evaluated by the customer before trial and/or production stamping dies are made. In particular, the method provides a computer processing unit (CPU), which is accessible to the customer, and wherein the CPU provides die blank and stamping die CAD/CAM designing and manufacturing capabilities, data storage and retrieval, and coordinates all or particular functions involved in the manufacture of proposed die blanks and trial or production stamping dies.
(2) Description of Related Art
The manufacture of many three-dimensional shaped products is a two step process. In the first step, a planar sheet of material is cut into a two-dimensional precise die blank by a production stamping die. In the second step, the precise die blank is formed into a three dimensional shape by a shaping die. Many products are made according to this two step process. For example, to make an auto body fender, flat sheet metal is cut into a precise shape (precise die blank) by a production stamping die. The precise die blank is then transferred to a shaping die which forms the precise die blank into the three-dimensional shape of the fender. It is a goal in the design of stamping dies that the precise die blank be of a configuration that when the final shape of the product is formed, the finished product has a minimum of trim which would interfere with the alignment of the shaped product with another shaped product. It is also a goal in the design of stamping dies that the stamping die have a configuration that will produce a maximum number of precise die blanks from a given unit area of the flat sheet material. This conserves material by minimizing the production of low-value scrap. However, achieving these goals can be expensive since (1) several die blank configurations may need to be evaluated before a die blank configuration is found that enables the shaped product to be formed with the minimum amount of trim, and (2) several stamping die configurations may need to be fabricated before a die configuration is found that enables the maximum number of die blanks to be produced from a given unit area of the flat sheet material.
In general, the fabrication of production stamping dies for making precise die blanks is an expensive and time consuming process costing hundreds of thousands of dollars and requiring many months to develop a production stamping die from an estimated design that is suitable for use the production of precise die blanks. The time and expense in making production stamping dies is due to the trial and error nature of the process for designing and making the dies. According to the prior art, a die design, provided by the customer, is made into a steel rule die which is then used to produce die blanks which are tested in the shaping die. Any deficiencies in the die blank configuration are noted, and a corrected steel rule die is fabricated that incorporates the modifications that correct these deficiencies. The corrected rule die is then used to produce die blanks which are again tested in the shaping die. Any deficiencies that did not become manifest in the previous trial are noted and a new corrected steel rule die is fabricated. This trial and error process is repeated until a die blank of the precise configuration is produced. Once a die blank having the precise configuration is produced, a production stamping die is fabricated having the precise configuration necessary to produce the precise die blank. The production stamping die is then used in a limited production run to make sure the production stamping die will function under production conditions. Sometimes during these limited production runs, defects in the design of the production stamping die will become manifest. Therefore, a second production stamping die is then made which incorporates the modifications which are needed to correct the defects. This process for fabricating production stamping dies is expensive because it requires the machining of hardened steels.
In die manufacturing, as in all manufacturing industries, there is constant pressure for greater speed and accuracy in part design. The use of computer-operated machine tools (numerical control machines) provides great savings in machining time and improved accuracy. The related prior art has provided computerized methods for manufacturing processes. Examples include, U.S. Pat. No. 3,860,803 to Levine which provides a method and apparatus for fabricating a progressive die to be used in manufacturing a piecepart; U.S. Pat. No. 5,089,970 to Lee et al. which provides an integrated manufacturing system for managing and distributing information necessary for effecting the production of products in a factory; U.S. Pat. No. 5,463,555 to Ward et al. which provides a system and method for integrating a business environment with a process control environment to make a product specified in a work order; U.S. Pat. No. 5,864,482 to Hazama et al. which provides an apparatus and method for managing and distributing design and manufacturing information throughout a factory in order to facilitate the production of bent sheet metal components; and U.S. Pat. No. 5,890,134 to Fox which discloses a scheduling optimizing algorithm that improves the scheduling capabilites of existing programs for managing the plurality of tasks associated with manufacturing a product such as an aircraft from components. While the aforementioned U.S. Patents use computerized methods for controlling the manufacture of products, none of the aforementioned provide a method for improving the production of stamping dies for producing precise die blanks.
Thus, there remains a need for a method for designing and fabricating stamping dies that produce die blanks which is cost effective and which reduces the amount of time between the initial stamping die design and the final stamping die design. It is preferable that the method minimize the amount of materials and labor used in the process of adapting the initial die design to the final form of the die. Optimally, the method would be a computer-based method that coordinates the entire process for producing a final stamping die from an estimated die design.
SUMMARY OF THE INVENTION
The present invention provides a system and method for a manufacturing operation for fabricating production stamping dies for making precise die blanks wherein the manufacturing operation is controlled by computer. The system and method produces proposed die blanks from a customer's proposed die blank configuration which are evaluated by the customer before trial and/or production stamping dies are made. In particular, the method provides a computer processing unit which is accessible to the customer and wherein the computer provides die blank and stamping die CAD/CAM designing and manufacturing capabilities, and data storage and retrieval, and coordinates all or particular functions involved in the manufacture of proposed die blanks and trial or production stamping dies.
Thus, the present invention provides a method for manufacturing a production stamping die for producing a precise die blank, the steps comprising: (a) receiving a trial configuration of a proposed die blank for producing the production stamping die; (b) producing the proposed die blank from the trial configuration, preferably, wherein the proposed die blank is produced by a cutting method selected from the group consisting of fluid jet cutting, electric wire machining, electrode discharge machining, and electrochemical machining; (c) providing the proposed die blank produced in step (b) for testing in a shaping die; (d) producing a trial stamping die fo
Demmer Corporation
Frank Elliot
McLeod Ian C.
LandOfFree
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