Method and apparatus for forming bend controlling displacements in sheet material

Abstract

An apparatus for forming bend controlling displacements in sheet materials includes one or more punch blades, a punch blade block having one or more recesses dimensioned and configured to receive the punch blades, a die block having one or more recesses corresponding in number to the number of punch blades, and a die block unit having a receptacle configured to receive the die block, one of the punch blade block and the die block unit being configured to reciprocate with respect to the other. The punch blades and the die block may include hardened steel and the punch blade block and the die block may include non-hardened steel. A method of using the sheet material with bend controlling displacements and method for forming the same is also disclosed.

1 . A tooling assembly for forming bend-controlling displacements in a sheet of material suitable for bending along a bend line, the tooling assembly comprising:
 one or more punch blades;   a punch blade block having one or more recesses dimensioned and configured to receive the punch blades;   a die block having one or more recesses corresponding in number to the number of punch blades; and   a die block unit having a receptacle configured to receive the die block, one of the punch blade block and the die block unit being configured to reciprocate with respect to the other;   wherein the punch blades and the die block include hardened steel and the punch blade block and the die block include non-hardened steel.   
     
     
         2 . The tooling assembly of  claim 1  wherein,
 at least one of the punch blade block and the die block are removable.   
     
     
         3 . The tooling assembly of  claim 1  wherein,
 the punch blades and the die block recesses are configured to form displacements with a portion of the periphery of the displacement extending along and adjacent to the bend line.   
     
     
         4 . The tooling assembly of  claim 1  wherein,
 the punch blade block is configured to position the portion of the periphery adjacent the bend line with an edge and the sheet of material with a corresponding opposed face configured and positioned to produce edge-to-face engagement of the sheet of material during bending.   
     
     
         5 . The tooling assembly of  claim 1  wherein,
 a plurality of punch blades are arranged along a plurality of bend lines and configured to form a plurality of bend lines simultaneously.   
     
     
         6 . The tooling assembly of  claim 1  wherein,
 at least one of the punch blades are electrical-discharged-machined hardened steel.   
     
     
         7 . The tooling assembly of  claim 1  wherein,
 at least one of the punch blades are ground, sectioned and cut to length.   
     
     
         8 . The tooling assembly of  claim 1  wherein,
 at least one of the punch blades includes a plurality of shear surfaces and is removably received in its respective recess of the punch blade block, wherein the punch blade may be reoriented in its respective recess to utilize a second one of said shear surfaces after a first one of said shear surfaces wears.   
     
     
         9 . The tooling assembly of  claim 1  wherein,
 the punch blade may be reoriented in its respective recess to utilize a second, third and/or fourth one of said shear surfaces after a first one of said shear surfaces wears.   
     
     
         10 . The tooling assembly of  claim 1  wherein,
 at least one of the punch blades includes a detent for releasable securement within a respective recess of the punch blade block.   
     
     
         11 . The tooling assembly of  claim 10  wherein,
 the tooling assembly further includes a fastener and an expandable washer dimensioned and configured to engage the detent for securing a respective punch blade within a respective recess of the punch blade block.   
     
     
         12 . The tooling assembly of  claim 11  wherein,
 the detent includes a shoulder against which the expandable washer abuts against for removal of the punch blade from the respective recess.   
     
     
         13 . The tooling assembly of  claim 12  wherein,
 the tooling assembly further includes an extractor for removing the expandable washer and, in turn, the punch blade from the punch blade block.   
     
     
         14 . The tooling assembly of  claim 13  wherein,
 the expandable washer includes internal threads for threaded engagement with the extractor.   
     
     
         15 . The tooling assembly of  claim 1  wherein,
 the die block unit includes a receptacle configured to removably receive the die block.   
     
     
         16 . The tooling assembly of  claim 15  wherein,
 the receptacle has a channel.   
     
     
         17 . The tooling assembly of  claim 15  wherein,
 the receptacle has a shape that substantially corresponds to the shape of the die block.   
     
     
         18 . The tooling assembly of  claim 17  wherein,
 the receptacle is configured to receive two die blocks.   
     
     
         19 . The tooling assembly of  claim 17  wherein,
 the two die blocks are oriented at an angle to one another.   
     
     
         20 . The tooling assembly of  claim 15  wherein,
 the die block includes a shear bar and a discrete joggle bar.   
     
     
         21 . The tooling assembly of  claim 20  wherein,
 the shear bar and the joggle bar include mating surfaces.   
     
     
         22 . The tooling assembly of  claim 21  wherein,
 the mating surfaces are inclined.   
     
     
         23 . The tooling assembly of  claim 15  wherein,
 the die block includes one or more shims.   
     
     
         24 . The tooling assembly of  claim 15  wherein,
 the die block includes electrical-discharged-machined hardened steel.   
     
     
         25 . The tooling assembly of  claim 15  wherein,
 the die block includes a plurality of first shear surfaces and a plurality of second shear surfaces, wherein the die block may be removed from the die block unit after the first shear surfaces wear, turned upside down, and inserted into the die block to utilize the second shear surfaces.   
     
     
         26 . A punch press machine including the tooling assembly of  claim 1 . 
     
     
         27 . A method of forming for forming bend controlling displacements in a sheet material, the method comprising the steps:
 providing the tooling assembly of  claim 1 ;   inserting a sheet material between the punch blades and the die block; and   forming displacements on the sheet material.   
     
     
         28 . A sheet material formed by the method of  claim 27 . 
     
     
         29 . A three-dimensional article formed from the sheet material of  claim 28 . 
     
     
         30 . The three-dimensional article of  claim 1 , wherein the article is selected from the group consisting of: electronic components, automotive components, transport components, construction components, appliance parts, truck components, RF shields, HVAC components, and/or aerospace components.