Staged Tooling Technology

Abstract

The invention involves staged press brake tooling combinations. In some embodiments, the invention provides a staged press brake setup. In other embodiments, the invention provides a staged quick-change multiple forming recess press brake die.

1 . A staged quick-change multiple forming recess die for a press brake, the die having a first bearing face and a first workpiece-contact face, the first bearing face and the first workpiece-contact face being on opposed sides of the die, the first bearing face including a first bearing base and a first locating recess, the first workpiece-contact face having therein formed a first forming recess bounded by two converging surfaces, wherein two planes lying respectively on planar portions of said two converging surfaces intersect at a first theoretical sharp location, wherein a first theoretical-sharp distance is defined as the distance between the first bearing base and the first theoretical sharp location, the die having a second bearing face and a second workpiece-contact face, the second bearing face and the second workpiece-contact face being on opposed sides of the die, the second bearing face including a second bearing base and a second locating recess, the second workpiece-contact face having therein formed a second forming recess bounded by two convergent surfaces, wherein two planes lying respectively on planar portions of said two convergent surfaces intersect at a second theoretical sharp location, wherein a second theoretical-sharp distance is defined as the distance between the second bearing base and the second theoretical sharp location, the first forming recess having a first size, the second forming recess having a second size, wherein said first and second sizes are different and yet the first and second theoretical-sharp distances are substantially the same. 
   
   
       2 . The die of  claim 1  wherein the die has a first centerline defined by an axis that is perpendicular to the first bearing base and passes through the first theoretical sharp location, wherein the first locating recess is not directly aligned with the first forming recess, such that the first locating recess is spaced from the first centerline. 
   
   
       3 . The die of  claim 2  wherein the die has a second centerline defined by an axis that is perpendicular to the second bearing base and passes through the second theoretical sharp location, wherein the second locating recess is not directly aligned with the second forming recess, such that the second locating recess is spaced from the second centerline. 
   
   
       4 . The die of  claim 3  wherein the die has first and second die-locating dimensions that are substantially the same, the first locating recess having a width, the first die-locating dimension being defined as the distance between the first centerline and a midpoint of the width of the first locating recess, the second locating recess having a width, the second die-locating dimension being defined as the distance between the second centerline and a midpoint of the width of the second locating recess. 
   
   
       5 . The die of  claim 4  wherein the first locating recess is an elongated channel extending longitudinally along the die's first bearing face, and the second locating recess is an elongated channel extending longitudinally along the die's second bearing face. 
   
   
       6 . The die of  claim 1  wherein the die has first and second working heights that are different, the first working height being defined as the distance between the first bearing base and the first workpiece-contact face, the second working height being defined as the distance between the second bearing base and the second workpiece-contact face. 
   
   
       7 . The die of  claim 1  wherein the first and second workpiece-contact faces are substantially perpendicular to each other. 
   
   
       8 . The die of  claim 7  wherein the first and second bearing faces are substantially perpendicular to each other. 
   
   
       9 . The die of  claim 1  wherein the first forming recess is at least generally V-shaped. 
   
   
       10 . The die of  claim 9  wherein the second forming recess is at least generally V-shaped. 
   
   
       11 . The die of  claim 1  wherein said first size is a width of the first forming recess, said second size is a width of the second forming recess, wherein these two widths are different and yet the first and second theoretical-sharp distances are the same. 
   
   
       12 . The die of  claim 1  wherein the planar portions of said two converging surfaces are connected by a radiused valley section, such that the first forming recess would have a greater depth if its two converging surfaces converged at constant angles over their whole length until reaching a vertex at the first theoretical sharp location rather than being connected by a radiused valley section. 
   
   
       13 . The die of  claim 12  wherein the planar portions of said two convergent surfaces are connected by a radiused valley section, such that the second forming recess would have a greater depth if its two convergent surfaces converged at constant angles over their whole length until reaching a vertex at the second theoretical sharp location rather than being connected by a radiused valley section. 
   
   
       14 . The die of  claim 1  wherein the die has a length, and the first and second locating recesses extend entirely along the die's length. 
   
   
       15 . The die of  claim 14  wherein the first and second forming recesses extend entirely along the die's length. 
   
   
       16 . The die of  claim 1  wherein the first locating recess, the second locating recess, the first forming recess, and the second forming recess all extend in directions that are substantially parallel. 
   
   
       17 . The die of  claim 1  wherein the first and second locating recesses have substantially the same width, substantially the same depth, and substantially the same length. 
   
   
       18 . The die of  claim 17  wherein the first and second locating recesses are both rectangular channels. 
   
   
       19 . The die of  claim 1  wherein the die has six faces: the first bearing face, the first workpiece-contact face, the second bearing face, the second workpiece-contact face, and two end faces. 
   
   
       20 . A staged quick-change two-V press brake die, the die having first and second bending Vs formed respectively in first and second workpiece-contact faces of the die, said first and second workpiece-contact faces being at least generally perpendicular to each other, the first bending V having a first theoretical sharp location, the second bending V having a second theoretical sharp location, the die having first and second bearing faces, the first bearing face having formed therein a first elongated locating channel, the second bearing face having formed therein a second elongated locating channel, the first bearing face being at least generally parallel to the first workpiece-contact face, the second bearing face being at least generally parallel to the second workpiece-contact face, wherein a first theoretical-sharp distance is defined as the distance between the first bearing face and the first theoretical sharp location, and a second theoretical-sharp distance is defined as the distance between the second bearing face and the second theoretical sharp location, wherein the first and second bending Vs have different widths and yet the die is configured such that the first and second theoretical-sharp distances are substantially the same. 
   
   
       21 . A staged quick-change press brake system including a press brake with upper and lower beams, the system comprising:
 a plurality of press brake tools mounted in respective tool holders on the upper beam, each tool having a tang, the tangs being received in respective tool holders,   at least one of the tools having a tip configuration different from that of another tool of said plurality,   wherein there is an upwardly facing load-bearing shoulder on only one side of the tang of each tool, each such upwardly facing shoulder contacting a downwardly facing force-transmitting surface of a tool holder, each tool having a downwardly facing tip comprising two downwardly converging surfaces, wherein two planes lying respectively on planar portions of said two converging surfaces intersect at a tool theoretical sharp location, wherein a common vertical distance separates the tool theoretical sharp location and the upwardly facing load-bearing shoulder for all the tools of said plurality, and   a plurality of press brake dies, each mounted on a rail carried by the lower beam, each die having a bearing face with a bearing base and a locating recess in which a locating ridge of the rail is received, each die having a workpiece-contact face with an upwardly open forming recess bounded by two downwardly convergent surfaces, wherein two planes lying respectively on planar portions of said two convergent surfaces intersect at a die theoretical sharp location, wherein a shared vertical distance separates the die theoretical sharp location and the bearing base for all the dies of said plurality.   
   
   
       22 . The press brake system of  claim 21  wherein the tool holders on the upper beam of the press brake have a centerline that extends vertically downwardly and passes through all of the following: (a) said downwardly facing force-transmitting surface of each tool holder, (b) said upwardly facing load-bearing shoulder of each tool, (c) the tool theoretical sharp location of each tool, and (d) the die theoretical sharp location of each die. 
   
   
       23 . The press brake system of  claim 22  wherein the locating recess of each die is not directly aligned with said centerline, such that the locating recesses of the dies are spaced from said centerline. 
   
   
       24 . The press brake system of  claim 22  wherein the locating recess in each die has a width, and the dies all have a common die locating dimension, the die locating dimension being defined as the distance between said centerline and a midpoint of said width. 
   
   
       25 . The press brake system of  claim 21  wherein the tools and dies when mated all have a common shut height, the shut height being defined as the vertical distance between the bearing base and the upwardly facing load-bearing shoulder of a mated tool and die pair. 
   
   
       26 . The press brake system of  claim 21  wherein at least one mateable tool and die pair is adapted to create a first bend, and at least one other mateable tool and die pair is adapted to create a second bend, the first and second bends being different, and wherein said tools are punches. 
   
   
       27 . The press brake system of  claim 26  wherein the first and second bends are two different bends selected from the group consisting of a 90-degree bend, a 60-degree bend, a 30-degree bend, an offset bend, and a hemming bend. 
   
   
       28 . The press brake system of  claim 27  wherein the first or second bend is a 90-degree bend. 
   
   
       29 . The press brake system of  claim 21  wherein a first mateable tool and die pair is adapted to create a first bend, a second mateable tool and die pair is adapted to create a second bend, and a third mateable tool and die pair is adapted to create a third bend, the first, second, and third bends all being different. 
   
   
       30 . The press brake system of  claim 21  wherein at least one of the dies has a working height different from that of another die of said plurality, the working height of a die being defined as the distance between its bearing base and its workpiece-contact face. 
   
   
       31 . The press brake system of  claim 30  wherein at least one of the dies has a working height at least 1/16 inch greater than that of another die of said plurality. 
   
   
       32 . The press brake system of  claim 30  wherein, on at least one of the dies, the planar portions of said two convergent surfaces are connected by a radiused valley section, such that the forming recess would have a greater depth if its two convergent surfaces converged at constant angles over their whole length until reaching a vertex at the die theoretical sharp location rather than being connected by a radiused valley section. 
   
   
       33 . The press brake system of  claim 21  wherein at least a plurality of the tools are punches with tangs each having a safety recess formed in one side. 
   
   
       34 . The press brake system of  claim 21  wherein the tool holders have seating mechanisms that, in response to clamping movements of the tool holders, move said upwardly facing shoulders of the tools into contact with the respective downwardly facing force-transmitting surfaces of the tool holders. 
   
   
       35 . A tooling combination for a press brake having upper and lower beams, the combination comprising:
 a plurality of press brake tools adapted to be mounted in respective tool holders on the upper beam, each tool having a tang, the tangs being adapted for receipt in respective tool holders,   at least one of the tools having a tip configuration different from that of another tool of said plurality,   wherein there is a load-bearing shoulder on only one side of the tang of each tool, each such shoulder being adapted to contact a downwardly facing force-transmitting surface of a tool holder when the tools are operatively mounted in respective tool holders, each tool having a tip comprising two converging surfaces, wherein two planes lying respectively on planar portions of said two converging surfaces intersect at a tool theoretical sharp location, wherein a common distance separates the tool theoretical sharp location and the load-bearing shoulder for all the tools of said plurality, and   a plurality of press brake dies, each adapted to be mounted on a rail carried by the lower beam, each die having a bearing face with a bearing base and a locating recess adapted to receive a locating ridge of the rail, each die having a workpiece-contact face with a forming recess bounded by two convergent surfaces, wherein two planes lying respectively on planar portions of said two convergent surfaces intersect at a die theoretical sharp location, wherein a shared distance separates the die theoretical sharp location and the bearing base for all the dies of said plurality.   
   
   
       36 . The combination of  claim 35  wherein the tools and dies when mated all have a common shut height, the shut height being defined as the distance between the bearing base and the load-bearing shoulder of a mated tool and die pair. 
   
   
       37 . The combination of  claim 35  wherein at least one of the dies has a working height different from that of another die of said plurality, the working height of a die being defined as the distance between its bearing base and its workpiece-contact face. 
   
   
       38 . The combination of  claim 37  wherein at least one of the dies has a working height at least 1/16 inch greater than that of another die of said plurality. 
   
   
       39 . The combination of  claim 35  wherein, on at least one of the dies, the planar portions of said two convergent surfaces are connected by a radiused valley section, such that the forming recess would have a greater depth if its two convergent surfaces converged at constant angles over their whole length until reaching a vertex at the die theoretical sharp location rather than being connected by a radiused valley section. 
   
   
       40 . The combination of  claim 35  wherein at least one mateable tool and die pair is adapted to create a first bend, and at least one other mateable tool and die pair is adapted to create a second bend, the first and second bends being different, and wherein said tools are punches. 
   
   
       41 . The combination of  claim 40  wherein the first and second bends are two different bends selected from the group consisting of a 90-degree bend, a 60-degree bend, a 30-degree bend, an offset bend, and a hemming bend. 
   
   
       42 . The combination of  claim 35  wherein a first mateable tool and die pair is adapted to create a first bend, a second mateable tool and die pair is adapted to create a second bend, and a third mateable tool and die pair is adapted to create a third bend, the first, second, and third bends all being different. 
   
   
       43 . The combination of  claim 35  wherein at least a selected one of the tools includes a seating mechanism, the seating mechanism being adapted to seat the load-bearing shoulder of the selected tool against a downwardly facing force-transmitting surface of a selected tool holder in response to a clamping movement of the selected tool holder. 
   
   
       44 . The combination of  claim 35  further including the press brake, wherein each of a plurality of the tool holders comprises a pivotable clamp. 
   
   
       45 . A fabrication method involving a press brake with upper and lower beams, the method comprising:
 providing a plurality of press brake tools, each tool having a tang, at least one of the tools having a tip configuration different from that of another tool of said plurality, wherein there is a load-bearing shoulder on only one side of the tang of each tool, each tool having a tip comprising two converging surfaces, wherein two planes lying respectively on planar portions of said two converging surfaces intersect at a tool theoretical sharp location, wherein a common distance separates the tool theoretical sharp location and the load-bearing shoulder for all the tools of said plurality,   providing a plurality of press brake dies, each die having a bearing face with a bearing base and a locating recess, each die having a workpiece-contact face with a forming recess bounded by two convergent surfaces, wherein two planes lying respectively on planar portions of said two convergent surfaces intersect at a die theoretical sharp location, wherein a shared distance separates the die theoretical sharp location and the bearing base for all the dies of said plurality,   providing an arrangement of tools and dies on the press brake by: (i) mounting the tools in respective tool holders of the upper beam such that the load-bearing shoulders of the tools confront downwardly facing force-transmitting surfaces of respective tool holders, and (ii) mounting each die on a rail carried by the lower beam such that the locating recess of each die receives a locating ridge of the rail,   positioning a workpiece between a first mateable tool and die pair and then forming a first bend in the workpiece by bringing the upper and lower beams of the press brake together so as to deform the workpiece between the tool and die of the first mateable pair, and without changing the arrangement of tools and dies on the press brake, positioning the workpiece between a second mateable tool and die pair and then forming a second bend in the workpiece by bringing the upper and lower beams of the press brake together so as to bend the workpiece between the tool and die of the second mateable pair, wherein the first and second bends are two different types of bends.   
   
   
       46 . The method of  claim 45  wherein the tool holders on the upper beam have a centerline that extends vertically downwardly and passes through all of the following: (a) said downwardly facing force-transmitting surface of each tool holder, (b) said load-bearing shoulder of each mounted tool, (c) the tool theoretical sharp location of each mounted tool, and (d) the die theoretical sharp location of each mounted die. 
   
   
       47 . The method of  claim 46  wherein the locating recess of each mounted die is not directly aligned with said centerline, such that the locating recesses of the mounted dies are spaced from said centerline. 
   
   
       48 . The method of  claim 46  wherein the locating recess of each die has a width, and the mounted dies all have a common die locating dimension, the die locating dimension being defined as the distance between said centerline and a midpoint of said width. 
   
   
       49 . The method of  claim 45  wherein the tools and dies when mated all have a common shut height, the shut height being defined as the distance between the bearing base and the load-bearing shoulder of a mated tool and die pair. 
   
   
       50 . The method of  claim 45  wherein the first and second bends are two different bends selected from the group consisting of a 90-degree bend, a 60-degree bend, a 30-degree bend, an offset bend, and a hemming bend. 
   
   
       51 . The method of  claim 50  wherein the first or second bend is a 90-degree bend. 
   
   
       52 . The method of  claim 45  wherein the method further comprises using a third mateable tool and die pair to make a third bend in the workpiece, the first, second, and third bends all being different types of bends.