Cantilevered Flange Die Insert for a Rotary Cam Having a Reduced Diameter Portion

Abstract

A sheet metal forming die set includes a rotary cam that is received in a cavity of one of the dies. The rotary cam has a cylindrical body portion and a bullet nose portion that is smaller in diameter than the body portion. A cantilevered insert is provided on the die adjacent to the bullet nose portion.

What is claimed: 
     
         1 . A die set for forming a panel in a press comprising:
 an upper die;   a lower die cooperates with the upper die;   a rotary fill cam is assembled to the lower die, the rotary fill cam is pivoted about an axis, the rotary fill cam having a cylindrical portion and a reduced diameter portion on at least one end; and   a cantilevered flange die insert is secured to the lower die to extend over the reduced diameter portion of the rotary fill cam filling the space between the upper die and the reduced diameter portion of the rotary fill cam.   
     
     
         2 . The die set of  claim 1  wherein the reduced diameter portion of the rotary fill cam is formed in the shape of a bullet nose that is provided on one end of the cylindrical portion. 
     
     
         3 . The die set of  claim 1  wherein the rotary fill cam defines a first extended forming surface and the cantilevered flange die insert defines a second extended forming surface of the lower die. 
     
     
         4 . The die set of  claim 3  wherein the first extended forming surface of the rotary fill cam is disposed adjacent the second extended forming surface of the lower die surface when the panel is formed in the press. 
     
     
         5 . A rotary fill cam that is operatively assembled to a die, the rotary fill cam comprising:
 a body portion that is assembled to the die to pivot within the die;   a bullet nose portion that is provided on one end of the body portion and that pivots with the body portion; and   wherein the die has a cantilevered flange die insert that over hangs the bullet nose portion of the rotary fill cam and is supported by the bullet nose portion.   
     
     
         6 . The rotary fill cam of  claim 5  wherein the body portion is cylindrical. 
     
     
         7 . The rotary fill cam of  claim 6  wherein the cylindrical body portion has an axis about which the body portion pivots, wherein the outer periphery of the body portion is disposed at a radius R from the axis and wherein the bullet nose portion defines a forming surface that is disposed at a distance from the axis that is less than R. 
     
     
         8 . The rotary fill cam of  claim 5  wherein the die has a die surface, and the bullet nose portion defines a first extended portion of the die surface. 
     
     
         9 . The rotary fill cam of  claim 8  wherein the cantilevered flange die insert defines a second extended portion of the die surface. 
     
     
         10 . A die assembly used to form a panel comprising:
 a die that defines a cavity;   a rotary cam received in the cavity, the rotary cam having a cylindrical portion and having a re-entrant portion;   a cantilevered extension attached to the die and extending into the re-entrant portion;   a first forming surface provided on the cantilevered extension; and   a second forming surface provided on the rotary cam that is rotated to a position adjacent to the first forming surface to form a portion of the panel.   
     
     
         11 . The die assembly of  claim 10  wherein the re-entrant portion has a partially spherical convex surface and the extension has a partially spherical concave surface that is assembled over the partially spherical convex surface. 
     
     
         12 . The die assembly of  claim 10  wherein the re-entrant portion has a partially spherical convex surface and the extension has a partially spherical concave surface that is assembled over the partially spherical convex surface. 
     
     
         13 . The die assembly of  claim 10  wherein the first and second forming surfaces cooperate to back up a compound flange portion of the panel. 
     
     
         14 . The die assembly of  claim 10  wherein the first forming surface is arcuate in shape and is disposed on one edge of the extension, and further wherein the second forming surface is arcuate in shape and is disposed on one edge of the rotary cam. 
     
     
         15 . The die assembly of  claim 10 , further comprising a second die that includes a third forming surface that engages the panel on the opposite side of the panel from the first and second forming surfaces when they are adjacent to each other and wherein the rotary cam rotates the second forming surface to a position that is not adjacent to the first forming surface to facilitate removal of the panel from the first die.