Metal-forming die and method for manufacturing same

• US 7,086,267 B2
• Filed: 07/27/2004
• Issued: 08/08/2006
• Est. Priority Date: 02/18/2004
• Status: Expired due to Fees

• Current Assignee: Frank W. Dworak
• Original Assignee: Frank W. Dworak
• Inventors: Dworak, Frank W., Dworak, Bruce E.
• Primary Examiner(s): Crane, Daniel C.
• Application Number:
  US10/899,819
• Publication Number:
  US 20050178182A1
• Time in Patent Office: 742 Days
• Field of Search: 724/16, 724/13, 724/12, 724/69, 724/78, 76/13, 76/14, 761/071
• US Class Current: 72/413
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/07264 characterised by its staple forming cavities, e.g. geometry or material
• CPC Class Codes: B21D 13/02 by pressing

Abstract

A metal-forming die according to the present invention includes die blades with convoluted opposed side surfaces that correspond to variable-width features on the working surface of the die. The convoluted side surfaces and variable-width working surface features permit the impression left by one die blade to fill space taken from an impression made by a laterally adjacent die blade. Such a die permits formation of working surface shapes not possible with flat-sided die components. The die is manufactured in discrete longitudinally extending components, or blades. Dividing the working surface of the die into longitudinally extending portions, each carried by a die blade allows conventional machining processes to be employed in forming the working surface on each die blade. An additional machining process cuts complementary shapes on the sides of the die blades. The die blades and their corresponding working surfaces interfit, or nest together.

Claims

1. A metal-forming die comprising:

a plurality of blades extending in a first direction, each said blade having a working surface, opposed side surfaces extending away from said working surface and forming contacting surfaces between adjacent blades, a width measured between said opposed side surfaces and a rear surface opposed to said working surface, the working surface of at least one of said blades defining features to be formed on a workpiece, at least one of said features being a first variable-width feature having a lateral dimension which varies along the length of said blade,

wherein the width of said at least one blade varies with the lateral dimension of said first variable-width feature and the side surfaces of adjacent blades are complementary to the variable width of said at least one blade.

2. The metal-forming die of claim 1, wherein said first variable-width feature comprises an expanded lateral dimension and the working surface of a blade adjacent said at least one blade includes a second variable-width feature to be formed on the work piece,

wherein said second variable-width feature comprises a reduced lateral dimension and said expanded lateral dimension of said first variable-width feature is laterally adjacent to said reduced lateral dimension of said second variable-width feature.

3. The metal-forming die of claim 1, wherein the width of said at least one blade is substantially constant from said working surface to said rear surface.

4. A method of manufacturing a metal-forming die adapted for use in a press, said die comprising a plurality of adjacent die bodies having longitudinally extending working surfaces, opposed side surfaces extending from said working surface and a width between said opposed side surfaces, said die bodies clamped together with said side surfaces against one another and adjacent working surfaces defining a forming surface of the die, said method comprising:

forming a variable-width feature on the working surface of at least one die body, said variable-width feature having a lateral dimension which varies along the length of said at least one die body;

shaping the opposed side surfaces of said at least one die body so that the width between said side surfaces is substantially equal to a corresponding lateral dimension of said variable-width feature;

forming a second variable-width feature on the working surface of a die body, said second variable-width feature having a lateral dimension which varies along the length of said die body;

shaping the opposed side surfaces of said die body so that the width between said side surfaces is substantially equal to a corresponding lateral dimension of said second variable-width feature.

5. The method of claim 4, comprising:

configuring the side surface of a die body adjacent one of the opposed side surfaces of said at least one die body to be complementary to said one of the opposed side surfaces.

6. The method of claim 4, comprising:

forming a variable-width feature having an expanded lateral dimension on at least one die body; and

forming a second variable-width feature having a reduced lateral dimension on a die body next to said at least one die body such that the expanded lateral dimension of said variable-width feature corresponds to a reduced lateral dimension of said second variable-width feature.