Brake punch inserts

Abstract

A tool system for brake forming having a punch or a die and at least one insert. In one embodiment, two inserts are removably attached to a die. The die has a defined shape running along a longitudinal axis. Each insert has a protrusion with a particular cross-sectional shape running along the same longitudinal axis. The die has two cavities, each cavity having a cross-sectional shape matching the cross-sectional shape of the protrusion of one of the inserts. In another embodiment, the die has two protrusions and each insert has a cavity for receipt of one of the protrusions of the die. When one of the protrusions is inserted into one of the cavities, the insert is removably fixed to the die. At least one surface of each insert corresponds to and combines with the defined shape of the die, forming a bending surface against which a sheet of metal is formed. After press braking, the sheet of metal is substantially conformed to the defined shape of the die. In another embodiment, an insert is removably attached to a punch such that the insert forms the entire surface of the punch system that contacts the sheet of metal to be shaped during press braking. The inserts are positioned such that they encounter most of the wear caused by the brake forming, whereas the punch and the die encounter only minimal wear. As a result, the inserts are inexpensively repaired or replaced when needed, but the punch and the die remain in good condition during extended use.

1 . An apparatus, comprising: 
 a punch having a longitudinal axis and a lateral axis, the punch having a cavity along the longitudinal axis and a width along the lateral axis, wherein the cavity has a cross-sectional shape; and    an insert having a longitudinal axis that corresponds to the longitudinal axis of the punch, the insert having a protrusion along the longitudinal axis of the insert and at least one surface for shaping the sheet of metal, wherein the at least one surface is at least about as wide along the lateral axis of the punch as the width of the punch and wherein the protrusion has a cross-sectional shape that matches the cross-sectional shape of the cavity;    such that the protrusion of the insert may be inserted into the cavity of the punch to result in a removably fixed mechanical interlock between the cavity and the protrusion and such that the sheet of metal does not contact the punch during the shaping of the sheet of metal.    
   
   
       2 . The apparatus of  claim 1 , wherein: 
 the punch and the insert are made of the same material.    
   
   
       3 . The apparatus of  claim 1 , wherein: 
 the insert is made of steel.    
   
   
       4 . The apparatus of  claim 3 , wherein: 
 the insert is heat treated to at least about 50 Rockwell.    
   
   
       5 . The apparatus of  claim 4 , wherein: 
 the insert is heat treated to between about 55 Rockwell and about 60 Rockwell.    
   
   
       6 . The apparatus of  claim 3 , wherein: 
 the insert is coated with a thermal diffusion coating.    
   
   
       7 . The apparatus of  claim 3 , wherein: 
 the at least one surface of the insert is substantially v-shaped.    
   
   
       8 . The apparatus of  claim 3 , wherein: 
 the at least one surface of the insert is substantially u-shaped.    
   
   
       9 . The apparatus of  claim 3 , wherein: 
 the at least one surface of the insert is substantially channel-shaped.    
   
   
       10 . The apparatus of  claim 9 , wherein: 
 the at least one surface of the insert is substantially hat channel-shaped.    
   
   
       11 . The apparatus of  claim 3 , wherein: 
 the at least one surface of the insert is substantially offset-shaped.    
   
   
       12 . The apparatus of  claim 3 , wherein: 
 the at least one surface of the insert is substantially flat.    
   
   
       13 . The apparatus of  claim 3 , wherein: 
 the protrusion of the insert has a substantially dove-tailed cross-sectional shape.    
   
   
       14 . The apparatus of  claim 3 , wherein: 
 the protrusion of the insert has a substantially T-shaped cross-sectional shape.    
   
   
       15 . An apparatus, comprising: 
 a punch having a longitudinal axis and a lateral axis, the punch having a protrusion along the longitudinal axis and a width along the lateral axis, wherein the protrusion has a cross-sectional shape; and    an insert having a longitudinal axis that corresponds to the longitudinal axis of the punch, the insert having a cavity along the longitudinal axis of the insert and at least one surface for shaping the sheet of metal, wherein the at least one surface is at least about as wide along the lateral axis of the punch as the width of the punch and wherein the cavity has a cross-sectional shape that matches the cross-sectional shape of the protrusion;    such that the protrusion of the punch may be inserted into the cavity of the insert to result in a removably fixed mechanical interlock between the cavity and the protrusion and such that the sheet of metal does not contact the punch during the shaping of the sheet of metal.    
   
   
       16 . The apparatus of  claim 15 , wherein: 
 the punch and the insert are made of the same material.    
   
   
       17 . The apparatus of  claim 15 , wherein: 
 the insert is made of steel.    
   
   
       18 . The apparatus of  claim 17 , wherein: 
 the insert is heat treated to at least about 50 Rockwell.    
   
   
       19 . The apparatus of  claim 18 , wherein: 
 the insert is heat treated to between about 55 Rockwell and about 60 Rockwell.    
   
   
       20 . The apparatus of  claim 17 , wherein: 
 the insert is coated with a thermal diffusion coating.    
   
   
       21 . The apparatus of  claim 17 , wherein: 
 the at least one surface of the insert is substantially v-shaped.    
   
   
       22 . The apparatus of  claim 17 , wherein: 
 the at least one surface of the insert is substantially u-shaped.    
   
   
       23 . The apparatus of  claim 17 , wherein: 
 the at least one surface of the insert is substantially channel-shaped.    
   
   
       24 . The apparatus of  claim 23 , wherein: 
 the at least one surface of the insert is substantially hat channel-shaped.    
   
   
       25 . The apparatus of  claim 17 , wherein: 
 the at least one surface of the insert is substantially offset-shaped.    
   
   
       26 . The apparatus of  claim 17 , wherein: 
 the at least one surface of the insert is substantially flat.    
   
   
       27 . The apparatus of  claim 17 , wherein: 
 the protrusion of the punch has a substantially dove-tailed cross-sectional shape.    
   
   
       28 . The apparatus of  claim 17 , wherein: 
 the protrusion of the punch has a substantially inverted-T cross-sectional shape.