Machine and method for forming inter-sheet registering contours in metal blanks for separation

Abstract

An apparatus for making one or more registering contour features in a workpiece. At least some of the registering contour features have an outer annular rim and basin-shaped portion there within. One embodiment has: (i) one or more first tools, each tool being adapted to form the outer annular rim in one or more registering contour features; and (ii) one or more second tools for forming in cooperation with the first set of insert tools one or more of the basin-shaped portions that lie within the outer annular rims, thereby forming a set of one or more registering contour features in the workpiece so that workpieces in a stack are separated to facilitate subsequent handling by removing an uppermost workpiece from the stack.

What is claimed is: 
     
         1 . An apparatus for making one or more registering contour features in a workpiece at the same location in each workpiece to enable a stack of such workpieces to be separated, each registering contour feature having an annular rim and a basin-shaped portion lying there within, the apparatus comprising:
 (i) an upper tool adapted to form the annular rim in one or more registering contour features; and   (ii) a lower tool for forming in cooperation with the upper tool an inner basin-shaped portion that lies within the annular rim, thereby forming a set of one or more registering contour features in the workpiece, whereby the registering contour features of adjacent workpieces in a stack provide an inter-workpiece separation of intermediate sections of the workpieces that lie between the registering contour features, wherein the registering contour features are formed prior to the bottom of a press stroke and/or prior to a cutting of the workpiece to remove regions thereof that include the registering contour features.   
     
     
         2 . The apparatus of  claim 1 , wherein the upper tool is a female tool. 
     
     
         3 . The apparatus of  claim 2 , wherein the lower tool is a male tool. 
     
     
         4 . The apparatus of  claim 3 , wherein one or more of the male tools include rounded leading ends. 
     
     
         5 . The apparatus of  claim 2 , wherein the female tool includes the basin-shaped portion. 
     
     
         6 . An apparatus for making one or more registering contour features in a workpiece at the same location in each workpiece to enable a stack of such workpieces to be separated, each registering contour feature having an annular rim and a basin-shaped portion lying there within, the apparatus comprising:
 (i) a lower tool adapted to form the annular rim in one or more registering contour features; and   (ii) an upper tool for forming in cooperation with the lower tool the inner basin-shaped portion that lies within the annular rim, thereby forming a set of one or more registering contour features in the workpiece, whereby the registering contour features of adjacent workpieces in a stack provide an inter-workpiece separation of intermediate sections of the workpieces that lie between the registering contour features, wherein the contour features are formed prior to the bottom of a press stroke and/or prior to a cutting of the workpiece to remove regions thereof that include the registering contour features.   
     
     
         7 . The apparatus of  claim 1 , wherein the workpiece comprises a material that can receive and resist a closure pressure non-destructively as the upper and lower dies converge without imparting damage to the workpiece. 
     
     
         8 . An array of stacked workpieces, one or more workpieces in the stack having an intermediate planar portion and one or more registering contour features extending from the intermediate planar portion, one or more of the registering contour features in a first workpiece having
 an outer annular rim; and   a basin-shaped portion that lies within the annular rim.   
     
     
         9 . The array of  claim 8 , wherein the outer annular rim of the registering contour feature of the first workpiece at least partially cooperate with the outer annular rim in a registering contour feature of an adjacent workpiece. 
     
     
         10 . The array of  claim 8 , wherein the basin-shaped portion in a registering contour feature of the first workpiece is spaced apart from the basin-shaped portion in a registering contour feature of an adjacent workpiece. 
     
     
         11 . The array of  claim 8 , further including a space between planar portions of adjacent workpieces. 
     
     
         12 . The array of  claim 8 , wherein a space lies between the outer annular rim of the registering contour feature of the first workpiece and the outer annular rim in a registering contour feature of an adjacent workpiece. 
     
     
         13 . The array of  claim 8 , in which the planar section of one or more workpieces in the stack has an imaginary datum plane, a top of the rim of the outer annular rim lying above the imaginary datum plane and the basin-shaped portion has a lowermost portion that lies below the datum plane. 
     
     
         14 . A method for making a registering contour feature in a workpiece comprising the steps of
 (A) providing:
 (i) one or more upper tools, each upper tool being adapted to form an outer annular rim in one or more registering contour features; and 
 (ii) one or more lower tools for forming in cooperation with the upper tool a basin-shaped portion to lie within an outer annular rim, thereby forming a set of one or more registering contour features in the workpiece; 
   (B) inserting a workpiece between the die sets;   (C) closing the die sets so that they form a localized contour feature in the workpiece;
 (i) prior to the die being completely closed; and/or 
 (ii) prior to any cutting of the workpiece; 
   (D) opening the die sets; and   (E) withdrawing the workpiece.   
     
     
         15 . A method for making a registering contour feature in a workpiece comprising the steps of
 (A) providing:
 (i) one or more lower tools, each lower tool being adapted to form an outer annular rim in one or more registering contour features; and 
 (ii) one or more upper tools for forming in cooperation with the lower tool a basin-shaped portion to lie within an outer annular rim, thereby forming a set of one or more registering contour features in the workpiece; 
   (B) inserting a workpiece between the die sets;   (C) closing the die sets so that they form a localized contour feature in the workpiece;
 (i) prior to the die being completely closed; and/or 
 (ii) prior to any cutting of the workpiece. 
   (D) opening the die sets; and   (E) withdrawing the workpiece.