Two methods are developed for production of folded structures: synchronous and cyclic.
Synchronous method
The point in synchronous method is simultaneous deforming of the sheet along the lines of the template. Deformation is performed using transformable mandrels and conjugate or non-conjugate schemes.
Advantages
- Short time of sheet deformation into a finished folded structure
- Doesn’t depend on the material: folded core may be produced from different materials without additional adjustment of production unit
- Diversity of reliefs and dimensions of the cores being manufactured
Disadvantages
- Difficult to apply this method to continuous roll materials
- Difficult to make the process automatic and continuous
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| Production unit for synchronous z-crimp manufacturing | Production unit for hybrid manufacturing of Z-crimp core |
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| Experimental production unit Holst-1 for synchronous folded core manufacturing | Production unit for synchronous manufacturing of Z-crimp folded core |
Production unit Holst-1 for synchronous folded core manufacturing
Production unit for synchronous manufacturing of Z-crimp folded core
Cyclic method
The point of cyclic method is gradual deformation of prepared sheet. Deformation is performed by step-by-step transformation of preliminary folded linear crimp into folded core. Deformation is performed either by transversal crimping or into transformable stamps.
Advantages
- Possibility to produce folded core from continuous roll material
- A possibility to make the process automatic and highly efficient
Disadvantages
- Sensibility to the material: it is necessary to select individual parameters of the process for each material
- Attachment of the process to a given relief – it is possible to change only separate parameters of core relief
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| Folded core production unit – transversal crimping method | Unit for preliminary preparation of the material |
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| Folding unit of transversal crimping machine | 3D model of folding unit of transversal crimping machine |
