Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 1003
COMPLETE SPECIFICATION
[See section 10, Rule 13]

TITLE OF INVENTION
A DIE ASSEMBLY FOR FORMING ARTICLES

APPLICANT
Mahindra & Mahindra Limited, an Indian company, having its address at Mahindra Research Valley, Mahindra World City, Plot No:41/1, Anjur P.O., Chengalpattu, Kanchipuram District, Tamil Nadu – 603004, India

PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed:

FIELD OF THE INVENTION
[001] The present invention relates to a field of die casting and more particularly to a die assembly for forming articles.

BACKGROUND OF THE INVENTION
[002] A die assembly is widely and commonly used in manufacturing industries to form articles of desired shape or profile. It has been observed that due to growing demands of customers, manufacturers are required to produce different variations of the same article to meet the customer preferences, aesthetic and/or utility requirements. In other words, manufacturers are required to cater to customer customization whereby while main body of the article remains same, a portion of the article is varied/changed as per requirement. To produce such variations of the same article, separate die assemblies are required for each variation of the same article which increases the manufacturing costs, time, and also increases manufacturing complexities.
[003] It has also been observed that in some industries, especially in the automobile industry, the manufacturers are required to comply with the legal regulations requiring the manufactures to adapt changes or variations as prescribed thereunder. In such situations, the extra burden shifts on the manufacturers to comply with the legal regulations to create variations of the articles for that particular jurisdiction. This increases the manufacturing costs and complexities due to requirement of additional die assemblies.
[004] Thus, there is a need in the art for a die assembly which can easily produce different variations of the same article and addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[005] In one aspect, a die assembly for forming articles is disclosed. The die assembly includes a lower die having a die region with an opening. The die assembly includes an upper die having a die region with an opening. The upper die is disposed above the lower die. The die assembly includes a blank holder configured to operably hold a blank between the upper die and the lower die. Each of the lower die and the upper die corresponds with a body of the article being formed. The die assembly includes an upper die member and a lower die member. The upper die member having an additional die region. The upper die member is configured to be detachably received inside the opening of the upper die. The lower die member having an additional die region. The lower die member configured to be detachably received inside the opening of the lower die. The upper die member and the lower die member when received in the openings of the upper die and the lower die forms a total die region comprising the die regions of the upper die and the lower die and the additional die regions of the upper die member and the lower die member. The total die region corresponds with the shape/configuration as required to impart to the blank to form the article with the additional die regions configured to vary a portion of the article as per requirement.
[006] In an embodiment, the lower die member includes a base plate, a plurality of supporting members and a forming plate. The forming plate is configured to impart a predefined shape to the article. The plurality of supporting members extend from the base plate in an upward direction and towards the upper die member. Each of the plurality of supporting members includes a first end and a second end. The first ends of the plurality of supporting members are attached to the base plate of the lower die member. The second ends of the plurality of supporting members are adapted to be attached to the forming plate.
[007] In an embodiment, each of the second ends of plurality of supporting members of the lower die member includes a mounting recess. Each of the mounting recess is configured to receive fastening means for attaching the forming plate of the lower die member.
[008] In an embodiment, the upper die member includes a base plate, a plurality of supporting members and a forming plate. The forming plate is configured to impart a predefined shape to the subject article. The plurality of supporting members extends from the base plate in a downward direction and towards the lower die member. Each of the plurality of supporting members includes a first end and a second end. The first ends of the plurality of supporting members are attached to the base plate of the upper die member. The second ends of the plurality of supporting members are adapted to be attached to the forming plate.
[009] In an embodiment, each of the second ends of plurality of supporting members of the upper die member includes a mounting recess. Each of the mounting recess is configured to receive fastening means for attaching the forming plate of the upper die member.

BRIEF DESCRIPTION OF THE DRAWINGS
[010] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a schematic front cross sectional view of a die assembly for forming articles, in accordance with an embodiment of the invention.
Figure 2 illustrates a front view of the die assembly in an assembled state, in accordance with an embodiment of the invention.
Figure 3 illustrates an exploded front view of the die assembly, in accordance with an embodiment of the invention.
Figure 4a is a bottom view of the upper die of the die assembly illustrating a die region, in accordance with an embodiment of the invention.
Figure 4b is a bottom perspective view of the upper die of the die assembly illustrating an opening formed in the die region, in accordance with an embodiment of the invention.
Figure 5a illustrates a bottom perspective view of the upper die member of the die assembly, in accordance with an embodiment of the invention.
Figure 5b illustrates a bottom perspective view of another upper die member of the die assembly, in accordance with an embodiment of the invention.
Figure 6 illustrates an exploded view of the upper die member, in accordance with an embodiment of the invention.
Figure 7a is a bottom view of the lower die of the die assembly illustrating a die region, in accordance with an embodiment of the invention.
Figure 7b is a top perspective view of the lower die of the die assembly illustrating an opening formed in the die region, in accordance with an embodiment of the invention.
Figure 8a illustrates a top perspective view of the lower die member of the lower die, in accordance with an embodiment of the invention.
Figure 8b illustrates a top perspective view of another lower die member of the die assembly, in accordance with an embodiment of the invention.
Figure 9 illustrates an exploded view of the lower die member, in accordance with an embodiment of the invention.
Figure 10 illustrates a front cross-sectional view of the upper die, in accordance with an embodiment of the present invention.
Figure 11 illustrates a front cross-sectional view of the lower die, in accordance with an embodiment of the present invention.
Figure 12 illustrates a dash panel as per an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[011] The present invention is directed towards a die assembly for forming articles, whereby the die assembly enables customization/modification of a portion of the article i.e., at-least a portion of the article can be varied as per requirement. The die assembly is thus designed to produce multiple variations of the same article.
[012] Figure 1 illustrates a schematic cross-sectional view of a die assembly 100 for forming articles in accordance with an embodiment of the invention. The die assembly 100 includes a lower die 110, an upper die 140, and a blank holder 130 disposed between the lower die 110 and the upper die 140. Each of the die 110, 140 corresponds with a body of the article being formed from the blank. The blank holder 130 is a floating element being guided through the lower die 110. The blank holder 130 is configured to operably hold a blank between the upper die (140) and the lower die (110). The upper die 140 being configured to move in a downward direction and contact the blank being held by the blank holder 130. The blank is a sheet of material of which the article is formed. In a non-limiting example, the blank being, but not limited to, a metal, a plastic, or any other material of which the article is being made.
[013] In an embodiment, the upper die 140 and the lower die 110 of the die assembly 100 are configured to detachably receive an upper die member 150 and a lower die member 120 respectively. Each of the lower die 110 and the upper die 140 includes a die region (not shown) which corresponds with a body of the article being formed by the die assembly 100, and the lower die member 120 and the upper die member 150 correspond with a portion of the body of the article being formed.
[014] . Figure 2 illustrates a front view of the die assembly 100 in an assembled state, in accordance with an embodiment of the invention. Figure 3 illustrates an exploded front view of the die assembly 100 in accordance with an embodiment of the invention. As shown, the upper die 140 includes a plurality of clamping slots 146 formed on an upper side of the upper die 140. Each clamping slot 146 is configured to receive fastening means to clamp the upper die 140 to an upper press bolster plate (not shown). The fastening means include, not being limited to, a fastener, screw, nut and/or bolt etc. The upper die 140 includes wear plates 148 being formed on a lower side of the upper die 140. The wear plates 148 act as a guiding element when the upper die 140 moves downward and contacts an upper portion of the blank holder 130. The upper portion of the blank holder 130 includes a plurality of block members 132 for receiving a lower side of the upper die 140 when the upper die 140 is moved downward by the upper press bolster plate. The blank holder 130 has blank gauges 134 mounted on the upper portion of the blank holder 130. The blank gauges 134 being configured to locate the blank therebetween, at a predefined position, in accordance with the requirements of the formation of the article. The blank holder 130 includes a pair of pneumatic cylinders 136. The pneumatic cylinders 136 being configured to eject the formed article out of the die assembly 100 by applying a pneumatic force on a portion of the article. The lower die 110 includes a plurality of clamping slots 118 formed on a bottom side of the lower die 110. Each clamping slot 118 is configured to receiving fastening means to clamp the lower die 110 with a lower press bolster plate (not shown). The lower press bolster plate is configured to hold stationary the lower die 110. The lower die 110 includes block members 116 formed on an upper portion of the lower die 110. The block members 116 being configured to balance the upper die 140 along with the blank holder 130 while the die assembly 100 is in a closed state for forming the article. During the downward movement of the upper die 140, the wear plates 148 of the upper die 140 are guided through inner surfaces 116a of the block members 116 of the lower die 110. The lower die 110 has wear plates 117. The wear plates 117 act as a guiding element to guide the blank holder 130 while contacting the lower die 110.
[015] Figure 4a and 4b show the upper die 140 of the die assembly 100 in accordance with an embodiment of the invention. A die region 141 is configured with a desired shape/configuration as required to form the upper portion of the body of the article being formed. As shown in figure 4a and 4b, an opening 145 is provided which is configured to receive the upper die member 150 (shown in Figure 1) to form an additional die region 143. Further, the opening has plurality of ribs 142. As shown, at-least one rib is provided horizontally and at-least one rib is provided vertically. Each rib has mounting holes for allowing the forming plate 156 of the upper die member 150 to be mounted thereon. The ribs allow the support members to pass through and support the forming plate 156. Accordingly, the forming plate 156 is supported by the supporting members 154 and the ribs 142.
[016] Figure 5a illustrates a perspective view of the upper die member 150 in accordance with an embodiment of the invention. As shown in Figure 5a, the upper die member 150 includes a base plate 152, a plurality of supporting members 154 and a forming plate 156. The forming plate 156 of the upper die member 150 is detachably mounted on the plurality of supporting members 154. The plurality of supporting members 154 are further attached to the base plate 152. The forming plate 156 is configured with a desired shape/configuration as required to form the variable portion of the upper body of the article being formed.
[017] As shown in Figure 5b, the upper die member 150 includes another forming plate 256 having a different shape/ configuration from the forming plate 156 (shown in Figure 5a). The forming plate 256 is detachably mounted on the plurality of supporting members 154. Accordingly, depending upon requirement, the forming plate can be attached to the supporting members.
[018] Figure 6 illustrates an exploded view of the upper die member 150, in accordance with an embodiment of the invention. As shown, the base plate 152 includes mounting recess 153a formed on a surface of the base plate 152. Each of the plurality of supporting members 154 includes a first end 154a and a second end 154b. The first ends 154 of the supporting members 154 includes recesses aligned with the mounting recess 153a of the base plate 152 and configured to receive fastening means. The fastening means include, but not limited to, fasteners, screw, rivets, nut and/or bolt arrangement etc. Alternately, the supporting members 154 can be welded or affixed with the base plate 152. Further, the second ends 154b includes mounting recess 155a. The mounting recess 155a are configured to attach or mount the forming plate 156 through fastening means which include, but not limited to, fasteners, screw, rivets, nut and/or bolt arrangement etc. The fastening means may be undone to remove and/or change or replace the forming plate as per requirement.
[019] Figures 7a and 7b show the lower die 110 of the die assembly 100 in accordance with an embodiment of the invention. The die region 111 is configured with a desired shape/configuration as required to form the lower portion of the body of the article being formed. As shown in figures 7a and 7b, an opening 115 is provided which is configured to receive the lower die member 120 (shown in Figure 1) to form an additional die region 113. Further, the opening has plurality of ribs 112. As shown, at-least one rib is provided horizontally and at-least one rib is provided vertically. Each rib has mounting holes for allowing the forming plate 126 of the lower die member 120 to be mounted thereon. The ribs allow the support members to pass through and support the forming plate 126. Accordingly, the forming plate 126 is supported by the supporting members 124 and the ribs 112.
[020] Figure 8a illustrates a perspective view of the lower die member 120 of the die assembly, in accordance with an embodiment of the invention. As shown in Figure 8a, the lower die member 120 includes a base plate 122, plurality of supporting members 124 and a forming plate 126. The forming plate 126 of the lower die member 120 is detachably mounted on the plurality of supporting members 124. The plurality of supporting members 124 are further attached to the base plate 122. The forming plate 126 is configured with a desired shape/configuration as required to form the variable portion of the lower body of the article being formed.
[021] As shown in Figure 8b, the lower die member 120 includes another forming plate 226 having a different shape/ configuration from the forming plate 126 (shown in Figure 8a). The forming plate 226 is detachably mounted on the plurality of supporting members 124. Accordingly, depending upon requirement the forming plate can be attached to the supporting members.
[022] Figure 9 illustrates an exploded view of the lower die member 120, in accordance with an embodiment of the invention. As shown, the base plate 122 includes mounting recess 123a formed on a surface of the base plate 122. Each of the plurality of supporting members 124 includes a first end 124a and a second end 124b. The first ends 124a includes recesses aligned with the mounting recess 123a of the base plate 122 and configured to receive fastening means. The fastening means include, but not limited to, fasteners, screw, rivets, nut and/or bolt arrangement etc. Alternately, the supporting members 124 can be welded or affixed with the base plate 122. Further, the second ends 124b of the supporting members 124 includes mounting recess 125a. The mounting recess 125a are configured to attach or mount the forming plate 126 through fastening means which include, but not limited to, fasteners, screw, rivets, nut and/or bolt arrangement etc. The fastening means may be undone to remove and/or change or replace the forming plate 126 as per the requirement.
[023] Figure 10 illustrates a front cross-sectional view of the upper die 140 in accordance with an embodiment of the present invention. As shown, the upper die member 150 is adapted to the upper die 140, wherein the die region of the upper die 140 and the additional die region of the upper die member 150 form a total die region which corresponds with the shape/configuration as required to form the upper portion of the body of the article being formed. Similarly, as illustrated in figure 11, the lower die member 120 is adapted to the lower die 110, wherein the die region of the lower die 110 and the additional die region of the lower die member 120 form a total die region which corresponds with the shape/configuration as required to form the lower portion of the body of the article being formed. Accordingly, the upper die member 150 and the lower die member 120 when received by the upper die 140 and the lower die 110 forms additional die regions, which are in addition/combination with the die regions formed by the lower die 110 and the upper die 140. The additional die regions thus vary at-least portion of the article as per requirement of the articles. Basis the requirements of the article, different upper and lower die members of different shape and/or configuration may be disposed inside the die regions of the upper die 140 and the lower die 110 of the die assembly 100 to form different variations, modifications and/or variable portions of the same article.
[024] In operation, the die assembly 100 is opened and the blank is received and/or held by the blank holder 130. The blank is located by the blank gauges 134 on the blank holder 130. The upper die is assembled with at-least one upper die member and the lower die is assembled with at-least one lower die member as per requirement. In this regard, as discussed hereienbefore, depending upon modification/customization required in the article, the upper die member and the lower die member are received by the upper die and the lower die. The upper die 140 is configured to move downward by a movement of the upper press bolster plate and contact an upper portion of the blank with a predetermined pressure being applied by the upper press bolster plate. Thereafter, the upper die 140 along with the blank holder 130 is moved downward to contact the lower die 110. A bottom portion of the blank contact with the lower die 110. Since, the lower die 110 is held stationary by the lower press bolster, the blank or a predetermined portion of the blank is operably pressed from both sides by the upper die 140 and the lower die 110 to form the article. In a non-limiting example, the upper die 140 being configured to receive shearing means to shear the article from the blank. The upper portion of the blank is imparted with a predetermined shape/ profile by the upper die 140 and the lower portion of the blank is imparted with a predetermined shape/ profile by the lower die 110. After forming and shearing the article, the upper die 140 is retracted by the upper press bolster to move upwardly and the formed article placed on the blank holder 130 is ejected by the pneumatic cylinders 136.
[025] Figure 12 illustrates a dash panel as per an exemplary embodiment of the invention. As shown, the dash panel has a main body with a first part P1 or a second part P2. The first part P1 or the second part P2 are integrally formed with the main body by the die assembly of the present invention. In this regard, to form the main body with first part P1, the die assembly will have an upper die and a lower die with a die region corresponding to the main body, and an upper die member and a lower die member with additional die region corresponding with the first part P1. Similarly, to form the main body with second part P2, the die assembly will have the same upper die and the lower die, and an upper die member and a lower die member with additional die region corresponding with the second part P2. Accordingly, the forming plates 156, 126 of the upper die member 150 and the lower die member 120 (shown in Figure 1) are configured to vary the additional die region of the die assembly 100 to form the first part P1. Similarly, for the second part P2, the forming plates of the die assembly 100 forming the first part P1 are removed and replaced with the forming plates having the profile adapted for P2.
[026] Advantageously, the present invention provides a die assembly for forming articles. The die assembly includes an upper die member and the lower die member which are detachably received in openings of the upper die and the lower die respectively, to form additional die regions configured to vary the body of the article as per requirement. The upper and lower members enable the die assembly to produce different variable portions using the same die assembly and thus eliminates the need of separate die assembly required for each variable portion which results in saving the manufacturing costs, time and reducing the manufacturing complexities. The die assembly enhances the scope of article customization. Further, the configuration of the die assembly is simple in construction and operation.
[027] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
, Claims:We Claim:
1. A die assembly (100) for forming articles, the die assembly comprising:
a lower die (110) having a die region (111) with at least one opening (115);
an upper die (140) disposed above the lower die (110), the upper die (140) having a die region (141) with at least one opening (145); each of the die (110, 140) corresponds with a body of the article being formed;
a blank holder (130) configured to operably hold a blank between the upper die (140) and the lower die (110);
at least one upper die member (150) having an additional die region (143), the upper die member (150) configured to be detachably received inside the opening (145) of the upper die (140); and
at least one lower die member (120) having an additional die region (113), the lower die member (120) configured to be detachably received inside the opening (115) of the lower die (110), the upper die member (150) and the lower die member (120) when received in the openings (145, 115) of the upper die (140) and the lower die (110) form a total die region comprising the die regions (111, 141) and the additional die regions (143,113), the total die region corresponds with the shape/configuration as required to impart to the blank to form the article, with the additional die regions (143,113) configured to vary a portion of the article as per requirement.

2. The die assembly (100) as claimed in claim 1, wherein the lower die member (120) comprises a base plate (122); a plurality of supporting members (124); and a forming plate (126), the forming plate (126) is configured to impart a predefined shape to the article.

3. The die assembly (100) as claimed in claim 2, wherein the plurality of supporting members (124) extends from the base plate (122) in an upward direction and towards the upper die member (150), each of the plurality of supporting members (124) comprises a first end (124a) and a second end (124b).

4. The die assembly (100) as claimed in claim 3, wherein the first ends (124a) of the plurality of supporting members (124) being attached to the base plate (122) of the lower die member (120).

5. The die assembly (100) as claimed in claim 3, wherein the second ends (124b) of the plurality of supporting members (114) being adapted to be attached to the forming plate (126).

6. The die assembly (100) as claimed in claim 1, wherein the upper die member (150) comprises a base plate (152); a plurality of supporting members (154); and a forming plate (156), the forming plate (156) is configured to impart a predefined shape to the article.

7. The die assembly (100) as claimed in claim 6, wherein the plurality of supporting members (154) extends from the base plate (152) in a downward direction and towards the lower die member (120), each of the plurality of supporting members (154) comprises a first end (154a) and a second end (154b).

8. The die assembly as claimed in claim 7, wherein the first ends (154a) of the plurality of supporting members (154) being attached to the base plate (152) of the upper die member (150).

9. The die assembly (100) as claimed in claim 7, wherein the second ends (154b) of the plurality of supporting members (154) being adapted to be attached to the forming plate (156).

10. The die assembly (100) as claimed in claim 3 or claim 7, wherein each of the second ends (124b, 154b) of plurality of supporting members (124, 154) comprises a mounting recess (125a, 155a), the mounting recess (125a, 155a) is configured to receive fastening means (125b, 155b) for attaching the forming plates (126, 156).

Dated this 9th day of June 2023

MAHINDRA & MAHINDRA LIMITED
By their Agent & Attorney

(Janaksinh Jhala)
of Khaitan & Co
Reg No IN/PA-2193