Calculation method for panel springback warp and optimization method for panel springback warp

Abstract

The application provides a panel spring-back warping calculation method, which provides a first panel spring-back warping formula, which can calculate the spring-back warping of a panel with different radii of curvature. The application also provides a panel spring-back warping optimization method, which comprises the following steps: obtaining a radius of curvature of a panel to be manufactured, wherein the radius of curvature is the radius of curvature corresponding to the maximum radial length of the panel to be manufactured; calculating the spring-back warping of the panel to be manufactured with the radius of curvature according to the first panel spring-back warping formula; and determining an eligible radius of curvature. The application can optimize the spring-back warping of the panel and reduce the waste rate.

Description

Technical Field

[0001] This application relates to the field of panel processing, and in particular to a method for calculating panel springback warp and an optimization method for panel springback warp. Background Technology

[0002] Panel components, used in vehicles, furniture, and other products, are typically manufactured using molds according to design requirements. During the forming process, panels are prone to springback and warping, leading to changes in the shape of the finished part, such as inaccurate shape accuracy or distortion. Such parts often cause significant difficulties in subsequent assembly and welding processes. Therefore, in industrial applications, parts with severe springback and warping are often discarded as scrap.

[0003] To reduce scrap rates, current methods primarily focus on mold design, employing springback compensation to optimize panel springback warpage. However, these methods have limited effectiveness in optimizing panel springback warpage, especially for panels with a certain curvature, and they also increase costs associated with mold processing. Summary of the Invention

[0004] This application provides a method for calculating the springback warp of a panel. The springback warp of the panel can be estimated based on the curvature radius of the panel, thereby facilitating the selection of the curvature radius of the panel to optimize the springback warp of the panel, while also avoiding the generation of other costs.

[0005] The specific technical solutions provided in this application are as follows:

[0006] A method for calculating panel springback warp, using the following first panel springback warp formula:

[0007] Warp = -0.0006L 2 +0.000001R 2 -0.0002L·R-0.196L+0.125R-100

[0008] Where Warp is the springback warp of the panel, L is the maximum radial length of the panel, and R is the radius of curvature corresponding to the maximum radial length of the panel.

[0009] To address the same technical problem, this application also provides an optimization method for panel springback warping, comprising the following steps:

[0010] Obtain the radius of curvature of the panel to be manufactured, wherein the radius of curvature is the radius of curvature corresponding to the maximum radial length of the panel to be manufactured;

[0011] The springback warpage of the panel is calculated based on the first panel springback warpage formula when the panel to be manufactured is made using the above-mentioned radius of curvature.

[0012] Determine the acceptable radius of curvature.

[0013] Preferably, the step of determining the acceptable radius of curvature includes:

[0014] Calculate the difference between the rebound warp of the panel and the preset maximum rebound warp;

[0015] When the difference is less than the threshold, the radius of curvature is determined to be a qualified radius of curvature.

[0016] Preferably, the step of determining the acceptable radius of curvature includes:

[0017] Calculate the difference between the rebound warp of the panel and the preset maximum rebound warp;

[0018] When the difference is less than the threshold, simulation software is used to simulate the panel to be manufactured.

[0019] When the difference between the simulated springback warp of the panel and the preset maximum springback warp is less than the threshold, the radius of curvature is determined to be a qualified radius of curvature.

[0020] Preferably, after the qualified radius of curvature is determined, the following steps are also included:

[0021] Get the maximum radial diameter of the panel to be manufactured;

[0022] Obtain the material parameters of the panel material, wherein the material parameters include the elastic modulus and yield strength of the panel material;

[0023] The springback warpage of the panel when the panel to be manufactured is calculated using the aforementioned panel material according to the second panel springback warpage formula, wherein the second panel springback warpage formula is as follows:

[0024]

[0025] Where Warp is the springback warp of the panel; E is the elastic modulus of the panel material; σ b L represents the yield strength of the panel material; L represents the maximum radial diameter of the panel.

[0026] Identify suitable panel materials.

[0027] Preferably, the step of determining the qualified panel material includes:

[0028] Calculate the difference between the rebound warp of the panel and the preset maximum rebound warp;

[0029] When the difference is less than the threshold, the panel material is determined to be a qualified panel material.

[0030] Preferably, the step of determining the qualified panel material includes:

[0031] Calculate the difference between the rebound warp of the panel and the preset maximum rebound warp;

[0032] When the difference is less than the threshold, simulation software is used to simulate the springback warp of the panel corresponding to the panel material.

[0033] When the difference between the simulated rebound warp of the panel and the preset maximum rebound warp is still less than the threshold, the panel material is determined to be a qualified panel material.

[0034] Preferably, the simulation software is one of PAM-STAMP and Autoform.

[0035] Preferably, when the panel is used on a vehicle body, the threshold is 1 mm.

[0036] Preferably, when the panel is used in home appliances, the threshold is 2 mm.

[0037] In this embodiment, the aforementioned first panel springback warp formula can predict the springback warp of each panel with different radii of curvature before panel processing. This eliminates radii of curvature that do not meet requirements, i.e., the springback warp of the formed panel exceeds the range, leading to the scrapping of the panel parts. This facilitates the selection of a suitable radius of curvature before panel processing. Furthermore, since the aforementioned first panel springback warp formula is an empirical formula fitted based on experimental data of panels with different radii of curvature, it has a certain degree of universality in the panel processing field, is easy to operate, and incurs no additional costs.

[0038] The panel springback warp calculation method provided in this embodiment can predict the springback warp of each panel under different curvature radii by using the first panel springback warp formula, thereby optimizing the panel springback warp from the curvature radius level to reduce the scrap rate of the panel during processing. Attached Figure Description

[0039] Figure 1 This is a flowchart of the optimized method for panel springback warping in Embodiment 1 of this application;

[0040] Figure 2 This is a flowchart of the optimization method for panel springback warping in Embodiment 4 of this application. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not limit the scope of protection of this invention.

[0042] Example 1:

[0043] This embodiment provides a method for calculating panel springback warp, using the following first panel springback warp formula:

[0044] Warp = -0.0006L 2 +0.000001R 2 -0.0002L·R-0.196L+0.125R-100

[0045] Wherein, Warp is the springback warp of the panel, L is the maximum radial length of the panel, and R is the radius of curvature corresponding to the maximum radial length of the panel; where, according to actual processing data, the panel is prone to large springback warp at the maximum radial diameter, therefore, in this embodiment, the first panel springback warp formula is derived based on the maximum radial diameter.

[0046] To adapt to different vehicle bodies or boxes, or to improve aesthetics, some panels need to be processed into a certain curvature, that is, to have a certain radius of curvature. The springback warp formula of the first panel can be used to predict the springback warp of the panel to be manufactured when it has a certain radius of curvature.

[0047] The aforementioned first panel springback warp formula can predict the springback warp of panels with different radii of curvature before processing, thus eliminating radii of curvature that do not meet requirements (i.e., the springback warp of the formed panel exceeds the range, leading to the scrapping of the panel part). This facilitates the selection of a suitable radius of curvature before panel processing. Furthermore, since the aforementioned first panel springback warp formula is an empirical formula fitted based on experimental data of panels with different radii of curvature, it has a certain degree of universality and is easy to operate in the field of panel processing.

[0048] The panel springback warp calculation method provided in this embodiment can predict the springback warp of each panel under different curvature radii by using the first panel springback warp formula, thereby optimizing the panel springback warp from the curvature radius level to reduce the scrap rate of the panel during processing.

[0049] Example 2:

[0050] This embodiment provides an optimization method for panel springback warp, such as... Figure 1 As shown, the specific steps include:

[0051] Step S1: Obtain the radius of curvature of the panel to be manufactured, wherein the radius of curvature is the radius of curvature corresponding to the maximum radial length of the panel to be manufactured;

[0052] In this embodiment, the shape of the panel to be manufactured is similar to that of the panel to be manufactured in Embodiment 2. Therefore, the radius of curvature corresponding to its maximum radial length also refers to the diagonal radius of curvature of the panel.

[0053] Step S2: Calculate the springback warp of the panel when the panel to be manufactured is made using the above-mentioned radius of curvature according to the first panel springback warp formula;

[0054] Step S3: Determine the acceptable radius of curvature;

[0055] In this embodiment, the acceptable radius of curvature can be determined by comparing a threshold. Of course, other methods can be used in other embodiments. Specifically, the difference between the panel's springback warp and a preset maximum springback warp can be calculated first. Then, this difference is compared with a threshold. When the difference is less than the threshold, the radius of curvature is considered acceptable. The preset maximum springback warp can be the maximum springback warp after panel processing, defined by experience or relevant standards, second only to the maximum warp at which a defective panel is produced. The threshold can be specifically defined according to industry standards as follows: when the panel is used in a vehicle body, the threshold is 1 mm; when the panel is used in a home appliance, the threshold is 2 mm.

[0056] Example 3:

[0057] The difference between this embodiment and Embodiment 2 lies in the step of determining the qualified radius of curvature. Specifically, in this embodiment, when determining the qualified radius of curvature, the difference between the panel's springback warp and the preset maximum springback warp is first calculated. Then, this difference is compared with a threshold. When the difference is less than the threshold, the radius of curvature is initially determined to meet the requirements. However, the radius of curvature still needs further verification. Therefore, simulation software is then used to simulate the springback warp of the panel corresponding to the radius of curvature. Specifically, existing simulation software, such as PAM-STAMP or Autoform, is used to simulate the springback warp of the panel after it has been manufactured at the radius of curvature. When the difference between the simulated panel's springback warp and the preset maximum springback warp is still less than the threshold, the radius of curvature can be determined to be a qualified radius of curvature.

[0058] In this embodiment, the two-step operation of formula combined with simulation in determining the qualified radius of curvature can further ensure that the selected qualified radius of curvature meets the requirements, so as to further reduce the scrap rate in the subsequent actual processing and thus achieve the optimization purpose.

[0059] Example 4:

[0060] The difference between this embodiment and Embodiment 2 is that, in this embodiment, after determining the qualified radius of curvature, the following steps are added, see... Figure 2 :

[0061] Step S4: Obtain the maximum radial diameter of the panel to be manufactured;

[0062] In this embodiment, the panel to be manufactured is a part used as a car door, and its shape is approximately rectangular. Its maximum radial diameter can be considered as the diagonal length of the rectangular panel. Of course, in other embodiments, considering the shape of the panel to be manufactured, the maximum radial diameter can be a non-diagonal length.

[0063] Step S5: Obtain the material parameters of the panel material, wherein the material parameters include the elastic modulus and yield strength of the panel material;

[0064] The elastic modulus and yield strength of the panel material are variables in the second panel springback warp formula, and they are directly related to the panel material. Therefore, in order to facilitate subsequent steps, the relevant material parameters of the panel material can be directly obtained from existing data in this step.

[0065] Step S6: Calculate the springback warp of the panel when the panel to be manufactured is made using the above-mentioned panel material, according to the second panel springback warp formula, wherein the second panel springback warp formula is as follows:

[0066]

[0067] Where Warp is the springback warp of the panel; E is the elastic modulus of the panel material; σ b L represents the yield strength of the panel material; L represents the maximum radial diameter of the panel.

[0068] In this step, you only need to input the elastic modulus, yield strength and maximum radial diameter of the panel material into the calculation of the springback warp of the first panel.

[0069] Step S7: Determine the qualified panel material;

[0070] In this embodiment, this step can determine qualified panel materials by performing a threshold comparison. Of course, other methods can be used in other embodiments. Specifically, the difference between the panel's springback warp and the preset maximum springback warp can be calculated first, and then the difference can be compared with a threshold. When the difference is less than the threshold, the panel material can be determined to be a qualified panel material.

[0071] Example 5:

[0072] The difference between this embodiment and Embodiment 4 lies in the step of determining qualified panel materials. Specifically, in this embodiment, when determining qualified panel materials, the difference between the panel's springback warp and the preset maximum springback warp is first calculated. Then, this difference is compared with a threshold. When the difference is less than the threshold, the panel material is initially determined to meet the requirements. However, the panel material still needs further verification. Therefore, simulation software is then used to simulate the springback warp of the panel corresponding to the panel material. Specifically, existing simulation software, such as PAM-STAMP or Autoform, is used to simulate the springback warp of the panel after the panel to be manufactured is produced using the panel material. When the difference between the simulated panel's springback warp and the preset maximum springback warp is still less than the threshold, the panel material can be determined to be a qualified panel material.

[0073] In this embodiment, the two-step process of formula and simulation in determining qualified panel materials can further ensure that the selected panel materials meet the requirements, thereby further reducing the scrap rate in the subsequent actual processing and achieving the optimization goal.

[0074] It is understood that in the above embodiments, when the difference is greater than or equal to the threshold during the threshold comparison process, it indicates that the panel material or radius of curvature does not meet the requirements. Thus, the above steps can be repeated by changing the corresponding value until a qualified panel material or a qualified radius of curvature is selected.

[0075] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A method for calculating springback warp of a panel, characterized in that, a first panel springback warp formula is used to calculate: Warp1 = -0.0006L 2 +0.000001R 2 -0.0002L.R - 0.196L + 0.125R - 100 wherein Warp1 is the springback warp of the panel, L is the maximum radial length of the panel, and R is the radius of curvature corresponding to the maximum radial length of the panel.

2. A method for optimizing springback warpage of a panel, said method employing the calculation method of claim 1, characterized in that, The optimization method comprises the following steps: obtaining a radius of curvature of a panel to be manufactured, wherein the radius of curvature is the radius of curvature corresponding to the maximum radial length of the panel to be manufactured; calculating the springback warp of the panel to be manufactured using the first panel springback warp formula with the above-mentioned radius of curvature; determining an eligible radius of curvature. 3.The optimization method for calculating springback warp of a panel according to claim 2, characterized in that, the step of determining the eligible radius of curvature comprises: calculating the difference between the springback warp of the panel and a preset maximum springback warp; when the difference is less than a threshold value, determining that the radius of curvature is an eligible radius of curvature. 4.The optimization method for calculating springback warp of a panel according to claim 2, characterized in that, the step of determining the eligible radius of curvature comprises: calculating the difference between the springback warp of the panel and a preset maximum springback warp; when the difference is less than a threshold value, simulating the panel to be manufactured using simulation software; when the difference between the springback warp of the simulated panel and the preset maximum springback warp is less than the threshold value, determining that the radius of curvature is an eligible radius of curvature. 5.The optimization method for calculating springback warp of a panel according to any one of claims 2-4, characterized in that, after the eligible radius of curvature is determined, the method further comprises the following steps: obtaining the maximum radial diameter of the panel to be manufactured; obtaining material parameters of the panel material, wherein the material parameters include the elastic modulus and yield strength of the panel material; calculating the springback warp of the panel to be manufactured using the panel material according to a second panel springback warp formula, wherein the second panel springback warp formula is as follows: wherein Warp2 is the springback warp of the panel; E is the modulus of elasticity of the panel material; σ b is the yield strength of the panel material; and L is the maximum radial diameter of the panel. determining an eligible panel material. 6.The optimization method for calculating springback warp of a panel according to claim 5, characterized in that, the step of determining the eligible panel material comprises: calculating the difference between the springback warp of the panel and a preset maximum springback warp; when the difference is less than a threshold value, determining that the panel material is an eligible panel material. 7.The optimization method for calculating springback warp of a panel according to claim 5, characterized in that, the step of determining the eligible panel material comprises: calculating the difference between the springback warp of the panel and a preset maximum springback warp; when the difference is less than a threshold value, simulating the springback warp of the panel corresponding to the panel material using simulation software; when the difference between the springback warp of the simulated panel and the preset maximum springback warp is still less than the threshold value, determining that the panel material is an eligible panel material. 8.The optimization method for calculating springback warp of a panel according to claim 4 or 7, characterized in that, the simulation software is one of PAM-STAMP and Autoform. 9.The optimization method for calculating springback warp of a panel according to any one of claims 3-4, 6-7, characterized in that, when the panel is used for a vehicle body, the threshold value is 1mm.

10. A method of optimizing springback warp of a panel according to any one of claims 3-4, 6-7, characterized in that, when the panel is used for a home appliance, the threshold value is 2 mm.

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