Aluminum Sheet Local Cooling for Deep Drawing
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Solution Overview
Problem
Existing methods for forming aluminum sheets are limited in achieving high degrees of deformation due to uniform cooling, which leads to stress-related failures and restricted forming capabilities, making them inefficient and unreliable.
Innovation Solution
Pre-cooling specific critical areas of the aluminum sheet while keeping other areas uncooled, allowing material flow and reducing stress, thereby increasing forming capacity and process reliability, and using a partially cooled forming tool to maintain low temperatures and prevent failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the aluminum sheet is cooled over its entire surface before forming, then the tensile strength and elongation at break are increased, but the degree of forming is limited due to stress distribution issues
Solution Approach 1:
The patent applies local quality by cooling only specific critical areas of the aluminum sheet (such as areas prone to failure or high stress zones) rather than the entire surface. This localized cooling approach increases tensile strength and elongation at break in critical regions while allowing other areas to remain at higher temperatures, enabling better material flow and achieving higher degrees of forming without the stress distribution problems associated with uniform cooling.
2Strength
If the aluminum sheet is deep-cooled over its entire surface, then strength values are increased, but the degree of forming remains comparatively low due to different stresses in the forming tool
Solution Approach 1:
The invention implements local quality by selectively cooling only the failure-critical sheet areas that require enhanced strength properties, while leaving other areas uncooled or less cooled. This approach allows the material to achieve necessary strength values in critical zones while maintaining better formability and material flow in non-critical areas, thereby increasing the overall degree of forming achievable in the process.
Solution Approach 2:
The patent applies partial action by cooling only the necessary portions of the aluminum sheet (the failure-critical areas) rather than the entire surface. This partial cooling strategy achieves the required strength enhancement where needed while avoiding the negative effects of over-cooling other areas, thus enabling higher degrees of forming without compromising strength requirements.
3Reliability
If the entire aluminum sheet is pre-cooled, then formability is improved, but the process effort and cost increase significantly
Solution Approach 1:
The patent reduces process effort and cost by applying local quality - cooling only the specific failure-critical areas of the aluminum sheet rather than the entire surface. This localized cooling approach maintains the formability improvements necessary for successful forming while significantly reducing the energy consumption, equipment complexity, and process time associated with cooling the whole sheet, making the process more economical and efficient.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables higher degrees of deformation with increased tensile strength and elongation at break, ensuring process reliability and dimensional accuracy, particularly suitable for deep-drawing processes, and can be applied cost-effectively with simple handling and tool design.
Implementation Method 1
at least one pre-cooled, failure-critical sheet area of the aluminum sheet being formed with at least one cooled tool area at such a low temperature that a failure-free change in shape of the aluminum sheet is possible
Implementation Method 2
the aluminum sheet, in particular undeformed, is pre-cooled at least in regions before it is shaped, in particular deep-drawn, using a shaping tool
Data Source
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AI summary
Producing a molded part made of aluminum sheet (2) containing aluminum alloy, comprises: at least partially pre-cooling, preferably deep drawing an un-molded aluminum sheet, prior to its molding carried out with a molding tool; and introducing the pre-cooled aluminum sheet into a molding tool that is cooled at least in areas, for molding, where at least one pre-cooled- and critically failed sheet metal area (6) of the aluminum plate with at least one cooled mold area, is molded at low temperature, such that a failure-free molding on the aluminum plate is carried out. An independent claim is also included for a body side wall, preferably for a motor vehicle, comprising a door frame area (14) that is critical failed during the deep-drawing, made of the aluminum sheet having 6xxx aluminum alloy, by the above method.