Body Frame Wavy Pre-Strain Molding for Higher Yield Strength
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Solution Overview
Problem
Existing methods for enhancing the bending and compression resistance of body frames, such as upgrading materials or adding reinforcing elements, are costly and disadvantageous for weight reduction.
Innovation Solution
A manufacturing method involving pre-strain press molding of a wavy shape portion in the body frame to increase yield stress without material upgrades or thickness increases, where the pre-strain is applied in a range of plastic strain to enhance the body frame's strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If material is upgraded to a more highly strong material, then strength is improved, but cost increases
Solution Approach 1:
The invention changes the physical state and mechanical properties of the existing material by applying pre-strain through press molding. By controlling the strain parameters (wave height, wave pitch, pressurization force) during the pre-strain step, the yield stress of the material is increased without changing the material composition or grade, thus avoiding cost increase while achieving improved strength
2Strength
If a reinforcing material is added, then strength is improved, but weight increases
Solution Approach 1:
Instead of adding reinforcing materials, the invention changes the mechanical parameters of the base material through pre-strain press molding. The controlled plastic deformation increases the yield stress and strengthens the material in-situ, achieving enhanced strength without any additional weight from reinforcing elements
3Strength
If plate thickness is increased, then strength is improved, but weight increases
Solution Approach 1:
The invention achieves strength improvement by changing the material's mechanical properties through pre-strain rather than increasing geometric dimensions. The press molding process with controlled wave parameters induces plastic strain that increases yield stress, allowing thin plates to achieve the strength of thicker plates without the associated weight penalty
4Strength
If pre-strain is applied through press molding, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The pre-strain press molding step is merged with the existing basic molding process. The same press molding equipment is used, and the pre-strain can be applied either after basic molding or simultaneously with the last press molding operation. This integration avoids adding separate complex equipment or processes while still achieving yield stress enhancement
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 effectively increases the body frame's withstand load without material upgrades or thickness increases, efficiently improving bend and compressive strength while maintaining cost-effectiveness and reducing weight.
Implementation Method 1
a pre-strain step of press molding a wavy shape portion in the body frame to apply pre-strain after any press molding... the pre-strain may be within a range of plastic strain to increase yield stress of a press-molded product
Data Source
AI summary
A manufacturing method of a body frame includes a pre-strain step of press molding a wavy shape portion in the body frame to apply pre-strain after any press molding to mold the body frame.