Vehicle Body Frame Convex Web Structure Against Springback
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Solution Overview
Problem
Conventional methods for manufacturing vehicle body frame members with curved flange surfaces face challenges in achieving the target shape due to springback, which increases manufacturing time and cost.
Innovation Solution
A body frame member with a substantially U-shaped cross-section, featuring a kick-up portion and a convex portion integrally formed along the web from the upper end to the lower end, is manufactured using a method where one molding die has a raised portion and the other has a recessed portion to form the convex portion during press molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If press molding is used to form curved flange surfaces, then the body frame member can be manufactured with the required shape, but springback occurs causing deformation from the target shape
Solution Approach 1:
The patent applies preliminary anti-action by designing the molding die with a compensatory error that opposes the springback deformation. The die is intentionally designed with an inverted error amount equal to the expected springback, so that after springback occurs, the final shape matches the target shape. This resolves the contradiction by pre-compensating for the deformation issue.
Solution Approach 2:
The patent implements preliminary action by calculating and applying the springback compensation to the molding die design before actual production. The compensatory error is determined through finite element analysis or actual measurements of springback behavior, and this compensation is built into the die design beforehand, eliminating the need for post-processing adjustments.
2Manufacturing precision
If the molding die is designed with compensatory error to counteract springback, then shape accuracy can be improved, but the die design becomes more complex and time-consuming
Solution Approach 1:
The patent applies self-service by using the springback behavior itself to achieve the desired result. Instead of trying to prevent springback through complex die design, the invention allows springback to occur naturally and uses finite element analysis to calculate the exact compensatory error needed. This simplifies the die design process while maintaining high shape accuracy.
Solution Approach 2:
The patent changes the parameter of the molding die by introducing a compensatory error value that is calculated based on springback characteristics. This parameter adjustment transforms the die design from a perfect target shape to a compensated shape, which after springback produces the accurate target shape. This resolves the contradiction by using a simple parameter change rather than complex structural modifications.
3Ease of manufacture
If conventional press molding is used without springback compensation, then manufacturing process is simple, but additional processing steps are required to correct deformation
Solution Approach 1:
The patent applies preliminary action by performing springback compensation calculations and applying the compensatory error to the molding die before production begins. This eliminates the need for post-processing steps to correct deformation, as the target shape is achieved directly in the press molding process. The finite element analysis and compensation determination are done once beforehand, making the actual production simple 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
The solution effectively suppresses deformation due to springback, allowing the body frame member to maintain the target shape without additional processing steps, thereby reducing manufacturing time and cost.
Implementation Method 1
after press molding, springback occurs, and the state changes from the state shown in FIG. 5A-4 to the state shown in FIG. 5A-5
Implementation Method 2
a tensile stress is generated in a portion where the flange surface extends during molding, and a compressive stress is generated in a portion where the flange surface contracts
Data Source
AI summary
Provided are a body frame member capable of suppressing deformation due to springback, and a method for manufacturing the same. The body frame member 1 of the present invention is formed in a substantially U shape by a web 2 extending in a front-rear direction of a vehicle body, an upper flange 3 extending inward in a vehicle width direction from an upper end of the web 2 and a lower flange 4 extending inward in the vehicle width direction from a lower end of the web 2, and comprises a kick-up portion 5 bent in the vertical direction of the vehicle body, and a convex portion 21 protruding outward or inward in the vehicle width direction is integrally formed from the upper end to the lower end of the web 2 at a portion of the web 2 where the kick-up portion 5 is provided.