Automotive Body Panel Tool Assembly with Retention Tabs
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Solution Overview
Problem
Traditional automotive body panel stamping processes face challenges in achieving high precision dimensions and quality, leading to increased costs, safety issues, and poor surface quality due to the need for additional dies, air trimming, and lancing operations.
Innovation Solution
A method and tool assembly for manufacturing body panels that involve drawing a metal sheet, forming cross members with retention tabs, and creating flanges using a dual-die system with upper and lower trim steels and retainer components to improve dimensional accuracy and safety, reducing the need for additional dies and air trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional stamping processes use additional dies, air trimming, and lancing to achieve dimensional capability, then dimensional precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple operations (trimming, flange forming, retention tab formation) into a single integrated die assembly. The upper die integrates trim steels, flange steels, and retainer components that perform multiple functions simultaneously, eliminating the need for separate dies for each operation.
Solution Approach 2:
The upper die assembly serves multiple functions: trimming the cross member, forming flanges on opening edges, creating retention tabs, and providing panel support. This multi-functional design replaces what would traditionally require multiple specialized dies.
2Productivity
If air trimming is used to trim the body panel, then manufacturing efficiency is improved, but body panel quality deteriorates due to deflection and trim steel wear out
Solution Approach 1:
The retainer components hold the retention tabs in position before the flange forming operation occurs. This preliminary positioning prevents panel deflection during trimming and ensures consistent trim quality throughout the process.
Solution Approach 2:
The retainer components act as intermediaries between the upper die and the retention tabs, providing controlled support during the trimming operation. This intermediary support system prevents both excessive panel deflection and trim steel wear.
3Manufacturing precision
If lancing operations are used to achieve dimensional capability, then manufacturing precision is improved, but safety deteriorates due to overhanging scrap interfering with handling
Solution Approach 1:
The trim steels are designed to remove and separate the cross member scrap from the main panel body during the trimming operation. By extracting the scrap material cleanly at the desired location, the process eliminates overhanging scrap that would interfere with subsequent handling operations.
Data Source
AI summary
A method for manufacturing a body panel, the method includes drawing a metal sheet into a body panel, trimming a first and second portion of the body panel to form a first and second opening and a cross member. The cross member extends between the first and second openings. The method further includes trimming a portion of the cross member to form a first and a second retention tab and forming a flange in the edge of the first opening, the edge of the second opening and the first and second retention tabs. The method further includes trimming the first and second retention tabs at the edge of the first and second opening.