Vehicle Bumper Beam Hot Stamping Process
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Solution Overview
Problem
Conventional bumper beam manufacturing methods using roll forming result in non-uniform dents on the curvature radius direction inner cross-section due to heel tap, affecting collision stiffness and requiring additional welding processes.
Innovation Solution
A manufacturing method involving hot stamping of a circular pipe into a bumper beam with at least two closed cross-sections, eliminating the need for welded portions and using high-strength cold-rolled steel plates heated to 900°C for improved structural rigidity and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If roll forming method is used to manufacture bumper beam, then manufacturing process is established, but non-uniform dents are generated on curvature radius direction inner cross-section due to heel tap
Solution Approach 1:
The patent changes the material parameter from room temperature steel to heated steel (heated to austenite transformation temperature or higher), which fundamentally alters the material's formability and eliminates the heel tap denting issue during curvature molding
Solution Approach 2:
The patent performs heating and curvature molding before final cooling and straightening. By performing the curvature molding action while the material is in its high-temperature austenite state, the patent prevents the heel tap denting problem that occurs in conventional room-temperature roll forming
2Device complexity
If welded portions are used in conventional manufacturing, then structural assembly is achieved, but additional welding processes are required increasing complexity
Solution Approach 1:
The patent merges the curvature molding operation with the formation of continuous closed cross-sections. The curved surface itself forms the complete structural component without requiring separate welding operations to join segments, thereby eliminating welding complexity
Solution Approach 2:
The patent extracts and eliminates the welding process from the manufacturing sequence entirely. By forming the complete curved structure with continuous closed cross-sections in a single hot stamping operation, the patent removes the need for welded portions that would otherwise require additional welding processes
3Strength
If material thickness is increased to improve collision stiffness, then structural strength is improved, but weight increases
Solution Approach 1:
The patent changes the material's temperature and phase parameters, heating the steel to austenite transformation temperature or higher. This parameter change enables the formation of high-strength martensite structure upon cooling, achieving high collision stiffness with reduced material thickness and consequently reduced weight
4Device complexity
If hot stamping molding is used to eliminate welded portions, then manufacturing complexity is reduced, but process temperature control is required
Solution Approach 1:
The patent utilizes temperature as a control parameter to achieve phase transformation in the steel material. By heating to austenite transformation temperature and then controlling the cooling rate, the patent achieves both the elimination of welding complexity and the desired high-strength structure, managing temperature as a beneficial process parameter rather than a constraint
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 simplifies the manufacturing process, reduces material thickness by 10%, enhances collision capability, and prevents non-uniform dents by distributing stress, thereby improving the bumper beam's structural integrity and reducing the need for additional welding.
Implementation Method 1
heating the circular pipe to a set temperature in a heating furnace
Implementation Method 2
pressurizing and molding the circular pipe heated in the heating furnace and having flexibility, while inserting the circular pipe between an upper mold and a lower mold
Implementation Method 3
rapidly cooling the molding beam to form the molding beam into a high-strength molding beam
Data Source
AI summary
A manufacturing method for a bumper beam of a vehicle may include pipe making, producing a circular pipe by pipe molding a steel plate having a predetermined thickness between first and second molding rolls, heating the circular pipe to a set temperature in a heating furnace, pressurizing and molding the circular pipe heated in the heating furnace and having flexibility, while inserting the circular pipe between an upper mold and a lower mold to form a molding beam, and thereafter, rapidly cooling the molding beam to form the molding beam into a high-strength molding beam, and curvature-molding the high-strength molding beam at a predetermined curvature through a curvature molding machine.