Composite Cross-Section Member With Local Core Reinforcement
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Solution Overview
Problem
Existing methods for manufacturing composite structural members struggle to achieve both weight reduction and localized strength enhancement, particularly in roll forming, where local changes in cross-sectional shape or thickness are difficult to implement effectively.
Innovation Solution
A method involving the local insertion of a discontinuous light-metal core during roll forming of a continuous metal strip, allowing for the creation of a composite cross-section member with enhanced bending strength in specific areas, while maintaining overall weight reduction, using an existing roll former with additional core insertion equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If roll forming is used to manufacture steel sheet parts, then weight reduction is achieved, but local strength enhancement becomes difficult
Solution Approach 1:
The patent applies composite materials by combining a light-metal core (aluminum or magnesium) with a steel sheet in a composite cross-section member. The steel sheet provides overall structural strength while the light-metal core is strategically placed in specific regions to enhance local bending strength. This composite structure enables both weight reduction through light-metal usage and local strength enhancement where the core is inserted, resolving the contradiction between weight reduction and local strength enhancement in roll-formed parts.
2Strength
If cross-sectional shape or sheet thickness is changed to increase local strength, then local strength is improved, but the entire part must be changed in the longitudinal direction
Solution Approach 1:
The patent applies local quality by inserting the light-metal core only in specific regions where bending strength is required, rather than changing the entire cross-sectional shape or thickness along the longitudinal direction. This localized approach allows strength enhancement at targeted positions while maintaining the original roll forming process for the steel sheet, thereby improving local strength without increasing overall process complexity.
3Strength
If a composite structural member is formed by integrating steel sheet and light-alloy member, then both weight reduction and strength increase are achieved, but manufacturing method is not specifically described
Solution Approach 1:
The patent applies preliminary action by inserting the light-metal core into the steel sheet during the roll forming process at specific stages, rather than attempting to integrate two separately formed components. The core insertion is performed at an arbitrary stage of roll forming, and the steel sheet is then bent to integrate the core. This approach simplifies manufacturing by combining the integration step with the existing roll forming process, making the composite member easier to manufacture while achieving both weight reduction and strength increase.
Data Source
AI summary
In a method for manufacturing a composite cross-section member, a continuous steel sheet is fed to a manufacturing device and bent and roll-formed into a predetermined cross-sectional shape, a discontinuous aluminum core is locally inserted at an arbitrary stage of the roll forming, and the steel sheet is bent such that the core and the steel sheet are integrated, to obtain a composite cross-section member.