Press-Formed Corner Flange Shaping to Prevent Buckling
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Solution Overview
Problem
Existing press forming methods for high tensile strength steel materials face challenges in achieving high dimensional accuracy and are prone to buckling at the connection portion of the corner flange due to the complexity of the die structure and the generation of wrinkles and folds.
Innovation Solution
A manufacturing method that includes an intermediate forming step with a step-shaped portion bulging outward at the root of the outward flange, allowing the outward flange to be formed by bending and raising, thereby preventing buckling by winding around the die in the initial stage of press forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complicated die structure is used to prevent buckling, then manufacturing reliability improves, but device complexity increases
Solution Approach 1:
The patent applies preliminary action by forming a step-shaped portion at the root of the outward flange before the main press forming operation. This preliminary geometric modification prevents buckling during subsequent forming without requiring a complicated die structure, thereby resolving the contradiction between manufacturing reliability and device complexity
Solution Approach 2:
The patent changes the geometric parameters of the workpiece by introducing a step-shaped portion with specific dimensions (height h1 and width w1). This parameter change modifies the stress distribution and prevents buckling during press forming, achieving reliable manufacturing without complex die structures
2Strength
If high tensile strength steel material is used, then strength improves, but manufacturing precision deteriorates due to buckling
Solution Approach 1:
By preliminarily forming the step-shaped portion, the patent prevents buckling of high tensile strength steel materials during press forming. This preliminary geometric modification ensures that the high strength material maintains its dimensional accuracy without developing wrinkles or folds, thus resolving the contradiction between strength and manufacturing precision
3Productivity
If outward flange portion is formed continuously, then productivity improves, but manufacturing precision deteriorates due to fracture risk
Solution Approach 1:
The step-shaped portion is formed as a preliminary structure before the outward flange portion is fully formed. This preliminary action creates a geometric feature that guides the deformation process, preventing fracture at the tip of the corner flange while maintaining continuous forming operations, thus resolving the contradiction between productivity and manufacturing precision
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
Stable production of press formed parts with high dimensional accuracy is achieved without using a complicated die structure, effectively preventing buckling at the connection portion of the corner flange.
Implementation Method 1
a top plate portion 5, vertical wall portions 7, and ridge portions 9 that connect the top plate portion 5 and the vertical wall portions 7
Implementation Method 2
forming the outward flange portion by bending and raising the outward flange corresponding portion of the intermediate formed part outward
Data Source
AI summary
A manufacturing method of a press formed part, the press formed part including at least a main body portion, which has a top plate portion and vertical wall portions formed via ridge portions, and an outward flange portion formed continuously with the top plate portion, the ridge portions, and the vertical wall portions at an end portion of the main body portion, the method includes: an intermediate forming step of forming an intermediate formed part having the top plate portion and the vertical wall portions formed via the ridge portions, and including a step-shaped portion bulging outward at a root portion of an outward flange corresponding portion which is to be formed into the outward flange portion; and a target shape forming step of forming the outward flange portion by bending and raising the outward flange corresponding portion of the intermediate formed part outward, and acquiring a target shape.