Curved Polygonal Structural Component Press Forming
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Solution Overview
Problem
Conventional methods for producing polygonal closed cross-section structural components with a curved form along their longitudinal direction, such as hydroforming and roll forming, face challenges including slow production rates, high equipment costs, and difficulties in weight reduction due to the need for welding flange portions, while press forming methods struggle with end face buttting and limited weight reduction.
Innovation Solution
A method involving press forming a metal sheet into a gutter-shaped pre-processed part with specific curvature and ridge lines, where the pre-processed part is deformed inward to butt flange portions, reducing the length of ridge lines and preventing wrinkles, allowing for cost-effective production of polygonal closed cross-section components with reduced weight by minimizing flange portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hydroforming or roll forming is used to produce closed cross-section structural components with curved form, then the component can be produced with curved form, but the production rate is slow and equipment cost is high
Solution Approach 1:
The method performs preliminary actions by first forming the metal sheet into a developed shape with predetermined ridge lines and flange portions, then subsequently forming it into the final curved closed cross-section shape. This two-stage approach allows the use of simpler, more productive press forming equipment while achieving the desired curved form, thereby resolving the contradiction between shape capability and production rate.
2Shape
If hydroforming or roll forming is used to produce closed cross-section structural components with curved form, then the component can be produced with curved form, but the equipment cost is high
Solution Approach 1:
The invention divides the forming process into two stages: first creating a developed shape with ridge lines and flange portions using simple press forming equipment, then forming the final curved shape. This preliminary action allows the use of cost-effective press forming equipment instead of expensive hydroforming or roll forming equipment, while still achieving the desired curved closed cross-section shape.
3Ease of manufacture
If press forming is used to produce closed cross-section components, then production cost is reduced, but it is difficult to perform butting of end faces in components with curved form
Solution Approach 1:
The method performs preliminary action by first forming the metal sheet into a developed shape where ridge lines and flange portions are clearly defined. This preliminary configuration enables precise butting of end faces during subsequent forming, as the ridge lines serve as natural alignment features. This resolves the contradiction by maintaining low production cost through press forming while achieving precise end face butting through the pre-established ridge line geometry.
4Ease of manufacture
If conventional press forming is used to produce closed cross-section components with curved form, then production cost is reduced, but weight reduction is limited due to requirement of welding flange portions
Solution Approach 1:
The invention extracts and eliminates the flange portions from the final component structure. By forming the metal sheet into a developed shape where flange portions are created temporarily for the forming process, and then deforming these flange portions inward to butt the ridge lines, the method removes the need for separate flange welding. This extraction of unnecessary flange portions achieves weight reduction while maintaining the cost advantages of press forming.
5Ease of manufacture
If the radius of curvature of ridge lines in pre-processed part is made equal to component ridge lines, then forming is simplified, but surplus material causes wrinkles in the component
Solution Approach 1:
The method applies preliminary anti-action by intentionally designing the radius of curvature of ridge lines in the pre-processed developed shape to be smaller than that of the final component ridge lines. This preliminary design choice prevents surplus material accumulation during forming, thereby preventing wrinkle formation. The smaller initial radius compensates for material redistribution during the forming process, ensuring smooth surface quality while maintaining forming simplicity.
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 enables the production of lightweight polygonal closed cross-section components with a curved form through press forming, reducing production costs and preventing wrinkles by minimizing flange portions and ensuring accurate deformation, thus overcoming the limitations of existing methods.
Implementation Method 1
the pre-processed part is then press-formed to deform inwardly in the cross-sectional direction at a position of one or more of the plural ridge lines to butt the ridge lines located at the innermost side and the flange portions to each other
Data Source
AI summary
A method of producing a polygonal closed cross-section structural component includes press-forming a metal sheet into a gutter-shaped pre-processed part with a curved form along its longitudinal direction having plural ridge lines corresponding to corner portions of the polygonal closed cross-section in a cross-sectional form developed by cutting the component at a position corresponding to the ridge line located at the innermost side in the radial direction to provide a flange portion extending along the ridge line at the resulting respective ends, and press-forming the pre-processed part to deform inwardly in the cross-sectional direction at a position of one or more of the plural ridge lines to butt the ridge lines located at the innermost side and the flange portions to each other.