Deep-Drawn Component Bottom Calibration Without Base Undulations
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Solution Overview
Problem
Deep-drawn components, especially open profile components like U-shaped or hat-shaped ones, experience dimensional inaccuracies due to elastic rebound after production, leading to surface imperfections and thickness variations in the base region during the calibrating process, especially when using high-tensile steel or aluminum materials with minor sheet-metal thicknesses.
Innovation Solution
The method involves preforming a workpiece to create a component with a material surplus in the transition region between the base and side-plate regions, allowing for calibration without modifying the base region's geometry, thereby minimizing face faults and maintaining a smooth surface by providing the surplus material in the peripheral regions, particularly at the transition areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material surplus is accommodated in the form of undulations in the base region for calibrating, then dimensional accuracy is improved, but surface quality deteriorates due to face faults and residual undulations
Solution Approach 1:
The invention extracts the material surplus from the base region and relocates it to the side-plate region. By positioning the additional material where it is needed for calibration without affecting the base region geometry, the method eliminates face faults and residual undulations in the base while still achieving dimensional accuracy through calibration of the side plates.
Solution Approach 2:
The invention applies local quality by differentiating the treatment of different regions. The base region maintains its original smooth geometry without undulations, while the side-plate region receives the material surplus for calibration purposes. This localized approach ensures that each region receives the appropriate material distribution for its specific functional requirements.
2Manufacturing precision
If calibrating is applied to counteract elastic rebound, then dimensional accuracy is improved, but surface quality deteriorates due to collapsing undulations
Solution Approach 1:
The invention removes the problematic undulations from the base region and places the material surplus in the side-plate region. This extraction eliminates the source of face faults and collapsing undulations while preserving the calibration function needed to counteract elastic rebound and achieve dimensional accuracy.
3Manufacturing precision
If material surplus is provided in the base region for calibration, then dimensional accuracy is improved, but manufacturing complexity increases due to multiple undulation collapse stages
Solution Approach 1:
The invention simplifies the process by extracting the material surplus from the base region and relocating it to the side-plate region. This eliminates the complex multi-stage undulation collapse process in the base region, reducing manufacturing complexity while maintaining the calibration function for achieving dimensional accuracy.
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 approach results in dimensionally true components with reduced or eliminated face faults and surface imperfections, achieving a smooth base region with minimal undulations, thereby improving the surface quality and reducing the need for further trimming.
Implementation Method 1
preforming a workpiece to a preformed component having a base region, a side-plate region
Implementation Method 2
shape changes by virtue of the inevitable elastic rebound arise in most instances after the retrieval of the component from the tool
Implementation Method 3
calibrating step by means of superimposing compressive stress such that an at least in regions finally formed, dimensionally true component is created
Data Source
AI summary
The invention relates to a method for producing a component, said method comprising: preforming a workpiece to a preformed component having a base region, a side-plate region, and optionally a flange region, such that the preformed component has a material surplus for the side-plate region and/or the base region and/or optionally the flange region; and calibrating the preformed component to an at least in regions finally formed component having a base region, a side-plate region, and optionally a flange region; wherein the base region of the preformed component has substantially the geometry and/or the local cross sections of the base region of the at least in regions finally formed component. The invention moreover relates to a device for producing a component, in particular for carrying out the method.