Hollow Extruded Profile Correction for Accurate Mating Surfaces
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Solution Overview
Problem
Extruded materials, such as aluminum alloys used in vehicle frames, face challenges in achieving high dimensional accuracy, particularly for mating surfaces, which is crucial for assembly and structural integrity.
Innovation Solution
A method involving the extrusion of metal materials with a peripheral wall and middle rib structure, where the extruded material is corrected by expanding the peripheral wall outward at predetermined portions using a mold and rubber bulge forming, transferring the inner surface shape of the mold to the outer surface, thereby improving dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional extrusion molding is used to produce extruded materials, then production efficiency and structural complexity are improved, but dimensional accuracy of mating surfaces deteriorates
Solution Approach 1:
The patent applies preliminary action by designing the middle rib with a predetermined curvature in the extrusion die before the actual extrusion process. This pre-planned curvature compensation ensures that after extrusion and subsequent cutting, the mating surfaces achieve the required dimensional accuracy without requiring additional post-processing operations.
Solution Approach 2:
The patent applies local quality by introducing a curved middle rib structure specifically at critical sections where dimensional accuracy is needed, while maintaining straight peripheral walls for other portions. This localized structural modification allows selective improvement of mating surface accuracy without affecting the entire extruded member.
2Ease of manufacture
If conventional extrusion molding is used to produce extruded materials, then production cost is reduced, but dimensional accuracy of mating surfaces deteriorates
Solution Approach 1:
The patent applies preliminary action by incorporating curvature compensation directly into the extrusion die design and middle rib geometry before production. This upfront design consideration eliminates the need for expensive post-extrusion machining or corrective operations, thereby maintaining low production costs while achieving high dimensional accuracy.
Solution Approach 2:
The patent applies parameter changes by modifying the middle rib curvature parameter in the extrusion process to compensate for dimensional deviations. By adjusting this geometric parameter during design, the patent achieves accurate mating surfaces without requiring costly additional processing steps.
3Device complexity
If the middle rib is made straight to simplify structure, then manufacturing complexity is reduced, but the ability to maintain dimensional accuracy during peripheral wall expansion deteriorates
Solution Approach 1:
The patent applies local quality by making only the middle rib curved while keeping the peripheral walls straight. This selective curvature application provides the necessary flexibility for dimensional correction at critical sections while maintaining the simplicity and structural integrity of the overall extruded member.
Solution Approach 2:
The patent applies dynamics by introducing curvature into the middle rib structure, which provides the flexibility needed to accommodate dimensional corrections during the peripheral wall expansion process. The curved geometry allows the middle rib to deform appropriately during correction, enabling achievement of high 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 method enhances the dimensional accuracy of extruded materials, specifically at mating surfaces, reducing production costs and time while ensuring the structural integrity of components like vehicle frames.
Implementation Method 1
compressing the rubber in the longitudinal direction to bulge the rubber in a direction intersecting the longitudinal direction, and expanding the peripheral wall outward by the bulged rubber
Data Source
AI summary
An extruded material includes a peripheral wall having a closed loop-shaped cross-section and defining a hollow, and a middle rib connected to an inner peripheral surface of the peripheral wall and dividing the hollow. The extruded material is provided with a corrected portion set at a predetermined portion in a longitudinal direction and subjected to correction processing, and an uncorrected portion not subjected to the correction processing. The peripheral wall is expanded outward with respect to an original shape of the uncorrected portion in the corrected portion. While the middle rib is curved with respect to an imaginary straight line connecting connecting portions connected with the peripheral wall at both end portions of the middle rib in the uncorrected portion, the middle rib has a smaller degree of curvature than the original shape of the uncorrected portion in the corrected portion.