Vehicle Floor Member Bead Layout to Prevent Weld Breakage
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Solution Overview
Problem
The existing method of manufacturing press-formed products with reinforcing steel plates in contact with the main steel plate leads to potential breakage at the joined parts due to shear forces during press forming.
Innovation Solution
A method involving forming beads on a body member, arranging thicker reinforcing members to cover certain parts, welding them, and performing cold press forming to create lower ridgeline parts that absorb stretching, thereby inhibiting breakage at the joined parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reinforcing steel plate is arranged in contact with inner peripheral surface of main steel plate at bent parts, then manufacturing simplicity is improved, but shear force is generated in joined part leading to breakage
Solution Approach 1:
The patent introduces beads as intermediary structures between the reinforcing steel plate and main steel plate. These beads protrude from the lower surface of the body member and provide a buffer zone that absorbs stretching during press forming, preventing direct transmission of shear forces to the welded joints and eliminating the need for complex joint arrangements
Solution Approach 2:
The beads are formed in advance on the body member before the reinforcing steel plate is attached. This preliminary formation of beads creates predetermined stress-absorbing structures that will protect the joints during subsequent press forming operations, preventing breakage before it can occur
2Manufacturing precision
If cold press forming is performed on joined member, then floor member shape is formed, but stretching occurs in body member around lower ridgeline parts
Solution Approach 1:
The patent converts the harmful stretching effect during press forming into a beneficial stress-absorbing mechanism. The beads are strategically positioned to absorb the stretching forces that naturally occur during cold press forming around the lower ridgeline parts, transforming a potentially damaging effect into a protective feature that prevents joint breakage
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
The method effectively prevents breakage at the joined parts between the body member and reinforcing members by absorbing stretching with the beads and improving stiffness, while allowing the reinforcing members to extend beyond the body member for additional reinforcement.
Implementation Method 1
when the cold press forming is performed on the joined member, stretching occurring in the body member around its one or more lower ridgeline parts can be absorbed with the bead part(s)
Implementation Method 2
welding the body member and the two or more reinforcing members that are arranged in the respective two or more covered parts, to thereby form a joined member
Data Source
AI summary
A method of manufacturing a floor member of a vehicle includes: forming beads in respective bead parts in a body member; arranging two or more reinforcing members in respective two or more covered parts in the body member; welding the body member and the two or more reinforcing members, to thereby form a joined member; and performing cold press forming on the joined member. One or more lower ridgeline parts are formed by the cold press forming so as to correspond to each of the two or more reinforcing members. Each lower ridgeline part extends along a ridgeline. The lower ridgeline part is bent so as to protrude towards the body member in a cross-section orthogonal to the ridgeline. Each bead part is located at or near a corresponding one lower ridgeline part of the one or more lower ridgeline parts.