Front Axle Beam Inward Flange Bending Rigidity
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Solution Overview
Problem
Current front axle beams face limitations in achieving high rigidity while maintaining a compact size, which is essential for supporting vehicle weight and ensuring driving stability without increasing cross-sectional size, and existing production methods constrain shape flexibility.
Innovation Solution
A production method involving die forging followed by bending to form a front axle beam with a web part and flange parts, where at least one flange part is bent inward, creating a narrower space between flange edges than the web length, thereby increasing rigidity without enlarging the cross-sectional size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the front axle beam uses a conventional H-shaped cross section with standard flange positioning, then the manufacturing process is simple, but the bending and torsional rigidity is insufficient
Solution Approach 1:
The flange parts are bent inward toward the central axis of the web part, creating a curved or angled configuration instead of a straight perpendicular arrangement. This curvature brings the outer edges of the flange parts closer together, increasing the space efficiency and improving the bending and torsional rigidity of the front axle beam while maintaining manufacturing feasibility
2Strength
If the front axle beam is designed with high rigidity requirements, then the structural strength is improved, but the cross-sectional size increases
Solution Approach 1:
By bending the flange parts inward at angles less than 90 degrees relative to the web part, the structure achieves higher rigidity through improved geometric distribution of material without increasing the overall cross-sectional footprint. The curved configuration allows the flange outer edges to be positioned closer together while maintaining structural strength
Solution Approach 2:
The flange parts are positioned in a three-dimensional configuration rather than a simple planar arrangement. By bending the flanges inward toward the central axis, the structure utilizes spatial optimization to achieve higher rigidity within the same cross-sectional boundaries, effectively using the third dimension to improve performance without increasing area
3Productivity
If die forging is used to produce the front axle beam, then manufacturing efficiency is high, but draft angles are required which constrain shape flexibility
Solution Approach 1:
The flange parts are bent inward after the initial die forging process creates the basic H-shaped structure. This preliminary formation of the web and flanges followed by a secondary bending operation allows the manufacturing process to maintain the efficiency of die forging while achieving the complex inward-bent configuration that would be difficult to create in a single forging step
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 enhances the bending and torsional rigidity of the front axle beam, allowing for a lighter weight with comparable or improved rigidity to conventional designs, facilitating easier manufacturing and integration in tight spaces.
Implementation Method 1
a material is forged by dies which are paired with each other at a central axis of the web part in the cross section of the beam part
Implementation Method 2
at least one specified flange part, which is at least one of the flange parts, is bent toward another one of the flange parts that is opposed to the specified flange part
Data Source
AI summary
The production method disclosed is a method for producing a front axle beam. The production method includes a die forging step and a bending step. The die forging step is a step of forging a steel material with dies to produce a forged product including a rough web part, which is to be formed into a web part, and four plate-shaped rough flange parts protruding frontward and rearward from an upper side and a lower side of the rough web part, respectively. The bending step is a step of pressing at least one specified rough flange part, which is at least one of the four rough flange parts, with a first die to form a bent portion in the specified rough flange part such that the bent portion is bent inward in an up-down direction of the forged product.