Hat-Section Component Forming to Prevent Wall Boundary Cracking
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Solution Overview
Problem
In the manufacture of hat-shaped cross-section components, secondary processing can lead to cracking at the boundary portions between bent and stretched vertical walls, especially when both processes are performed simultaneously.
Innovation Solution
A method involving a gripping process, followed by a bending and stretching process, and a bend back process, where the vertical walls are manipulated to change the height of the component while separating the bending and stretching operations to prevent cracking, and allowing for sequential rather than simultaneous deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bending and stretching processes are performed simultaneously on vertical walls, then productivity is improved, but cracking occurs at boundary portions between processed sections
Solution Approach 1:
The processing device is divided into multiple independent processing sections (first processing section for bending, second processing section for stretching) that can operate on different vertical wall portions simultaneously. This segmentation allows parallel processing without causing cracking at boundary portions, as each section processes its designated area independently.
Solution Approach 2:
A non-processing section is introduced between the first processing section and the second processing section. This intermediary zone prevents direct interaction between the bending and stretching processes, eliminating the harmful effect of simultaneous processing at boundary portions while still allowing both processes to occur in parallel.
2Loss of time
If bending and stretching are performed at the same time, then manufacturing time is reduced, but stress concentration causes cracking at boundary portions
Solution Approach 1:
The manufacturing process is segmented into distinct processing zones along the length direction of the preliminarily formed component. The first processing section performs bending on vertical walls at one end, while the second processing section performs stretching on vertical walls at the other end. This spatial segmentation enables time-efficient parallel processing without creating stress concentration at shared boundaries.
Solution Approach 2:
A non-processing section serves as a mediator between the bending and stretching operations. This intermediate zone isolates the two processes, preventing stress concentration and cracking at boundary portions while allowing both operations to proceed simultaneously, thus reducing overall manufacturing time.
3Adaptability or versatility
If vertical walls are bent and stretched to increase height, then component design flexibility is improved, but cracking occurs due to simultaneous deformation
Solution Approach 1:
The processing device segments the height adjustment process into separate bending and stretching operations performed in different spatial zones. This allows the component to achieve the desired height and design flexibility while avoiding the manufacturing precision issues that arise from simultaneous deformation at boundary portions.
Solution Approach 2:
The non-processing section acts as an intermediary that prevents the transmission of deformation stresses between the bending and stretching zones. This maintains surface integrity and prevents cracking while still enabling the component to achieve the required height and geometric flexibility.
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 effectively changes the height of the hat-shaped cross-section component without causing cracking, by ensuring that bending and stretching operations are performed sequentially rather than simultaneously, thus preventing stress concentration at the boundary portions.
Implementation Method 1
using the die to bend and stretch the vertical walls toward an opposite side to the top plate at one side in a length direction of the preliminarily formed component
Implementation Method 2
using the holder to bend back the vertical walls toward a top plate side at another side in the length direction of the preliminarily formed component
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2
AI summary
A method for manufacturing a hat-shaped cross-section component includes a gripping process, a bending and stretching process, and a bend back process. In the gripping process, a pair of vertical walls of an elongated preliminarily formed component that has been formed into a hat-shaped cross-section formed into a hat shaped cross section profile are disposed at a width direction outside of a punch, and a top plate of the preliminarily formed component is gripped using the punch and a pad. In the bending and stretching process, after the gripping process, a die provided on both width direction sides of the pad is moved toward the punch side relative to the preliminarily formed component, and the die is used to bend and stretch the vertical walls toward the opposite side to the top plate at one side in the length direction of the preliminarily formed component. In the bend back process, after the gripping process, a holder provided on both width direction sides of the punch is moved toward the pad side relative to the preliminarily formed component, and the holder is used to bend back the vertical walls toward the top plate side at another side in the length direction of the preliminarily formed component.