Hat-Section Curved Projection Forming to Prevent Top Plate Cracks
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Solution Overview
Problem
The manufacturing of hat-shaped section components with curved projection portions faces challenges in preventing longitudinal displacement of the top plate during the molding process, leading to potential cracks and decreased productivity due to the need for increased pad thickness to restrain the workpiece.
Innovation Solution
A manufacturing apparatus and method where the top plate is only partially restricted by a pad during the molding process, using a curved projection portion mold surface to prevent longitudinal displacement, allowing for a shorter pad length and reduced biasing force, thereby preventing cracks and maintaining productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pad thickness is increased to prevent longitudinal displacement of the workpiece, then the reliability of preventing cracks is improved, but the productivity deteriorates due to longer cycle time
Solution Approach 1:
The pad is designed to restrict only the curved projection portion and its surrounding area rather than the entire top plate. This localized restriction approach provides sufficient prevention against longitudinal displacement and crack formation in the critical curved region while avoiding the need for excessive pad thickness that would extend the ejection cycle time and reduce productivity.
2Strength
If the pad thickness is increased to restrain the workpiece, then the strength of the pad is improved, but the time required for the pad to reach sufficient height is increased
Solution Approach 1:
The pad thickness is optimized to provide adequate strength and restriction capability specifically in the curved projection portion area where longitudinal displacement occurs. By concentrating the restriction function in this critical local region rather than using a uniformly thick pad across the entire top plate, the design achieves necessary strength while minimizing the overall pad thickness and associated ejection time losses.
3Reliability
If the workpiece is restricted over the whole length in longitudinal direction, then the prevention of longitudinal displacement is improved, but the device complexity increases due to additional pad requirements
Solution Approach 1:
The manufacturing apparatus incorporates a pad configured to restrict only the curved projection portion and its surrounding area rather than the entire top plate length. This selective local restriction eliminates the need for complex full-length restriction mechanisms while effectively preventing longitudinal displacement in the critical curved region where cracks are most likely to occur.
Solution Approach 2:
The restriction function is segmented to apply only to the specific curved projection portion area rather than uniformly across the entire workpiece. This segmentation allows the pad to be positioned and configured to provide precise local control, simplifying the overall device structure compared to full-length restriction systems.
Data Source
AI summary
Provided is a manufacturing apparatus for manufacturing a hat-shaped section component including a curved projection portion such that a to-become-top-plate portion is pressed by a punch in a state where a to-become-flange portion is sandwiched between a die and a holder. The manufacturing apparatus includes the punch having a first mold surface including a curved projection portion mold surface, the holder, and the die having a fourth mold surface facing the first mold surface. An opening is formed in a part, of the fourth mold surface, that corresponds to the curved projection portion mold surface. The manufacturing apparatus includes a pad provided in the die and having a fifth mold surface facing the curved projection portion mold surface, the pad being configured to be relatively movable upward against downward biasing force so that the fifth mold surface becomes flush with the fourth mold surface.