Hat-Section Restriking with Top-Plate Support for Spring-Back Positioning
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Solution Overview
Problem
In the manufacturing of hat-shaped cross-section components, the issue of unstable positioning during restriking arises due to spring-back, leading to contact with die edges, which affects the precision and accuracy of the forming process.
Innovation Solution
A method involving a supporting process where a semi-finished component is positioned between a restriking punch and die, with a support member extending from the punch to stabilize the top plate, and a positioning process using recess portions in the die to maintain the component's width direction alignment, ensuring precise restriking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the semi-finished formed component is restrained by contacting the opening edges of the forming recess, then the component can be positioned in the width direction, but the position becomes unstable due to spring-back deformation
Solution Approach 1:
A support member is introduced as an intermediary element between the punch and the semi-finished formed component. This support member extends from the punch toward the die side and contacts the top plate of the component, providing stable support that prevents spring-back deformation and ensures reliable positioning in the width direction during restriking.
Solution Approach 2:
The support member is positioned in advance before restriking occurs. By preliminarily supporting the top plate of the semi-finished formed component, the system prevents spring-back deformation from affecting positioning accuracy during the subsequent restriking process, ensuring the component maintains proper alignment with the forming recess.
2Manufacturing precision
If the vertical walls are formed larger in the width direction to suppress spring-back, then spring-back is reduced, but the component cannot be disposed at the proper position with respect to the punch due to contact with shoulder portions
Solution Approach 1:
The support member serves as a mediator that allows the vertical walls to be formed larger in the width direction for spring-back suppression while preventing contact with the shoulder portions of the punch. The support member absorbs the positioning function, enabling the component to be properly disposed with respect to the punch despite the enlarged vertical walls.
3Reliability
If a support member is used to support the top plate, then positioning stability is improved, but the device complexity increases
Solution Approach 1:
The support member performs multiple functions: it supports the top plate of the semi-finished formed component, prevents spring-back deformation, ensures proper positioning in the width direction, and prevents contact with shoulder portions of the punch. By consolidating these functions into a single element, the increase in device complexity is minimized while achieving reliable positioning.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2
AI summary
A hat shaped cross-section component manufacturing method includes: a supporting process of disposing a semi-finished formed component with a hat-shaped cross-section between a restriking punch and a restriking die, and supporting a top plate of the semi-finished formed component using a support member extending from the restriking punch; a positioning process of housing the top plate inside a first recess portion of a forming recess that is formed to the restriking die, gripping the top plate using the support member and the restriking die, and positioning the semi-finished formed component in a width direction using the first recess portion and a pair of vertical walls of the semi-finished formed component; and a restriking process of inserting the restriking punch inside a second recess portion of the forming recess, and restriking the semi-finished formed component using the restriking punch and the restriking die.