Hat-Section Forming with Top Restraint to Prevent Wall Buckling
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Solution Overview
Problem
The existing manufacturing apparatus for hat-shaped cross-section components often results in deformation during mold release due to excessive pressing forces, leading to buckling of upright walls, and requires complex equipment and high manufacturing costs to manage these forces effectively.
Innovation Solution
A manufacturing apparatus and method that incorporates restraint portions to suppress displacement of the top forming part during the molding process, reducing the need for large pressing forces by engaging the top forming part with ragged or uneven surfaces and contact members to maintain the hat-shaped cross-section's integrity, thereby minimizing deformation during mold release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extensive processing equipment or complex metal mold structure is provided to restrict pressing force during mold release, then deformation of the hat-shaped cross-section component is suppressed, but device complexity and manufacturing cost increase
Solution Approach 1:
The restraint portions are provided in advance on the punch and/or die surfaces during mold design, so that during mold release the top forming part is automatically restrained by these pre-positioned structures without requiring additional complex equipment or control systems
Solution Approach 2:
The restraint portions utilize the existing mold structures (punch and die surfaces) to automatically restrain the top forming part during mold release, making the mold structure itself serve the dual function of forming and restraining without needing separate restraining mechanisms
2Shape
If large pressing force is applied by the pad during mold release to maintain component shape, then shape integrity is improved, but upright walls buckle and deformation occurs
Solution Approach 1:
The restraint portions act as intermediary structures that provide localized restraint at critical positions (top forming part edges) during mold release, allowing the pad to apply pressing force without causing buckling, as the intermediary restraint portions distribute and control the stress
3Manufacturing precision
If the pad pressing force is reduced to prevent buckling, then upright wall deformation is suppressed, but the top forming part displacement increases
Solution Approach 1:
The restraint portions are provided at specific local positions (edges of top forming part) rather than uniformly across the entire surface, providing localized restraint where displacement occurs while allowing other areas to maintain shape integrity with reduced pressing force
Data Source
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AI summary
A manufacturing apparatus (1) for a hat-shaped cross-section component includes a die (10) having first molding surfaces (13a), a pad (20) having a second molding surface (20a), a punch (30) having a third molding surface (30a), a holder (40) having fourth molding surfaces (40a), and a first restraint portion (50). An upright wall (83) is molded between a top (81) and each of flanges (85) by moving the pad (20) and the punch (30) relative to the die (10) and the holder (40), or moving the die (10) and the holder (40) relative to the pad (20) and the punch (30). The first restraint portion (50) is configured to, during a period from when a top forming part (71) is sandwiched by the second molding surface (20a) and the third molding surface (30a) to when the upright walls (83) are molded, suppress displacement of the top forming part (71) in a longitudinal direction of the top forming part (71) relative to the second molding surface (20a) and the third molding surface (30a).