Hat-Section Forming Restraints 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, which complicates the metal mold structure and increases manufacturing costs.
Innovation Solution
Incorporating a first restraint portion to suppress displacement of the top forming part in the longitudinal direction and a second restraint portion to prevent spreading of upright walls and flanges, both of which reduce the required pressing force and maintain the hat-shaped cross-section's integrity during mold release with a simple configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the die and pad are moved downward to form the hat-shaped component, then the component shape is formed, but the upright walls may buckle during mold release due to excessive pressing force
Solution Approach 1:
The patent applies preliminary anti-action by providing restricting portions on the die and holder that prevent excessive movement of the pad and holder during mold release. These restricting portions are positioned to limit the downward movement of the pad and upward movement of the holder, thereby preventing excessive pressing forces that would cause buckling of the upright walls during component removal
Solution Approach 2:
The patent changes the physical parameters of the molding system by introducing mechanical constraints (restricting portions) that alter the movement range and pressing force parameters. The restricting portions define specific movement limits for the pad and holder, transforming the uncontrolled pressing force into a controlled parameter that prevents deformation while maintaining forming capability
2Object-affected harmful factors
If restricting portions are added to prevent pad and holder movement during mold release, then buckling is prevented, but the metal mold structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent applies local quality by adding restricting portions only at specific critical locations where buckling would occur, rather than complicating the entire mold structure. The restricting portions are localized features on the die and holder that provide precise control only where needed, maintaining simplicity in other areas of the molding system
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 solution effectively reduces deformation and maintains the hat-shaped cross-section's shape by minimizing the pressing force needed during mold release, thereby simplifying the manufacturing process and reducing costs without compromising the structural integrity of the component.
Implementation Method 1
a pad (20) having a second molding surface (20a) oriented in the first pressing direction (X), the pad (20) being provided in the die (10) so as to be relatively movable in a second pressing direction (Y) and be pushed into the opening (17) against a downward urging force
Implementation Method 2
the punch enters into the opening of the die while pushing the pad upward
Implementation Method 3
a holder (40) having fourth molding surfaces (40a) oriented in the second pressing direction (Y) and facing the first molding surfaces (13a), the holder (40) being provided around the punch (30) so as to be movable upward against a downward urging force
Data Source
AI summary
A manufacturing apparatus for a hat-shaped cross-section component includes a die having first molding surfaces, a pad having a second molding surface, a punch having a third molding surface, a holder having fourth molding surfaces, and a first restraint portion. An upright wall is molded between a top and each of flanges by moving the pad and the punch relative to the die and the holder, or moving the die and the holder relative to the pad and the punch. The first restraint portion is configured to, during a period from when a top forming part is sandwiched by the second molding surface and the third molding surface to when the upright walls are molded, suppress displacement of the top forming part in a longitudinal direction of the top forming part relative to the second molding surface and the third molding surface.