Hat-Section Press Forming With Controlled Wall Compression
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Solution Overview
Problem
Press-forming technologies face challenges in achieving accurate dimensional precision for hat cross-sectional components without flange portions, particularly due to springback deformation and warping issues in components with curved vertical walls, where existing solutions are either not applicable or complicate the die structure and adjustment processes.
Innovation Solution
A press form device that applies compression stress to vertical wall portions using a punch, pad, and bending blades, with stoppers constraining the ends and a cushion system to manage stress differences, allowing for controlled compression within specific ranges to reduce warping and prevent buckling, while maintaining die integrity for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compression stress is applied to vertical wall portions to reduce warping, then dimensional accuracy is improved, but blank buckling occurs
Solution Approach 1:
The patent applies preliminary compression stress to the vertical wall portions during the press-forming process itself, rather than as a separate post-processing step. The compression amount is carefully controlled to be within a specific range (0.5-5mm) to achieve warping reduction while preventing buckling. This preliminary action integrates the countermeasure into the main forming process.
Solution Approach 2:
The patent changes the compression parameter from a fixed value to a controlled range. By specifying that the compression amount should be 0.5-5mm (which corresponds to 1-10% of the vertical wall height), the patent optimizes the compression stress to achieve the best balance between warping reduction and buckling prevention. This parameter optimization resolves the contradiction between applying enough compression to reduce warping and avoiding excessive compression that causes buckling.
2Manufacturing precision
If existing countermeasure technologies are applied to hat cross-sectional components without flange portions, then warping reduction is achieved, but the die structure becomes complicated and adjustment becomes difficult
Solution Approach 1:
The patent creates a universal press-forming die structure that can handle both conventional components with flange portions and novel components without flange portions using the same basic mechanism. The compression stress application mechanism integrated into the press-forming die can be applied to various component types without requiring fundamentally different die designs, thus avoiding increased complexity while maintaining warping reduction effectiveness.
Solution Approach 2:
The patent incorporates the compression stress application as a preliminary action within the standard press-forming process sequence. The compression is applied during the forming operation itself through the die structure, eliminating the need for separate post-forming adjustment mechanisms or complex additional die components. This integration maintains die simplicity while achieving warping control.
3Weight of moving object
If thin high-tensile steel sheets are used to reduce body weight, then weight reduction is achieved, but springback increases causing poor dimensional accuracy
Solution Approach 1:
The patent converts the harmful springback effect into a beneficial outcome by applying compression stress to counteract it. The high-tensile steel sheets naturally exhibit large springback, but the patent uses this characteristic by applying a controlled compression amount (1-10% of vertical wall height) that precisely offsets the springback deformation. This transforms the material's problematic elastic recovery into an opportunity for achieving high dimensional accuracy through controlled compression.
Solution Approach 2:
The patent adjusts the compression parameter based on the material properties of thin high-tensile steel sheets. By setting the compression amount within the specific range of 0.5-5mm (1-10% of vertical wall height), the patent optimizes the countermeasure for thin-walled high-strength materials. This parameter optimization ensures that the compression is sufficient to counteract the large springback of high-tensile steel while avoiding excessive compression that could damage the thin material.
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 warping and improves dimensional accuracy of press-formed articles with hat cross-sectional shapes, enabling precise formation of components with linear and curved vertical walls without flange portions, enhancing the reliability and efficiency of the press-forming process.
Implementation Method 1
a cushion component that applies elastic force in the press direction to the punch
Implementation Method 2
a second process of applying compression by a preset compression amount in a direction along the press direction to the vertical wall portions
Implementation Method 3
springback deformation due to elastic recovery occurs in a press-formed article after form release
Data Source
AI summary
A punch and a pad sandwiching a top sheet portion, bending blades for bend-forming the vertical wall portions, and stoppers facing the bending blades are provided. The punch is supported by a first cushion component. The bending blades each have an upper die component and a lower die component disposed facing each other in the press direction with an interval equal to a set compression amount in the range of 2% or more and 6% or less of the heights of the vertical wall portions and a second cushion component interposed between the upper die component and the lower die component, maintaining the interval, and contractible in the press direction. The cushion pressure of the second cushion component is lower than the cushion pressure of the first cushion component and has such cushion pressure that the second cushion component does not contract during the bend-forming of the vertical wall portions.