Hat-Section Press Forming with Cushioned Blades to Reduce Wall Warping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Press-forming technologies face challenges in achieving accurate dimensional stability for components with hat cross-sectional shapes lacking flange portions, particularly due to springback deformation and warping issues in vertical wall portions, especially when using thin high-tensile steel sheets, which complicates the application of compression stress and increases the risk of buckling.
Innovation Solution
A press forming device that applies compression stress to vertical wall portions using a punch and pad with bending blades and stoppers, where the bending blades are divided and supported by cushion components to maintain a preset interval, allowing for controlled compression and preventing buckling, thereby reducing warping and improving dimensional accuracy.
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 the risk of buckling increases
Solution Approach 1:
The bending blades are divided into multiple segments along the vertical wall portion, allowing differential compression at different locations. This segmentation enables application of compression stress to reduce warping while distributing the load to prevent buckling in any single location
Solution Approach 2:
The bending blades apply compression stress locally to specific regions of the vertical wall portions based on where warping occurs. The cushion components provide localized support at critical points, allowing compression to be applied where needed without over-compressing the entire structure and causing buckling
2Weight of moving object
If thin high-tensile steel sheets are used to reduce body weight, then weight reduction is achieved, but springback deformation increases
Solution Approach 1:
The cushion components are positioned in advance at locations where springback deformation is expected to occur. During press-forming, these pre-positioned cushion components provide support to counteract the elastic recovery of the thin high-tensile steel sheet, preventing excessive springback while maintaining the weight benefits of using thin material
Solution Approach 2:
The cushion components modify the pressure distribution parameters during press-forming, providing increased support at critical locations where thin high-tensile steel sheets are prone to springback. This allows the use of thinner materials for weight reduction while maintaining dimensional accuracy through optimized pressure application
3Manufacturing precision
If the bending blades are divided with an interval to apply compression, then warping reduction is improved, but the device complexity increases
Solution Approach 1:
The cushion components serve as intermediaries between the divided bending blades and the vertical wall portions. These cushion components simplify the overall structure by providing a unified support mechanism that compensates for the intervals between divided bending blades, reducing warping control without requiring a highly complex integrated die structure
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 by applying controlled compression, making it suitable for mass production without the risk of buckling, even with thin high-tensile steel sheets.
Implementation Method 1
a punch supported by a first cushion component elastically expandable and contractible in the press direction
Implementation Method 2
a second cushion component interposed between the upper die component and the lower die component, contractible in the press direction at a predetermined pressure or more
Implementation Method 3
springback deformation due to elastic recovery occurs in a press-formed article after forming release
Data Source
AI summary
To reduce warping of vertical wall portions without causing buckling occurring in a component shape not having a flange portion. A punch and a pad sandwiching a top sheet portion therebetween in the sheet thickness direction, bending blades for bend-forming the vertical wall portions, and stoppers facing the bending blades in the press direction and constraining end portions of a material to be machined are provided. The punch is supported by a first cushion component elastically expandable and contractible in the press direction. 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 (D) equal to or larger than a set compression amount and a second cushion component interposed between the upper die component and the lower die component, maintaining the interval (D), and contractible in the press direction at a predetermined pressure or more. 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.