Hat-Shaped Cross-Section Component Forming Apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hat-shaped cross-section components undergo deformation during demolding due to pressing forces from the pad and holder, leading to creasing and cracking, especially when using high-strength materials with low extensibility.
Innovation Solution
A hat-shaped cross-section component manufacturing apparatus with a die, punch, pad, holder, and pressure limiting device that grips and forms the metal sheet to suppress deformation by limiting pressure during demolding, preventing simultaneous pressure from the pad and holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pad and holder press the metal sheet during forming, then the hat-shaped cross-section component is formed with high precision, but the component deforms during demolding due to pressing forces
Solution Approach 1:
The pressing force applied by the pad and holder is made dynamic rather than static. The pressing force is applied during forming and then released during demolding, allowing the component to be formed with high precision without sustaining deforming forces during removal. This dynamic control of force application resolves the contradiction between achieving precise forming and preventing deformation during demolding.
Solution Approach 2:
The pressing action follows a periodic cycle: applied during the forming stage to achieve high manufacturing precision, then removed during the demolding stage to prevent deformation. This periodic application and removal of pressing force allows the system to achieve both objectives - precise forming and stable component composition during demolding.
2Strength
If high-strength materials with low extensibility are used, then the component strength is improved, but the component is more prone to creasing and cracking during demolding
Solution Approach 1:
The component is fully formed under controlled pressing forces before demolding begins. This preliminary forming action ensures the component achieves its final shape and strength characteristics while the material is still pliable. By completing the forming action before releasing the presses, high-strength materials can be used without risking creasing or cracking during demolding, as the component structure is already established.
Solution Approach 2:
The pressing force is dynamically controlled to match the material's extensibility characteristics. For high-strength materials with low extensibility, the pressing force is applied in a controlled manner during forming and then completely released during demolding, preventing the material from undergoing stress that would cause creasing or cracking while maintaining the strength benefits of the high-strength material.
3Stability of the object's composition
If the pad and holder maintain continuous pressure, then the component is securely held during forming, but the component cannot be easily removed during demolding
Solution Approach 1:
The pressing action follows a periodic cycle: applied continuously during forming to securely hold and form the component with high positioning stability, then removed during demolding to enable easy component removal. This periodic control of pressing force resolves the contradiction between secure holding during forming and easy removal during demolding.
Solution Approach 2:
The pressing force is dynamically adjusted based on the process stage: maintained at high levels during forming to ensure component positioning stability, then reduced to zero during demolding to facilitate easy component removal. This dynamic control allows the system to achieve both secure holding and easy demolding.
Data Source
AI summary
A hat-shaped cross-section component manufacturing apparatus includes: a die that includes a forming face that grips and presses a metal stock sheet; a blank holder, that includes a forming face that grips and presses the metal stock sheet so as to configure a forming face corresponding to the forming face of the die, a pad that is disposed inside the opening formed in the die, and that includes a forming face that grips and presses the metal stock sheet; and a punch that is disposed facing the pad and that includes a forming face that grips and presses the metal stock sheet so as to configure a forming face corresponding to the forming face of the pad. The hat-shaped cross-section component manufacturing apparatus further includes a pressure limiting device that limits a formed curving component from being pressed between the pad and the blank holder during demolding.