Hat-Shaped Cross-Section Forming Apparatus with Pressure Limiting Device
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Solution Overview
Problem
Hat-shaped cross-section components undergo deformation during demolding due to excessive pressure 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 pressure limiting device that interposes between the pad and holder, limiting pressure on the component during demolding, and a method involving a die, punch, pad, and holder that grip the metal sheet to form the component, allowing controlled up-down movement to minimize deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pad and holder press the metal sheet to form the hat-shaped cross-section component, then the component is formed with the desired shape, but excessive pressure causes deformation and creasing during demolding
Solution Approach 1:
The holder is designed to move independently relative to the die during demolding. After forming, the holder can be retracted or positioned to reduce pressure on the formed component, allowing the pad and holder to separate without causing deformation. This dynamic adjustment of the holder's position resolves the contradiction between maintaining shape accuracy during forming and preventing damage during demolding.
Solution Approach 2:
The forming apparatus is divided into independent components: the die, the punch, the pad, and the holder. Each component can move independently, allowing the holder to be separated or repositioned during demolding while the pad remains in place to support the component. This segmentation enables selective pressure application and release, preventing creasing and deformation.
2Strength
If high-strength materials with low extensibility are used to improve component strength, then the component has higher strength, but the material is more prone to creasing and cracking during forming and demolding
Solution Approach 1:
The dynamic movement of the holder allows for controlled pressure release during demolding, which is particularly beneficial for high-strength materials with low extensibility. The holder can be retracted to minimize friction and pressure on the formed component, preventing creasing and cracking that would otherwise occur with rigid, continuous pressure on brittle materials.
Solution Approach 2:
The independent holder design provides a cushioning effect by allowing gradual pressure release during demolding. The holder can be positioned to maintain slight contact for support while avoiding excessive pressure that would cause damage to high-strength, low-extensibility materials. This beforehand cushioning prevents cracking and creasing before they occur.
Data Source
AI summary
A hat-shaped cross-section component manufacturing apparatus includes: a die that includes a forming face that presses both side portions of a metal stock sheet; a punch that includes a forming face that presses a central portion of the metal stock sheet; a pad that includes a forming face that presses and grips the central portion of the metal stock sheet against the punch; and a blank holder that includes a forming face that presses and grips the both side portions of the metal stock sheet against the die. The hat-shaped cross-section component manufacturing apparatus further includes a pressure limiting device configured including a floating block that moves together with the blank holder when forming of a curving component has been completed, that is interposed between the pad and the blank holder, and that limits pressing of the formed curving component between the pad and the blank holder during demolding.