Hemming Accuracy Management Through Rigidity-Movement Correlation
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Solution Overview
Problem
Conventional methods fail to accurately predict and adjust the rigidity and fitting accuracy of parts undergoing hemming processing due to discrepancies between simulated and actual product evaluations, lacking a correlation between rigidity and movement at specific points.
Innovation Solution
A manufacturing and accuracy management method utilizing finite element analysis to evaluate deformation ratios, acquire measurement data, and adjust rigidity based on correlation to ensure accurate fitting, involving processes like averaging and rigidity changing to align with allowable values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional simulation and evaluation methods are used for hemming processing, then the analysis and evaluation can be performed, but the simulated results do not coincide with actual product evaluations and there is no correlation between rigidity per point and amount of movement
Solution Approach 1:
The patent changes the evaluation parameters from point-by-point analysis to area-based integration. By integrating deformation amounts over the entire folded portion area and calculating area ratios, the method transforms discrete point data into continuous area-based metrics that accurately reflect the overall rigidity and movement correlation in hemming processing.
Solution Approach 2:
The patent introduces an area ratio as an intermediary parameter that bridges the gap between simulation and actual product evaluation. This area ratio serves as a mediator that correlates the deformation characteristics across the folded portion, enabling accurate prediction of fitting accuracy by representing the overall structural behavior rather than isolated point measurements.
2Manufacturing precision
If point-by-point evaluation is performed on sub-completed parts, then local deformation can be analyzed, but peripheral influences are not considered and accuracy adjustment is difficult
Solution Approach 1:
The patent merges multiple point evaluations into a unified area-based assessment. By combining the deformation data from multiple points within the folded portion into an integrated area ratio, the method simplifies the evaluation process while capturing peripheral influences, making accuracy adjustment more manageable through a single comprehensive metric.
Solution Approach 2:
The patent transitions from one-dimensional point evaluation to two-dimensional area evaluation. By expanding the assessment from individual points to the entire folded portion area, the method captures spatial distribution of deformation and peripheral influences, enabling more accurate manufacturing precision adjustment through area-based ratios.
3Manufacturing precision
If rigidity of the second member is changed to adjust accuracy, then fitting accuracy can be improved, but the relationship between rigidity ratio and movement ratio must be accurately correlated
Solution Approach 1:
The patent implements a feedback mechanism where the area ratio derived from simulation is compared with actual measurement data, and the rigidity parameters are adjusted based on this feedback. This iterative process ensures that the correlation between rigidity ratio and movement ratio is maintained and refined, enabling accurate fitting while preserving the essential relationship information.
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
Enables precise adjustment of completed member accuracy by considering peripheral influences, reducing setting errors, and achieving higher correlation between rigidity and movement, thereby enhancing manufacturing precision.
Implementation Method 1
analyzing, with a finite element method using a model of the completed member, a ratio, among a plurality of evaluation portions provided on the folded portion, between an amount of deformation at a certain one of the evaluation portions when a load is applied to the certain one of the evaluation portions and amounts of deformation at other ones of the evaluation portions
Data Source
AI summary
Included are: an averaging process of performing averaging on measurement data in accordance with a ratio of amounts of deformation calculated in a first analysis process at other evaluation portions than a certain evaluation portion, with respect to the certain evaluation portion; an adjustment process of adjusting the ratio to achieve a higher correlation between a ratio of rigidity calculated from results of analyses between a second member and a first member and a ratio of movement calculated from the measurement data; and a rigidity changing process of changing, when a value of the measurement data at one of the evaluation portions on the completed member exceeds an allowable value, rigidity of the second member based on the correlation having undergone the adjustment in the adjustment process to allow the value of the measurement data to be below the allowable value.