Hot Press Forming Draw Radius With Low-Friction Die Member
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Solution Overview
Problem
Conventional hot press forming processes often result in cladding on the die surfaces, leading to increased friction, wear, and reduced quality of the formed metal parts, especially around the draw radius where significant lateral displacement occurs.
Innovation Solution
A hot press forming apparatus with a member attached to a die having a draw radius, where the member defines a first press forming surface with lower friction compared to the second press forming surface on the die, thereby reducing the force required to form the blank and minimizing cladding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hot press forming is performed between two dies, then the blank is formed into a metal part, but cladding remains on the press forming surface of the die after press forming
Solution Approach 1:
A Teflon®-coated member is introduced as an intermediary element between the blank and the die surface. This member acts as a mediator that reduces friction and prevents direct contact between the blank and the die, thereby eliminating cladding while still enabling the press forming process to proceed efficiently
2Manufacturing precision
If high friction exists adjacent to or on the draw radius, then the blank material experiences increased strain or elongation, but this increases the risk of fractures in the resulting metal part
Solution Approach 1:
The Teflon®-coated member is specifically positioned adjacent to or on the draw radius where friction is most problematic. This localized application of low-friction coating precisely where needed reduces strain and fracture risk at the critical draw radius area without compromising the overall forming process
3Force
If cladding occurs on the die, then the friction experienced by the blank changes and increases, but this increases the force required for forming and the risk of fractures
Solution Approach 1:
The Teflon®-coated member serves as a permanent intermediary that prevents cladding from forming on the die surface. By maintaining a consistent low-friction interface between the blank and die, it eliminates the friction increase that would otherwise occur with cladding, reducing the force required for forming
4Duration of action of stationary object
If cladding occurs on the die, then wear on the dies increases and maintenance requirements increase
Solution Approach 1:
The Teflon®-coated member acts as a protective intermediary layer that prevents direct contact and adhesive wear between the blank and the die surface. This significantly reduces die wear and extends die service life, eliminating the need for frequent maintenance while maintaining production continuity
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 enhances deformability and reduces cladding on the dies, leading to improved quality and reduced wear of the metal parts, along with more stable friction and lower lubricant requirements.
Implementation Method 1
The member and the die, which holds the member, are configured such that during the same hot press forming, a first friction arises between the blank and the first press forming surface when the blank is in contact with the member and a second friction arises between the blank and the second press forming surface when the blank is in contact with the die holding the member. The first friction is lower than the second friction.
Data Source
AI summary
A method for a hot press forming apparatus and a hot press forming apparatus (102; 202) for forming a blank (104), the hot press forming apparatus (102; 202) comprising a first die (106; 206) and a second die (108), wherein the first die (106; 206) has at least one die cavity (110; 210), and the second die (108) has at least one die protrusion (112), wherein the hot press forming apparatus (102; 202) is configured to, by means of the first and second dies (106, 108; 206, 108), press form the blank (104) placed between the first and second dies (106, 108; 206, 108). At least one of the first and second dies (106, 108; 206, 108) has a draw radius (116; 216), wherein a member (118; 218) is attached to a die (106; 206) which has a draw radius (116; 216). At least a portion (119; 219) of the member (118; 218) is positioned adjacent to or on the draw radius (116; 216). The member (118; 218) defines a first press forming surface (120; 220), and the die (106; 206) holding the member (118; 218) defines a second press forming surface (122; 222) outside the first press forming surface (120; 220). The member (118; 218) and the die (106; 206), which holds the member (118; 218), are configured such that during the same hot press forming, a first friction arises between the blank (104) and the first press forming surface (120; 220) when the blank (104) is in contact with the member (118; 218) and a second friction arises between the blank (104) and the second press forming surface (122; 222) when the blank (104) is in contact with the die (106; 206) which holds the member (118; 218), the first friction being lower than the second friction.