Hot Press Molding Apparatus with Ejection Cooling Holes
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Solution Overview
Problem
In hot press molding of metal plate materials, existing methods face challenges such as springback, wrinkling, die galling, and inefficient cooling, leading to defective shapes and reduced productivity due to increased friction and heat storage issues.
Innovation Solution
A metal plate material hot press molding apparatus and method that incorporates supply and discharge piping for a cooling medium within the mold, with ejection holes and projections to enhance cooling efficiency, using a cooling medium that can be ejected to specific areas of low heat transfer coefficient, thereby accelerating cooling and reducing heat storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-tensile steel plate is used to reduce part weight, then strength increases, but springback and wrinkling occur causing defective shapes
Solution Approach 1:
The patent applies parameter changes by heating the metal plate material to high temperature (e.g., 500-1000°C) before molding, which changes the material's physical state and improves ductility. This temperature parameter change allows high-strength steel to be molded without springback and wrinkling, while maintaining the strength benefits after cooling
2Strength
If high-tensile steel plate is used to reduce part weight, then strength increases, but friction force exceeds lubricant withstand load causing die galling and mold damage
Solution Approach 1:
The patent changes the temperature parameter by heating the metal plate to high temperature before molding. This reduces the material's flow stress and friction characteristics, allowing conventional lubricants to effectively prevent die galling and mold damage while still achieving high-strength parts after cooling
Solution Approach 2:
The patent uses lubricant oil as an intermediary substance between the metal plate and mold surface. By heating the metal plate, the lubricant's lubricating effect is enhanced, enabling it to mediate the high friction forces that would otherwise cause die galling and mold damage in high-strength steel forming
3Speed
If refrigerant is supplied through grooves in the mold to cool the metal plate, then cooling rate increases, but uniform cooling becomes difficult due to temperature gradient and groove deformation
Solution Approach 1:
The patent segments the cooling system by providing multiple refrigerant supply ports distributed across the mold surface, rather than using continuous grooves. This segmentation allows independent control of cooling at different locations, enabling uniform cooling throughout the metal plate even as it deforms during molding
Solution Approach 2:
The patent implements a dynamic cooling system where refrigerant supply to each port can be independently controlled based on real-time temperature feedback. This dynamic adjustment compensates for metal plate deformation during molding, maintaining optimal cooling uniformity throughout the process
4Device complexity
If air cooling is used after hot press molding, then cooling process is simple, but cooling efficiency is low due to air's low heat capacity and heat conductivity
Solution Approach 1:
The patent transitions from gas (air) cooling to liquid (refrigerant) cooling by introducing a hydraulic cooling system with supply ports and circulating fluid through the mold. This hydraulic approach dramatically increases heat transfer efficiency due to the refrigerant's superior heat capacity and conductivity, while the distributed port design keeps the system relatively simple
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 enables rapid and uniform cooling of the mold and molded product, improving strength, dimensional accuracy, and productivity while suppressing heat storage and die galling, resulting in higher-quality pressed products with reduced manufacturing costs.
Implementation Method 1
supply piping for a cooling medium, ejection holes for the cooling medium... rapid and uniform cooling of the mold and molded product
Implementation Method 2
a cooling medium is ejected from the mold during and/or after molding to forcibly cool the molded piece and the mold
Data Source
AI summary
A metal plate material hot molding apparatus is provided for press molding a heated metal plate material. The apparatus may include supply piping for a cooling medium in a mold, and ejection holes penetrating from a molding surface of the mold to the supply piping. The exemplary apparatus may also include discharge piping for the cooling medium situated in the mold, and discharge holes penetrating from the molding surface of the mold to the discharge piping, and cooling piping. Molding procedure can be performed while the cooling medium is ejected from the ejection holes to a gap between the metal plate material and the mold.