Hot Stamping Mold Gap Design for Wrinkle Control
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Solution Overview
Problem
The existing cold stamping process for manufacturing mechanical parts with rounded corners is inefficient due to the low ductility of steel plates at normal temperatures, leading to multiple-step forming and welding, increased steel consumption, and high rejection rates with hot stamping due to irregular wrinkle accumulation and potential cracking.
Innovation Solution
A mold design with a stamping gap width at rounded corners set to be larger than the thickness of wrinkles, allowing for smooth wrinkle accumulation and preventing cracking, combined with a heating and cooling system for optimal steel plate ductility and part formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cold stamping process is used to manufacture mechanical parts with rounded corners, then the steel plate can be formed at normal temperature, but the steel plate has low ductility and cannot pass through rounded corners, requiring multiple-step forming and welding which increases steel consumption
Solution Approach 1:
The patent changes the temperature parameter from normal temperature to high temperature (heating the steel plate to 800-950°C), which fundamentally alters the material properties of steel, giving it high ductility and enabling one-step forming through rounded corners without welding and reducing steel consumption
2Manufacturing precision
If hot stamping process is used to manufacture mechanical parts, then the steel plate has good ductility and can pass through rounded corners in one-step forming, but wrinkles are generated and accumulated irregularly causing cracks and increasing rejection rate
Solution Approach 1:
The patent applies local quality by providing heating units specifically at the rounded corner areas of the mold, ensuring that the steel plate is locally heated to high temperature at these critical zones, which provides the necessary ductility for smooth forming without wrinkles or cracks, while other areas maintain appropriate temperature characteristics
Solution Approach 2:
The patent implements preliminary action by pre-heating the steel plate before it enters the stamping process, and pre-positioning heating units at the rounded corner areas of the mold, so that when the steel plate encounters these areas during forming, the high temperature and ductility are already in place, preventing wrinkle formation and cracks
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
This approach reduces the number of cracked products, lowers production costs, and minimizes steel resource consumption by enabling one-step forming of mechanical parts with improved tensile strength and reduced irregular wrinkles.
Implementation Method 1
a steel plate blank to be heated; heating the heated steel plate blank
Implementation Method 2
cooling the formed mechanical part in the mold; cooling system for cooling the formed mechanical part
Data Source
AI summary
A method for manufacturing a mechanical part by hot stamping, and a mold and a system thereof. The method includes: heating a steel plate blank at a predetermined heating temperature; and placing the steel plate blank into a mold of the mechanical part, and stamping the steel plate blank to form wrinkles at a rounded corner of the mold and form the mechanical part in the mold: wherein, the mold of the mechanical part includes a female mold and a male mold, a stamping gap configured to accommodate the steel plate blank is provided between the female mold and the male mold, and a width of the stamping gap at the rounded corner of the mold is larger than a thickness of the wrinkles.