Sheet Metal Inclined Portion Forming With Segmented Clamping
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Solution Overview
Problem
Existing methods struggle to efficiently manufacture structural members with inclined portions, particularly those made from ultra-high strength steel, due to issues such as wrinkles and cracks during cold deformation processing.
Innovation Solution
A method involving the use of restraining parts to partially pull and separate a metal material sheet, forming an inclined portion by restraining a first region with a first part and a second region with a second part, and then relatively separating these parts along an intersecting direction to suppress wrinkles and stabilize the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cold drawing is used to form structural members with inclined portions, then manufacturing efficiency is improved, but wrinkles easily occur in edge portions of the inclined portion
Solution Approach 1:
The blank holder is divided into multiple independent blank holders that can be displaced separately. This allows different regions of the sheet metal to be constrained with different forces and displacements during forming, preventing wrinkle formation at critical areas while maintaining manufacturing efficiency.
Solution Approach 2:
The blank holders are designed to be dynamically adjustable during the forming process. They can be displaced in stages - first along the press axis direction to constrain the sheet, then in an outward direction to expand and form the inclined portion. This dynamic adjustment prevents wrinkles while maintaining productivity.
2Strength
If cold deformation processing is used on ultra high strength steel to form inclined portions, then structural strength is improved, but cracks easily occur in addition to wrinkles
Solution Approach 1:
The sheet metal is first constrained by the blank holders before the forming action begins. This preliminary constraint prevents unintended deformation and stress concentration that could lead to cracks. The blank holders are positioned and engaged with the sheet metal in advance, ensuring controlled stress distribution during subsequent forming operations on ultra high strength steel.
Solution Approach 2:
The forming process uses controlled parameter changes including staged displacement of blank holders and controlled pressing forces. This allows the ultra high strength steel to be formed into inclined portions without exceeding its ductility limits, preventing crack formation while maintaining the desired structural strength.
3Adaptability or versatility
If the inclination angle of the inclined portion changes according to a portion, then design flexibility is improved, but it becomes more difficult to suppress wrinkle generation
Solution Approach 1:
The blank holder system is segmented into multiple independently controllable units. Each segment can be displaced by different amounts and in different directions, allowing the formation of inclined portions with varying angles across different regions of the sheet metal. This segmentation enables complex variable-angle geometries while maintaining surface quality through localized control.
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 allows for the efficient and stable production of structural members with high strength, effectively suppressing wrinkles and ensuring consistent quality by maintaining controlled sheet thickness and stress distribution.
Implementation Method 1
forming a first region WF1 and an inclined portion WS connected to the first region WF1 by forming a metal material sheet by cold deformation processing
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
This structural member (W1) is manufactured using a structural member manufacturing device including: a first clamping part (10) having a first lower clamping member (11) and a second upper clamping member (12) disposed to face each other and capable of being opened and closed; a second clamping part (20) having a third lower clamping member (21) and a fourth upper clamping member (22) disposed to face each other corresponding to the first lower clamping member (11) and the second upper clamping member (12) and capable of being opened and closed; and clamping part driving means for allowing the first clamping part (10) and the second clamping part (20) to be relatively separated from each other while causing a position in an X-axis direction and a position in a Z-axis direction to correspond to each other. That is, the structural member (W1) is manufactured by a structural member manufacturing method in which the first clamping part (10) and the second clamping part (20) are relatively separated from each other by the clamping part driving means.