Forming and processing method
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Solution Overview
Problem
Existing methods for forming and processing high tensile strength steel plates face issues with stretch-flange cracks due to residual strain, where heating electrodes either wear out from direct contact or heat beyond the intended area when used non-contactedly.
Innovation Solution
A method involving a heating coil that is disposed non-contactedly to face the punched end of the steel plate, using high-frequency induction heating to locally heat the end face, thereby stabilizing the current value and limiting the heating range to only the vicinity of the punched end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heating electrode is brought into direct contact with the punched end for heating, then heating effectiveness is improved, but the heating electrode wears out and current value becomes unstable
Solution Approach 1:
The patent introduces a heating coil as an intermediary device that generates an electromagnetic field to induce eddy currents in the punched end for heating, rather than using direct electrical contact. This mediator approach eliminates electrode wear while maintaining heating effectiveness through electromagnetic induction.
Solution Approach 2:
The patent replaces the mechanical contact-based heating electrode system with an electromagnetic field-based heating coil system. This substitution eliminates the mechanical wear problem by using electromagnetic induction to generate heat internally in the workpiece without physical contact.
2Reliability
If a heating electrode is used in non-contact manner to avoid wear, then electrode durability is improved, but heating range extends beyond the punched end
Solution Approach 1:
The heating coil is positioned and configured to concentrate the electromagnetic field specifically at the punched end location. The coil's geometry and positioning create a localized heating zone that matches the punched end area, ensuring heat is applied only where needed without affecting surrounding regions.
Solution Approach 2:
The patent transitions from one-dimensional direct contact heating to three-dimensional electromagnetic field heating. The heating coil generates an electromagnetic field that penetrates the workpiece and induces eddy currents specifically in the punched end region, providing precise spatial control over the heating zone through field distribution rather than physical contact.
3Reliability
If high-frequency induction heating is applied to the punched end, then residual strain is effectively removed, but energy consumption increases
Solution Approach 1:
The patent employs high-frequency alternating current through the heating coil to generate time-varying electromagnetic fields. This periodic action induces eddy currents in the punched end that continuously generate heat through resistive heating, effectively removing residual strain through repeated thermal cycles without requiring excessive total energy input.
Solution Approach 2:
The high-frequency induction heating induces thermal effects that facilitate phase transitions or microstructural changes in the steel at the punched end, relieving residual strain. The rapid heating and cooling cycles create controlled thermal gradients that promote stress relief through metallurgical phase transformations.
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 effectively removes residual strain while preventing electrode wear and maintaining the strength of the steel plate by locally heating only the punched end, ensuring improved heating efficiency and product performance without softening the base material.
Implementation Method 1
applying a current to the heating coil 1 to generate an induced electromotive force in the steel plate 100, thereby heating the end face 104
Implementation Method 2
using high-frequency induction heating to locally heat the end face
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A forming and processing method comprising: punching a steel plate (100); and disposing a heating coil (1) so as to face an end face (104) of a punched end (103) punched in the punching in a non-contact manner along the end face (104) of the punched end (103) and applying a current to the heating coil (1) to generate an induced electromotive force in the steel plate (100), thereby heating the end face (104).