L-Shaped Pressed Component Forming With Material Inflow Control
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Solution Overview
Problem
The existing methods for producing L-shaped pressed components with high tensile strength steel sheets often result in cracks and reduced material yield due to the formation of wrinkles and stretch flanges, especially when using ultrahigh tensile strength steel sheets or components with small radii of curvature, leading to inefficiencies in forming complex shapes like those with L-shapes.
Innovation Solution
A method and apparatus that incorporate a material inflow promoting portion during press working, allowing increased material flow into the flange area on the inner side of the curved portion, reducing tension and preventing cracks by forming the component using a punch and blank holder setup with specific geometries and a bending die that enhance material distribution and reduce deformation stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional press working is used to form L-shaped pressed components from ultrahigh tensile strength steel sheets, then the component strength is improved, but cracks occur in the flange portion on the inner side of the curved portion
Solution Approach 1:
A material inflow promoting portion is formed in advance on the blank before the main forming process. This preliminary feature guides material flow during subsequent press working, preventing cracks in the flange portion by ensuring adequate material supply to the inner side of the curved portion during forming.
Solution Approach 2:
The material inflow promoting portion is specifically located at the region corresponding to the flange on the inner side of the curved portion. This localized modification addresses the specific problem area without affecting other regions of the component, allowing targeted improvement of material flow where cracks typically occur.
2Shape
If conventional press working is used to form L-shaped pressed components, then the component shape is achieved, but material yield is reduced due to wrinkles and stretch flanges
Solution Approach 1:
The material inflow promoting portion is created beforehand on the blank to pre-condition the material distribution. This preliminary action ensures that during the forming process, material flows efficiently to where it is needed, reducing the formation of wrinkles and stretch flanges that would otherwise require material removal or result in defects.
Solution Approach 2:
The formation of the material inflow promoting portion changes the geometric parameters of the blank in a specific region. This parameter modification alters the material flow characteristics during forming, enabling better material distribution and reducing defects that lead to material loss.
3Strength
If high tensile strength steel sheets are used to improve component strength, then the collision safety performance is improved, but the ductility is reduced making forming difficult
Solution Approach 1:
The material inflow promoting portion is formed on the blank before the main forming process. This preliminary action compensates for the low ductility of ultrahigh tensile strength steel sheets by pre-establishing material flow paths, allowing the material to be formed into complex L-shapes without requiring high ductility during the critical forming stages.
Solution Approach 2:
The material inflow promoting portion is specifically positioned at the inner side of the curved portion where material flow is most critical. This localized approach addresses the formability issue in the most problematic region while maintaining the high strength properties of the material throughout the component.
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 enables the production of L-shaped pressed components with high yield rates and without cracks, even when using ultrahigh tensile strength steel sheets, by optimizing material flow and reducing deformation stress, thus improving the forming limit and material efficiency.
Implementation Method 1
press working by bending in a state where a portion of the blank to be formed into the top plate is held in a clamped state by the pad and the punch
Implementation Method 2
holding a portion of the blank to be formed into a portion disposed further outward of the curved portion than the portion of the blank to be formed into the top plate in a state of being clamped by the blank holder and the die
Data Source
AI summary
A method or apparatus to produce an L-shaped pressed component includes, where a portion of a blank, having tensile strength of 1180 MPa or more, is held in a state of being clamped by a blank holder and a die, and a portion of the blank, to be formed into a top plate is held in a state of being clamped by a pad and a punch; the second step where a vertical wall, a concave ridge and a flange on the inner side of a curved portion are formed by, bend forming with a bending die, forming one, two or more material inflow promoting portion; and the third step where the die is moved in a direction toward a side where the blank holder is disposed to form a vertical wall, a concave ridge, and a flange on the outer side of the curved portion by draw forming.