Molded Metal Plate Forming With Opposite Bends at Welded Joints
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Solution Overview
Problem
In the manufacturing of molded products through press working of metallic plates with reinforcing plates, the difference in extension lengths leads to shear stress and potential breakage at the welded portions, and gaps may form due to springback, making it difficult to weld the plates at vertical walls.
Innovation Solution
A method involving sequential bending of inner and outer metallic plates in opposite directions, forming oppositely curved portions to reduce gaps and stress concentration, with welding occurring after each bending step to facilitate joining while minimizing breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If press working is performed on welded metallic plates with reinforcing plates, then the strength of the metallic plate is increased, but shear stress occurs at the welded portion causing potential breakage
Solution Approach 1:
The patent applies preliminary action by forming oppositely curved portions on the outer metallic plate before performing press working. These pre-formed oppositely curved portions (first and second oppositely curved portions) are designed to compensate for the extension length difference between the inner and outer metallic plates during subsequent bending, thereby preventing shear stress concentration at the welded joining portions and avoiding breakage while maintaining structural strength
2Strength
If joining portions are disposed at vertical walls before press working, then the structure is strengthened, but gaps form due to springback making it difficult to weld
Solution Approach 1:
The patent forms oppositely curved portions on the outer metallic plate before welding and press working. These pre-formed oppositely curved portions are strategically designed to compensate for springback effects during press working, ensuring that the joining portions remain in close contact without gaps after forming, thereby facilitating easy welding while maintaining structural strength at vertical walls
Solution Approach 2:
The oppositely curved portions serve as a preliminary anti-action mechanism by pre-compensating for the springback that would otherwise create gaps. The first and second oppositely curved portions are formed with specific curvatures that counteract the expected springback deformation, preventing gap formation at joining portions before press working occurs
3Reliability
If sequential bending in opposite directions is performed, then gaps and stress are reduced, but the process complexity increases
Solution Approach 1:
The patent segments the bending process into distinct sequential steps: first forming oppositely curved portions in one direction, then performing press working, and finally forming additional oppositely curved portions in opposite directions. This segmentation allows each bending step to serve a specific function in compensating for extension differences and reducing stress, making the complex process more controllable and manageable
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 method effectively reduces gaps and stress on joining portions, allowing easy formation of welds without breakage, even with differences in extension lengths, by strategically bending and welding the plates in alternating directions.
Implementation Method 1
welding an inner metallic plate to an outer metallic plate after placing the inner metallic plate and the outer metallic plate on each other to form a first joining portion
Implementation Method 2
bending, after forming the first joining portion, the outer metallic plate with the inner metallic plate in a first direction by performing a first press working
Implementation Method 3
bending, after the first press working, the outer metallic plate with the inner metallic plate in a second direction, which is opposite from the first direction, by performing a second press working
Data Source
AI summary
A method of manufacturing a molded product is provided. The method of manufacturing a molded product includes forming a first joining portion by placing an inner metallic plate and an outer metallic plate on each other and welding them together; bending, after forming the first joining portion, the outer metallic plate with the inner metallic plate in a first direction by performing a first press working; and forming, after the first press working, a first surface, a second surface, and a curved portion on the outer metallic plate by performing a second press working. In the second press working, the outer metallic plate is bent with the inner metallic plate in a second direction to form an oppositely curved portion which is bent in a direction opposite from a bending direction of the curved portion on the outer metallic plate.