Multi-Physical Properties Part Manufacturing via Localized Cooling
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Solution Overview
Problem
Current methods for manufacturing multi physical properties parts, such as those required for automotive components, face challenges in achieving lightweight collision safety while being economically and simply manufactured, particularly with ultra high-strength steels which have limitations in forming due to low elongation and require complex processes like hot press forming (HPF).
Innovation Solution
A method using two or more separated die sets to create multi physical properties parts by differing cooling conditions, allowing for regions with varying physical properties like tensile strength, yield strength, and elongation, without the need for additional heating devices or die surface treatment, by positioning a heated formed article in separate die sets and controlling cooling rates to form martensite in high-strength regions and ferrite, bainite, or pearlite in low-strength regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot press forming is used to manufacture ultra high-strength steel parts, then tensile strength is improved, but elongation becomes very low and forming limitations increase
Solution Approach 1:
The patent applies different cooling rates to different regions of the steel sheet during hot press forming. By using a cooling rate control section in the die, specific areas receive intensified cooling to achieve martensite transformation for high strength, while other areas receive standard cooling to maintain formability and achieve desired microstructures like ferrite or bainite.
Solution Approach 2:
The patent changes the cooling rate parameter spatially across the die surface. The cooling rate control section modifies the thermal parameters by providing additional cooling pathways (cooling holes or channels) in specific regions, thereby creating localized variations in cooling rate that result in different microstructures and mechanical properties in different parts of the formed component.
2Ease of manufacture
If uniform cooling is applied in hot press forming, then processing is simple, but all regions have same physical properties which is insufficient for multi-functional parts
Solution Approach 1:
The patent introduces a cooling rate control section that creates localized cooling zones within the die. This allows different regions of the steel sheet to experience different cooling rates, producing a gradient of microstructures (martensite, bainite, ferrite) and corresponding mechanical properties (strength, ductility) tailored to specific functional requirements of different parts of the component.
Solution Approach 2:
The die is segmented into different cooling zones: a standard cooling section and a cooling rate control section. This segmentation allows independent control of cooling parameters in different areas, enabling the manufacture of multi-physical property parts from a single steel sheet while maintaining process integration.
3Manufacturing precision
If additional heating devices or die surface treatment are used to create multi physical properties, then physical property control is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The die serves multiple functions: it provides the forming geometry, standard cooling, and localized intensified cooling through the integrated cooling rate control section. By combining these functions into a single tooling component, the patent avoids the need for separate heating devices or die surface treatments, thereby maintaining manufacturing simplicity while achieving precise physical property control.
Solution Approach 2:
The die structure itself provides the cooling rate control function through its internal cooling channels or holes. The die serves its own cooling control needs without requiring external heating devices or complex surface treatments, thereby reducing overall system complexity while achieving the desired multi-physical property outcomes.
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 economical and simple manufacturing of multi physical properties parts with controlled strength distribution, reducing processing costs and complexity, and achieving high-strength regions with martensite and low-strength regions with desired microstructures, thus addressing the limitations of existing HPF techniques.
Implementation Method 1
a heated formed article into a multi physical properties part including two or more regions having different physical properties by differing cooling conditions in the respective die set
Data Source
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AI summary
Provided is a multi physical properties part used in automotive components required to be lightweight and provide collision safety, and a method of manufacturing a multi physical properties part, in which the multi physical properties part may be more economically and simply manufactured by using two or more separated die sets without using an additional heating device or treating a die surface. According to an aspect of the present invention, there is provided a method of manufacturing a multi physical properties part, which includes positioning a single heated formed article in two or more die sets, and then manufacturing a multi physical properties part including two or more regions having different physical properties by differing cooling conditions in the respective die set.