Multistage Hot Press Forming for Complex High-Strength Parts
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Solution Overview
Problem
The hot press forming method faces limitations in manufacturing complex shapes with high strength due to the requirement of rapid cooling, making it difficult to apply multistage forming processes, and existing methods incur additional costs and complexity with indirect hot press forming or require extensive heating furnace lengths.
Innovation Solution
A method and apparatus for a multistage hot press forming process involving heating, notching, blanking, forming, and trimming of a strip material using a single press with multiple molds, allowing for rapid heating and uniform temperature distribution, and minimizing cooling time to achieve complex shapes with high tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single hot press forming process is used to manufacture parts, then high strength can be achieved through rapid cooling, but it is not possible to manufacture complex part shapes that require multiple forming steps
Solution Approach 1:
The patent divides the forming process into multiple stages by installing multiple molds (first forming mold, second forming mold, trimming mold) on a single press. The strip material sequentially passes through notching, blanking, forming, and trimming operations in one continuous process, enabling complex shape creation while maintaining strength through controlled cooling at each stage.
2Shape
If indirect hot press forming is used to manufacture complex shapes, then multi-step forming can be achieved, but additional production costs and special heating equipment are required
Solution Approach 1:
The patent combines multiple forming operations (notching, blanking, forming, trimming) and heating functionality into a single integrated press system. All molds are mounted on one press that provides both forming action and heating capability, eliminating the need for separate heating furnaces and reducing production costs while achieving complex shapes.
3Shape
If multiple presses and molds are used for multistage forming, then complex shapes can be manufactured, but productivity decreases due to extensive transfer and positioning time
Solution Approach 1:
The patent installs multiple molds (notching mold, blanking mold, first forming mold, second forming mold, trimming mold) on a single press, allowing continuous sequential processing of the strip material without transfer between presses. This integration maintains high productivity while achieving complex shapes through coordinated multi-stage forming.
4Strength
If rapid cooling is applied to secure high strength, then tensile strength of 1,300 MPa or more is achieved, but cooling time must be precisely controlled to prevent excessive cooling before forming is complete
Solution Approach 1:
The patent applies notching and blanking operations to the strip material before the main forming process while the material is still at high temperature. This preliminary action creates expansion spaces that facilitate subsequent forming operations, and the sequential process design ensures optimal cooling control at each stage to achieve high strength without excessive cooling.
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 stable and efficient production of hot press formed members with improved productivity and formability, achieving complex shapes with a tensile strength of 1,300 MPa or more, while reducing heating furnace length and operational costs.
Implementation Method 1
a heating step of heating a strip material
Implementation Method 2
rapid cooling of a high-temperature material
Data Source
AI summary
Provided are a method and apparatus for manufacturing hot press formed parts for a multi-step process, the method comprising: a heating step for heating a strip material; a transferring step for transferring the heated strip material to a processing apparatus having mounted on a press a plurality of molds comprising a notching mold and/or a blanking mold, a forming mold, and a trimming mold; a notching step, for obtaining a notched material connected to the strip by means of a web portion by cutting a part of the material by means of the notching mold, and/or a blanking step for obtaining a blanked material separated from the strip by cutting a part of the material by means of the blanking mold; a forming step of transferring and positioning the material which has gone through the notching step and/or the blanking step near the forming mold, and then forming the material by means of the forming mold; and a trimming step for removing, by means of the trimming mold, an outer edge portion of the material which is unnecessary for a final product shape.