Press-Molding Pad Member for Vertical Wall Thickening
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Solution Overview
Problem
Press molding techniques face challenges in thickening vertical wall portions without causing buckling, particularly in vehicle parts where increased strength and rigidity are required.
Innovation Solution
A press-molding apparatus and method that includes support members, a punch member, and a pad member with a position adjustment mechanism to maintain contact with the vertical wall portion during the thickening process, preventing buckling by adjusting the distance and position to ensure uniform thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If press molding is performed to reduce the height of the vertical wall portion, then the vertical wall portion is thickened to increase strength, but buckling occurs in the vertical wall portion
Solution Approach 1:
A pad member is introduced as an intermediary element between the punch member and the vertical wall portion. The pad member applies distributed pressure along the vertical wall portion during press molding, preventing buckling while enabling thickness increase. The pad member acts as a mediator that transforms the concentrated force from the punch into a distributed support force along the wall portion.
Solution Approach 2:
The pad member is positioned in advance along the vertical wall portion before the press molding process begins. This preliminary positioning ensures that support is already in place when the punching force is applied, preventing buckling from occurring during the thickening process. The support structure is prepared beforehand to handle the upcoming deformation.
2Reliability
If the vertical wall portion is thickened by press molding, then collision safety and body rigidity are improved, but the molding process becomes difficult to control due to buckling
Solution Approach 1:
The pad member serves as a mediator that enables precise control of the vertical wall portion during thickening. By distributing the molding force along the wall portion, the pad member prevents unpredictable buckling and ensures uniform thickness increase, thereby improving manufacturing precision while achieving the desired reliability enhancement.
Solution Approach 2:
The pad member changes the pressure distribution parameter during press molding, transforming it from a concentrated point load to a distributed line load along the vertical wall portion. This parameter change in force distribution prevents buckling and enables precise control over the thickening process, ensuring uniform shape transformation.
3Manufacturing precision
If a pad member is introduced to prevent buckling, then the vertical wall portion can be thickened appropriately, but the device complexity increases
Solution Approach 1:
The pad member is designed as a flexible element that can conform to the vertical wall portion's shape during press molding. This flexibility allows the pad to distribute pressure evenly along the wall portion, ensuring uniform thickness increase. The simple yet effective design of the flexible pad member adds minimal complexity to the apparatus while achieving precise molding control.
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 solution effectively thickens vertical wall portions while preventing buckling, enhancing the strength and rigidity of press-molded products, such as vehicle components, by maintaining contact and adjusting the distance between components during the molding process.
Implementation Method 1
a biasing member that biases the pad member toward the vertical wall portion
Implementation Method 2
a pressing portion that is formed in the punch member and presses the inclined surface to cause the pad member to move in a direction going away from the first support member during the press working
Data Source
AI summary
[Object] To provide a press-molding apparatus capable of appropriately thickening a vertical wall portion while preventing the occurrence of buckling. [Solution] Provided is a press-molding apparatus configured to mold a press-molded product by performing press working on a work, the press-molding apparatus including: a support member that supports the work with a first thickness having a hat-shaped cross-section or a U-shaped cross-section; a punch member that moves relative to the support member to execute press working so as to reduce a height of a vertical wall portion of the work and thicken the vertical wall portion to a second thickness; and a pad member that faces the support member with the vertical wall portion to be thickened placed therebetween, the pad member being biased by a biasing member and having its distance to the support member kept equal to or smaller than the second thickness during the press working.