Piercing Die for Press-Formed Boss Swaging
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Solution Overview
Problem
The existing methods for forming press-formed metal components with tubular boss and flange portions, particularly with high-strength materials, suffer from low manufacturing efficiency and are prone to forming defects like breakage and cracking due to separate steps for swaging and projection end portion removal.
Innovation Solution
A method that integrates the removal of the projection end portion and swaging into a continuous single step using a piercing die and punch, where the piercing punch and die move relative to each other to punch out and thicken the preform boss portion, eliminating the need for separate steps and enhancing accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate steps are used for swaging and projection end portion removal, then each step can be performed independently, but manufacturing efficiency is low and production time is increased
Solution Approach 1:
The patent combines the swaging process and projection end portion removal process into a single integrated operation. The piercing die performs both functions simultaneously: the main body of the die swages the boss portion to increase wall thickness, while the inwardly extending portion with cutting edge removes the projection end portion in one continuous action, thereby improving manufacturing efficiency without requiring separate processing steps
2Manufacturing precision
If ordinary press forming method is applied to high strength material, then the material can be formed, but the boss portion is likely to suffer forming defects such as breakage and cracking
Solution Approach 1:
The piercing die features a specialized inwardly extending portion with a cutting edge that is specifically designed for high strength materials. This local structural modification allows the projection end portion to be cleanly cut rather than deformed, preventing breakage and cracking that would occur with conventional press forming methods. The cutting edge portion provides localized quality enhancement exactly where needed for high strength material processing
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 improves manufacturing efficiency and ensures accurate formation of press-formed components with tubular boss and flange portions, even with high-strength materials, by integrating the projection end removal and swaging processes, reducing defects and allowing for the use of thinner materials with minimal machining requirements.
Implementation Method 1
causing the piercing die and the piercing punch to move relative to each other so as to cause the piercing punch to enter the piercing die and separate a projection end portion of the preform boss portion
Implementation Method 2
press the preform boss portion by the inwardly extending portion of the second forming portion of the piercing die to thereby swage the preform boss portion
Data Source
AI summary
A die apparatus for forming a press-formed component includes a piercing die, a piercing punch, and a support. The piercing die includes a tubular first forming portion for forming a boss portion and a second forming portion having a cutting edge and an inwardly extending portion. The second forming portion is adapted to perform pressing of a preform while cutting a portion thereof. A cutting edge which cooperates with the cutting edge of the second forming portion is formed at a distal end of the piercing punch. When forming a press-formed component, a projection end portion of a preform formed from a blank by drawing is cut and removed by the two cutting edges, and a preform boss portion is then pressed and swaged by the inwardly extending portion.