Rounding Polymer Automotive Edges via Segmented Stamping
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Solution Overview
Problem
The existing stamping process for producing openings in polymer automotive components is inflexible, costly, and prone to white fracture formation, with limited design freedom and high costs associated with tool changes for different vehicle models.
Innovation Solution
A 2-stage process where openings are first created, followed by a separate step to stamp rounded edges using an embossing tool with a contour matching the desired radius, allowing for maximum flexibility and cost-effectiveness, and avoiding stress whitening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a stamping process is used to produce openings with rounded edges, then the edges can be rounded, but the process is inflexible and costly with high tooling costs for each hole geometry
Solution Approach 1:
The process is divided into two separate stages: first creating the opening (breakthrough) and then separately stamping the radius on the peripheral edge. This segmentation allows different tools and methods to be used for each function, enabling flexibility in opening creation while maintaining rounded edges through the separate radius stamping step.
Solution Approach 2:
The radius stamping tool is designed to be universal and can be used for different opening geometries and vehicle models. By separating the radius stamping function from the opening creation, a single radius stamping tool can serve multiple purposes across different products, reducing the need for dedicated tools for each hole geometry.
2Shape
If a stamping process is used to produce openings with rounded edges, then the edges can be rounded, but the costs are very high due to separate punching tools and replacement tools for each hole geometry
Solution Approach 1:
By separating opening creation from radius stamping, the process allows use of simpler, more cost-effective methods for each function. The radius stamping can be performed with a single universal tool rather than requiring expensive dedicated punching tools for each opening geometry.
Solution Approach 2:
The invention changes the process parameters by separating the radius stamping step from opening creation, allowing the use of more cost-effective tools and methods for each function, thereby reducing overall production costs while maintaining quality rounded edges.
3Ease of manufacture
If a stamping process is used to produce openings, then openings can be created, but white fracture formation occurs on the cut surfaces
Solution Approach 1:
The process separates opening creation from edge rounding, allowing the use of cutting methods optimized for opening creation without the constraint of avoiding white fracture. The subsequent radius stamping step then addresses the edge quality without compromising the opening creation process.
4Adaptability or versatility
If punching tools are redesigned for each vehicle model, then openings can be adapted to different models, but the costs are very high for article changes
Solution Approach 1:
The radius stamping tool is designed as a universal tool that can be used across different vehicle models and opening geometries. This universality eliminates the need to redesign radius stamping tools for each article change, significantly reducing tooling costs for model updates and facelifts.
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 method significantly reduces production costs, eliminates the risk of stress whitening, and provides maximum design flexibility, ensuring a smooth appearance even after coating, by separating the opening creation from radius imprinting and allowing for CNC-controlled production.
Implementation Method 1
this embossing tool is now pressed against the surrounding edge along the inner border, which triggers a local flow of material on the sharp edge with an accompanying rounding of the edge
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The invention relates to a method for producing a polymer motor vehicle component (2), in particular an outer add‑on part in the form of a bumper, spoiler, sill, mud guard or the like. First of all, a polymer body shell part (6) is produced, preferably by means of an injection‑moulding method, wherein, then, at least one aperture (3) is produced in the body shell part (6), optionally by means of a first automated method step, the aperture then defining an inner border (7) of the body shell part (6), and wherein, then, in a separate, second automated method step, a stamped formation (R) of a radius onto the peripheral edge (9) formed by the outer body shell‑part surface (8) and inner border (7) and/or onto an outer edge formed by the outer border of the body shell part (6) takes place by a stamping tool (10) having a contour corresponding to the desired radius (r) of the stamped formation (R) being pressed along the inner border (7) against the peripheral edge (9) and/or along the outer border of the body shell part (6) against the outer edge.