Press-Molded Article Forming With Pre-Bent Stock for Wall Precision
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Solution Overview
Problem
The existing pressed component manufacturing methods face challenges in maintaining dimensional precision of vertical walls due to excessive width direction dimension changes caused by variations in the projection amount of the punch-side pad, limiting the range of acceptable projection amounts and requiring precise adjustments.
Innovation Solution
A method involving the use of an intermediate stock with pre-bent portions and a press configuration where the inner pad projects from the punch and the die pad projects from the die, allowing for the formation of vertical walls and a top plate while suppressing the second moment, thereby regulating the width direction displacement of the vertical walls using primarily the first moment, expanding the range of acceptable projection amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the projection amount of the punch-side pad is increased to suppress spring-back, then the dimensional precision of the pressed component is improved, but the width direction dimension of the vertical wall changes excessively
Solution Approach 1:
The intermediate stock is pre-formed with bent portions at specific positions before the main pressing operation. These pre-formed bent portions are positioned at locations corresponding to where the first and second moments act on the vertical wall, allowing the pressing operation to work with pre-positioned stress distribution rather than creating excessive moments during forming.
Solution Approach 2:
The invention changes the geometric parameters of the intermediate stock by forming bent portions with specific curvature and positioning them at predetermined locations. This parameter modification allows the subsequent pressing operation to achieve the desired vertical wall dimensions without excessive width direction displacement, even when using larger pad projection amounts.
2Stability of the object's composition
If the projection amount of the punch-side pad is reduced to minimize width direction displacement, then the vertical wall dimension stability is improved, but the spring-back suppression becomes insufficient
Solution Approach 1:
The intermediate stock is pre-formed with bent portions that create favorable stress distribution before pressing. This preliminary action ensures that when the pad presses the vertical wall, the pre-positioned bent portions work together with the pressing force to suppress spring-back effectively, even when using smaller pad projection amounts that maintain dimensional stability.
Solution Approach 2:
By modifying the intermediate stock geometry with pre-formed bent portions at specific locations and curvatures, the invention enables effective spring-back suppression with reduced pad projection amounts. The pre-formed geometric parameters compensate for the reduced pressing force, maintaining both stability and precision.
3Productivity
If the range of punch-side pad projection amounts is expanded for productivity, then the manufacturing efficiency is improved, but the dimensional precision control becomes difficult
Solution Approach 1:
The pre-formed intermediate stock with bent portions creates a robust process that is less sensitive to variations in pad projection amount. The preliminary geometric configuration ensures that even with larger variations in projection amount (expanded range), the first and second moments remain controlled, maintaining dimensional precision across a wider operating range and improving productivity.
Solution Approach 2:
The invention changes the intermediate stock parameters (bent portion geometry and positioning) to create a process window that tolerates larger variations in pad projection amount. This parameter modification decouples the tight relationship between projection amount and dimensional precision, allowing expanded projection amount ranges without sacrificing precision 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
This method secures dimensional precision of the pressed component's vertical walls within tolerance even with an expanded range of projection amounts, enhancing productivity by reducing the need for precise adjustments and minimizing excessive width direction displacement.
Implementation Method 1
A method to manufacture a pressed component from an intermediate stock by employing a press including a die that is provided with a die pad, and a punch that is disposed opposing the die and that is provided with an inner pad... with a pair of bent portions inflected toward the one plate thickness direction side... suppressing the second moment, thereby regulating the width direction displacement of the vertical walls using primarily the first moment
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
In a pressed component manufacturing method according to the present disclosure, a pressed component is manufactured from an intermediate stock. The pressed component manufacturing method employs a press including a die provided with a die pad, and a punch provided with an inner pad. The intermediate stock includes a pair of bent portions inflected toward one plate thickness direction side, with a spacing between the pair of bent portions set as a narrower spacing than a width of a top plate of the pressed component. The pressed component manufacturing method includes a first step, a second step, and a third step. The first step involves gripping a portion of the intermediate stock between the pair of bent portions with the inner pad and the die pad in a state in which the inner pad projects from the punch toward the die side, and one plate thickness direction side of the intermediate stock is on the side of the inner pad. The second step involves moving the die toward the punch side and forming the vertical walls of the pressed component. The third step involves integrating the die and the die pad into a single unit, and then moving the integrated die and the die pad, and the inner pad toward the punch side to form the top plate of the pressed component.