Sheet Metal Preform Torsion Offsets for Accurate Sizing

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Solution Overview

Problem

Existing methods for producing sheet metal components face challenges in achieving dimensional accuracy due to springback and torsion issues, especially with ultra-high-strength materials, leading to deviations in the final component geometry.

Innovation Solution

The method involves configuring the preforming tool's effective surfaces to create a sheet metal preform with specific torsion and curvature differences relative to the sizing tool, allowing for minimal deviation from the final component geometry by compensating for springback and torsion during the sizing process, thereby ensuring high dimensional accuracy without additional forming steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If deep drawing with an active outer blank holder is used to produce the preform, then material distribution can be controlled, but tensile forces increase causing excessive springback and torsion in ultra-high-strength materials

Engineering Contradiction:

Improvematerial distribution uniformityVSAvoidspringback and torsion

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The preforming tool effective surfaces are configured to establish a torsion angle difference that pre-compensates for the springback and torsion that will occur during sizing. By intentionally creating a counteracting torsion state in the preform, the harmful effects are neutralized in the final component.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The invention changes the geometric parameters of the preforming tool effective surfaces relative to the sizing tool effective surfaces. Specifically, a torsion angle difference of at least 0.2° is established between the two tool sets, which alters the preform geometry to compensate for subsequent springback.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If the preforming tool effective surfaces are configured to match the sizing tool effective surfaces, then the process is simple, but the final component geometry deviates from the setpoint due to springback

Engineering Contradiction:

Improvetool configuration simplicityVSAvoidfinal component geometry accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Instead of matching the tool surfaces, the preforming tool effective surfaces are deliberately configured with a torsion angle difference relative to the sizing tool surfaces. This preliminary anti-action creates a preform that, after springback, achieves the desired final geometry.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The preforming tool is pre-configured with specific geometric deviations (torsion angle difference ≥0.2°) before the forming process begins. This preliminary action ensures that when springback occurs during sizing, the final component matches the setpoint geometry.

Inventive Principle:

Principle #10Preliminary action

3Object-generated harmful factors

If crash forming or stamping/edging without an outer blank holder is used, then tensile forces are reduced, but uncontrolled stretching occurs leading to excessive material distribution variations

Engineering Contradiction:

Improvetensile forcesVSAvoidmaterial distribution control

Core Design Contradiction:

Object-generated harmful factorsVSManufacturing precision

Solution Approach 1:

The invention changes the geometric parameters of the preforming tool effective surfaces to establish a torsion angle difference relative to the sizing tool. This parameter change allows the use of low-tensile-force forming methods while still achieving controlled material distribution through the compensatory geometry.

Inventive Principle:

Principle #35Parameter changes

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 production of sheet metal components with minimal deviation from the setpoint geometry, reducing the need for complex correction processes and ensuring reliable insertion and sizing results, even with high-strength materials.

Implementation Method 1

the unwanted, batch-dependent springback of the component, which occurs especially in the case of ultra-high-strength materials

Methodology Applied

Scientific EffectSpringback: Elastic Recovery

Implementation Method 2

this additional excess material is compressed in the direction of the sheet plane. During this process, the inhomogeneous state of stress of the preform is realigned

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS20240335870A1Method for the production of sheet metal parts and device therefor

Publication Date: 2024.10.10 THYSSENKRUPP STEEL EUROPE AG PATENTE PATENT DEPARTMENT

AI summary

The invention relates to a method and to a device for producing sheet metal components with substantially reduced springback.