Press Component Free Bending with Flange Crack Prevention
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Solution Overview
Problem
The free bending method for manufacturing press components often results in cracking in the flange on the inner circumferential side of the curved portion, especially when using ultra-high tensile strength steel sheets with specific dimensions and curvatures, limiting the forming capability and increasing manufacturing defects.
Innovation Solution
The method involves providing material inflow facilitating portions in the blank, such as beads or recesses, to increase the inflow amount of material into the flange area during press working, thereby reducing tensile stress and preventing cracking, and using a press-forming apparatus with a die and die pad to control the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If free bending method is used to manufacture press components with ultra-high tensile strength steel sheets, then strength is improved, but cracking occurs in the flange area
Solution Approach 1:
The patent applies preliminary action by providing material inflow facilitating portions (beads or recesses) on the blank before the press working process. These pre-formed features control material flow during forming, preventing cracking in the flange area while maintaining the use of ultra-high tensile strength steel sheets. The beads or recesses are created in advance to guide material inflow during the subsequent bending forming process.
Solution Approach 2:
The patent applies local quality by creating localized material inflow facilitating portions (beads or recesses) at specific locations on the blank where cracking is likely to occur. These local modifications alter the material flow characteristics only in critical areas, allowing the rest of the blank to maintain its original properties. This localized approach prevents cracking without requiring changes to the entire blank or reducing material strength.
2Ease of manufacture
If conventional free bending method is used, then manufacturing process is simple, but forming limit is low and cracking occurs
Solution Approach 1:
The patent maintains process simplicity while improving forming capability by adding a preliminary step of forming beads or recesses on the blank. This preliminary action is integrated into the existing press working process and does not require complex additional equipment. The beads or recesses are formed using standard pressing operations, keeping the manufacturing process simple while significantly expanding the range of formable components and preventing cracking.
Solution Approach 2:
The patent applies parameter changes by modifying the geometric parameters of the blank through the addition of beads or recesses. These geometric modifications change the material flow parameters during forming, enabling the process to handle more complex geometries and larger curvature radii without cracking. The parameter changes are achieved through controlled deformation during the pressing process itself.
3Adaptability or versatility
If material inflow facilitating portions are provided, then forming limit is improved, but device complexity increases
Solution Approach 1:
The patent applies self-service by designing the material inflow facilitating portions (beads or recesses) to be formed directly on the blank during the press working process itself. The blank serves its own dual function: as the material to be formed and as the carrier of the facilitating portions. This eliminates the need for separate devices or tools to create the beads or recesses, as the pressing apparatus itself performs both functions through controlled deformation.
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 raises the forming limit of the free bending method, allowing the manufacture of press components without cracking in the flange area, even under conditions where conventional methods fail, and enables the use of high-strength steel sheets with reduced sheet thickness, improving yield and reducing weight and cost.
Implementation Method 1
press working on a blank or a pre-formed blank disposed between a die and a die pad, and a punch that is disposed facing the die and die pad
Implementation Method 2
increasing an inflow amount by which a portion of the blank to be formed into an end portion flows into a portion of the blank to be formed into the flange on an inner circumferential side of the curved portion
Data Source
AI summary
A method and apparatus for manufacturing a press component without generating cracks in a flange on an inner circumferential side of a curved portion includes press working by a free bending method on a blank consisting of an ultra-high tensile strength steel sheet. A press component is manufactured by performing cold press working on a blank of an ultra-high tensile strength steel sheet. By the press working, a material inflow facilitating portion that increases the amount by which a portion of the blank to be formed into an end portion of the press component flows into a portion of the blank to be formed into a flange on an inner circumferential side of the curved portion of the press component is provided in the vicinity of the portion of the blank to be formed into the flange on an inner circumferential side of the curved portion of the press component.