Press-Forming Blank Geometry for Crack-Free Hat-Section Curves
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Solution Overview
Problem
The free bending method for pressing L-shaped, T-shaped, and Y-shaped profile components often results in cracking at the flange and top plate edges due to excessive inflow of the blank, particularly when the width of the top plate section is long, and there is no established technique to prevent these issues effectively.
Innovation Solution
A blank with an excess portion at the edge of the flange section, featuring a protrusion and recesses, is used to control the inflow and reduce deformation, thereby preventing flange cracking and top plate edge cracking by allowing the protrusion to absorb excess displacement and the recesses to straighten out and reduce stress concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressing by bending is used to manufacture L-shaped, T-shaped, and Y-shaped profile components, then manufacturing efficiency is improved, but cracking occurs at the flange and top plate edges due to excessive inflow of the blank
Solution Approach 1:
The invention applies preliminary action by pre-forming the blank with an excess portion, protrusion, and recesses before the actual pressing operation. This pre-shaping controls the material flow during pressing, preventing excessive inflow that causes cracking while maintaining the efficiency of the bending process. The excess portion is strategically designed to compensate for material displacement in critical areas.
Solution Approach 2:
The invention applies local quality by creating non-uniform features (excess portion, protrusion, recesses) at specific locations on the blank rather than uniform modifications throughout. The excess portion is positioned at the edge of the flange section where cracking is most likely to occur, and the protrusion and recesses are strategically placed to control local material flow and stress distribution during forming.
2Strength
If the width of the top plate section is increased, then the structural strength is improved, but the risk of cracking at the edges increases due to greater material displacement
Solution Approach 1:
The invention applies preliminary action by pre-forming the blank with an excess portion and surface modifications before pressing. This allows wider top plate sections to be manufactured without edge cracking, as the excess portion compensates for the greater material displacement that occurs during forming of wider sections.
Solution Approach 2:
The invention applies parameter changes by modifying the blank geometry (adding excess portion, protrusion, and recesses) to change the material flow characteristics during pressing. This allows the manufacturing of components with larger dimensions (wider top plate sections) that would otherwise cause cracking due to excessive material displacement.
3Manufacturing precision
If drawing method is used to suppress creasing, then surface quality is improved, but a broad trim region is required which reduces manufacturing yield
Solution Approach 1:
The invention applies preliminary action by pre-forming the blank with excess portion and surface modifications before pressing. This controls material flow during forming, suppressing creasing without requiring a broad trim region, thereby maintaining high manufacturing yield while achieving good surface quality.
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 effectively suppresses creasing and cracking in the press formed articles, enabling the use of high-strength blanks without weight or cost increases, and allows for longer top plate section widths without modification, improving the manufacturing yield and quality.
Implementation Method 1
pressing by bending to form a press formed article; the blank is pressed by bending to form a press formed article
Data Source
AI summary
A blank that is a material for an elongated press formed article having a substantially hat shaped lateral cross-section profile including a top plate section, a ridge line section, a flange section, and vertical wall section, and configured with a first portion in which the top plate section has a fixed width, and a second portion including a curved portion in which the top plate section exhibits an L-shape in plan view due to the vertical wall section, the ridge line section, and the flange section curving along with the width of the top plate section gradually increasing. The blank has a shape of an opened-out shape of the press formed article, additionally with a first recess, a protrusion, and a second recess provided to an edge of an excess portion additionally provided at an edge of a location that will form the flange section configuring the curved portion.