Press-Formed Blank Correction for Shape Variation Accuracy
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Solution Overview
Problem
Existing press forming technologies fail to account for and mitigate the influence of shape variations in blanks extracted from metal sheets, leading to deviations in dimensional accuracy of press-formed articles, particularly in high-strength steel sheets used in vehicle bodies.
Innovation Solution
A method involving press forming analysis with reference and corrugated blank models to identify deviation amounts, followed by specifying measures-required portions and correcting the die and blank shapes to reduce the impact of shape variations, using beads to improve forming accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press forming is performed on a blank extracted from a metal sheet having shape variation, then the manufacturing process can be completed, but the dimensional accuracy of the press-formed article deviates from target specifications
Solution Approach 1:
The patent performs press forming analysis in advance using both a flat blank model and a corrugated blank model (with wavelength and amplitude matching actual blanks) to predict deviation portions before actual manufacturing. This preliminary simulation identifies which areas will be affected by shape variations, allowing preventive measures to be planned beforehand.
Solution Approach 2:
The patent identifies specific deviation portions in the press-formed article that are most affected by blank shape variations. Instead of treating the entire article uniformly, it applies corrective measures (such as providing beads) specifically to these identified deviation portions, making the correction targeted and efficient.
2Productivity
If multiple blanks are extracted from the same metal sheet at different positions, then material utilization is improved, but each blank has different shape variations making consistent quality control difficult
Solution Approach 1:
The patent incorporates the wavelength and amplitude parameters of the metal sheet's shape variation into the corrugated blank model for simulation. By matching these parameters to actual conditions, the analysis accurately predicts how different blank positions will behave, enabling quality control despite variations between blanks from the same sheet.
3Manufacturing precision
If beads are provided to the die or blank to correct deviation portions, then dimensional accuracy is improved, but the device complexity and manufacturing process become more complicated
Solution Approach 1:
The patent applies beads only to specific deviation portions identified through simulation, rather than adding beads to the entire die or blank. This localized approach improves dimensional accuracy in critical areas while minimizing the increase in overall device complexity.
Data Source
AI summary
A press-formed article manufacturing method that can reduce the influence of a shape variation of a blank. The press-formed article manufacturing method includes: a reference press-formed article shape acquisition step of acquiring a reference press-formed article shape; a corrugated blank press-formed article shape acquisition step of acquiring a corrugated blank press-formed article shape; a first deviation amount acquisition step of finding first deviation amounts between the reference press-formed article shape and the corrugated blank press-formed article shape; a period-shifted corrugated blank press-formed article shape acquisition step of acquiring a period-shifted corrugated blank press-formed article shape; a second deviation amount acquisition step of finding second deviation amounts between the reference press-formed article shape and the period-shifted corrugated blank press-formed article shape; a measures-required portion specifying step of specifying measures-required portions; and a bead providing step of providing beads for an actual die.