Press-Formed Sheet Rigidity Positioning for Springback Reduction
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Solution Overview
Problem
Conventional methods for reducing springback in press-forming of high-strength steel sheets are inadequate, especially for components with low rigidity, as they fail to effectively specify positions for rigidity improvement and may introduce new stresses, leading to incomplete springback suppression.
Innovation Solution
A press-forming method that involves repeatedly performing springback analysis on a virtually rigidified analysis model to identify positions for rigidity improvement, allowing for efficient suppression of springback by restricting stretch and shrink deformation while permitting rotation, and applying rigidity measures to these specified positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional springback measures (emboss crushing, excess bead formation, or shape optimization analysis) are applied, then residual stress uniformity is improved, but the device complexity and difficulty of detecting and measuring springback reduction increase
Solution Approach 1:
The patent replaces complex mechanical springback control methods (emboss crushing, excess bead formation) with a computational approach using finite element analysis. The system uses software-based springback analysis to automatically determine optimal rigidity improvement positions, substituting mechanical process complexity with computational analysis that is easier to implement and control.
Solution Approach 2:
The patent creates a virtual copy of the press-formed product using finite element analysis models. By analyzing the virtual model to determine springback characteristics and rigidity improvement positions, the system avoids the need for physical trial-and-error testing, thereby reducing device complexity while maintaining precision.
2Manufacturing precision
If shape optimization analysis is performed to detect rigidity contributory positions, then springback suppression effectiveness is improved, but the ease of operation and time required for analysis decrease
Solution Approach 1:
The patent performs preliminary springback analysis using finite element methods before the actual press-forming process. By pre-determining the rigidity improvement positions through computational analysis, the system eliminates the need for time-consuming trial-and-error physical testing, thereby reducing overall analysis time while maintaining suppression effectiveness.
Solution Approach 2:
The patent replaces time-consuming physical shape optimization analysis with computational finite element analysis. The system uses software to rapidly evaluate springback characteristics and determine optimal rigidity improvement positions, significantly reducing analysis time compared to traditional mechanical testing methods.
3Manufacturing precision
If rigidity improvement measures are applied to specified positions, then springback is reduced, but new stresses may be introduced that require additional analysis
Solution Approach 1:
The patent employs an iterative feedback process where finite element analysis is performed, springback is evaluated, rigidity improvement positions are determined, and the effects of rigidity improvement measures are analyzed. This closed-loop feedback system automatically identifies and compensates for new stresses introduced by rigidity improvement measures, maintaining precision while managing analysis complexity through systematic iteration.
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 enables precise specification of optimal rigidity improvement positions, effectively reducing springback and improving shape fixability in press-formed products without requiring complex optimization analyses.
Implementation Method 1
restricting a stretch and shrink deformation while permitting rotation with respect to a specific position of a formed-product model
Implementation Method 2
The springback is caused by elastic recovery generated when a bending moment due to a non-uniform residual stress is released at the removal of the press-formed product from the die
Implementation Method 3
crushing the emboss to apply a compressive stress to the stretch flange portion and a tensile stress to the shrink flange portion
Data Source
AI summary
An object to provide a press-forming method that can efficiently suppress springback and easily specify a position where a springback reduction effect by rigidity improvement is large, and the press-forming method used in producing a press-formed product having a predetermined shape by press-forming a sheet material, the method including: a first process that repeatedly performs a springback analysis, while changing a position to be restricted, to specify a position where a springback reduction effect by rigidity improvement is large; a second process that performs a rigidity improvement measure on a position of the sheet material corresponding to the position of the formed-product model specified in the first process; and a third process that produces the press-formed product by press-forming the sheet material on which the rigidity improvement measure has been performed.