Vehicle Press-Formed Wall Structure for Wrinkle Suppression
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Solution Overview
Problem
Wrinkles easily form on the curved surface of press-formed products, particularly in the region closer to the flange, which affects the appearance quality.
Innovation Solution
The press-formed product design includes a wall with a first curved surface and a second curved surface, where the radius of curvature of the second surface is smaller than the first, and a stepped surface is introduced to disperse material flow, inhibiting buckling and reducing wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the radius of curvature of the curved surface near the flange is reduced, then the circumferential length increases and material flow is dispersed, but the structural complexity increases due to the need for multiple curved surfaces with different radii
Solution Approach 1:
The patent applies local quality by differentiating the radius of curvature in different regions of the curved surface. Specifically, the curved surface is divided into a first region (farther from flange) with a first radius of curvature and a second region (closer to flange) with a second radius of curvature that is smaller than the first. This local differentiation allows material flow to be dispersed in the circumferential direction where wrinkles are most likely to form, while maintaining appropriate curvature in other regions.
Solution Approach 2:
The curved surface is segmented into multiple regions with different curvature characteristics. The segmentation creates distinct zones: a first curved surface region with larger radius of curvature and a second curved surface region with smaller radius of curvature near the flange. This segmentation enables targeted control of material flow in different areas, particularly dispersing material flow in the second region to prevent wrinkle formation.
2Manufacturing precision
If a stepped surface is added to the wall, then material flow is dispersed in the extension direction enhancing anti-buckling effect, but the device complexity increases
Solution Approach 1:
The patent introduces a stepped surface that extends in the axial direction (extension direction of the wall), adding a dimensional element to the curved surface geometry. This stepped portion creates an additional dimension for material flow dispersion, allowing material to spread not only in the circumferential direction but also in the axial direction, thereby enhancing the anti-buckling effect and further preventing wrinkle formation.
3Reliability
If the circumferential length of the wall near the flange is increased, then material flow is dispersed and buckling is inhibited, but the wall length in extension direction increases
Solution Approach 1:
The patent utilizes curvature variations to achieve the desired effect. By reducing the radius of curvature in the second region (near the flange) compared to the first region, the curved surface creates a geometry that naturally disperses material flow in the circumferential direction. This curvature-based approach increases the effective circumferential length and enhances the anti-buckling effect without requiring a proportional increase in the axial length of the wall.
Data Source
AI summary
A press-formed product of the present disclosure includes a plate-shaped portion, a wall, and a flange. The wall includes at least one curved surface having an arcuate cross-sectional shape that bulges radially outward in a cross-section taken along the plate-shaped portion. The at least one curved surface includes a first curved surface and a second curved surface. The second curved surface is a portion closer to the flange than the first curved surface. A radius of curvature of the second curved surface in the cross-section is configured to be smaller than a radius of curvature of the first curved surface in the cross-section.