Press-Forming Accuracy Evaluation Using Measured Blank Shape
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Solution Overview
Problem
Conventional press-forming analyses assume a flat blank, failing to accurately evaluate the analysis accuracy when press forming is performed using a metal sheet with shape variations, leading to potential deviations in dimensional accuracy of the press-formed parts.
Innovation Solution
An analysis accuracy evaluation method that generates an actual press-formed part shape and an actual blank model based on measured data, performs a press-forming analysis using these models, and compares the results to evaluate the accuracy of the analysis by determining the deviation amount of shape change.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flat blank is used in press-forming analysis, then the analysis process is simple and conventional methods can be applied, but the analysis accuracy deteriorates when the actual metal sheet has large shape variations
Solution Approach 1:
The patent applies preliminary action by measuring and capturing the actual shape of the metal sheet blank before press-forming analysis. The shape measurement data is obtained in advance and used to create a realistic blank model that reflects the actual waveform of the metal sheet, thereby improving analysis accuracy from the outset rather than assuming a flat blank
Solution Approach 2:
The patent changes the fundamental parameter of the blank model from an idealized flat shape to a realistic waveform shape based on actual measurement data. This parameter change allows the analysis to reflect the true conditions of press-forming with non-flat blanks, resolving the contradiction between simplicity and accuracy
2Ease of manufacture
If the shape variation of the metal sheet is ignored, then the analysis process remains conventional and simple, but the dimensional accuracy of the press-formed part cannot be obtained accurately when shape variation is large
Solution Approach 1:
The patent applies copying by creating a digital model that accurately replicates the actual shape of the metal sheet blank based on measurement data. This copied model preserves the waveform characteristics of the original blank, enabling reliable analysis without requiring complex physical prototypes or simplifying assumptions
3Productivity
If conventional press-forming analysis is performed without evaluating analysis accuracy, then the analysis can be completed quickly, but the reliability of the press-formed part shape prediction cannot be ensured
Solution Approach 1:
The patent applies feedback by comparing the analysis result obtained using the actual blank model with the actual press-formed part shape. This comparison provides feedback on the accuracy of the analysis, allowing users to evaluate whether the analysis results are reliable and making informed decisions about design iterations or process optimizations
Data Source
AI summary
An analysis accuracy evaluation method includes: generating, based on measurement data obtained by measurement of a shape after die release of an actual press-formed part press-formed with a predetermined tool of press forming by utilization of an actual blank taken from a metal sheet having shape variation; generating an actual blank model having a same shape as the actual blank based on measurement data; acquiring a press-formed part shape after die release as an analysis press-formed part shape by performing, by using the actual blank model, a press-forming analysis of when press forming is performed with a model of a tool of press forming which model has a same shape as the predetermined tool of press forming; and comparing the actual press-formed part shape and the analysis press-formed part shape, obtaining a deviation amount of shape change of the both shapes, and evaluating accuracy of the press-forming analysis.