Press-Forming Blank Variation Analysis for Shape Deviation Prediction

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Solution Overview

Problem

Existing methods fail to predict the effect of shape variation in blanks on press-formed parts, leading to potential deviations from target dimensional accuracy due to unevenness in metal sheets used for automotive parts, and do not identify susceptible portions within the press-formed parts.

Innovation Solution

A press forming analysis method and apparatus that generates and compares various blank models to predict shape variation effects, using steps such as shape acquisition, deviation amount calculation, and identification of portions requiring countermeasures, including springback analysis and comparison of flat, waveform, and cycle deviation models.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a flat blank model is used for press forming analysis, then the analysis process is simple, but the prediction accuracy of shape variation effects is insufficient

Engineering Contradiction:

Improveanalysis process complexityVSAvoidprediction accuracy of shape variation effects

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The invention performs preliminary actions by generating multiple blank models with different shape variation patterns (waveform blanks, cycle deviation waveform blanks) before the actual press forming analysis. This allows the system to pre-assess how different blank variations will affect the final press-formed part geometry, thereby improving prediction accuracy without significantly complicating the overall analysis workflow.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention creates multiple copies of the blank model with different shape variations (flat blank, waveform blank, cycle deviation waveform blank) to simulate real-world variability. By analyzing these copied models with varying degrees of shape variation, the system can predict the range of possible outcomes and identify critical areas without requiring complex experimental setups.

Inventive Principle:

Principle #26Copying

2Manufacturing precision

If multiple types of blank models with different shape variations are generated and analyzed, then the prediction accuracy of shape variation effects is improved, but the analysis time and computational resources increase

Engineering Contradiction:

Improveprediction accuracy of shape variation effectsVSAvoidanalysis time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The invention segments the analysis process into distinct stages: generating a flat blank model, generating waveform blank models with specific wavelength and amplitude, and generating cycle deviation waveform blank models. Each segment focuses on a specific aspect of shape variation, allowing for targeted analysis that reduces overall computational burden while maintaining comprehensive coverage of variation effects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies local quality by focusing analysis on specific portions of the blank that are most susceptible to shape variation effects. By identifying and analyzing critical regions (such as areas with high curvature or thin sections) separately from less critical areas, the system achieves high prediction accuracy for key features without unnecessarily analyzing the entire blank model in detail.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If the shape variation of individual blanks is considered in the analysis, then the prediction accuracy for specific blank positions is improved, but the complexity of the analysis process increases

Engineering Contradiction:

Improveprediction accuracy for specific blank positionsVSAvoidanalysis process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention systematically changes key parameters (wavelength, amplitude, cycle deviation) of the blank models to represent different shape variation scenarios. By varying these parameters in a controlled manner, the analysis can predict how specific blank positions will behave under different variation conditions without requiring completely separate analyses for each scenario, thus managing complexity while improving accuracy.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4446026B1Press-forming analysis method, press-forming analysis device, and press-forming analysis program

Publication Date: 2026.02.04 JFE STEEL CORP

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AI summary

A press forming analysis method according to the present invention includes: a shape acquisition step of a standard press-formed part; a generation step of a waveform blank model of generating a waveform blank model 7; a shape acquisition step of a press-formed part using the waveform blank model of acquiring a shape 9 of a waveform blank press-formed part; a first deviation amount acquisition step of obtaining a deviation amount of shape change between the shape 5 of the standard press-formed part and the shape 9 of the waveform blank press-formed part; a generation step of a cycle deviation waveform blank model of generating a cycle deviation waveform blank model 11; a shape acquisition step of a press-formed part using the cycle deviation waveform blank model of acquiring a shape 13 of a cycle deviation waveform blank press-formed part; a second deviation amount acquisition step of obtaining a deviation amount of shape change between the shape 5 of the standard press-formed part and the shape 13 of the cycle deviation waveform blank press-formed part; and a step to identify portions requiring countermeasures of identifying a portion requiring countermeasures.