Press Forming Blank Waveform Analysis for Shape Deviation Prediction
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Solution Overview
Problem
Existing techniques cannot predict the effect of shape variation in blanks on the dimensional accuracy of press-formed parts, nor can they identify which portions of the press-formed part are susceptible to shape variation in the blank.
Innovation Solution
A press forming analysis method that involves generating waveform and cycle deviation waveform blank models to simulate the shape variation of actual blanks, and comparing these models with standard press-formed parts to identify portions with significant shape deviations and determine the necessary countermeasures.
Engineering Contradictions & Design Principles
Engineering 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 poor
Solution Approach 1:
The patent applies preliminary action by generating waveform blank models with predetermined wavelengths and amplitudes before the press forming analysis. These pre-generated models with controlled shape variations allow the system to predict how different blank conditions will affect the final press-formed part dimensions, thereby improving prediction accuracy while maintaining systematic analysis complexity.
Solution Approach 2:
The patent changes the parameters of the blank model by introducing waveform characteristics (wavelength and amplitude) to represent shape variations. By systematically varying these parameters and analyzing their effects on press-formed part dimensions, the method achieves accurate prediction of shape variation effects without requiring overly complex analysis processes.
2Measurement precision
If waveform blank models with multiple cycle deviations are generated, then the prediction accuracy of shape variation effects is improved, but the analysis time and computational load increase
Solution Approach 1:
The patent segments the analysis by dividing it into distinct steps: generating waveform blank models with specific cycle deviations, performing press forming analysis on each, comparing results with standard press-formed parts, and identifying deviation amounts. This segmentation allows systematic analysis of multiple cycle deviations while organizing the computational load into manageable phases.
Solution Approach 2:
The patent applies partial action by focusing the analysis on specific waveform parameters (wavelength and amplitude) and generating a representative set of cycle deviation models rather than analyzing all possible variations. This approach achieves sufficient prediction accuracy by examining key deviation patterns without requiring exhaustive analysis of every possible blank variation.
3Measurement precision
If the shape of actual blanks is measured and actual blank models are generated, then the prediction accuracy is improved, but the measurement and data processing complexity increases
Solution Approach 1:
The patent creates simplified copies of actual blank shapes through waveform blank models. Instead of directly using complex measured data from actual blanks, the system generates representative waveform models that capture the essential shape variation characteristics. This copying approach maintains prediction accuracy while significantly reducing measurement and data processing complexity.
Data Source
AI summary
A press forming analysis method includes: (a) acquiring a shape of a standard press-formed part; (b) generating a waveform blank model; (c) acquiring a shape of a waveform blank press-formed part; (d) comparing the shape of the standard press-formed part and the shape of the waveform blank press-formed part, and obtaining a deviation amount of shape change; (e) generating one or more types of cycle deviation waveform blank models; (f) acquiring a shape of a cycle deviation waveform blank press-formed part; (g) comparing the shape of the standard press-formed part with one or more types of the shape of the cycle deviation waveform blank press-formed part, and obtaining a deviation amount of shape change; and (h) identifying, as a portion requiring countermeasures, a portion having a deviation amount of shape change exceeding a threshold among the deviation amounts of shape change obtained in (d) and (g).