Press-Forming Mold Position Control for Variable Sheet Thickness
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Solution Overview
Problem
Press-forming techniques struggle to maintain consistency in shape for products with varying sheet thicknesses, leading to deviations from the target shape due to uncontrolled mold positions during the manufacturing process.
Innovation Solution
A method that captures the thickness of each sheet and adjusts the initial position of movable mold parts relative to the die and punch based on sheet thickness, ensuring precise control during press-forming to reduce shape deviations among press-formed products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If press-forming is performed under pre-set press conditions for all sheets in a manufacture lot, then the manufacturing process is simple and efficient, but shape deviations occur when sheet thickness varies
Solution Approach 1:
The mold part is designed to be movable rather than fixed, allowing its position to be dynamically adjusted based on sheet thickness measurements. This enables the press-forming process to adapt to varying sheet characteristics while maintaining consistent product quality, resolving the contradiction between efficient batch production and shape precision.
Solution Approach 2:
The position of the mold part is changed as a variable parameter based on sheet thickness. By measuring the actual sheet thickness and adjusting the mold part position accordingly, the system maintains manufacturing precision across varying sheet characteristics without sacrificing productivity.
2Ease of manufacture
If the first press-formed product is used to set press conditions, then setup is simple, but subsequent products with varying sheet characteristics deviate from target shape
Solution Approach 1:
The sheet thickness is measured in advance before press-forming, and the mold part position is predetermined based on this measurement. This preliminary action ensures that each sheet is processed with optimized parameters, maintaining shape accuracy while keeping the overall process simple and efficient.
Solution Approach 2:
The system automatically adjusts the mold part position based on measured sheet thickness without requiring manual intervention or complex setup procedures. This self-adjusting capability maintains manufacturing precision while preserving ease of manufacture.
3Manufacturing precision
If movable mold parts are introduced to adjust for sheet variations, then shape precision improves, but device complexity increases
Solution Approach 1:
The mold is divided into a fixed part and a movable part, with only the necessary portion being adjustable. This segmentation allows for precise control of shape consistency while minimizing the complexity increase, as only specific mold components require adjustment mechanisms rather than the entire mold structure.
Data Source
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Figure 3A~3B
AI summary
A method of manufacturing a press-formed product includes: capturing the sheet thickness of a sheet B; and using a die 6, a punch 7, and a movable mold part capable of moving relative to both the die 6 and punch 7 to press-form the sheet B into a press-formed product. During press-forming, the initial position of the movable mold part relative to the die 6 or punch 7 is controlled depending on the sheet thickness of the sheet B.