Press Forming Analysis for Blank Shape Variation Deviations

Solution Overview

Problem

Existing press forming techniques cannot predict the influence of shape variations in metal blanks on the dimensional accuracy of press formed parts, nor identify susceptible portions, leading to potential deviations from targeted dimensions.

Innovation Solution

A press forming analysis method that generates a first shape based on actual press formed parts and compares it with a second shape from a flat blank model to determine deviation amounts and identify critical areas requiring countermeasures, using tools like CAE analysis and finite element methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If press forming is performed using an actual blank taken from a metal sheet with shape variation, then the manufacturing process reflects real-world conditions, but the dimensional accuracy of the press formed part deviates from targeted specifications

Engineering Contradiction:

Improvedimensional accuracy of press formed partVSAvoidhandling of shape variation in blank

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent performs press forming analysis using a flat blank model before actual production to predict the influence of shape variation on the press formed part. By conducting the analysis in advance and comparing the predicted shape with the target shape, the system identifies problematic areas and enables preliminary countermeasures, thereby ensuring dimensional accuracy while accommodating shape variation in actual blanks.

Inventive Principle:

Principle #10Preliminary action

2Measurement precision

If existing techniques compare shapes of press formed parts after press forming, then post-production quality check is achieved, but the influence of blank shape variation on press formed part shape cannot be predicted

Engineering Contradiction:

Improveshape measurement accuracyVSAvoidprediction capability of shape variation influence

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The patent performs press forming analysis using a flat blank model before actual production to predict the influence of shape variation on the press formed part. By conducting the analysis in advance and comparing the predicted shape with the target shape, the system identifies problematic areas and enables preliminary countermeasures, thereby ensuring dimensional accuracy while accommodating shape variation in actual blanks.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates a flat blank model as a simplified copy of the actual blank, eliminating shape variation to serve as a baseline for analysis. This model copy enables prediction of how shape variation would influence the press formed part shape, providing measurement and prediction capabilities that post-production comparison alone cannot achieve.

Inventive Principle:

Principle #26Copying

3Productivity

If no analysis is performed on blank shape variation, then the manufacturing process is simple and fast, but portions susceptible to shape variation influence cannot be identified

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoididentification of susceptible portions

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent performs press forming analysis using a flat blank model before actual production to predict the influence of shape variation on the press formed part. By conducting the analysis in advance and comparing the predicted shape with the target shape, the system identifies problematic areas and enables preliminary countermeasures, thereby ensuring dimensional accuracy while accommodating shape variation in actual blanks.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250012562A1Press forming analysis method, press forming analysis apparatus, and press forming analysis program

Publication Date: 2025.01.09 JFE STEEL CORP

AI summary

A press forming analysis method includes: generating a first shape having a same shape as an actual press formed part based on measurement data obtained by measuring a shape after die release of the actual press formed part, the actual press formed part being press-formed with a predetermined tool of press forming by using an actual blank taken from the metal sheet having the shape variation; acquiring a shape of a press formed part after die release as a second shape by performing press forming analysis in a case where press forming is performed with a tool-of-press-forming model having a same shape as the predetermined tool of press forming by using a flat blank model having a flat shape; and determining a portion where both the shapes deviate from each other and a deviation amount by comparing the second shape and the first shape with each other.