Press Forming Apparatus Stepped Punch Surface Deformation Control
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Solution Overview
Problem
In press forming, the use of a pad with a blank holder can lead to deformation of the workpiece when the punch and die are separated, necessitating a locking mechanism that may increase equipment costs and reduce productivity due to potential timing deviations and complex structures.
Innovation Solution
A press forming apparatus and method that includes a punch with a stepped surface corresponding to the flange portion, a blank holder, and a pad, where the outer peripheral portion of the workpiece gets out from between the blank holder and die, preventing deformation by shaping the flange portion with the stepped surface of the punch and die, and maintaining an interval between the blank holder and die to prevent excessive pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a locking mechanism is used to prevent workpiece deformation during punch and die separation, then workpiece shape stability is improved, but device complexity and equipment cost increase
Solution Approach 1:
The invention extracts and eliminates the locking mechanism from the press forming apparatus. Instead of using a separate locking device to prevent workpiece deformation during separation, the design relies on the inherent structural features of the punch (specific surface configuration) and the timing control of the pad and blank holder to achieve the same protective function without the added complexity
Solution Approach 2:
The workpiece is prevented from deformation during separation through self-service mechanisms: the pad and blank holder are controlled to maintain positioning during separation, and the punch's specific surface configuration naturally prevents deformation. The system uses its own existing components and their controlled operation rather than requiring an external locking mechanism
2Stability of the object's composition
If a locking mechanism is used to prevent workpiece deformation, then workpiece shape stability is improved, but productivity decreases due to timing deviations and complex structures
Solution Approach 1:
By removing the locking mechanism entirely, the invention eliminates the sources of timing deviations and operational complexity that reduced productivity. The system achieves deformation prevention through simpler, more reliable means that do not require additional timing coordination
Solution Approach 2:
The pad and blank holder are controlled to automatically maintain workpiece positioning during separation through coordinated timing control, and the punch structure naturally prevents deformation. This self-service approach eliminates the need for complex locking operations that would reduce productivity
3Shape
If the outer peripheral portion remains between blank holder and die during separation, then workpiece positioning is maintained, but workpiece deformation occurs due to excessive pressure
Solution Approach 1:
The invention applies dynamic control to the pad and blank holder timing, allowing the outer peripheral portion to be released from between the blank holder and die at the appropriate moment during separation. This dynamic timing control maintains positioning when needed while preventing excessive pressure deformation during separation
Solution Approach 2:
The pad and blank holder are controlled in advance to release the outer peripheral portion before complete separation occurs, preventing the harmful effect of excessive pressure while maintaining adequate positioning throughout the separation process
Data Source
AI summary
A press forming apparatus includes: a punch; a blank holder disposed adjacent to the punch; a die being a counterpart of the punch; and a pad disposed to face the punch. The punch has a tip surface, an outside surface, and a stepped surface having shapes corresponding to a web portion, vertical wall portions, and a flange portion of a product, respectively. When the punch and the die are relatively moved in a pressing direction in a state where a middle portion in a width direction of a workpiece is sandwiched by the pad and punch and an outer peripheral portion in the width direction of the workpiece is bound by the blank holder and the die, the workpiece's outer peripheral portion in the width direction gets out from between the blank holder and the die, and the flange portion is shaped by the die and the punch's stepped surface.