Press-Forming Method for Thick-Walled Cup Components
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Solution Overview
Problem
Conventional methods for manufacturing cup-shaped components with thick-walled vertical walls are inefficient due to the need for welding separate members, which reduces productivity.
Innovation Solution
A press-forming method using a press mold with specific punch and die configurations to compress and shape a cup-shaped workpiece, including an inner punch, intermediate punch, outer punch, inner die, intermediate die, and outer die, to perform thickness reduction and increase processing, thereby enhancing the thickness of the vertical wall without material flow away from the central axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding method is used to manufacture thick-walled cup-shaped components, then the vertical wall thickness requirement is met, but productivity deteriorates due to multiple welding steps
Solution Approach 1:
The patent merges multiple separate manufacturing operations (forming and thickening) into a single integrated press-forming process. The cup-shaped workpiece is formed and the vertical wall thickness is increased simultaneously in one operation, eliminating the need for separate welding steps to join thick-walled components.
Solution Approach 2:
The patent performs preliminary compression of the bottom wall part to reduce its thickness before the main forming operation. This preliminary action creates the conditions necessary for subsequent material flow that will increase the vertical wall thickness during the press-forming process.
2Productivity
If single press-forming operation is used to form cup-shaped workpiece, then productivity is improved, but the vertical wall part cannot achieve required thick-walled structure
Solution Approach 1:
The patent employs dynamic control of the press-forming process with multiple stages of compression and material flow control. The forming process is made dynamic by sequentially applying compression to different parts of the workpiece and controlling material flow to achieve thickness increase in the vertical wall part during the same operation.
Solution Approach 2:
The patent changes physical parameters during the press-forming process, specifically controlling compression forces, material flow directions, and deformation stages. By adjusting these parameters sequentially, the process achieves both high productivity and the required thick-walled structure in the vertical wall part.
3Ease of manufacture
If material is allowed to flow freely during press-forming, then forming is simplified, but thickness distribution becomes inconsistent
Solution Approach 1:
The patent applies different compression forces and constraints to different local regions of the workpiece. The bottom wall part receives compression to reduce thickness, while the vertical wall part is protected from excessive material flow to maintain thickness. This local differentiation of compression quality ensures consistent thickness distribution.
Solution Approach 2:
The patent controls material flow by changing compression parameters at different stages and locations. By adjusting the compression force and direction locally, the process maintains simplicity while achieving uniform thickness distribution through controlled material flow rather than free flow.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the efficient manufacture of cup-shaped workpieces with thick-walled vertical walls, improving productivity by eliminating the need for welding and ensuring consistent thickness distribution.
Implementation Method 1
compressing a first compression part in a bottom wall part of a workpiece formed into a cup shape by the inner punch and the inner die
Implementation Method 2
compressing a second compression part being an outer end portion in a radial direction of the workpiece by the outer punch and the outer die and moving the second compression part in a direction to approach the intermediate die, to thereby suppress the workpiece in the second compression part from material-flowing in a direction to get away from the central axis
Data Source
AI summary
While a compression part (B1) in a bottom wall part of a cup-shaped workpiece (B) is compressed by an inner punch (11) and an inner die (14) and moved in a direction to get away from an intermediate die (15), the inner die (14) is pushed toward the inner punch (11); and a compression part (B2) being an outer end portion in a radial direction of the workpiece (B) is compressed by an outer punch (13) and an outer die (16) and moved in an direction to approach the intermediate die (15), to thereby suppress the workpiece (B) in the compression part (B2) from material-flowing in a direction to get away from a central axis (10), whereby thickness reduction processing of the compression part (B1) and thickness increase processing of a vertical wall part (B3) of the workpiece (B) sandwiched by an intermediate punch (12) and the inner die (15) and a vertical wall part (B4) of the workpiece (B) sandwiched by the intermediate punch (12) and an outer die (16) are performed.