Press-Forming Line Control for Sheet Thickness Variation
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Solution Overview
Problem
During press-forming, variations in sheet thickness among multiple sheets can result in deviations from the target shape of press-formed products, even if the initial product meets the desired shape criteria.
Innovation Solution
A method that involves capturing the sheet thickness of each sheet separately and controlling the initial position of a movable mold part relative to the die or punch during press-forming, based on the sheet thickness, to adjust the shape of the press-formed product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
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 the shape precision of press-formed products varies when sheet thickness varies
Solution Approach 1:
The press conditions are made dynamic and adjustable based on the actual sheet thickness. The movable mold part can change its position relative to the die and punch, allowing the press-forming parameters to be adapted for each sheet rather than using fixed pre-set conditions for all sheets in a manufacture lot.
Solution Approach 2:
The initial position of the movable mold part is changed as a control parameter based on the measured sheet thickness. By adjusting this positional parameter according to the actual sheet thickness, the press-forming process compensates for thickness variations and maintains consistent shape precision across all sheets.
2Manufacturing precision
If the same press conditions are used for all sheets in a manufacture lot, then the manufacturing efficiency is high, but the shape consistency of press-formed products deteriorates when sheet characteristics vary
Solution Approach 1:
The sheet thickness is measured in advance before press-forming, and the initial position of the movable mold part is predetermined based on this measurement. This preliminary measurement and positioning action allows each sheet to be prepared with optimized press conditions before entering the forming process, ensuring shape consistency without significantly reducing throughput.
Solution Approach 2:
The manual or fixed mechanical adjustment of press conditions is replaced by an automated measurement and control system. The sheet thickness measurement device and controller work together to automatically determine the optimal initial position of the movable mold part, reducing the need for manual intervention while maintaining high shape consistency.
3Manufacturing precision
If the initial position of the movable mold part is controlled based on sheet thickness, then the shape precision of press-formed products is improved, but the device complexity and measurement requirements increase
Solution Approach 1:
The mechanical measurement of sheet thickness is replaced by an optical or non-contact measurement system. This substitution makes the measurement process faster, more accurate, and easier to integrate into the automated press-forming line, reducing the overall difficulty of detection and measurement while improving shape precision.
Data Source
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.