Press-Forming Tool With Variable Thickness Wrinkle Suppression Mold
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Solution Overview
Problem
Existing press-forming tools face challenges in effectively suppressing springback, especially in high-strength metal plates, due to limitations in wrinkle suppression force distribution, particularly in regions with extension flange deformation, leading to dimension accuracy defects like wall warpage and waviness.
Innovation Solution
A press-forming tool with an integral-type wrinkle suppression mold featuring a pressure receiving portion and a wrinkle suppression force increasing portion on the punch, which elastically deforms to enhance wrinkle suppression force locally at the end phase of press forming, ensuring sufficient force transmission to the blank material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wrinkle suppression force is increased in the entire wrinkle suppression portion, then the springback is suppressed, but the site capable of disposing the spring is limited and the wrinkle suppression force cannot be sufficiently increased in high-strength metal plates
Solution Approach 1:
The invention divides the wrinkle suppression mold into multiple regions (first region, second region, third region) with different thicknesses. The first region has a larger thickness to provide higher wrinkle suppression force in areas requiring stronger suppression, while the second and third regions have smaller thicknesses. This local differentiation allows the mold to provide varying levels of wrinkle suppression force across different areas without requiring a complete increase in the entire mold structure.
Solution Approach 2:
The wrinkle suppression mold is segmented into multiple regions with different thickness characteristics. By segmenting the mold structure, the invention enables selective application of wrinkle suppression force in specific areas where it is most needed, rather than uniformly increasing the force across the entire mold surface.
2Manufacturing precision
If a variable die cushion device using a servo valve is used to increase the wrinkle suppression force in the end phase of press forming, then the springback is decreased, but the device complexity and cost increase
Solution Approach 1:
The wrinkle suppression mold is pre-designed with regions of different thicknesses before the press forming process. This preliminary structural configuration enables the mold to automatically provide varying wrinkle suppression forces during the pressing process without requiring complex control systems or variable die cushion devices.
Solution Approach 2:
The invention replaces expensive and complex variable die cushion devices with a simpler, cost-effective wrinkle suppression mold that has varying thickness regions. This simpler mold structure achieves the same effect of controlling springback without requiring sophisticated servo valves or complex control systems.
3Manufacturing precision
If the wrinkle suppression force is increased in regions with extension flange deformation, then the wall warpage and waviness are reduced, but the wrinkle suppression force distribution becomes more complex
Solution Approach 1:
The wrinkle suppression mold is designed with the first region having a larger thickness specifically positioned to correspond to areas requiring higher wrinkle suppression force, such as regions with extension flange deformation. This local thickness variation enables targeted wrinkle suppression in critical areas while maintaining simpler geometry in other regions.
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 configuration significantly reduces springback in press-formed products, even with high-strength materials, by effectively increasing wrinkle suppression force in both shrinkage and extension flange deformation regions, thereby improving dimension accuracy.
Implementation Method 1
a wrinkle suppression mold which includes a first surface which opposes the plate portion and comes into contact with the plate portion at a press-forming ending point
Implementation Method 2
a wrinkle suppression force increasing portion which is disposed on the plate portion so as to oppose the first surface, protrudes toward the pressure receiving portion, and generates a reaction force in a direction opposite to a pressing direction when being pressed in the pressing direction
Data Source
AI summary
A press-forming tool comprising: a punch including a punch portion and a plate portion transferring shape to a blank material; a die paired with the punch and opposes the punch portion; a wrinkle suppression mold including a first surface opposing the plate portion and comes into contact with the plate portion at a press-forming ending point, a second surface opposing the die and holds the blank material along with the die, and a third surface continued between the first and second surface and opposes the punch portion, and disposed between the third surface and the punch portion via a gap; a pressure receiving portion including a groove portion on the first surface of the wrinkle suppression mold; and a wrinkle suppression force increasing portion disposed on a surface opposing the first surface of the plate portion, protrudes toward the pressure receiving portion, and generates a reaction force opposed to a pressing direction when pressed in the pressing direction in end-phase of a press-forming.