Press-Forming Warp Compensation With Movable Mold Positioning
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Solution Overview
Problem
Press-forming techniques struggle to maintain precision in shape dimensions for multiple sheets with varying characteristics, leading to deviations from the target shape due to differences in warp among sheets.
Innovation Solution
A method that captures the warp in each sheet and adjusts the initial position of a movable mold part relative to the die and punch during press-forming, using a die, punch, and movable mold part capable of changing position, to control the shape of the press-formed product based on the warp amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press-forming is performed under pre-set press conditions for all sheets, then the manufacturing process is simple and efficient, but the shape precision of press-formed products varies when sheets have different warp characteristics
Solution Approach 1:
The movable mold part is introduced to dynamically adjust the press-forming conditions based on the warp characteristics of each sheet. The movable mold part can change its position relative to the die and punch, allowing the press-forming process to adapt to varying sheet conditions rather than using fixed pre-set conditions for all sheets.
Solution Approach 2:
The initial position of the movable mold part is adjusted as a controllable parameter based on the captured warp amount of each sheet. By changing the position parameter of the movable mold part according to sheet-specific warp characteristics, the press-forming process compensates for variations in sheet quality and maintains consistent shape precision.
2Productivity
If the same press conditions are used for all sheets in a manufacture lot, then productivity is maintained, but shape deviations occur when sheets have varying warp characteristics
Solution Approach 1:
The warp amount of each sheet is captured before press-forming begins. This preliminary measurement allows the system to determine the appropriate initial position of the movable mold part in advance, so that when press-forming starts, the correct adjusted conditions are already in place, maintaining both speed and precision.
Solution Approach 2:
The system captures the actual warp characteristics of each sheet and uses this information to adjust the initial position of the movable mold part. This feedback mechanism ensures that each sheet is press-formed with conditions optimized for its specific characteristics, maintaining shape consistency across the manufacture lot.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A method of manufacturing a press-formed product includes: capturing the amount of warp in a sheet to be pressed separately for each sheet; and using a die 6, a punch 7, and a movable mold part to press-form the sheet into a press-formed product. During press-forming, the initial position of the movable mold part 9 relative to the die 6 or punch 7 is controlled depending on the amount of warp in the sheet.