Press-Formed Article Line Without Punch-Side Pads
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Solution Overview
Problem
The existing press-formed article manufacturing method is limited by a narrow range of protruding amount for the punch-side pad, leading to sensitive changes in standing wall position and increased complexity and cost due to the need for precise adjustment and suitable bearing capability, which complicates the pressing apparatus structure.
Innovation Solution
A method using a combination of three pressing apparatuses with specific configurations to form a press-formed article, where the second and third pressing apparatuses eliminate the need for a punch-side pad by sandwiching the material between the die pad and convex portion, allowing for a wider range of protruding amounts and reducing the complexity of the pressing apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protruding amount of the punch-side pad is increased to suppress springback, then the springback is reduced, but the standing wall position becomes highly sensitive to protruding amount changes and the allowable range becomes narrow
Solution Approach 1:
The invention removes the punch-side pad from the pressing apparatus, extracting the problematic component that caused sensitive standing wall position changes. By eliminating this component entirely and using only a die-side pad, the patent achieves springback suppression without the detrimental effect on standing wall position stability.
Solution Approach 2:
Instead of increasing the protruding amount of the punch-side pad to suppress springback, the invention inverts the approach by placing the pad only on the die side and increasing its protruding amount. This reverse configuration achieves springback suppression while maintaining stable standing wall position.
2Manufacturing precision
If the protruding amount of the punch-side pad is accurately adjusted to control standing wall position, then the dimensional accuracy is improved, but the apparatus structure becomes more complex and adjustment requirements increase
Solution Approach 1:
The invention simplifies the apparatus structure by removing the punch-side pad entirely, eliminating the need for complex adjustment mechanisms and reducing structural complexity while maintaining or improving standing wall position accuracy.
Solution Approach 2:
The die-side pad is designed to perform multiple functions: suppressing springback, controlling standing wall position, and forming the press-formed article. This multi-functional design eliminates the need for separate punch-side pad adjustment mechanisms.
3Reliability
If a punch-side pad is used to form press-formed articles, then springback is suppressed, but the bearing capability requirements increase and facility restrictions occur
Solution Approach 1:
The invention removes the punch-side pad that imposed bearing capability requirements and facility restrictions, replacing its springback suppression function with a die-side pad configuration that has fewer restrictions and greater adaptability.
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 approach expands the allowable range of protruding amounts, simplifies the pressing apparatuses, and improves the management of dimensional accuracy for standing walls by limiting moments to primarily first and third moments, reducing sensitivity to protruding amount changes and eliminating the need for punch-side pads.
Implementation Method 1
a material metal plate is sandwiched by the punch-side pad protruding from the punch and the die-side pad protruding from the die, and in this state, the die is pushed to the punch side to form the press-formed article
Implementation Method 2
the portions of the material metal plate bent by the shoulder portions of the punch are pushed out to base end sides of standing walls and are formed as the standing walls
Data Source
AI summary
Provided is a press-formed article manufacturing method including pressing a blank with the first pressing apparatus to form a first intermediate formed article having a pair of bent portions bent to one side in the plate thickness direction and having a spacing between the bent portions narrower than the width of the top plate and equal to or more than the width of the top portion of the convex portion, and moving the second die relative to the second punch side punch with respect to the die pad and the second punch and forming a second intermediate formed article in a state where a portion between the bent portions is sandwiched between the die pad and the convex portion, with one side of the first intermediate formed article in the plate thickness direction as the convex portion side of the second pressing apparatus.