Press-Molded Member Bending Sequence to Prevent Local Thinning
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Solution Overview
Problem
The existing method for manufacturing automobile frame members by press molding metal plates often results in distortion and local thinning, leading to incomplete thickening and potential cracking due to material stretching during the formation of microbeads before pressing.
Innovation Solution
A method involving the formation of corner portions in a pressed member, which is then molded between dies to create first and second bent portions, allowing for controlled material flow and prevention of local thinning, enabling the achievement of a desired shape and improved strength in the press molded product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If microbeads are formed by bending the flat plate member before pressing, then the pressed portion can be thickened, but the material is stretched causing distortion and local thinning
Solution Approach 1:
The pressed portion is pre-formed with a bent shape and corner portions before the actual press molding process. This preliminary shaping allows the material to be pre-positioned and pre-oriented, so that during subsequent pressing, the material flows more uniformly without excessive stretching that would cause distortion and thinning.
Solution Approach 2:
Corner portions are specifically formed at predetermined locations in the pressed portion. These corner portions act as localized material reservoirs that control and guide material flow during pressing, ensuring uniform thickening at critical areas while preventing distortion in other regions.
2Volume of moving object
If the material is stretched during bending to form microbeads, then the microbeads can be pressed to increase thickness, but heavy local thinning occurs creating starting points for cracks
Solution Approach 1:
Corner portions are strategically placed at locations where material flow needs to be controlled. These corner portions create localized material accumulation zones that prevent heavy thinning in critical areas, thereby eliminating starting points for cracks while still achieving the desired thickness increase in the pressed portion.
Solution Approach 2:
The bent shape with corner portions is prepared in advance before pressing. This preliminary configuration ensures that material is pre-distributed in a way that prevents excessive stretching during pressing, maintaining material integrity and preventing crack formation while achieving uniform thickening.
3Manufacturing precision
If corner portions are formed in the pressed portion, then material flow is facilitated for forming bent portions, but the process complexity increases
Solution Approach 1:
The mold structure is segmented into multiple independent components: a main body mold and separate holding portions that can be independently positioned and adjusted. This segmentation allows the corner portions and bent portions to be formed in a controlled sequence, improving precision while managing complexity through modular design.
Solution Approach 2:
Holding portions are provided only at specific locations where corner portions need to be formed, rather than throughout the entire mold. This localized approach to complexity ensures that additional structural elements are added only where necessary for precision, minimizing overall device complexity while achieving the desired manufacturing accuracy.
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 effectively prevents local thinning and achieves a desired shape with improved strength by facilitating material flow and ensuring uniform thickening, reducing the likelihood of cracking and enhancing the manufacturing process efficiency.
Implementation Method 1
press molding the pressed portion by relatively moving the first die and the second die toward each other to decrease a height of the pressed portion
Data Source
AI summary
A method for manufacturing a press molded product includes forming a plurality of corner portions in a pressed portion of a pressed member, providing the pressed member between a first die and a second die, and press molding the pressed portion to decrease a height of the pressed portion. The press molding includes forming a pair of first bent portions in the pressed portion by means of the corner portions, the pair of first bent portions being bent to protrude toward the second die, forming a second bent portion in the pressed portion by means of the corner portions while holding the pair of first bent portions by a pair of holding portions, the second bent portion being bent to protrude toward the first die from a position between the pair of first bent portions, and pressing and deforming the second bent portion.