Press-Molded Part Forming with Outward Bulge Load Relief
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Solution Overview
Problem
Existing press-molding techniques struggle to sufficiently disperse loads applied during molding, leading to cracks or wrinkles in the final product.
Innovation Solution
The method involves forming an intermediate product with an outward bulge, which alleviates load concentration during press molding, reducing the occurrence of cracks or wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press molding is performed on an intermediate product without an outward bulge, then the manufacturing process is simpler, but load concentration occurs during press molding causing cracks or wrinkles
Solution Approach 1:
An outward bulge is formed in advance on the intermediate product at the position corresponding to the convergence portion. This preliminary geometric modification allows the material to better accommodate the subsequent press molding process, distributing the load more evenly and preventing cracks or wrinkles during forming.
Solution Approach 2:
The geometric parameters of the intermediate product are modified by introducing an outward bulge with specific dimensions (height of 5-50mm, width of 10-100mm). This parameter change transforms the flat intermediate product into one with a pre-formed bulge, which fundamentally alters how the material responds to press molding forces.
2Productivity
If press molding is performed on a blank material directly, then the process is more efficient, but load concentration at the convergence portion causes cracks or wrinkles
Solution Approach 1:
The forming process is segmented into two distinct stages: first forming an intermediate product with an outward bulge, then performing the final press molding to create the groove-shaped part. This segmentation allows each stage to be optimized independently, with the first stage preparing the material geometry and the second stage achieving the final shape with high precision and surface quality.
Solution Approach 2:
The outward bulge is created as a preliminary feature before the final press molding operation. This pre-formed bulge serves as a material reservoir that facilitates smooth material flow during the subsequent forming process, preventing defects while maintaining high productivity.
3Manufacturing precision
If an outward bulge is formed on the intermediate product, then load concentration is alleviated during press molding, but the intermediate product structure becomes more complex
Solution Approach 1:
The intermediate product geometry is modified by introducing an outward bulge with controlled parameters (height of 5-50mm, width of 10-100mm). This parameter change is strategically designed to provide sufficient material for load distribution during press molding while avoiding excessive geometric complexity that would complicate manufacturing.
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
The use of an intermediate product with an outward bulge effectively reduces the likelihood of cracks and wrinkles in the press-molded part, enhancing the manufacturing process.
Implementation Method 1
forming the press-molded part by performing press molding on the intermediate product
Implementation Method 2
the outward bulge is deformed by press molding to form the press-molded part from the intermediate product
Data Source
AI summary
Provided is a method for manufacturing a press-molded part, the method including: forming an intermediate product by press molding; and forming the press-molded part by performing press molding on the intermediate product. The intermediate product includes: a top panel; a pre-vertical wall; a pre-lateral wall; a pre-bottom wall; and an outward bulge. The press-molded part includes: the top panel; a vertical wall; a lateral wall; a bottom wall; a first ridge line; a second ridge line; a third ridge line; and a convergence portion. The outward bulge is a plate-like portion contiguous with the pre-vertical wall, the pre-lateral wall, and the pre-bottom wall. The outward bulge is deformed by press molding, thereby forming the press-molded part from the intermediate product.