Press-Molded Article Manufacturing Method with Dual Pad Segmentation
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Solution Overview
Problem
Existing press-molded article manufacturing methods are sensitive to the projection amount of the punch-side pad, leading to excessive displacement of side walls and dimensional inaccuracies, requiring precise adjustment and a narrow range of projection amounts to maintain dimensional precision.
Innovation Solution
A manufacturing method using a press apparatus with an inner pad and a die pad separated by a predetermined distance greater than the metal sheet blank thickness, allowing for controlled flexing and suppression of the second moment, thereby stabilizing the side wall dimensions and enabling a broader range of projection amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the projection amount of the punch-side pad from the punch is increased to suppress spring-back, then the spring-back suppression is improved, but the dimensional precision of side walls deteriorates due to excessive displacement
Solution Approach 1:
The pressing operation is divided into two distinct stages: first pressing the side walls using only the die pad, then pressing the top plate using both pads. This segmentation allows the die pad to control side wall dimensions independently while the inner pad suppresses spring-back during top plate formation, resolving the contradiction between spring-back suppression and dimensional precision
Solution Approach 2:
The die pad is positioned to contact and press the side walls before the inner pad contacts the top plate. This preliminary action establishes the side wall dimensions first, preventing subsequent displacement when the inner pad is engaged, thereby maintaining dimensional precision while still allowing spring-back suppression
2Manufacturing precision
If the projection amount of the punch-side pad is precisely adjusted to maintain dimensional precision, then the manufacturing precision is improved, but the ease of operation deteriorates due to narrow adjustment range
Solution Approach 1:
The pressing process is segmented into side wall pressing (die pad only) and top plate pressing (both pads), which decouples the interdependence between projection amount and dimensional precision. This allows a broader range of projection amounts to produce acceptable side wall dimensions while maintaining spring-back suppression capability
Solution Approach 2:
The pressing sequence is made dynamic rather than static: the die pad presses first to establish side wall dimensions, then the inner pad presses to form the top plate. This dynamic sequencing allows flexible adjustment of projection amounts without compromising dimensional precision, improving ease of operation
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 method ensures dimensional precision of press-molded articles by adjusting the first moment and reducing the influence of the second moment, allowing for easier management of projection amounts and improved productivity.
Implementation Method 1
forming the side walls using the die and the punch, and integrating the die pad with the die; and a third process of moving the die and the die pad, which have been integrated, and the inner pad, toward a side of the punch relative to the punch to form the top plate
Data Source
AI summary
A method of manufacturing a press-molded article includes: projecting an inner pad, provided at an apex portion of a punch, from the punch toward a side of a die, and disposing a metal sheet blank on the inner pad; and projecting a die pad, provided at the die, from the die toward a side of the punch to dispose the die pad at a position separated from the inner pad by a predetermined distance that is greater than a plate thickness of the metal sheet blank; forming a side walls by moving the die toward the punch side relative to the die pad, the inner pad, and the punch, and integrating the die pad with the die; and forming a top plate by moving the die and the die pad, which have been integrated, and the inner pad, toward the punch side relative to the punch.