Press Forming Tool Protrusion Patterns for Blank Shape Variation
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Solution Overview
Problem
The use of metal sheets with shape variations in press forming leads to deviations in the dimensional accuracy of press formed parts, as existing methods fail to identify and address the specific portions affected by shape variation, resulting in inconsistent quality.
Innovation Solution
A method involving press forming analysis with reference and wave-shaped blank models to identify deviations, followed by providing protrusion patterns on the tools to mitigate shape variation effects, ensuring accurate press forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a blank with shape variation is used for press forming, then the manufacturing process can proceed without additional processing steps, but the dimensional accuracy of the press formed part deteriorates
Solution Approach 1:
The invention performs press forming analysis in advance using both a flat blank model and a wave-shaped blank model to predict dimensional deviations before actual production. Based on the predicted deviation amounts, protrusion patterns are designed and provided to the press forming tool in advance. This preliminary action allows the tool to compensate for shape variation effects during actual press forming, achieving high dimensional accuracy without requiring additional processing steps or blank preprocessing.
2Device complexity
If conventional press forming is performed without identifying specific affected portions, then the process is simple, but the ability to control dimensional accuracy deteriorates
Solution Approach 1:
The invention performs press forming analysis to identify specific portions of the press formed part where dimensional deviations occur due to blank shape variation. Instead of applying uniform compensation across the entire part, protrusion patterns are selectively provided only to the tool portions corresponding to the identified deviation locations. This local quality approach ensures that dimensional accuracy is controlled precisely where needed, without unnecessarily complicating the overall process.
3Measurement precision
If multiple types of wave-shaped blank models with different periods are analyzed, then the identification of countermeasure required portions becomes more accurate, but the analysis complexity increases
Solution Approach 1:
The invention performs press forming analysis using multiple types of wave-shaped blank models with different periods (e.g., first period, second period) to comprehensively identify countermeasure required portions. By analyzing multiple periodic variations, the method ensures that all potential deviation locations are captured, even though this increases analysis complexity. The excessive action of analyzing multiple periods provides more accurate and complete identification of affected portions compared to using a single period model.
Data Source
AI summary
A press formed part manufacturing method includes: acquiring a reference press formed part shape; acquiring a wave-shaped blank press formed part shape; comparing the reference press formed part shape with the wave-shaped blank press formed part shape to obtain a portion where both shapes are deviated from each other and an amount of deviation; acquiring a periodically deviated wave-shaped blank press formed part shape; comparing the reference press formed part shape with the periodically deviated wave-shaped blank press formed part shape to obtain a portion where both shapes are deviated from each other and an amount of deviation; identifying a countermeasure required portion; providing a protrusion pattern to a portion of an upper tool and a lower tool of an actual tool for forming the press formed part; and press forming a blank using the upper tool and the lower tool provided with the protrusion pattern.