Pressed Component Die Design for Multi-Step Material Inflow Control
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Solution Overview
Problem
Existing methods for press forming, such as those described in PTL 1 and PTL 2, face challenges in forming component shapes that require significant elongation and struggle with material distribution, leading to limitations in forming complex shapes without defects like cracks and wrinkles.
Innovation Solution
A method involving multiple press steps with drawing, where the inflow amount of material is determined based on the increase in cross-sectional line length of the final component shape, distributed across steps, and die shapes are designed to achieve the desired preformed shapes, ensuring proper material flow and minimizing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single press step is used to form the metal sheet into the final component shape, then the manufacturing process is simple, but the component shape cannot be achieved when the line length increase exceeds the uniform elongation of the material
Solution Approach 1:
The single press step is divided into multiple press steps (first press step and second press step). The first press step forms a preformed shape with controlled material inflow, and the second press step completes the final component shape. This segmentation allows the total line length increase to be distributed across multiple steps, each within the uniform elongation capability of the material.
Solution Approach 2:
The first press step performs preliminary forming to create a preformed shape that prepares the material for the final forming step. By pre-distributing some of the material inflow and elongation in the first step, the second step can complete the forming without exceeding material elongation limits, enabling complex shapes that would be impossible in a single step.
2Manufacturing precision
If material inflow is increased to achieve complex component shapes, then the desired shape can be formed, but material distribution becomes uncontrolled leading to defects like cracks and wrinkles
Solution Approach 1:
The total material inflow required for forming the final component shape is divided and distributed across multiple press steps. The first press step distributes a controlled amount of material inflow to create the preformed shape, and the second press step distributes the remaining inflow. This segmented distribution prevents localized excessive inflow that would cause wrinkles and cracks.
Solution Approach 2:
The die shapes and pressing parameters are optimized for each individual step based on the required material inflow distribution. The first die is designed with specific geometry to control material flow during the first press step, and the second die is designed accordingly for the second step. This parameter optimization ensures uniform material distribution and prevents defects.
3Manufacturing precision
If multiple press steps are used to achieve complex component shapes, then the component shape accuracy improves, but the manufacturing process complexity increases
Solution Approach 1:
The forming process is segmented into exactly two press steps, which is the minimum number required to achieve complex shapes while maintaining reasonable process simplicity. This segmentation balances the need for shape accuracy with process complexity by dividing the forming into a first press step for preforming and a second press step for final shaping.
Solution Approach 2:
The first press step performs preliminary forming to create a preformed shape that simplifies the requirements for the second press step. By preparing the material in advance with appropriate pre-forming, the second step can focus on achieving the final precise shape, thereby reducing the overall process complexity compared to using more steps.
4Productivity
If the uniform elongation of the material is exceeded in a single press step, then the forming speed is fast, but the material cannot be formed without defects
Solution Approach 1:
The total elongation required for forming is segmented across multiple press steps. The first press step accommodates elongation within the uniform elongation limit of the material to create the preformed shape, and the second press step accommodates the remaining elongation. This segmentation maintains forming quality by ensuring each step stays within material capabilities, while still achieving the final complex shape efficiently.
Data Source
AI summary
A method for producing a pressed component and for designing a die applicable even when a component shape that cannot be formed without being greatly drawn is produced. A method for producing a component for press forming a metal sheet into a final component shape through two or more press steps including a step carried out by drawing includes: determining the inflow amount of a material required for forming the metal sheet into the final shape based on the increase in the cross-sectional line length of the shape with respect to the line length of the sheet before forming in the press forming of the sheet into the final component shape by a step; and distributing the determined inflow amount of the material to each step including a final press step, and determining a preformed shape after forming in steps other than the final step based on the inflow amount