Profiled Component Partial Hardening for Low-Distortion Strength Zoning
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Solution Overview
Problem
Existing methods for producing profile components with varying hardness levels face challenges such as distortion due to temperature differences, high energy consumption, and limited design flexibility, particularly in vehicle structural components like sills and side impact beams, which require a balance of strength, energy absorption, and lightweight design.
Innovation Solution
A method involving a multi-stage bending process followed by heating the unhardened areas to a medium temperature (400-450°C) and the hardened sections to a high temperature (900-950°C), with rapid cooling to prevent distortion, using electromagnetic heating and a water shower, and adjusting the thermal tool's performance for precise hardness transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous furnaces are used for hardening structural components, then the required strength is achieved, but the space requirement and energy consumption increase significantly
Solution Approach 1:
The patent divides the hardening process into discrete segments by moving the structural component through a stationary induction heater in steps, heating only the required sections at each pass rather than heating the entire component continuously, thereby reducing energy consumption while achieving the required strength in hardened areas
Solution Approach 2:
The patent employs periodic heating cycles where the structural component is moved through the induction heater multiple times, with each pass heating specific sections that require hardening, allowing for controlled and energy-efficient heat treatment rather than continuous heating of the entire component
2Strength
If continuous furnaces are used for hardening structural components, then the required strength is achieved, but the device size increases
Solution Approach 1:
The patent segments the hardening operation into multiple discrete passes through a compact induction heater, eliminating the need for a large continuous furnace by performing sequential heating of individual sections, thus reducing the overall device footprint while maintaining the required strength
Solution Approach 2:
The patent uses a movable support structure and positioning system as intermediaries to transfer the structural component through the stationary induction heater, enabling flexible and space-efficient hardening of different sections without requiring a large continuous heating chamber
3Manufacturing precision
If the entire profile component is heated to high temperature for hardening, then uniform hardness is achieved, but distortion occurs due to temperature differences
Solution Approach 1:
The patent applies heat treatment locally to only those sections of the structural component that require increased hardness, rather than heating the entire component uniformly, thereby achieving the necessary local hardness properties while minimizing thermal stresses and distortion in unheated areas
Solution Approach 2:
The patent divides the structural component into distinct heating zones, processing each section separately through the induction heater, which allows for controlled heat treatment of specific areas needing hardening while maintaining the original shape and dimensions of non-critical sections
4Strength
If cold-formable high-strength steels are used, then the required strength is achieved, but the forming properties deteriorate
Solution Approach 1:
The patent changes the temperature parameter of the steel during manufacturing, initially working with the steel in a softer, more formable state at lower temperatures to achieve complex profiles, then subsequently heating specific sections to austenitizing temperatures followed by rapid cooling to induce hardening, thus achieving both good forming properties and required strength
5Shape
If hardenable steels are formed in soft state and then hardened subsequently, then complex profiles are achieved, but the production time increases
Solution Approach 1:
The patent uses periodic heating cycles where the structural component is moved through the induction heater in multiple passes, with each pass heating specific sections that require hardening, enabling efficient sequential processing that reduces overall production time compared to conventional methods
Solution Approach 2:
The patent replaces conventional slow heating methods with induction heating technology, which provides rapid and localized heating of the steel sections, significantly reducing the time required to achieve the necessary austenitizing temperature and subsequent hardening, thus accelerating the overall production cycle
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 approach reduces distortion, allows for precise control of hardness zones, and enables continuous hardness transitions, enhancing the component's ability to absorb kinetic energy while maintaining structural integrity and reducing material costs.
Implementation Method 1
an inductor with a trailing cooling unit is moved relative to the structural component
Implementation Method 2
a method for manufacturing a profile component that is first formed and then partially inductively hardened
Implementation Method 3
followed by controlled cooling to achieve the desired hardness
Implementation Method 4
an inductor with a trailing cooling unit is moved relative to the structural component
Data Source
AI summary
The invention relates to a method for producing a profiled component (1) having at least one section (8, 9, 10) of elevated hardness and at least one region (4, 6, 7) of unchanged hardness. First a component blank is shaped by means of a bending process, and then the section (8, 9, 10) to be hardened is heated to a high temperature level. Then the profiled component (1) is cooled to a low temperature level. The profiled component (1) and a thermal tool move relative to each other. The invention further relates to a profiled component (1) having at least one spatially bounded section (8, 9, 10) of elevated hardness and one unhardened region (4, 6, 7).