Reinforced Composite Blanks for Lightweight Vehicle Forming
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Solution Overview
Problem
The reduction in material gauge for vehicle components to reduce weight compromises their strength, stiffness, and energy absorption, and existing reinforcement methods are limited in achieving spatially variable properties and efficient manufacturing processes.
Innovation Solution
A method involving ultrasonic welding of a metal reinforcement to a metal blank, creating a composite blank that is then formed into a vehicle component, allowing for spatially varying material properties and reinforcement in specific locations to enhance strength, stiffness, and energy absorption, using dissimilar metals and fiber reinforcements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the gauge of sheet metal blank is reduced to reduce weight, then the weight of the vehicle component is reduced, but the strength and stiffness of the formed component is compromised
Solution Approach 1:
The patent applies composite materials by combining a base metal blank with dissimilar metal reinforcements (e.g., aluminum blank with steel reinforcement, or steel blank with aluminum reinforcement) to create a hybrid structure that leverages the weight advantages of lightweight materials while incorporating localized reinforcement to maintain required strength and stiffness properties
Solution Approach 2:
The patent implements local quality by placing metal reinforcements selectively at specific high-stress or high-stiffness regions of the component rather than uniformly throughout, allowing the majority of the component to use thinner, lighter gauge material while maintaining performance where needed through localized reinforcement
2Weight of moving object
If dissimilar metals are used for reinforcement, then weight reduction and spatially variable properties are achieved, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent applies preliminary action by performing ultrasonic welding of the metal reinforcement to the base blank before the forming operation, creating a pre-assembled composite blank that simplifies subsequent manufacturing steps and ensures proper material placement prior to deformation
Solution Approach 2:
The patent replaces conventional mechanical welding or adhesive bonding methods with ultrasonic welding technology, which uses high-frequency mechanical vibrations to join dissimilar metals without requiring extensive preparation, filler materials, or complex positioning fixtures, thereby reducing overall process complexity
3Productivity
If ultrasonic welding is used to join dissimilar metals, then manufacturing efficiency and joint strength are improved, but the equipment investment and process control difficulty increase
Solution Approach 1:
The patent applies parameter changes by optimizing ultrasonic welding parameters (frequency, amplitude, pressure, duration) specifically for dissimilar metal combinations to achieve reliable joints efficiently, and by controlling blank temperature and reinforcement geometry to facilitate successful welding and forming operations
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 enables the use of thinner gauge materials while maintaining performance characteristics, reducing manufacturing costs, and providing localized reinforcement for improved structural integrity and reduced weight.
Implementation Method 1
ultrasonic welding the reinforcement to the metal blank to provide a composite blank
Data Source
AI summary
A method of adding a reinforcement to a metal blank prior to a forming process. The reinforcement is attached via ultrasonic additive manufacturing (UAM) to create a composite blank which is then subjected to a forming process to bend and deform the composite blank and form a reinforced vehicle component. The reinforcement is placed on the metal blank such that after being subjected to the forming process, there is reinforcement in key areas of the formed vehicle component. The reinforcement results in the final formed vehicle component having enhanced properties such as lower density, increased strength, stiffness, or energy absorption capabilities.