Reinforcement Flange Forming to Prevent Corner Breakage
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Solution Overview
Problem
Automobile parts with flange structures suffer from deformation and breakage at the flange corner portions during press molding, leading to reduced connection rigidity and gaps between parts.
Innovation Solution
A method of forming a reinforcing structure involving three forming operations: folding a steel plate to create a side flange, forming a pair of side wall flanges, and folding the side flange to distribute deformation evenly, preventing concentration at any one point, thus forming a continuous flange without notches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a notch portion is formed by cutting the flange corner portion to prevent deformation and breakage, then the susceptibility to deformation and breakage is reduced, but gaps between parts occur and connection rigidity is lowered
Solution Approach 1:
The patent applies preliminary action by performing multiple forming operations in a specific sequence before final assembly. The side flange is first formed at a preliminary position, then the side wall flange is formed, and finally the side flange is folded to its final position. This sequential preliminary formatting prevents deformation concentration at the flange corner while maintaining continuous material structure, thereby preserving connection rigidity without requiring notches
2Ease of manufacture
If press molding is performed to form the automobile structural member, then the structural member is formed with flange structures, but deformation is concentrated in the flange corner portion causing breakage
Solution Approach 1:
The patent segments the forming process into three distinct operations: first forming the side flange, then forming the side wall flange, and finally folding the side flange to its final position. This segmentation of the forming process distributes the deformation across different stages and locations, preventing deformation concentration at the flange corner portion while still achieving the desired flange structure
Solution Approach 2:
The patent introduces a temporal dimension to the forming process by performing operations in sequence rather than simultaneously. The side flange is formed, then the side wall flange is formed, and finally the side flange is folded - this temporal sequencing allows deformation to be managed in stages, preventing concentration at critical corners while maintaining manufacturing feasibility
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
Improves the formability, rigidity, and connection rigidity of automobile parts, enhancing airtightness, watertightness, and safety by distributing deformation uniformly and eliminating the need for notches.
Implementation Method 1
a first forming operation of forming a side flange to form a flange angle with a bottom surface of a steel plate by folding up an edge of the steel plate
Implementation Method 2
folding the steel plate in a second direction, and simultaneously, bending at least a portion of the side flange
Data Source
AI summary
The present invention relates to a method for forming a reinforcement structure, and the reinforcement structure. The method for forming a reinforcement structure according to the present invention may include: a first forming step of bending an edge of a steel plate in a first direction to form a side flange, which forms a flange angle with the bottom surface of the steel plate; a second forming step of bending the steel plate in a second direction to form a pair of side wall flanges, and bending at least a portion of the side flange in a direction opposite the first direction; and a third forming step of bending the side flange in the first direction.