Automotive Reinforcement Flange Forming for Crack-Resistant Corners
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Solution Overview
Problem
Automobile reinforcing structures face issues with deformation and breakage at flange corner portions during press molding, leading to reduced connection rigidity and load transfer characteristics between parts.
Innovation Solution
A method involving multiple forming operations to create a reinforcing structure with evenly distributed deformation by folding steel plates to form side flanges and side wall flanges at specific angles, preventing concentration of deformation and eliminating the need for notches, thereby enhancing the structural integrity and connection rigidity.
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 a gap between automobile parts is caused and connection rigidity is lowered
Solution Approach 1:
The flange corner portion is divided into multiple regions with different thicknesses through controlled folding operations. The first fold creates a thicker first flange corner region, while the second fold creates a thinner second flange corner region, allowing differential deformation characteristics in different zones of the same corner portion
Solution Approach 2:
The forming process uses multiple sequential folding operations that dynamically adjust the deformation characteristics of the flange corner portion during the forming process, transitioning from a single-fold to a double-fold structure to optimize both deformation resistance and connection rigidity
2Shape
If press molding is performed to form the automobile structural member, then the structural member is formed with bent flanges, but deformation is concentrated in the flange corner portion causing susceptibility to deformation or breakage
Solution Approach 1:
Different regions of the flange corner portion are given different thickness qualities through controlled folding. The first flange corner region has greater thickness than the second flange corner region, creating local quality differences that distribute deformation more effectively across the corner portion
Solution Approach 2:
The steel plate is pre-folded along specific fold lines before final forming to create predetermined thickness variations in the flange corner portion. This preliminary folding action prepares the material structure to better withstand subsequent deformation during press molding
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
The method improves the formability and rigidity of automobile reinforcing structures, enhances connection rigidity, and reduces the risk of deformation and breakage, resulting in improved airtightness, watertightness, noise reduction, and safety.
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
a second forming operation of forming a pair of side wall flanges by folding the steel plate in a second direction, and simultaneously, bending at least a portion of the side flange in a direction opposite to the first direction
Data Source
Figure 1
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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.