Vehicle Structural Reinforcement Press Forming for Wrinkle-Free Flat Surfaces
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Solution Overview
Problem
High-strength materials used in press forming for vehicle structural members, such as hinge reinforcements, tend to form wrinkles that are difficult to smooth and flatten, especially during the forming process, which is problematic for achieving accurate flatness and preventing undulation in critical areas like striker mounting surfaces.
Innovation Solution
The use of press forming dies with curved and convex die faces in both the drawing and unbending processes ensures that excess material is pushed aside, preventing wrinkles and allowing for the formation of flat surfaces with high accuracy, even with high-strength materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength material is used for hinge reinforcement, then side impact resistance is improved, but wrinkles form during press forming that are difficult to smooth and flatten
Solution Approach 1:
The patent applies preliminary action by performing a first press forming operation before the final forming step. In this preliminary operation, the material is pre-formed with controlled deformation, and then in the subsequent final press forming, the material can be properly flattened without forming difficult-to-remove wrinkles. This preliminary preparation enables the final high-strength material to achieve both strength and flatness accuracy.
Solution Approach 2:
The patent introduces an intermediary step in the press forming process - a first press forming operation that acts as a mediator between the material preparation and final forming. This intermediate operation controls the material flow and deformation characteristics, preventing wrinkle formation in the final high-strength material while maintaining the required flatness accuracy for mounting surfaces.
2Strength
If conventional press forming is used for high-strength material, then material strength is preserved, but wrinkles and undulation occur in flat surface portions
Solution Approach 1:
The patent performs a first press forming operation as a preliminary action that prepares the high-strength material for final forming. This preliminary operation controls material flow and prevents excessive deformation that would cause wrinkles, while preserving the material's high strength properties. The subsequent final press forming then achieves the desired shape with smooth flat surfaces.
Solution Approach 2:
The patent converts the potential harm of high-strength material rigidity (which causes wrinkle formation) into a benefit by using the material's strength characteristics in the preliminary press forming operation. The high-strength material's resistance to deformation is utilized to control material flow and prevent wrinkles, while the final forming achieves both strength preservation and surface smoothness.
Data Source
AI summary
A reinforcement for a vehicle structural member, includes a top wall, and opposite lateral walls extending from opposite edges of the top wall. At least one of the lateral walls includes a flat surface portion for mounting an additional vehicle part. The flat surface portion has an edge forward in a press direction in which the reinforcement is pressed, the edge being curved and convex in the press direction.