Roll-Forming System with Cutting Grooves for Bumper Beams
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Solution Overview
Problem
Conventional roll-forming systems for manufacturing bumper beams result in both ends having the same thickness as the middle portion, leading to interference with bumper covers and potential cracking due to tensile stress during assembly.
Innovation Solution
A roll-forming system that includes a blanking press to form cutting grooves at both ends of the panel before roll-forming, reducing thickness and alleviating stress concentrations by applying tensile stress after the most deformable portion is addressed through groove formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If both ends of the panel are pressed to reduce thickness, then interference with bumper covers is prevented, but tensile stress causes cracking at the ends
Solution Approach 1:
Cutting grooves are formed at both ends of the panel before the pressing operation. This preliminary action removes the most deformable portions that would otherwise be prone to cracking under tensile stress during subsequent pressing, allowing the ends to be pressed without causing cracks
2Adaptability or versatility
If both ends of the panel are pressed to reduce thickness, then design freedom is heightened and attractive design is achieved, but tensile stress causes cracking
Solution Approach 1:
The cutting grooves are formed in advance at both ends of the panel, enabling subsequent pressing operations to achieve attractive design freedom without causing cracking, thus resolving the contradiction between design versatility and structural strength
3Ease of manufacture
If the panel is roll-formed without cutting grooves, then manufacturing process is simpler, but both ends have same thickness causing interference with bumper covers
Solution Approach 1:
The panel is segmented by forming cutting grooves at both ends, creating distinct zones with different thickness characteristics. This segmentation allows the ends to have reduced thickness for proper bumper cover clearance while maintaining the simplicity of the roll-forming process
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 system effectively reduces thickness at both ends of the bumper beam, preventing interference with bumper covers and minimizing the risk of cracking, while allowing for attractive design and improved assembly.
Implementation Method 1
a blanking press, which cuts the panel to have a predetermined dimension and forms at least one of cutting grooves respectively at both ends of the panel
Implementation Method 2
a roll former unit provided at the rear of the brake press in the process line and sequentially bending the panel supplied through the straightener and the brake press in order to form a predetermined-shaped beam
Implementation Method 3
a round bender provided at the rear of the roll former unit in the process line and having at least one curvature-forming roll bending the shaped beam to have a predetermined curvature
Data Source
AI summary
The present invention relates to a roll-forming system and a method thereof that enables both ends of a panel to be formed attractively by roll-forming the panel after cutting grooves are formed at both ends of the panel by using a blanking press.