Roller Hemming Method for Flange Waving Control
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Solution Overview
Problem
In roller hemming methods, the tip of a flange tends to separate from the main body of a workpiece as it is folded, leading to an uneven contact and potential waving phenomena during the bending process.
Innovation Solution
A method involving a working roller with a full bending portion and a tapered temporary bending portion, where the flange is bent in a chevron-like shape by inclining the tip-side and base-side portions, ensuring the tip remains in contact with the main body after folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the flange is folded by pressing the working roller to the flange and moving it along the flange, then the flange is bent into contact with the main body, but the tip of the flange tends to separate from the main body due to inclination
Solution Approach 1:
The bending process is segmented into three distinct steps: first temporary bending step, second temporary bending step, and full bending step. Each step addresses specific portions of the flange (tip-side portion, base-side portion, and entire flange) to achieve precise control over the flange's final shape and contact position.
Solution Approach 2:
The first and second temporary bending steps are performed as preliminary actions before the full bending step. These preliminary steps create temporary bent states that position the flange in specific configurations, allowing the subsequent full bending step to achieve precise contact of the flange tip with the main body.
2Shape
If the entire temporary bending portion is used to fold the flange, then the flange is bent into temporary bent state, but a waving phenomenon occurs in the folded flange
Solution Approach 1:
Different portions of the temporary bending portion (tip-side and base-side portions) are used selectively for different bending steps. The base-side portion is specifically used in the first temporary bending step to bend the tip-side portion of the flange, while the tip-side portion is used in the second temporary bending step to bend the base-side portion of the flange. This localized application prevents waving phenomena.
Solution Approach 2:
The temporary bending portion is functionally segmented into tip-side and base-side portions, each serving specific purposes in different bending steps. This segmentation allows precise control over which portion of the flange is bent at each step, preventing the waving phenomenon that occurs when the entire temporary bending portion is used simultaneously.
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 maintains contact between the flange tip and the main body, preventing waving phenomena and ensuring a satisfactory fold, even if a crease formed during bending disappears.
Implementation Method 1
folding a flange erected from a workpiece by pressing a working roller to the flange and moving the working roller relative to the flange
Data Source
AI summary
In a roller hemming method for folding a flange erected from a workpiece by pressing a working roller against the flange and moving the working roller relative to the flange, the flange is folded by: a first temporary bending step of bending a tip-side portion of the flange into a state that the tip-side portion is inclined; a second temporary bending step of bending a remaining, base-side portion of the flange into a state that the base-side portion is inclined; and a full bending step of bending the thus-bent flange into a final shape so that the flange is into contact with a flange-proximate portion.