Saddle-Shaped Press Molding for Longer Flanges in High-Strength Steel
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Solution Overview
Problem
High tensile strength sheet steel is difficult to mold and limits the design freedom, resulting in a limited extension length of flanges in saddle-shaped press-molded articles, especially when high-strength materials are used.
Innovation Solution
A manufacturing method involving curling and pressing a sheet metal blank with specific forces to form a saddle-shaped press-molded article, where the top plate configuration is curled outward and surplus material is channeled into the end portion flange configuration locations to increase flange extension length while suppressing thickness reduction and cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high tensile strength sheet steel is used to make the vehicle body floor lightweight and improve collision safety, then weight is reduced and strength is improved, but the material becomes difficult to mold and the extension length of flanges is limited
Solution Approach 1:
The patent applies preliminary curling to the top plate configuration location of the blank before final molding. This preliminary action creates excess material that can be redistributed to form longer flanges without requiring additional material, thereby enabling extended flange length while working with high tensile strength sheet steel that has limited formability.
2Strength
If the extension length of flanges is increased to improve join strength and torsional rigidity, then structural performance is improved, but the manufacturing difficulty increases with high strength materials
Solution Approach 1:
The patent introduces a curling dimension to the top plate configuration location, transforming the flat blank into a three-dimensional form with excess material. This dimensional change allows material redistribution to create extended flanges without increasing the two-dimensional footprint of the blank, thereby achieving longer flanges with high strength materials that have limited formability.
3Stability of the object's composition
If the extension length of flanges is increased to improve torsional rigidity, then structural stiffness is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary curling to the top plate configuration location before final molding. This preliminary action creates excess material that can be redistributed to form longer flanges with improved torsional rigidity, while the curling mechanism itself integrates into the existing molding process without requiring separate manufacturing steps.
4Weight of moving object
If high tensile strength sheet steel is used to reduce vehicle body floor weight, then weight is reduced, but the degree of freedom in design is limited
Solution Approach 1:
The patent introduces curling as a third dimension to the flat blank, creating excess material volume that can be redistributed to form extended flanges. This dimensional transformation enables new design configurations with longer flanges while maintaining the weight benefits of high tensile strength sheet steel, thereby expanding design freedom beyond conventional flat-blank limitations.
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 enables the extension length of flanges to be increased, enhancing the strength and rigidity of the saddle-shaped press-molded articles, improving collision safety and reducing weight by allowing for thinner components.
Implementation Method 1
applying the curl with a first force acting from an inner face side toward an outer face side of the blank at the top plate configuration location
Implementation Method 2
applying the curl with a net force configured by second forces acting in mutually facing directions and a third force acting in an opposing direction to the first force at the outer face side of respective vertical wall configuration locations
Data Source
AI summary
According to the present disclosure, a manufacturing method for a saddle-shaped press-molded article includes curling a blank at a top plate configuration location of the blank that will form a top plate portion, applying the curl with a first force acting from an inner face side toward an outer face side of the blank at the top plate configuration location, applying the curl with a net force configured by second forces acting in mutually facing directions and a third force acting in the opposing direction to the first force at the outer face side of respective vertical wall configuration locations of the blank that will be molded into vertical wall portions, and in a state in which the top plate configuration location is curled, restraining end portion inverted ridge configuration location that will be molded into end portion inverted ridge portion, the top plate configuration location, the vertical wall configuration locations, and end portion flange configuration location that will be molded into end portion flange.