Scrap Attitude Simulation for Press Die Quality
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Solution Overview
Problem
Existing press apparatus quality determination methods lack accuracy in predicting scrap failure, which can lead to defective products and die damage, despite high discharge probability simulations.
Innovation Solution
A simulation method that creates a three-dimensional model of a press die and scrap chute, applies a force of gravity and a random force to simulate scrap movement, calculating the change in fall attitude and using this data to determine the design quality of the press apparatus by assessing the degree of variation in scrap attitude change.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simulation method is used to predict scrap discharge probability, then the design process can be optimized, but the accuracy of predicting scrap failure is insufficient
Solution Approach 1:
The patent changes the simulation parameters from only gravitational force to include both gravitational force and random forces. This parameter change allows the simulation to account for unexpected movements during scrap falling, thereby improving prediction accuracy while maintaining design optimization capabilities
Solution Approach 2:
The patent applies preliminary action by calculating the change amount of fall attitude before the scrap actually fails. By predicting the attitude change in advance using enhanced simulation parameters, the system can identify potential failures before they occur, improving both reliability assessment and prediction accuracy
2Ease of manufacture
If only force of gravity is applied in simulation, then the calculation is simple, but the prediction accuracy of scrap failure is low
Solution Approach 1:
The patent modifies the simulation parameters by adding random forces to the gravitational force. This parameter enhancement makes the simulation more realistic and accurate in predicting scrap failure, while the random forces are applied in a controlled manner to maintain computational feasibility
3Productivity
If the scrap fall attitude is not monitored, then the simulation is faster, but the quality determination of press apparatus is inaccurate
Solution Approach 1:
The patent calculates the change amount of fall attitude as a preliminary metric before determining press apparatus quality. This preliminary calculation of attitude change provides a quantitative basis for quality assessment, improving manufacturing precision while maintaining simulation efficiency through focused measurement
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
Improves the accuracy of predicting scrap failure and determining press apparatus quality by focusing on the stability and consistency of scrap attitude change, allowing for design improvements to prevent scrap retention within the apparatus.
Implementation Method 1
causing a force of gravity and a force that has a random magnitude within a range of a predetermined magnitude to act on the scrap
Data Source
AI summary
A press apparatus quality determination method is to be performed with use of a simulation of falling of a scrap. The simulation includes creating a three-dimensional model of a press die of a press apparatus, the scrap generated from a workpiece being processed by the press die, and a scrap chute guiding the scrap to an outside of the press apparatus, and simulating a movement of the scrap to be fallen on the scrap chute and to be discharged to the outside. The press apparatus quality determination method includes causing a force of gravity and a force that has a random magnitude within a range of a predetermined magnitude to act on the scrap generated in an initial stage of falling of the scrap on the scrap chute, and calculating a change amount of a fall attitude of the scrap from a start to an end of the falling.