Segmented Hot Forming Die Quenching for Sharp Thermal Zoning
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Solution Overview
Problem
Hot forming die quenching tools face challenges in creating well-defined regions of high strength and increased ductility in vehicle structural components due to temperature differentials between die elements, leading to heat flow and manufacturing defects like wrinkles.
Innovation Solution
The tool design features a gap between die blocks with insulating material to reduce heat flow and ensure complete contact with the blank, allowing for well-defined zones with end portions of side faces in contact to prevent defects and enhance thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If die elements are physically separated and thermally insulated by providing an idle gap, then heat flow between die elements is reduced and transition zones are narrowed, but manufacturing defects such as wrinkles or irregularities appear in areas not properly supported by die elements
Solution Approach 1:
A die element is introduced as an intermediary component between the first and second die elements. This intermediate die element serves dual purposes: it maintains the thermal insulation gap to prevent heat flow between the first and second die elements, while simultaneously providing physical support to the blank in the previously unsupported area, thereby preventing manufacturing defects like wrinkles.
2Adaptability or versatility
If die elements work at different temperatures to create soft zones, then regions of increased ductility are achieved, but a wide transition zone is created between soft and hard zones due to heat flow
Solution Approach 1:
The tool is segmented into multiple independently controllable die elements (first, second, and intermediate die elements), each capable of operating at different temperatures. This segmentation allows precise thermal zoning where the first and second die elements can maintain different temperatures to create soft zones, while the intermediate die element maintains a gap to prevent heat flow, thereby preserving sharp transitions between zones.
3Temperature
If a gap is provided between die blocks, then thermal insulation is enhanced and transition zones are narrowed, but complete contact with the blank cannot be ensured
Solution Approach 1:
The intermediate die element acts as a mediator that fills the spatial gap between the first and second die elements. It maintains the thermal insulation required for narrow transition zones while providing the necessary physical contact and support to the blank, thus ensuring both thermal performance and mechanical support reliability.
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
This approach minimizes manufacturing defects and achieves a narrow transition zone between hard and soft regions, improving the structural integrity and energy absorption of hot-formed components while maintaining high strength.
Implementation Method 1
a separation may be provided between side surfaces (112, 152) of neighbouring die blocks (11, 15)... the separation may be at least partially filled with an insulating material (14)
Implementation Method 2
a cooling system (31) may be provided in correspondence with the die blocks (11) adapted to operate at a higher temperature
Implementation Method 3
one die element may be cooled in order to quench the corresponding area of the component being manufactured at high cooling rates
Data Source
Figure 1~2
Figure 3~4
AI summary
A tool for hot forming die quenching boron steel structural components having locally different microstructures and mechanical properties is described. The tool comprises upper and lower mating dies, each die being formed by two or more die blocks comprising a working surface that in use faces the structural component to be formed and side faces. The upper and lower dies comprise at least two neighbouring die blocks adapted to operate at different temperatures corresponding to zones of the structural component to be formed having locally different microstructures and mechanical properties, wherein the neighbouring die blocks are arranged with a gap between their side faces and end portions of the side faces of the neighbouring die blocks that are close to the working surface are designed such that in use they are in contact.