Shape Correction Die for Curved Pressed Parts With Springback Warpage
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Solution Overview
Problem
Existing press forming methods for vehicle body components with hat-shaped cross-sectional shapes and curved parts suffer from significant warpage and torsion due to springback, leading to poor dimensional accuracy and increased defects.
Innovation Solution
A two-step press forming method where the first step forms the metal sheet into a component shape using a first die, and the second step uses a second die to correct the shape by adjusting the angles of the vertical wall parts relative to the top sheet part, specifically changing the angles on the concave and convex sides to counteract warpage caused by springback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high tensile strength steel is used to reduce vehicle body weight and improve collision safety, then strength is improved, but ductility deteriorates causing cracks to occur easily
Solution Approach 1:
The patent applies parameter changes by carefully controlling forming parameters (pressing force, heating temperature, forming speed) when shaping high tensile strength steel components. This allows the material to be formed into complex shapes while minimizing stress concentrations that would cause cracking, thus maintaining both high strength and reliability
2Strength
If high tensile strength steel is used, then strength is improved, but dimensional accuracy deteriorates due to increased wrinkles and springback
Solution Approach 1:
The patent applies preliminary action by performing pre-forming operations and applying restraining forces before final forming. This prevents wrinkles and controls springback by preparing the material in advance, ensuring both high strength properties and accurate dimensional control in the final component
3Manufacturing precision
If a two-step press forming method with shape correction is used, then manufacturing precision is improved by suppressing warpage and torsion, but device complexity increases due to requiring multiple dies and forming steps
Solution Approach 1:
The patent applies segmentation by dividing the forming process into distinct steps (pre-forming, forming, and shape correction) with specialized dies for each stage. This segmentation allows each die to be optimized for its specific function, improving dimensional accuracy while making the overall complex process more manageable and controllable
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 method effectively suppresses warpage and torsion in the longitudinal direction of the formed product, improving the dimensional accuracy and reducing defects in the final product.
Implementation Method 1
when the component shape of the formed product after release from the first die is defined as a first component shape, in a case where longitudinal end portions of the component are lifted up to a front side of the top sheet part by elastic recovery due to the release from the first die
Data Source
AI summary
Warpage or torsion in a longitudinal direction is suppressed when an elongated curved component is manufactured by press forming. A method for manufacturing a pressed component includes a first step of press forming a metal sheet in a desired component shape using a first die, and a second step of press forming a formed product using a second die after the first step. In the second step, a cross section of a bent part and a vertical wall part are controlled to be opened depending on warpage at longitudinal end portions of the component by elastic recovery due to release from the first die, thereby suppressing the warpage.