Vehicle-Body Stamped Part Redesign Using Thinning Feedback
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Solution Overview
Problem
The high scrap rate of vehicle-body stamped parts, particularly those made of aluminum, due to increased forming difficulty and defects in mass production, leads to elevated manufacturing costs and slowed research and development processes.
Innovation Solution
A method involving scanning stamped parts to obtain point cloud data, constructing a three-dimensional model, and adjusting the shape, size, and/or material of specific portions to minimize defects, using simulation analysis to ensure compliance with preset defect probabilities and avoid interferences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If modifications are made to a new type of vehicle body design to speed up research and development, then the research and development speed is improved, but the scrap rate of stamped parts increases during mass production
Solution Approach 1:
The patent performs preliminary analysis of thinned portions in existing stamped parts before finalizing the design model. By scanning formed parts, constructing 3D models, identifying thinned portions exceeding standard rates, and adjusting the design model proactively, the method prevents defects before mass production begins, thus maintaining both fast R&D speed and high manufacturing precision
Solution Approach 2:
The patent establishes a feedback loop where actual stamped parts are scanned and measured, thinned portions are identified and analyzed, and the design model is adjusted based on this feedback. This continuous improvement process ensures that design modifications do not compromise stamped part quality while accelerating R&D through iterative optimization
2Weight of moving object
If aluminum plates are used for lightweight vehicle bodies, then the vehicle weight is reduced, but the forming difficulty and defect rate of stamped parts increase
Solution Approach 1:
The patent adjusts design parameters such as shape, size, and material properties of stamped parts based on identified thinned portions. By modifying these parameters proactively in the design phase, the method compensates for aluminum's inherent forming difficulties and reduces defect rates while maintaining the weight benefits of aluminum materials
Data Source
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AI summary
The invention relates to the technical field of vehicle design, and aims to solve the problem that an existing vehicle body design method is likely to cause a high scrap rate of a stamped part constituting a vehicle body in a manufacturing process. To this end, the invention provides a method for improving the design of a vehicle-body stamped part, the method including: obtaining thinned portions with thinning rates exceeding a standard rate on a stamped part that has been formed; screening a first portion with a defect rate and/or a defect type not meeting a preset requirement from the thinned portions; and adjusting a shape, a size, and/or a material of a second portion that is the same as the first portion on an original design model of the stamped part to obtain a target design model. In a process of improving the design of vehicle body styling, the improvement is made based on an original design model of a previous version of vehicle-body stamped part and actual information of the previous version of vehicle-body stamped part after mass production, and this can not only ensure a fast research and development speed, but also avoid a high scrap rate of a newly designed vehicle-body stamped part in a manufacturing phase, thereby greatly reducing research and development and manufacturing costs.