U-Shaped Pressed Product Undercut Flange Molding
Solution Overview
Problem
The existing methods for manufacturing pressed products with undercut flanges require an angle modification process, which complicates the molding process due to the need for specific mold orientations and interferes with the molding of the undercut flange.
Innovation Solution
A method that eliminates the angle modification process by bending a metallic sheet to form a U-shaped main body with undercut flanges, using a flange molding process that includes preflange molding, flange bending, and boundary molding, allowing the undercut flange to be molded without the need for angle adjustment, and subsequently reversing the bent parts to form a plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the angle modification process is performed before molding the undercut flange, then the undercut flange can be molded by the third metallic mold, but the molding process becomes complex and requires multiple process steps
Solution Approach 1:
The metallic sheet is pre-formed into a substantially U-shaped main body with plate portions and borders before the flange molding process. This preliminary shaping allows the flange to be molded directly in the final pressing operation without requiring intermediate angle modification processes, thereby simplifying the overall manufacturing process while maintaining molding precision.
2Shape
If the undercut flange protrudes towards the first metallic mold, then the flange can be formed, but the third metallic mold cannot be pressed from the same direction as the first metallic mold
Solution Approach 1:
The molding process utilizes different pressing directions for different features of the workpiece. The first metallic mold presses from one direction to form the main body, while the third metallic mold presses from an opposite direction to form the undercut flange. This dimensional approach allows both features to be molded effectively without interfering with each other, maintaining both shape accuracy and operational convenience.
3Manufacturing precision
If the third bent part is bent to move the first bent part towards the first press direction and the undercut flange towards the second press direction, then the undercut flange is molded accurately, but the first and second bent parts require subsequent reversing
Solution Approach 1:
The third bent part is utilized in advance during the flange molding process to position the first bent part and undercut flange accurately. Although this requires subsequent reversing of the bent parts, the preliminary positioning action ensures high molding precision that would be difficult to achieve through other means, and the reversing step is integrated into the overall efficient molding sequence.
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 simplifies the manufacturing process by avoiding the complexity of angle modification, ensuring accurate molding of undercut flanges without mold interference and allowing for efficient shaping of the pressed product.
Implementation Method 1
bending a metallic sheet due to a pressure applied to the metallic sheet in a thickness direction of the metallic sheet
Data Source
AI summary
Disclosed is an example of a method of manufacturing a pressed product including a substantially U-shaped main body and an undercut flange situated in the main body, in which an angle modification process can be eliminated. In the disclosed method, a third bent part, which is situated away from a first bent part towards a second bent part on a metallic sheet by a first length or more, is bent such that the first bent part is moved towards a first press direction and the undercut flange is moved towards a second press direction. The first press direction and the second press direction are opposite to each other. The first length is a length from a boundary between the undercut flange and a first plate portion to a tip of the undercut flange sized by projecting the undercut flange on an imaginary surface orthogonal to the first plate portion.