Variable Cross-Section Profile Deep-Drawing and Flange Cutting
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Solution Overview
Problem
Existing methods for producing profiles with variable cross-sections along their length are limited in achieving uniform dimensional stiffness and adaptability to specific strength requirements, particularly in motor vehicle construction.
Innovation Solution
A process involving deep-drawing and subsequent cutting of flanges from a unilaterally open profile, followed by bending to form a profile with a variable cross-section, which can be adapted for specific strength and space conditions, using Tailor-Rolled Blanks with variable thickness for enhanced stiffness and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a blank is deformed by deep-drawing to produce a unilaterally open profile with variable cross-section, then the profile achieves variable dimensional stiffness and strength, but flange irregularities occur during the deep-drawing operation requiring subsequent cutting
Solution Approach 1:
The profile production process is segmented into distinct stages: deep-drawing to form the variable cross-section profile, cutting to remove flange irregularities, and bending to achieve final shape. This segmentation allows each stage to optimize for its specific function while minimizing overall defects.
Solution Approach 2:
The deep-drawing operation is performed first to establish the variable cross-section geometry before cutting the flanges. This preliminary action creates the structural backbone of the profile, allowing subsequent cutting to only address flange irregularities rather than reshape the entire profile.
2Manufacturing precision
If flanges are cut from the unilaterally open profile, then flange irregularities are removed, but additional processing steps are required
Solution Approach 1:
The cutting operation is merged with the bending operation in sequence, where flanges are cut and then the profile is bent in the same production line. This combination reduces the need for separate handling and repositioning steps, minimizing overall process complexity despite adding a cutting step.
3Strength
If the profile is bent in a bending die to form a closed cross-section, then the profile achieves final shape and strength characteristics, but the seam line requires welding which complicates the process
Solution Approach 1:
The bending die creates a closed cross-section with a straight seam line in a specific location, concentrating the welding requirement to a single linear path rather than distributing welds throughout the profile. This localized approach simplifies welding fixture design and process control.
Solution Approach 2:
The bending operation is performed before welding, pre-positioning the profile in its final closed cross-section shape. This preliminary action ensures that the seam line is already aligned and accessible for welding, eliminating the need for complex positioning during the welding operation.
4Strength
If Tailor-Rolled Blanks with variable thickness are used, then the profile achieves enhanced stiffness and strength for specific applications, but the blank production process becomes more complex
Solution Approach 1:
Tailor-Rolled Blanks are produced with variable thickness at different locations along the blank length, allowing the profile to achieve enhanced stiffness and strength only where needed for crash resistance. This localized material property optimization avoids the complexity of using uniformly thick, over-engineered sections throughout the entire profile.
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
The process enables the production of profiles with variable dimensional stiffness and strength, allowing for easy adaptation to motor vehicle requirements, including crash scenarios, and facilitates efficient welding with simplified seam management.
Implementation Method 1
deforming the blank by deep-drawing in such a way that, as a result of the deep-drawing operation, there is provided a unilaterally open profile
Implementation Method 2
the unilaterally open profile is deformed in a bending die parallel to the longitudinal direction in order to vary the cross-section of the open profile
Data Source
AI summary
A process of producing profiles whose cross-section is variable in the longitudinal direction, characterized by the process stages of cutting a blank 31 with a substantially constant width along a longitudinal direction, deforming the blank 31 by deep-drawing to form an open profile whose cross-section is variable along the longitudinal direction, and cutting the flanges projecting from the open profile.