Vehicle Panel Flange Forming With Corner Unwinding Control
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Solution Overview
Problem
Traditional methods for forming flanges on sheet metal vehicle body panels often result in inconsistent bends and surface distortions, particularly at corners, requiring additional finishing operations that increase time, cost, and scrap rates.
Innovation Solution
A method and device using a set of stamping tools that deform the sheet metal workpiece to form flanges with controlled angles, including an unwinding region that adjusts its angle as it approaches the corner, ensuring flanges are bent greater than 90° without distorting the Class A surface, utilizing multiple flange steels and anvils to precisely shape the edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bending or stamping techniques are used to form flanges at corners, then the flanges can be bent to the required angle, but surface distortions and inconsistent bends occur in the Class A surface
Solution Approach 1:
The flange forming process is divided into two distinct stages: first forming the flange to an initial angle, then unwinding the corner region to a reduced angle. This segmentation allows different regions of the flange to be treated differently, preventing distortion at the corner while maintaining the required bend elsewhere.
Solution Approach 2:
The patent applies different forming characteristics to different regions of the flange. The majority of the flange is bent to the required angle, while the corner region is specifically unwound to a reduced angle. This local differentiation ensures that the corner area does not distort the Class A surface while other regions maintain their functional bends.
2Ease of operation
If flanges are bent greater than 90° to achieve desired functionality and aesthetics, then the flange bends back over the interior side, but post operation finishing work is required to correct distortions
Solution Approach 1:
The patent performs the unwinding action during the initial forming process rather than as a separate corrective operation. By incorporating the angle reduction into the primary forming step, the need for subsequent finishing operations is eliminated, saving time and resources.
Solution Approach 2:
The patent converts what would normally be a harmful distortion into a beneficial feature by intentionally designing the corner region with a reduced angle. This controlled angle reduction prevents the harmful effects of distortion while maintaining the functional requirements of the flange.
3Productivity
If typical stamping techniques are used to form flanges, then the process is simple and quick, but the geometry of the Class A surface cannot be returned to intended shape and tolerances
Solution Approach 1:
The forming process is segmented into distinct operational phases within a single stamping cycle. The first phase forms the flange to the required angle, and the second phase unwinds the corner region. This segmentation enables precise geometric control without requiring multiple separate operations, maintaining productivity while improving precision.
Solution Approach 2:
The patent employs dynamic control of the stamping tools to achieve different forming characteristics at different stages. The tools are positioned and moved to create the initial bend, then repositioned to create the unwinding effect at the corner. This dynamic approach allows precise geometric control while maintaining an efficient single-cycle process.
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 method effectively forms flanges greater than 90° without distorting Class A surfaces, reducing the need for post-operation finishing and minimizing manufacturing costs and errors.
Implementation Method 1
deforming the workpiece between a first set of stamping tools to form a first edge of the main surface and a second edge of the main surface
Data Source
AI summary
A method of forming a vehicle panel includes deforming a sheet metal workpiece between stamping tools to form a first and second edges that converge at a corner of the workpiece's main surface. The first edge is defined by a junction of the main surface and a first flange. The second edge is defined the main surface and a second flange. Forming the first and second edges includes deforming the workpiece so that the second flange has a first region bent to a first angle relative to the main surface and an unwinding region bent to an angle that unwinds from the first region as the second flange approaches the corner. The method includes deforming the workpiece between a second set of stamping tools that deform the first flange and the unwinding region of the second flange until the first and second flanges are bent greater than 90°.