Welded Plate Forming to Reduce Springback Gaps in Vertical Walls
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Solution Overview
Problem
The formation of gaps between plate members due to springback during the pressing process leads to inconveniences in subsequent operations such as welding or assembling in the manufacturing of formed products with top plate and vertical wall portions.
Innovation Solution
A method involving the use of a metal press mold to curve plate members by contacting an extending portion, followed by forming the top plate and vertical wall portions after slight curvature, utilizing a shoulder portion with a specific angle to reduce springback and facilitate effective welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If plate members are pressed to form vertical wall portions, then the formed product shape is achieved, but springback causes gaps between plate members
Solution Approach 1:
The extending portion is prepared in advance on the first plate member before pressing. This extending portion serves as a positioning feature that prevents gap formation between plate members during the pressing operation, addressing the springback issue before it occurs
Solution Approach 2:
The extending portion acts as an intermediary element between the first and second plate members. It provides a mechanical interface that maintains precise positioning and prevents gap formation, mediating the interaction between the pressed plate members
2Ease of manufacture
If plate members are pressed together, then the formed product is manufactured, but springback causes inconvenience in subsequent welding operations
Solution Approach 1:
The extending portion is created beforehand to establish precise positioning and reduce springback effects. This preliminary structural feature ensures that subsequent welding operations can be performed accurately without the complications of gap formation
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
Reduces springback in the vertical wall portions, minimizing gaps and enabling effective welding operations, suitable for manufacturing automobile parts.
Implementation Method 1
curving the first vertical wall corresponding portion, the second vertical wall corresponding portion, and the extending portion of the plate members toward the moving direction is performed by moving a metal press mold in the moving direction
Implementation Method 2
joining the first member and the second member to each other is performed by welding the first top plate corresponding portion and the second top plate corresponding portion to each other
Data Source
AI summary
A method of manufacturing a formed product is provided. The method includes: joining a first member and a second member to each other by welding top plate corresponding portions to each other in a state where the first member is placed on the second member to include an extending portion; curving vertical wall corresponding portions and the extending portion of the plate members toward a moving direction by making a metal press mold contact the extending portion; and forming top plate portion and vertical wall portion by pressing the vertical wall corresponding portions of the plate members by the metal press mold.