CN102489647A - Stepwise equal-thickness stamp-forging forming process for magnetic bracket - Google Patents
Stepwise equal-thickness stamp-forging forming process for magnetic bracket Download PDFInfo
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- CN102489647A CN102489647A CN2011104158504A CN201110415850A CN102489647A CN 102489647 A CN102489647 A CN 102489647A CN 2011104158504 A CN2011104158504 A CN 2011104158504A CN 201110415850 A CN201110415850 A CN 201110415850A CN 102489647 A CN102489647 A CN 102489647A
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Abstract
The invention belongs to the field of stamp-forging forming of metal plates, and in particular relates to a stepwise equal-thickness stamp-forging forming process for a magnetic bracket. The process comprises the following steps of: 1, stamping a peripheral notch on a left straight wall and a right straight wall of the magnetic bracket on a plate, and bending the plate at the notch according to a U shape to form the straight walls of the magnetic bracket and ensure that the sizes of the left straight wall and the right straight wall are equal to a given size of a product; 2, bending the plate between the left straight wall and the right straight wall of the magnetic bracket along a longitudinal central line to ensure that the distance between the left straight wall and the right straight wall of the magnetic bracket is shortened to be d1, putting the shortened plate material into a mold, adjusting positions of limiting blocks on the two sides of the plate to ensure that the distance d1 between the left straight wall and the right straight wall of the magnetic bracket is kept constant, and leveling the bent part of the plate by a cold forging method until the thickness of the plate is equal to that of the original plate; and 3, repeating the step 2 for N times to obtain d2,..., dn respectively, and cutting waste materials on the plate, wherein the dn is the given size of the distance between the left straight wall and the right straight wall of the magnetic bracket.
Description
[technical field]
The invention belongs to sheet metal press forging and forming field, more particularly, relate to a kind of step-by-step movement uniform thickness press forging and forming technology of magnetic force support.
[background technology]
In the electronic product, one type of magnetic force support handware (like Fig. 1, shown in 2) is arranged, on this support permanent magnet is housed, be evenly distributed, must guarantee magnetic force support thickness uniformity everywhere in order to guarantee the magnetic line of force.Roughly at a glance, this product seems to be common stamping parts, as forming with metallic plate punching, than being easier to guarantee magnetic force support thickness uniformity everywhere; But the height that examines two crooked directly walls in the middle of finding is bigger, flattens the rear section region overlapping, and therefore common Sheet Metal Forming Technology can't shape this type of special magnetic force support (as shown in Figure 3).
At present, the manufacturing process of this type of magnetic force support is summed up and mainly is divided into following three kinds of technologies:
(1) cold forging and milling group technology.The more equipment of this arts demand is accomplished, and production efficiency is lower.
(2) powder metallurgy injection molding technology.This technology is easy to generate pore, loosening reaches defectives such as in uneven thickness, and in addition, this technological requirement product thickness can not be too thin.
(3) common punching press and laser weld group technology.The magnetic force support is divided into the drawing respectively of left and right sides two halves, is put into again on the higher anchor clamps of high accuracy, automaticity and connects into a product through laser weld.This arts demand punch press, laser welding apparatus and the higher frock of automaticity, weld defect causes product qualified rate lower, and in addition, production efficiency is also lower.
In a word, above-mentioned three kinds of process equipments drop into higher, and production efficiency is lower, and product qualified rate is lower, has increased the manufacturing cost of this type of magnetic force support, will progressively be eliminated by market.
[summary of the invention]
Technical problem to be solved by this invention is to provide a kind of step-by-step movement uniform thickness press forging and forming technology of magnetic force support; Adopted and the diverse completely new approach of prior art; Through shortening the curved shape that magnetic force support two straight spans leave; Reach the purpose of uniform thickness press forging and forming, for the press forging and forming of this type of metal sheet that can't flatten provides new thinking.
Technical scheme of the present invention is: a kind of step-by-step movement uniform thickness press forging and forming technology of magnetic force support may further comprise the steps:
1. earlier in the perimeter gap of going out straight wall about the magnetic force support on the plate, the plate U type with indentation, there is bent to form the straight wall of magnetic force support again, guarantee simultaneously said about the size of straight wall equate with the product given size;
2. longitudinally center line is crooked with the plate between the straight wall about the magnetic force support, and making the hypotelorism of straight wall about said magnetic force support is d
1, then the plate after the said shortening is put into mould, through adjusting the limited block position on said plate both sides, make the spacing d of straight wall about said magnetic force support
1Remain unchanged, with the cold forging method clapped in this sheet metal bending place again, until with former plate uniform thickness;
3. repeating step is 2. n time, obtains d respectively
2..., d
n, d
nBe the given size of straight wall spacing about the magnetic force support, with the excision of the waste material on the said plate, promptly obtain the described magnetic force support of this method at last.
As the further improvement of said method, said step 2. in, with the plate between the straight wall about said magnetic force support longitudinally longitudinal centre line bend to streamlined.
As the further improvement of said method, said step 2. in, the limiting figure of the streamlined bending of said plate is drawn by following formula:
In the formula: α is the angle, flexural center, 0＜α≤90 °; L
1Be the straight wall of magnetic force support outside plate length, 15mm≤L
1＜27mm; R
3, R
4Be respectively the neutral layer radius of sheet metal bending part, L is the length of run of plate.
As another step improvement of said method; Shear work step for reducing the waste material that cold forging claps behind the work step; 1. on the plate during towards breach, the arc notch that is used to compensate said sheet metal deformation is gone out in the waste streams source to step in advance on the plate between the straight wall about the magnetic force support.
Principle of the present invention is: the finished product that is characterized as of press forging and forming is compared with former plate very obvious variation is arranged on the material thickness.It is constant with sotck thinkness that yet the thickness of some part (like the magnetic force support) keeps; But in forming process, need make with the method that punching press and cold forging combine material thickness change (for example thickening attenuate more earlier) just can reach the constant requirement of above-mentioned thickness, this also is a kind of new model of press forging and forming.Research to this problem does not at present also appear in the newspapers.The present invention breaks through traditional thinking; Provided the new method of dealing with problems: keep two straight wall height constant; With the pitch enlargement of two straight walls to the size that can flatten by common Sheet Metal Forming Technology; Constantly shorten two straight wall spacings through bending several times and the cold forging technology of clapping again, reach up to part till the size of drawing requirement.Shorten the distance between two straight walls of magnetic force support series products through bending process; This type of bending not only will be controlled material can not have tangible attenuation; And to note crooked shape, so that follow-up cold forging operation can not produce defective workmanships such as material is overlapping, wavy.Adopt the theoretical method that combines with experiment to optimize the curved shape that shortens two straight wall spacings.Defectives such as the result shows, adopt streamlined bending can avoid cold forging to clap material that work step produces is overlapping, wavy.
The invention has the advantages that: this process using step-by-step movement impact forging technology magnetic force support that is shaped; Can accomplish processing once the cover progressive die or multi-station progressive die, greatly reduce production cost, product percent of pass is also brought up to reasonable level; Not only can be shaped with mild steel is the magnetic force support class part of blank; But also can be shaped with the sheet metal is the sheet metal component of other similar structures of blank, is of universal significance, and is the important supplement of Sheet Metal Forming Technology.
[description of drawings]
In conjunction with embodiment invention is further described with reference to the accompanying drawings.
Fig. 1 is a magnetic force support vertical view,
Fig. 2 is a magnetic force support cutaway view,
Fig. 3 is the flattening figure of magnetic force support,
Fig. 4 is the comparison diagram of following axisymmetric bending type on the magnetic force support,
Fig. 5 is the crooked sketch map of magnetic force supporting plate materials flow line style,
Fig. 6 is the plate crooked limiting figure figure of line style for the first time,
Fig. 7 is plate streamlined crooked actual numerical value figure for the first time,
Fig. 8 is the plate crooked limiting figure figure of line style for the second time,
Fig. 9 is plate streamlined crooked actual numerical value figure for the second time,
Figure 10 is the streamlined for the third time crooked actual numerical value figure of plate,
Figure 11 is a FB(flow block) of the present invention,
Figure 12 is the variation sketch map of plate in each flow process of the present invention,
Figure 13 is the photo comparison diagram of plate in each flow process of the present invention.
[specific embodiment]
Further specify invention through embodiment below, and invention is not restricted to said embodiment, all similar with the invention structure, and only be that size, position are adjusted or change person to some extent, then all belong to the protection category of invention.
The specification requirement of magnetic force support is following: material is the mild steel of thickness t=1.0mm, and same magnetic force support thickness requirement everywhere equates that franchise is merely 4%t, and promptly same magnetic force support thickness deviation everywhere is ± 0.02mm that other tolerance grade not noted is ± 0.2mm.
The technological process of this magnetic force support progressively shortens to two straight wall spacing 18mm the 10mm of product requirement like Fig. 9, shown in 10 through step-by-step movement impact forging technology.To same magnetic force support everywhere thickness deviation be ± specification requirement of 0.02mm that two straight wall U type bending process belong to ripe Sheet Metal Forming Technology, can not cause the place's attenuation of straight wall, and the attenuation amount ratio of crooked root are easier to be controlled in the 0.02mm; And the streamlined bending → cold forging on the straight upper and lower both sides of the wall technology of clapping, as long as the limited block with the plate uniform thickness is set at the counterdie of cold-forging die, the material thickness located of just can guaranteeing easily to clap with the deviation of former plate thickness in 0.04mm.For tolerance grade not noted is ± specification requirement of 0.2mm then to reach more easily.
Since impact forging technology can guarantee the specification requirement of magnetic force support, the problem that how how two straight wall spacings shortened of research below, soon two straight wall spacing 18mm several steps of minimum branch shortened to the 10mm of product requirement.Adopt this technology magnetic force support that is shaped; Can accomplish once the cover progressive die (or multi-station progressive die), but confirm that the work step number (or station number) of the progressive die is not an easy thing: work step is too many, not only can cause progressive die appearance and size longer; Die manufacturing cost is higher; And the cold forging number of times of clapping is many more, can produce serious work hardening phenomenon, causes defective workmanships such as cold forging place cracking easily; Work step then can cause defectives such as part cold forging place is overlapping, wavy very little, even the fracture of cold forging place can take place.Therefore, guaranteeing under the product quality prerequisite that the minimum work step number of The layout just becomes in the magnetic force support progressive die is worth research very much.
In order to practice thrift cost, reduce the work hardening that technology brings of clapping of streamlined bending and cold forging, under the prerequisite that guarantees no defective workmanship, the clap work step number of technology of streamlined bending and cold forging is good more more less.Learn easily after the multiple streamlined crooked contrast of enumerating from Fig. 4: bigger R
1, R
2And lower height H can prevent the defective workmanship that streamlined bending and cold forging are clapped, but can increase the work step number of this technology like this, causes the serious work hardening in cold forging place, can produce defective workmanships such as cracking and crackle.Therefore, must seek an equalization point and solve this contradiction.The method that solves is: under the prerequisite that guarantees no defective workmanship, distance is minimum between the two straight walls of each streamlined crooked back, and just the work step number is minimum.As shown in Figure 3, can know according to streamlined crooked back neutral line length:
0＜α in the formula≤90 °, 15mm≤L
1＜27mm, R
3, R
4Be respectively neutral layer radius, L is a length of run.
Can know by formula (1):
When α=90 °,
From Fig. 4, find out easily, work as R
1+ R
2Hour, the spacing of two straight walls is minimum.According to top discussion and practical experience, R
3, R
4Get the defective workmanship such as overlapping, wavy that higher value helps preventing that cold forging from clapping and producing.Therefore, L
1Get 15mm, obtain following formula easily:
For the streamlined beaming limit first time, L=54mm can know according to formula (4),
Suppose the R among streamlined crooked Fig. 4
2Be 3mm, getting the bending neutral layer COEFFICIENT K is 0.4, and then the limiting figure of streamlined bending is for the first time seen Fig. 6, and the height dimension among the figure is a dimension limit, and overlapping, the undulatory defective workmanship whether under can causing the work step cold forging is clapped awaits to verify.In order to reduce experiment number, the method that adopts the experiment of numerical simulation and mould to combine is verified.Numerical simulation result shows when streamlined bending height size is reduced to 6.5mm by 8.84mm, and the cold forging work step defective workmanship complete obiteration of clapping according to simulation and experimental result, is for the first time streamlinedly crookedly schemed like Fig. 7.
For the streamlined beaming limit second time, according to formula (3) and Fig. 7, L=50.29mm gets L
1=15mm, at this moment
Suppose the R among Fig. 4
2Be 3mm, getting the bending neutral layer COEFFICIENT K is 0.4, and then the limiting figure of streamlined bending is for the second time seen Fig. 8, and the height dimension among the figure is the limiting altitude size after the streamlined bending for the second time, adopts the method for numerical simulation and mould experiment to verify this limiting altitude.Numerical simulation result shows when streamlined bending height size is reduced to 5mm by 7.66mm, the cold forging procedure technology defective complete obiteration of clapping, and according to simulation and experimental result, the streamlined bending second time such as Fig. 9.
Can know that by Fig. 9 distance is 11.98mm between two straight walls, does not still reach product requirement size 10mm, must carry out streamlined for the third time bending.Distance is under the 10mm situation in guaranteeing two straight walls, streamlined for the third time bending such as Figure 10.Set up threedimensional model by Fig. 9 size, this model is imported Deform 3D carry out the clap numerical simulation of operation of cold forging, the result shows no defective workmanship appearance.Carry out the mould experimental verification according to analog parameter, experimental result is coincide with the simulation result.
Sum up above result of study; As will be in a cover progressive die magnetic force support of shop drawings 1; Guaranteeing that cold forging claps under the prerequisite of work step zero lap, defective workmanship such as wavy, the The layout of magnetic force support needs streamlined crooked work step of three steps and the three step cold forgings work step of clapping at least, i.e. n >=3 of step in 3.; Could two straight wall spacings progressively be shortened to 10mm from 18mm, finally produce the magnetic force support that meets product requirement.According to above result of study, streamlined bending in this magnetic force support The layout and cold forging clap work step flow process such as Figure 11,12.According to the parameter of technological parameter among Figure 12 and numerical simulation, make the checking that experimentizes of each work step mould, for this magnetic force support multi-station progressive die of correct design provides foundation.Experimental result photo such as Figure 13 of whole flow process shear work step in order to reduce the waste material that cold forging claps behind the work step during experiment, specially increase the camber line breach that is used to compensate sheet metal deformation in the waste streams source and compensate (shown in Figure 13 a).
As can beappreciated from fig. 12, laboratory sample is at for the first time streamlined crooked back two straight wall spacing d
1=14.49mm is than the big 0.20mm of theoretical value 14.29mm of Fig. 4-20; Streamlined crooked back two straight wall spacings are also respectively than the big 0.12mm of theoretical value, the 0.07mm of Fig. 4-20 for the second time, for the third time, this be since the first time streamlined bending height bigger, knee material attenuation causes experiment value greater than theoretical value.Along with the height reduction of bending, the material attenuate is very little, and its theoretical value and experiment value are just very approaching.
The optimization of magnetic force support step-by-step movement press forging and forming technology
Step-by-step movement press forging and forming technology, under the constant prerequisite of the work step number that keeps the straight wall height and the progressive die, the R of streamlined bending
1, R
2Which kind of satisfying under the condition; Can two straight wall spacings of magnetic force support reach minimum of a value? In order to solve this difficult problem; The applicant's integrated use genetic algorithm (Genetic Algoritims; GA), Finite Element Method (Finite Element Method, FEM) and artificial neural network (Artificial Neural Network ANN) comes respectively streamlined radius of curvature R in the three step forming technologies mentioned above
1And R
2The value of (seeing accompanying drawing 4) is optimized, thereby obtains the minimum of a value of each crooked back magnetic force support two straight wall spacings, verifies according to the parameters optimization mfg. moulding die at last again.
1 first step parameter optimization in forming
1.1 first order bends technological parameter simulated experiment
According to R
1And R
2Different to component shaping quality influence degree, here to R
1Get 3 levels, R
2Get 5 levels and make up in twos, and through DEFORM-3D software various parameter combinations are carried out finite element modelling, making a half value of magnetic force support two straight wall spacings is d, sees table 1 in detail.
Table 1 is the bending die draft experiment for the first time
In second step and streamlined bending process of the 3rd step, the R of streamlined bending
1And R
2The analog result that the value of two technological parameters and combination in twos thereof obtain is respectively shown in table 2 and table 3.Neural metwork training process, genetic algorithm searching process and simplation verification and the above-mentioned first step are similar, and the result who finally obtains is respectively shown in table 4 and table 5.From the Optimization result of streamlined bending for the third time, the error that genetic algorithm optimization is separated with analog result is 0, the neural metwork training result that this explanation is three times and with the genetic algorithm optimization result be reliable.In addition, can know that the result after the optimization is littler than the test sample, explain that the technology of this joint proposition is rationally feasible by table 5.
Table 2 bending process parameter simulation experiment for the second time
Table 3 bending process parameter simulation experiment for the third time
The parameter optimization result and the analog result contrast table of the crooked for the second time back of table 4 two straight wall spacings
The parameter optimization result and the analog result contrast table of the crooked for the third time back of table 5 two straight wall spacings
3 process parameter optimizing conclusions
After three suboptimization, promptly bending step in 3. be n=3 the time, can reach 4.34 * 2=8.68mm apart from minimum range between the part two straight walls, numerical simulation result and genetic algorithm optimization result coincide, between two straight walls apart from having reduced 13.2%.
The applicant's integrated use genetic algorithm, Finite Element Method and artificial neural network are respectively to streamlined radius of curvature R of three steps
1And R
2Value be optimized, thereby obtain the minimum of a value of each crooked back magnetic force support two straight wall spacing 2d, analog result and Optimization result are identical.Streamlined crooked Optimization result of three steps and analog result see Table 6.
Three steps of table 6 streamlined crooked back two straight wall distance optimization result and analog results
4 experimental verifications
According to design of table 6 optimized parameters and mfg. moulding die.Having relatively high expectations of the processing of mould and detection.Use be careful silk thread cutting of Japanese Sha Dike to make punch, the die mold insert of experiment mould, use high-precision CNC projection device and three-coordinates measuring machine to detect punch, die mold insert.Carry out respectively three the step streamlined bendings and three the step cold forgings clap, obtaining two straight wall spacings at last is 8.69mm, experimental result is referring to Figure 13, and is very identical with artificial neural network and finite element modelling result.
Although illustrated and described inventive embodiment, for those of ordinary skill in the art, scope of invention is limited accompanying claims and equivalent thereof.
Claims (6)
1. the step-by-step movement uniform thickness press forging and forming technology of a magnetic force support is characterized in that may further comprise the steps:
1. earlier in the perimeter gap of going out straight wall about the magnetic force support on the plate, the plate U type with indentation, there is bent to form the straight wall of magnetic force support again, guarantee simultaneously said about the size of straight wall equate with the product given size;
2. longitudinally center line is crooked with the plate between the straight wall about the magnetic force support, and making the hypotelorism of straight wall about said magnetic force support is d
1, then the plate after the said shortening is put into mould, through adjusting the limited block position on said plate both sides, make the spacing d of straight wall about said magnetic force support
1Remain unchanged, with the cold forging method clapped in this sheet metal bending place again, until with former plate uniform thickness;
3. repeating step is 2. n time, obtains d respectively
2..., d
n, d
nBe the given size of straight wall spacing about the magnetic force support, with the excision of the waste material on the said plate, promptly obtain the described magnetic force support of this method at last.
2. according to the step-by-step movement uniform thickness press forging and forming technology of the said a kind of magnetic force support of claim 1, it is characterized in that: said step 2. in, with the plate between the straight wall about said magnetic force support longitudinally longitudinal centre line bend to streamlined.
3. according to the step-by-step movement uniform thickness press forging and forming technology of the said a kind of magnetic force support of claim 2, it is characterized in that: said step 2. in, the limiting figure of the streamlined bending of said plate is drawn by following formula:
In the formula: α is the angle, flexural center, 0＜α≤90 °; L
1Be the straight wall of magnetic force support outside plate length, 15mm≤L
1＜27mm; R
3, R
4Be respectively the neutral layer radius of sheet metal bending part, L is the length of run of plate.
4. according to the step-by-step movement uniform thickness press forging and forming technology of the said a kind of magnetic force support of claim 1, it is characterized in that: n >=3 of said step in 3..
5. according to the step-by-step movement uniform thickness press forging and forming technology of the said a kind of magnetic force support of claim 4, it is characterized in that: the n=3 of said step in 3..
6. according to the step-by-step movement uniform thickness press forging and forming technology of each said a kind of magnetic force support of claim 1-5; It is characterized in that: said step 1. in; On the plate during towards breach; The arc notch that is used to compensate said sheet metal deformation is gone out in waste streams source on the plate between the straight wall about the magnetic force support in advance.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104057005A (en) * | 2014-06-03 | 2014-09-24 | 合肥金海康五金机械制造有限公司 | Application method of stepping coefficient of equal-thickness stamping-forging of hardware with structure like Chinese character 'er' |
| CN104200008A (en) * | 2014-08-04 | 2014-12-10 | 合肥金海康五金机械制造有限公司 | Calculating method for deformation of hardware drawing structure in shape of left-facing letter L and letter L after uniform thickness stamp forging |
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| JP2004237330A (en) * | 2003-02-06 | 2004-08-26 | Asmo Co Ltd | Sheet metal product and sheet metal product manufacturing method |
| JP2008006457A (en) * | 2006-06-28 | 2008-01-17 | Asmo Co Ltd | Method of manufacturing formed goods of sheet metal and formed goods of sheet metal |
| CN201455080U (en) * | 2009-08-17 | 2010-05-12 | 天津华舜汽配制造有限公司 | Stabilizer bar arm stamping die |
| CN102189173A (en) * | 2011-03-09 | 2011-09-21 | 南京工业职业技术学院 | Carrier-free one-die two-piece forming method for bracket |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2004237330A (en) * | 2003-02-06 | 2004-08-26 | Asmo Co Ltd | Sheet metal product and sheet metal product manufacturing method |
| JP2008006457A (en) * | 2006-06-28 | 2008-01-17 | Asmo Co Ltd | Method of manufacturing formed goods of sheet metal and formed goods of sheet metal |
| CN201455080U (en) * | 2009-08-17 | 2010-05-12 | 天津华舜汽配制造有限公司 | Stabilizer bar arm stamping die |
| CN102189173A (en) * | 2011-03-09 | 2011-09-21 | 南京工业职业技术学院 | Carrier-free one-die two-piece forming method for bracket |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104057005A (en) * | 2014-06-03 | 2014-09-24 | 合肥金海康五金机械制造有限公司 | Application method of stepping coefficient of equal-thickness stamping-forging of hardware with structure like Chinese character 'er' |
| CN104057005B (en) * | 2014-06-03 | 2015-10-28 | 合肥金海康五金机械制造有限公司 | The application process of the stepping coefficient of a kind of ┛ ┗ type structure handware uniform thickness impact forging |
| CN104200008A (en) * | 2014-08-04 | 2014-12-10 | 合肥金海康五金机械制造有限公司 | Calculating method for deformation of hardware drawing structure in shape of left-facing letter L and letter L after uniform thickness stamp forging |
| CN104200008B (en) * | 2014-08-04 | 2017-06-06 | 合肥金海康五金机械制造有限公司 | The computational methods of ┛ ┗ type handware deep-drawing structures deformation after uniform thickness impact forging processing |
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| CN102489647B (en) | 2014-10-29 |
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Address after: 230601, peach blossom Industrial Park, Jing Qu District, Hefei City, Anhui Province, intersection of Yulan Avenue and Huanggang Road Applicant after: Hefei Jinhaikang Metal & Machine Co.,Ltd. Address before: 230601 Anhui city of Hefei province Zi Peng Lu economic and Technological Development Zone and Penglai Road intersection 100 meters south Applicant before: Hefei Jinhaikang Metal & Machine Co.,Ltd. |
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| CF01 | Termination of patent right due to non-payment of annual fee |
Granted publication date: 20141029 Termination date: 20181213 |