CN105522020A - Incremental forming method for hemispherical shell and auxiliary forming device for hemispherical shell - Google Patents
Incremental forming method for hemispherical shell and auxiliary forming device for hemispherical shell Download PDFInfo
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- CN105522020A CN105522020A CN201510954291.2A CN201510954291A CN105522020A CN 105522020 A CN105522020 A CN 105522020A CN 201510954291 A CN201510954291 A CN 201510954291A CN 105522020 A CN105522020 A CN 105522020A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
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Abstract
The invention relates to an incremental forming method for a hemispherical shell and an auxiliary forming device for the hemispherical shell. The incremental forming method comprises the following steps that 1, a basic path is designed, specifically, a target hemispherical shell is machined, multiple sets of hemispherical shells of different calibers are selected, and the incremental forming path of the target hemispherical shell is designed as the basic path; and 2, key variables are extracted, specifically, the key variables in the forming paths of the hemispherical parts of different calibers are b, r1, r2, a2, r3 and b3 respectively, wherein in the first pass of path, the coordinates of the intersecting point of the straight line with the dip angle of 41 degrees and the y axis are (0,b), r1 is the circular arc radius value of the second pass, r2 is the circular arc radius value of the upper portion of the third pass, a2 is the x-axis coordinate of the circular arc center of the upper portion of the third pass, r3 is the circular arc radius value of the lower portion of the third pass, and b3 is the y-axis coordinate of the circular arc center of the lower portion of the third pass. Massive and intelligent development of the incremental forming process is facilitated.
Description
Technical field
The present invention relates to plate progressive molding field, particularly a kind of progressive molding method of hemispherical shells and corresponding assist formation device.
Background technology
Plate progressive molding technique have employed the thought of the Layered manufacturing in RP technique, successively be shaped discrete for part to be formed for a series of two dimensional surface, drive former to carry out layering pointwise shaping to plate by numerical control program prepared in advance.Compared with traditional plate moulding process, due to its flexible forming, the manufacturing cycle shortens greatly, and without the need to mould or only need simple mould; Meanwhile, because forming process is that layering pointwise is shaped, the plasticity of material can effectively be played.Plate progressive molding technology is applicable to single-piece or the small lot batch manufacture of part, and this technology can meet the diversification of Vehicles Collected from Market, personalized Smart Market economic situation.
For the workpiece such as shallow cone part, shallow covering that forming angle is less, by once-forming, conveniently obtain target workpiece; For workpiece such as dark cone part, spherical parts and cylindrical member that forming angle is larger, need be shaped through multiple passage, forming path design is comparatively loaded down with trivial details, and through repeatedly inspection and amendment, successfully need could obtain target workpiece.Forming path by the equal proportion convergent-divergent of equal proportion convergent-divergent realize target workpiece, cannot redesign path and needs at substantial time and energy.
Summary of the invention:
Technical problem: the progressive molding method and the assist formation device thereof that the object of this invention is to provide a kind of hemispherical shells.
Summary of the invention: for solving the problems of the technologies described above, the invention provides a kind of progressive forming method of hemispherical shells, the method comprises the steps:
Step 1: design basis path;
Editing objective hemispherical shells, selects the hemispherical shells of some groups of different bores, path based on the progressive molding path designing above target hemispherical shells;
Step 2: extract key variables;
Key variables in the forming path of different bore half ball element are respectively: b, r
1, r
2, a
2, r
3, b
3;
Wherein: in first passage path, inclination angle be the straight line of 41 ° and y-axis intersecting point coordinate for (0, b), r
1be the second passage arc radius value, r
2be the 3rd passage top arc radius value, a
2be the 3rd circular arc center of circle, passage top x-axis coordinate, r
3be the 3rd passage bottom arc radius value, b
3it is the 3rd circular arc center of circle, passage bottom y-axis coordinate;
The general formula of the forming path equation of each passage is as follows:
formula 1
formula 2
formula 3
formula 4
Wherein y
1headed by the path equation of passage forming path three sections of straight lines, y
2be the path equation of circular arc in the second passage forming path, y
3be the path equation of two sections of tangent arcs in the 3rd passage forming path, y
4be four-pass forming path equation, be the bus of hemispherical shells;
Wherein the span of R is (0,2R);
According to the known parameters in differing formed path, with the oral area radius R of spherical parts for known variables, to b, r
1, r
2, a
2, r
3, b
3carry out linear fit, the goodness of fit ensures more than 0.99, fit equation is substituted in above-mentioned expression formula, can draw the general formula of hemispherical shells forming path equation; In addition, forming tool head radius gets R/10, and axial feed measures R/100.
The assist formation device that the progressive forming method that present invention also offers a kind of hemispherical shells is made, this device comprises:
Workbench, the bloom be arranged on tool stand, the base for supporting be arranged on bloom, the outline gripper shoe covering base for supporting, the pressing plate be covered in outline gripper shoe, be placed in plate in the middle part of pressing plate, be located at the tool heads be connected in the middle part of plate and with plate; Pressing plate, foreign steamer are crossed the gripper shoe surrounding place of keeping to the side and are provided with the circle circular hole surrounding rectangle, and have corresponding bolt hole in the corresponding position of base for supporting, this bolt hole is for placing bolt;
This device also comprises gad, and this gad is fixing on the table by stay bolt, and bloom pad is located at below gad; Gad is indicated and is also provided with briquetting;
Briquetting is engaged fixing with gad by sawtooth, its level altitude is adjustable, more regulates processing space by the height changing bloom;
Base for supporting lower end is provided with flange, is fixed on workbench by base for supporting by the combination of stay bolt, briquetting, gad.
Preferably, the tool heads bulb part that comprises straight bar part, the tapered intermediate portion be connected with straight bar part one end and be connected with the tapered intermediate portion other end.
Preferably, the diameter of straight bar part and the equal diameters of bulb part.
Beneficial effect: the advantage that the present invention has and good effect are:
(1) by the conclusion of elementary path, the equation expression formula of hemispherical shells forming path can be obtained within the specific limits, the forming path of any bore hemispherical shells within the scope of this can be obtained rapidly, the machined parameters such as tool heads radius, axial feeding can be obtained simultaneously, the rapid processing that can realize same class workpiece is shaped, eliminate the complicated processes of path design, be conducive to progressive molding technique to mass, intelligent direction development.
(2) head of forming tool head and bar portion excessive by taper, can effectively avoid straight bar part to the interference effect of forming process, by pointwise contact, pointwise processing, pointwise distortion, play the plasticity of plate to greatest extent, fully demonstrate the advantage of progressive molding technique.
(3) internal diameter of pressing plate and outline gripper shoe is close to the mouth diameters of target workpiece, and its clamping face is provided with the zigzag anti-slip veins in tangentially direction, can effectively prevent plate from sliding, the plate beyond shaped region is avoided to send out into distortion, reduce oral area in half spherical pieces forming process to sink and bottom sinkage, greatly improve the forming accuracy of target workpiece.
Accompanying drawing explanation
Forming path schematic diagram when Fig. 1 is R=50,
Fig. 2 is parametrization shaping path schematic diagram,
Fig. 3 is forming tool head schematic diagram,
Fig. 4 is pressing plate, outline gripper shoe and base for supporting schematic diagram,
Fig. 5 is zigzag anti-slip veins schematic diagram,
Fig. 6 is building mortion schematic diagram,
Fig. 7 is Linear Fit Chart.
Wherein, 1 is tool heads, and 2 is plate, and 3 is pressing plate, and 4 is outline gripper shoe, and 5 is base for supporting, and 6 is bolt, and 7 is stay bolt, and 8 is briquetting, and 9 is gad, and 10 is rectangle bloom, and 11 is workbench.
Detailed description of the invention
Below in conjunction with accompanying drawing, the present invention will be further described.
The present invention's hemispherical shells is in varing proportions target workpiece, by summing up its shaping law, explore the key variables in the hemispherical shells forming path of different proportion, realize the quick acquisition of the hemispherical shells forming path of different proportion, and by the collocation of simple die, coordinate corresponding former, design the assist formation device of a set of hemispherical shells.
The invention provides a kind of progressive forming method of hemispherical shells, the method comprises the steps:
Step 1: design basis path;
Editing objective hemispherical shells, selects the hemispherical shells of some groups of different bores, path based on the progressive molding path designing above target hemispherical shells;
Step 2: extract key variables;
Key variables in the forming path of different bore half ball element are respectively: b, r
1, r
2, a
2, r
3, b
3;
Wherein: in first passage path, inclination angle be the straight line of 41 ° and y-axis intersecting point coordinate for (0, b), r
1be the second passage arc radius value, r
2be the 3rd passage top arc radius value, a
2be the 3rd circular arc center of circle, passage top x-axis coordinate, r
3be the 3rd passage bottom arc radius value, b
3it is the 3rd circular arc center of circle, passage bottom y-axis coordinate;
The general formula of the forming path equation of each passage is as follows:
formula 1
formula 2
formula 3
formula 4
Wherein y
1headed by the path equation of passage forming path three sections of straight lines, y
2be the path equation of circular arc in the second passage forming path, y
3be the path equation of two sections of tangent arcs in the 3rd passage forming path, y
4be four-pass forming path equation, be the bus of hemispherical shells.
Wherein the span of R is (0,2R);
According to the known parameters in differing formed path, with the oral area radius R of spherical parts for known variables, to b, r
1, r
2, a
2, r
3, b
3carry out linear fit, the goodness of fit ensures more than 0.99, fit equation is substituted in above-mentioned expression formula, can draw the general formula of hemispherical shells forming path equation; In addition, forming tool head radius gets R/10, and axial feed measures R/100.
The assist formation device that the progressive forming method that present invention also offers a kind of hemispherical shells is made, this device comprises:
Workbench 11, the bloom 10 be arranged on tool stand 11, the base for supporting 5 be arranged on bloom 10, the outline gripper shoe 4 covering base for supporting 5, the pressing plate 3 be covered in outline gripper shoe 4, be placed in plate 2 in the middle part of pressing plate 3, be located at the tool heads 1 be connected in the middle part of plate 2 and with plate 2; Pressing plate 3, foreign steamer are crossed the gripper shoe 4 surrounding place of keeping to the side and are provided with the circle circular hole surrounding rectangle, and have corresponding bolt hole in the corresponding position of base for supporting 5, this bolt hole is for placing bolt 6;
This device also comprises gad 9, and this gad 9 is fixed on workbench 11 by stay bolt 7, and bloom 10 pad is located at below gad 9; Gad 9 is indicated and is also provided with briquetting 8;
Briquetting 8 is engaged fixing with gad 9 by sawtooth, its level altitude is adjustable, more regulates processing space by the height changing bloom 10;
Base for supporting 5 lower end is provided with flange, is fixed on workbench 11 by base for supporting 5 by the combination of stay bolt 7, briquetting 8, gad 9.
The bulb part that tool heads 1 comprises straight bar part, the tapered intermediate portion be connected with straight bar part one end and is connected with the tapered intermediate portion other end.
The diameter of straight bar part and the equal diameters of bulb part.
Detailed speech it,
1, the design in basic path
Decision condition using the uniform wall thickness degree of target workpiece as processing success or not, according to constant-volume principle (V
before shaping=V
after shaping) calculate be shaped after the theoretical wall thickness of plate, be set to t, and the wall thickness of actual measurement target workpiece, when its Thickness Distribution is within (0.85 ~ 1.15) t scope, think work pieces process success, otherwise process unsuccessfully.Select the half spherical pieces of 5 groups of different bores, its oral area radius is respectively 0.5R, R, 1.2R.1.5R, 2R, and the method combined by simulation and experiment repeatedly, designs the progressive molding path of above target workpiece as reference path.
For R=50mm, plate original depth t
0get 0.84mm, then the volume V=π r of sheet metal deformation part
2t
0according to constancy of volume principle, the average wall thickness t=0.42mm of target workpiece can be obtained, consider the error component that actual process exists, think that the wall thickness of target workpiece divides within (0.85 ~ 1.15) t scope, i.e. 0.357 ~ 0.483mm, can think target workpiece uniform wall thickness.
When first passage is shaped, the Thickness Distribution of workpiece obeys sine, i.e. t=t
0(90 ° of-θ), θ is forming angle.When forming angle is larger, workpiece sidewall there will be thinning band, and when forming angle is too small, between post forming passage, angle becomes large, cause distortion uneven with.For 1060 aluminium sheets that wall thickness when going out is 0.84mm, its critical forming angle θ
s=47 °, as forming angle θ > 47 °, the Thickness Distribution of target workpiece does not meet the primary condition of setting, and thinning band appears at axial depth about 8 ~ 10mm; Its limit forming angle θ
p=68 °, as forming angle θ > 68 °, target workpiece can be broken in the position of thinning band.
This target workpiece adopts four-pass to be shaped:
First passage path design: first passage path by three sections of rectilinear(-al)s, top-down forming mode.Not easily deform because plate oral area material is subject to the effect of pressing plate, therefore initial formation angle θ
1get θ
s+ (4 ° ~ 6 °), θ herein
1get 51 °.Because initial formation angle is greater than critical forming angle, there will be thinning band in the position of axial depth 8 ~ 10mm, therefore at Forming depth h
1when reaching about 8mm, forming angle reduces to 41 °, prevents the appearance of thinning band.In order to solve the defect of sinking bottom target workpiece, the Forming depth of first passage controls, at 0.88R, to get 44mm herein, and the forming angle of bottom section is down to 35.5 °, Forming depth h simultaneously
2be about 8 ~ 10mm, increase bottom section material thickness, to prevent from occurring breaking during follow-up chamfer machining from bottom to top.
Second passage path design: the second passage path is made up of one section of circular arc, adopts top-down forming mode.Its initial formation angle, i.e. circular arc top tangent line and horizontal direction angle theta
2=θ
1+ (12 ° ~ 14 °), its formative radius r
1get (1.8 ~ 2) R, get 96mm herein.In order to solve the defect of sinking bottom target workpiece, the Forming depth of the second passage controls, at 0.94R, to get 47mm herein.
3rd passage path design: the 3rd passage is made up of two sections of tangent circular arcs, adopts chamfer machining mode from bottom to top, effectively can increase the distortion of bottom section material.Its initial formation angle θ
3=θ
2+ (12 ° ~ 14 °).The axial working depth of two sections of circular arcs is substantially identical, top arc radius r
2get (1.2 ~ 1.4) R, get 62mm herein, top arc radius r
3get (0.8 ~ 1) R, get 44mm herein.Forming depth is with the second passage.
Four-pass is the bus of target workpiece, adopts top-down forming mode.
Its forming path as shown in Figure 1.
2, the extraction of key variables
Because target workpiece is revolving body workpieces, therefore, its forming path is represented with the bus of revolving body, as shown in Figure 2.Hemispherical shells is shaped by four-pass, and first passage is made up of three sections of broken lines, and its forming angle is followed successively by 51 °, 41 °, 35.5 °; Second passage is made up of one section of circular arc, and its arc radius is r
1; 3rd passage is made up of two sections of circular arcs, and its arc radius is r
2, r
3; Extreme trace is the bus of target workpiece.
In forming process, there is bottom sinkage to a certain degree in hemispherical shells, on the one hand because the marginal portion of plate clamping exists sliding phenomenon, be on the other hand due to plastic force larger time axial drawing effect is produced to plate.In order to ensure the levels of precision of target workpiece size, reducing its Forming depth respectively in previous three passes, reserving the sinking space of plate, as shown in Figure 2, first passage Forming depth is 0.88R, and the Forming depth of the two or three passage is 0.94R, and four-pass processes accurate target workpiece size.
In order to obtain the forming path of different bore hemispherical shells fast, need the forming path in Fig. 2 to carry out equation expression.The expression-form of three sections of broken lines in first passage forming path is the piecewise function of three linear equation compositions, and from right to left, the known quantity of three sections of broken lines is respectively: 51 °, (1) inclination angle, intersection point A (R, O); (2) 41 °, inclination angle, if its extended line and y-axis meet at a B, (0, b), wherein b is unknown number; (3) inclination angle is 35.5 °, intersection point C (0,0.88R).Second passage is one section of circular arc, and its radius is r
1, and cross some A (R, 0), D (0,0.94R), its centre point O
1coordinate be
the expression formula of this section of circular arc can be given expression to according to known conditions.3rd passage is two sections of tangent circular arcs, and from right to left, the known quantity of two sections of circular arcs is respectively: (1) radius is r
2, cross some A (R, 0), its centre point O
3coordinate be
wherein a
2for unknown number; (2) radius is r
3, cross some D (0,0.94R), its centre point O
3coordinate be
Wherein b
3for unknown number.
Analyze through above, the key variables in the forming path of different bore half ball element are respectively: b, r
1, r
2, a
2, r
3, b
3.According to set up rectangular coordinate system, can write out the general formula of the forming path equation of each passage respectively, result is such as formula shown in (1) ~ (3):
Wherein the span of R is (0,2R).
According to the known parameters in differing formed path, with the oral area radius R of spherical parts for known variables, to b, r
1, r
2, a
2, r
3, b
3carry out linear fit, the goodness of fit ensures more than 0.99, fit equation is substituted in above-mentioned expression formula, can draw the general formula of hemispherical shells forming path equation.In addition, forming tool head radius gets R/10, and axial feed measures R/100.
3, assist formation device
Assist formation device consists of the following components:
(1) its shape of forming tool head as shown in Figure 3, is grouped into by straight bar part, tapered intermediate portion, ball head, wherein the diameter of straight-bar and the equal diameters of bulb part, i.e. D
2=2R
0.The effect using taper excessive is the contact avoiding straight bar part and plate, prevents interference effect and disturbs its forming process.The lower end diameter D of conical section
1be about 0.8D2, the height H=D of conical section
1, material is high-speed tool steel.
(2) pressing plate, outline gripper shoe and base for supporting
As shown in Figure 4, wherein 2 is plate, and 3 is pressing plate, and 4 is outline gripper shoe, and 5 is base for supporting, and it is firm that material is normal carbon structure, and 6 is bolt.Pressing plate, foreign steamer are crossed the gripper shoe surrounding place of keeping to the side and are provided with the circle circular hole surrounding rectangle, arrange the bolt hole corresponding with bolt 6 in the corresponding position of base for supporting.
By fastening bolt by plate being clamped between pressing plate and outline gripper shoe tightly.Fig. 5 is the partial enlarged drawing in Fig. 4 circle, crosses the zigzag anti-slip veins that gripper shoe clamping plate one side is provided with tangentially direction, can effectively prevent plate from sliding, reduce bottom sinkage in half spherical pieces forming process at pressing plate and foreign steamer.
The circle hole radius of outline gripper shoe is R+ (0.5 ~ 1) mm, and wherein R is the bore of half spherical pieces, and the circle hole radius of pressing plate is identical with outline gripper shoe.Distortion sent out into by the plate that can reduce beyond shaped region, can prevent hemispherical shells oral area from sinking simultaneously, greatly improve the forming accuracy of target workpiece.
Base for supporting lower end is provided with flange, and be fixed on the workbench of lathe by the combination of stay bolt, briquetting, gad by base for supporting, wherein base for supporting lower end is lined with rectangle bloom, and object is for improving processing space.Its overall assist formation device as shown in Figure 6.
1060 aluminium sheets selected by plate, and the initial wall thickness of plate is 0.84mm, according to constant-volume principle (V
before shaping=V
after shaping) calculate be shaped after the theoretical wall thickness of plate be 0.42mm, to consider in forming process the factors such as frictional force is uneven, when the wall thickness deviation of product is in 15% scope of theoretical wall thickness, namely during 0.357 ~ 0.483mm, can be similar to and think its uniform wall thickness, product is processed successfully.Select the half spherical pieces of 5 groups of different bores, its oral area radius is respectively 25,50,60,75,100, and the method combined by simulation and experiment repeatedly, designs the progressive molding path of above target workpiece as reference path.Corresponding test parameters is as shown in the table.
The test machined parameters of target workpiece under the different bore of table 1
Extract the key variables in different bore half spherical pieces forming path, as shown in table 2, take radius R as independent variable, carry out linear fit according to the data in table 2 to each variable, fitting result as shown in Figure 7.The linear equation that formula (4) is fitting result.By calculating, the goodness of fit of fit equation is all more than 0.99.Fitting equations (7) is substituted into formula (1) ~ (3), and coefficient retains two-decimal, obtains the equation in half spherical pieces progressive molding path, shown in (5) ~ (8):
Equation key variables numerical value under the differing formed path of table 2
Claims (4)
1. a progressive forming method for hemispherical shells, it is characterized in that, the method comprises the steps:
Step 1: design basis path;
Editing objective hemispherical shells, selects the hemispherical shells of some groups of different bores, path based on the progressive molding path designing above target hemispherical shells;
Step 2: extract key variables;
Key variables in the forming path of different bore half ball element are respectively: b, r
1, r
2, a
2, r
3, b
3;
Wherein: in first passage path, inclination angle be the straight line of 41 ° and y-axis intersecting point coordinate for (0, b), r
1be the second passage arc radius value, r
2be the 3rd passage top arc radius value, a
2be the 3rd circular arc center of circle, passage top x-axis coordinate, r
3be the 3rd passage bottom arc radius value, b
3it is the 3rd circular arc center of circle, passage bottom y-axis coordinate;
The general formula of the forming path equation of each passage is as follows:
formula 1
Wherein y
1headed by the path equation of passage forming path three sections of straight lines, y
2be the path equation of circular arc in the second passage forming path, y
3be the path equation of two sections of tangent arcs in the 3rd passage forming path, y
4be four-pass forming path equation, be the bus of hemispherical shells.
Wherein the span of R is (0,2R);
According to the known parameters in differing formed path, with the oral area radius R of spherical parts for known variables, to b, r
1, r
2, a
2, r
3, b
3carry out linear fit, the goodness of fit ensures more than 0.99, fit equation is substituted in above-mentioned expression formula, can draw the general formula of hemispherical shells forming path equation; In addition, forming tool head radius gets R/10, and axial feed measures R/100.
2. the assist formation device made of the progressive forming method of hemispherical shells, it is characterized in that, this device comprises:
Workbench (11), the bloom (10) be arranged on tool stand (11), the base for supporting (5) be arranged on bloom (10), the outline gripper shoe (4) covering base for supporting (5), the pressing plate (3) be covered in outline gripper shoe (4), be placed in pressing plate (3) middle part plate (2), be located at plate (2) middle part and the tool heads (1) be connected with plate (2); Pressing plate (3), foreign steamer are crossed gripper shoe (4) the surrounding place of keeping to the side and are provided with the circle circular hole surrounding rectangle, have corresponding bolt hole in the corresponding position of base for supporting (5), this bolt hole is for placing bolt (6);
This device also comprises gad (9), and this gad (9) is fixed on workbench (11) by stay bolt (7), and bloom (10) pad is located at below gad (9); Gad (9) is indicated and is also provided with briquetting (8);
Briquetting (8) is engaged fixing with gad (9) by sawtooth, its level altitude is adjustable, more regulates processing space by the height changing bloom (10);
Base for supporting (5) lower end is provided with flange, is fixed on workbench (11) by base for supporting (5) by the combination of stay bolt (7), briquetting (8), gad (9).
3. the assist formation device made of the progressive forming method of hemispherical shells according to claim 2, it is characterized in that, the bulb part that tool heads (1) comprises straight bar part, the tapered intermediate portion be connected with straight bar part one end and is connected with the tapered intermediate portion other end.
4. the assist formation device made of the progressive forming method of hemispherical shells according to claim 3, is characterized in that, the diameter of straight bar part and the equal diameters of bulb part.
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|---|---|---|---|---|
| CN108196508A (en) * | 2017-12-27 | 2018-06-22 | 东南大学 | Busbar is the recessed Tapered Cup progressive molding method of circular arc |
| CN108196508B (en) * | 2017-12-27 | 2020-09-11 | 东南大学 | Method for gradually forming concave conical part with arc-shaped bus |
| CN108873817A (en) * | 2018-05-04 | 2018-11-23 | 东南大学 | A kind of method of the path parameter of revolving parts progressive molding |
| CN113523059A (en) * | 2021-07-19 | 2021-10-22 | 东南大学 | Method for forming flanging of outer flange |
| CN113523059B (en) * | 2021-07-19 | 2023-10-13 | 东南大学 | Outer flange flanging forming method |
| CN113714361A (en) * | 2021-09-02 | 2021-11-30 | 上海交通大学 | Flexible gradual flanging forming method based on robot |
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