CN109351835B - Integral spinning forming method for thin-wall shell with annular reinforcing rib and curved bus - Google Patents
Integral spinning forming method for thin-wall shell with annular reinforcing rib and curved bus Download PDFInfo
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- CN109351835B CN109351835B CN201811345038.7A CN201811345038A CN109351835B CN 109351835 B CN109351835 B CN 109351835B CN 201811345038 A CN201811345038 A CN 201811345038A CN 109351835 B CN109351835 B CN 109351835B
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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
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/14—Spinning
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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
- B21D41/00—Application of procedures in order to alter the diameter of tube ends
- B21D41/04—Reducing; Closing
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
The invention provides an integral spinning forming method of a curved bus thin-wall shell with annular reinforcing ribs, wherein the shell is formed by processing a tube blank by the forming method, the shell comprises a curved bus cylinder section and a straight cylinder section, the curved bus cylinder section is provided with the annular reinforcing ribs, and the forming method comprises the following steps: 1) preparing a tube blank; 2) stress removal treatment; 3) performing powerful spinning, and 3.1 determining a spinning starting position and a spinning finishing position on the tube blank; 3.2 determining the times of the powerful spinning, and completing the design of the powerful spinning track; 3.3, installing the tube blank; 3.4 designing a power spinning program based on the power spinning track, starting the power spinning program to start power spinning until the power spinning of the pass is finished; 3.5, repeating the step 3.4, and completing the powerful spinning forming process after multi-pass powerful spinning to obtain a semi-finished product of the tube blank with the step thickness; 4) closing and spinning. According to the technical scheme, the mold investment, maintenance cost and the like are greatly saved, and the production cost is reduced.
Description
Technical Field
The invention relates to the technical field of spinning forming, in particular to an integral spinning forming method of a curved bus thin-wall shell with a circumferential reinforcing rib.
Background
A curved bus bar thin-wall shell is a typical metal structural member in the field of aerospace, and the curved bus bar thin-wall shell is mainly produced in batches by adopting a precision casting mode aiming at the products. However, when the product is required to have a circumferential reinforcing rib structure, the precision casting process has the disadvantages of large subsequent turning allowance, low material utilization rate and incapability of ensuring the production efficiency. Spinning is a main forming method of a curved bus type rotary shell, and a short and thick tube blank can be spun into a long and thin tube blank semi-finished product by adopting a powerful spinning process; on the basis, a curved bus revolving body meeting the requirement of a designed profile can be formed on part of the tube blank through a closing spinning process.
The powerful spinning is also called thinning spinning, and is a near-allowance-free processing method developed on the basis of common spinning, which is characterized in that a spinning roller is used for increasing pressure on a blank, and the rotating blank is locally and gradually rolled along a forming die by means of external force to generate plastic deformation and be thinned, so that a high-precision thin-wall revolving body part is obtained.
The closing spinning is a special spinning method derived on the basis of spinning technology aiming at products with the requirements of back cover or half back cover, and a spinning wheel rolls materials heated to softening temperature according to a preset complex running track in the processing process, so that the outer contour presents a profile in the shapes of hemisphere, ellipsoid and other curved generatrices.
At present, a strong spinning preparation curved bus thin-wall shell with a circumferential reinforcing rib generally needs to adopt a split mold. In order to form the curved busbar cabin section, the outer surface of the split mold needs to be processed into a curved surface which can be attached to the inner wall of the curved busbar, and the split mold is difficult to process and high in cost. In addition, the assembling and disassembling processes of the split mold are very complicated, the assembling precision requirement between the split mold is extremely high, and otherwise, the precision of the inner surface of the curved bus cabin section of the product can be influenced. The inner surface of the curved busbar compartment section prepared by the split mold after spinning usually needs machining to meet the design requirements. The above factors make this lagging method unsuitable for low-cost, large-scale engineering production. Therefore, the powerful spinning adopting the split mold is a laggard production means.
The machining process is characterized in that a large machining allowance is usually reserved on the inner surface of a curved busbar cabin section prepared by a split mold, an inner profile is machined through a complex feed track in the machining process, and a tool is used for preventing large-cutting-amount machining deformation.
Aiming at the batch production of typical products such as a curved bus bar thin-wall shell with an axial reinforcing rib, the method is an effective method by combining the convenience of closing-up spinning in the aspect of preparing a curved thin-wall cabin section on the basis of strong spinning suitable for quickly preparing a thin-wall cylindrical part.
Disclosure of Invention
The invention aims to provide an integral spinning forming method of a curved bus thin-wall shell with a circumferential reinforcing rib. The method combines two spinning processes of powerful spinning and closing-up spinning, and only one powerful spinning die is used in the whole processing process, so that the integrated preparation of the thin-wall curved bus rotary shell with the circumferential reinforcing ribs can be realized, the backward means of forming the reinforcing ribs by adopting a common split die is avoided, the production efficiency and precision are obviously improved, and the production cost is reduced.
In order to achieve the above purpose, the invention provides the following technical scheme:
the integral spinning forming method of the curved bus thin-wall shell with the annular reinforcing ribs comprises the following steps: 1) preparing a tube blank, and preparing the tube blank according to design requirements; 2) stress relief treatment, namely performing heat treatment on the tube blank prepared in the step 1) to eliminate the processing internal stress of the tube blank; 3) performing powerful spinning, and 3.1 determining a spinning starting position and a spinning finishing position on the tube blank; 3.2 determining the times of the powerful spinning, and completing the design of the powerful spinning track; 3.3, installing the tube blank; 3.4 designing a power spinning program based on the power spinning track, starting the power spinning program to start power spinning until the power spinning of the pass is finished; 3.5, repeating the step 3.4, and completing the powerful spinning forming process after multi-pass powerful spinning to obtain a semi-finished product of the tube blank with the step thickness; 4) closing-in spinning, 4.1 setting a closing-in spinning track according to the molded surface of the final curved busbar cylinder section of the shell and the requirement of the annular reinforcing rib structure, and matching relevant parameters such as reasonable rotating speed, feeding and the like; 4.2 designing a closing spinning program based on the closing spinning track in the step 4.1; 4.3, clamping the semi-finished product of the tube blank obtained in the step 3 by a clamping tool of a closing-up spinning device, preheating part of the tube blank of the formed curved bus tube section, and then starting the closing-up spinning procedure in the step 4.2 until closing-up forming of the pass is completed; 4.4 repeating the step 4.3 until the whole closing-up spinning of the tube blank curved bus tube section is completed, and obtaining the curved bus thin-wall shell with the straight tube section and the curved bus tube section and provided with the annular reinforcing ribs.
In the forming method as described above, preferably, in the step 1, the tube blank is a cylindrical barrel, the wall thickness of the cylindrical barrel is determined according to the reduction rate of 60% -70%, the length of the tube blank is determined according to the volume invariance principle, and the reserved process margin is 18% -22% of the volume of the cylindrical barrel.
In the forming method, preferably, in the step 3.1, the start position is 5-10 mm away from the end surface of the tube blank, the length from the final rotation position to the start position is an effective deformation area of the straight cylinder section, and the final rotation position is determined according to the length and the wall thickness of the straight cylinder section and the volume invariance principle.
In the forming method as described above, preferably, in the step 3.1, the tube blank after the final spinning position is used for performing the step 4 closing spinning forming of the curved tubular section.
In the forming method as described above, preferably, in the step 3.2, the number of passes of power spinning is determined according to the initial wall thickness and the limiting reduction rate of the tube blank and the final wall thickness of the shell; and distributing the thinning rate of each pass, and setting the rotating speed and the feeding.
In the forming method as described above, preferably, in the step 3.4, the spinning process is performed by using a forward spinning outer spinning process.
In the forming method as described above, preferably, in the step 4.1, 2 to 3 times of forward rotation and reverse rotation are additionally provided before and after the position of the circumferential bead for the curved bus-bar barrel section having the requirement of the circumferential bead structure.
In the forming method as described above, preferably, in the step 4.3, the tube blank is subjected to heat compensation during the execution of the closing-in spinning program.
In the forming method as described above, it is preferable to further include, after the step 4: step 5), heat treatment; and carrying out quenching heat treatment on the shell, and then fully releasing the stress in a natural aging mode for 72 hours.
In the forming method as described above, it is preferable to further include, after the step 5: step 6), turning; and (4) turning and shaping the curved busbar barrel section and the annular reinforcing rib part.
The method combines two spinning processes of powerful spinning and closing-in spinning, processes the tube blank by the steps of preparing the tube blank, stress removing treatment, powerful spinning, closing-in spinning, heat treatment, turning and the like, integrally forms a shell consisting of a curved bus tube section and a straight tube section, and the curved bus tube section of the shell is provided with the annular reinforcing ribs.
(1) The invention adopts the composite spinning technology of combining the powerful spinning and the closing spinning, and directly forms the thick-wall tube blank into the curved bus thin-wall shell with the annular reinforcing ribs by using only one powerful spinning die, thereby greatly saving the cost of die investment, maintenance and the like and reducing the production cost;
(2) according to the invention, through repeated forward and backward spinning forming of the local area in the closing-up spinning process, the integrated forming of the annular reinforcing rib and the shell is realized, compared with the traditional spinning process for forming the annular reinforcing rib by using a split die method, the method has the obvious advantages of low cost, high efficiency, simplicity and convenience in operation and the like;
(3) the forming product has strong interchangeability, can be used for forming curved bus shells with various similar structures, can integrally form the curved bus shells by the process, and has good comprehensive performance, high forming precision and high reliability;
(4) the invention has high forming precision, the size of the straight cylinder section of the shell can be directly forced to the design size without turning, the quality of the inner surface is ensured by a forced spinning die, the design requirement is directly met after the closing-up and spinning of the outer molded surface of the curved bus section, a small machining allowance is left on the inner molded surface, and the size precision can be ensured by simple turning subsequently.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. Wherein:
FIG. 1 is a diagram of a manufacturing process of the present invention;
FIG. 2 is a view of the configuration of the tube blank according to the invention;
FIG. 3 is a schematic structural view of a curved bus bar thin-walled shell of the present invention;
FIG. 4 is a schematic view of a step-thickness hard spin semi-finished product according to the present invention;
FIG. 5 is a schematic view of the forming process of the closed spinning outer profile of the present invention;
FIG. 6 is a schematic view of a thin-walled shell formed by spinning a closed-end of the present invention and having a curved generatrix with an axial reinforcing rib.
Description of reference numerals: in fig. 2: internal diameter of pipe blank
The wall thickness t of the tube blank and the length L of the tube blank;
in fig. 3: the outer diameter D1 of the large end of the shell, the outer diameter D2 of the small end of the shell, the wall thickness t1 of the shell are 4.2mm, the width L3 of the annular reinforcing rib, the thickness t2 of the annular reinforcing rib, the length L1 of the straight cylinder section and the length L2 of the curved bus cylinder;
in fig. 4: the length of the forming section L4 was increased.
Detailed Description
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings. The various examples are provided by way of explanation of the invention, and not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. It is therefore intended that the present invention encompass such modifications and variations as fall within the scope of the appended claims and equivalents thereof.
In the description of the present invention, the terms "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, which are for convenience of description of the present invention only and do not require that the present invention must be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. The terms "connected," "connected," and "disposed" as used herein are intended to be broadly construed, and may include, for example, fixed and removable connections; they may be directly connected or indirectly connected through intermediate members, and specific meanings of the above terms will be understood by those skilled in the art as appropriate.
As shown in fig. 1 to 6, according to an embodiment of the present invention, there is provided an integral spin forming method for a curved generatrix thin-wall shell with a circumferential reinforcing rib. The shell is formed by processing a pipe blank by the forming method, the shell comprises a curved bus tube section and a straight tube section, and the curved bus tube section is provided with a circumferential reinforcing rib, and the method comprises the following steps:
1. preparing a tube blank;
the design material of the tube blank is selected according to the design requirement, the tube blank is prepared according to the conditions of the size of the shell, the thinning rate of the design material, the reserved process margin and the like, and the tube blank is processed according to the design size.
The tube blank is a cylindrical barrel, the wall thickness of the cylindrical barrel is determined by calculation according to the reduction rate of 60-70% (common use of conventional metal materials such as aluminum alloy, steel and the like), the inner diameter of the tube blank is jointed with a die after being processed by powerful spinning, the size after jointing meets the size requirement of the inner diameter of the shell, the length of the tube blank is obtained by product comprehensive calculation according to the volume invariance principle and considering the reserved process margin, and the process margin is 18-22% of the volume of the product, and is preferably 20%.
Internal diameter of pipe blank
Is composed of
The wall thickness t of the tube blank is
The length L of the tube blank is 520mm, the start slope angle is 15 degrees, and the end outer circle is chamfered by 5 multiplied by 30 degrees.
2. Stress removal treatment;
the tube blank prepared in the step 1) is subjected to heat treatment to eliminate the processing internal stress of the tube blank and reduce the strength of the tube blank, so that the tube blank meets the requirement of powerful spinning.
3. Performing powerful spinning;
determining a starting spinning position and a final spinning position on a tube blank, designing the spinning reduction rate of the tube blank for forming a curved bus tube section and a straight tube section of a curved bus thin-wall shell, completing the design of a powerful spinning track, determining a forming process, installing the tube blank, designing a powerful spinning program on the basis of the spinning track of each pass, moving a traction mechanism to a preset starting spinning position, starting powerful spinning, enabling the spinning program to automatically execute actions of pre-rotation, spinning along the preset track, stopping and the like, completing the powerful spinning forming process after multi-pass powerful spinning, and obtaining a tube blank semi-finished product (shown in figure 4) with step thickness, wherein the thickness of a thickening forming section is 9mm, the length L4 of the thickening forming section is about 200mm, and the tube blank is used for forming part of the curved bus tube section and a circumferential reinforcing rib; the thickness of the thin-wall section is about 4.2mm, the length is about 1350mm, and the thin-wall section is used for forming a straight cylindrical section and a curved cylindrical section of the rest part of a product. The specific process is as follows:
3.1, determining a starting position and a final position on the tube blank, wherein the starting position needs to fully consider the offset amount between the rotary wheels and the front and rear angles of the rotary wheels, and the phenomenon that the rotary pressure between the rotary wheels is seriously unbalanced due to the interference formed by the rotary wheels after the rotary wheels are sequentially screwed into the material is avoided. The start-up position is usually 5-10 mm away from the end face of the die. The length from the final rotation position to the start rotation position is an effective deformation area of a finally formed shell straight cylinder section, so that the final rotation position is calculated according to the length and the wall thickness of the shell straight cylinder section and the volume invariance principle, and in order to realize the smooth transition of materials, each rotating wheel is gradually lifted away from the machining surface of the tube blank in a small-angle slope mode when the rotating wheel runs to a distance of about 30mm before the final rotation position.
3.2, determining the number of times of powerful spinning according to the wall thickness t of the pipe blank, the wall thickness of the finally formed shell and the reduction rate of the material, reasonably distributing the reduction rate of each time, setting technological parameters such as rotating speed, feeding and the like, and completing the design of powerful spinning tracks.
3.3, installing the pipe blank, pressing the pipe blank on the spinning die through a material pressing disc connected with the tail top, installing the die on a traction mechanism of the equipment, wherein the traction mechanism can drive the die to realize axial movement and circumferential rotation, and the spinning pipe blank can rotate synchronously with the spinning die under the action of end face friction force.
3.4, designing a power spinning program on the basis of the power spinning track, starting the power spinning program to start power spinning, keeping the spinning wheel mechanism static, making the traction mechanism do axial motion, and spinning the pipe blank by adopting a forward spinning external spinning process under the control of the spinning program.
And 3.5, repeating the step A3.3, performing multi-pass powerful spinning and forming a tube blank semi-finished product with step thickness.
4. Closing in and spinning,
after the step 3 is completed, the tube blank after the final spinning position in the step 3 is used for carrying out closing spinning forming on the curved bus tube section, a closing spinning track and a closing spinning program of the curved bus tube section are determined according to the length and the wall thickness of the curved bus tube section and the structure of the annular reinforcing rib, and the multi-pass closing spinning program is executed after the tube blank is preheated. The specific process is as follows:
4.1, determining a closing-in spinning track and a closing-in spinning program according to the length and the wall thickness of the curved bus tube section and the structure of the annular reinforcing rib, calculating the length after strong spinning according to the volume invariance principle, reasonably distributing the reduction rate of each pass, setting process parameters such as rotating speed and feeding, and finishing the design of the closing-in spinning track. For a curved bus tube section provided with a circumferential reinforcing rib structure, the closing-up spinning track of the spinning wheel needs to be additionally provided with multiple times of forward spinning and reverse spinning before and after the circumferential reinforcing rib position, so that materials are accumulated to the circumferential reinforcing rib position and sufficient allowance is reserved for the subsequent turning forming of the circumferential reinforcing rib.
And 4.2, designing a closing-up spinning program based on the spinning track, wherein the closing-up spinning program enables the spinning wheel mechanism to automatically run according to the spinning track.
4.3, clamping the semi-finished product of the tube blank obtained in the step 3 by a clamping tool of a closing-up spinning device, preheating the tube blank of the formed curved bus tube section by using a spray gun, starting a closing-up spinning program in the step 4.2 to start closing-up spinning, automatically operating a spinning wheel mechanism according to a set track until the closing-up spinning of the pass is finished, and supplementing heat to the tube blank in the process of executing the closing-up spinning program;
4.4, repeating the step 4.3 until the whole closing-up spinning of the curved bus section of the tube blank is finished and obtaining the tube blank with the composite shape of the straight tube section and the curved bus tube section.
5. And (3) heat treatment: and (4) carrying out quenching heat treatment on the composite-shape tube blank obtained after the step (4), selecting a quenching heat treatment process according to the material of the tube blank, and fully releasing stress through natural aging for not less than 72 hours after the quenching heat treatment is finished so as to ensure that the heat treatment state and the mechanical property of the product meet the design requirements.
6. Turning: and turning and shaping the curved bus tube section and the annular reinforcing rib part formed by thickening, cutting off the allowance at the two ends in the length direction, and then processing special structures such as holes and grooves according to the requirements of a drawing to ensure that the product meets the design requirements.
Example 1:
machining a curved bus thin-wall shell as shown in figure 3, wherein the manufactured length of the shell is 1420mm, and the outer diameter of the large end of the shell is larger than that of the shell
575mm, 425mm of small end outer diameter D2 and 4.2mm of wall thickness t 1; the small end is provided with an annular reinforcing rib, the width L3 of the annular reinforcing rib is 30mm, and the thickness t2 of the annular reinforcing rib is 12 mm; the whole section comprises a straight cylinder section L1 with the length of 920mm and a curved bus cylinder section L2 with the length of 500mm, the curved bus section is a Karman curve, and the designed material is 2A12 aluminum alloy.
The processing technology is as shown in figure 1 and is realized by the following steps:
1. preparing a tube blank
The tube blank is designed into a structure as shown in figure 2, after the tube blank is subjected to powerful spinning processing, the inner surface of the tube blank is attached to a mold, the size after attachment meets the inner diameter size requirement of a final product, and the wall thickness t of the tube blank is determined according to the powerful spinning reduction rate and the final wall thickness of a straight tube section of the product through calculation. According to the characteristics of the 2A12 aluminum alloy, the reduction ratio was set to 68.9%, and the calculated thickness t of the obtained tube blank was 13.5 mm. The length L of the tube blank is 442mm calculated from the total length of the product according to the volume invariance principle, the process edge allowance needs to consider the machining allowance of the closed spinning thickening forming annular reinforcing rib and the curved bus section, 20% of the volume of the product is taken after comprehensive consideration, and the length L of the tube blank is 520mm after approximate calculation.
2. Tube blank working
The seamless pipe is processed into a preset size and shape by a turning method, and the end excircle is chamfered by 5 multiplied by 30 degrees, so that the blank is convenient to mount.
The requirements of the blank on machining size and precision are as follows:
tube blank inner diameter:
thickness of the tube blank:
length of formed section: 520 mm;
a rotation slope angle: 15 deg.
3. Stress relieving treatment
According to the relevant standard specification of 2A12 aluminum alloy heat treatment, the following heat treatment system is adopted to carry out heat treatment on the tube blank so as to reduce the strength of the tube blank and meet the spinning requirement:
and (3) heat treatment equipment: the temperature control precision of the aluminum alloy heat treatment furnace is not more than +/-5 ℃;
a heating mode: heating along with the furnace;
and (3) heat preservation temperature: 360 ℃;
and (3) heat preservation time: 1.5 h;
a cooling mode: cooling the mixture to 260 ℃ along with the furnace, and discharging the mixture out of the furnace.
4. High power spinning
According to the initial size of the tube blank and the final size of a product, the whole power spinning process is divided into 3 passes in total, and the specific process is as follows:
4.1, uniformly coating lubricating oil on the inner surface of the tube blank and the outer surface of the die to ensure that the inner surface of the tube blank is not scratched after spinning. Hoisting the tube blank, slowly sleeving the tube blank into the die under the action of the tail top and the material pressing disc until the back cover of the tube blank is tightly pressed with the end face of the die to finish the installation of the tube blank, wherein the difference between the inner diameter of the tube blank and the outer diameter of the die is 0.3 mm;
4.2, a power spinning program is compiled on the basis of the power spinning track to automatically execute actions such as pre-rotation, spinning along the preset track, stopping and the like, and parameters of the spinning process of each pass are as follows:
first primary spindle speed: 30 r/min;
first pass feeding speed: 75 mm/min;
the clearance between the first-pass spinning wheel and the die is as follows: 8.3 mm;
the rotation speed of the main shaft of the second pass is as follows: 30 r/min;
second-pass feeding speed: 90 mm/min;
the clearance between the second-pass rotary wheel and the die is as follows: 5.2 mm;
third secondary main shaft rotating speed: 30 r/min;
third feeding speed: 90 mm/min;
the third time revolves the wheel and mould clearance: 3.9 mm;
4.3, covering the whole effective length of the tube blank by the deformation area of the first pass, and writing a spinning program by combining the parameters of the step 4.2 to finish the first-pass powerful spinning, wherein the wall thickness of the tube blank is about 9mm after the first-pass deformation is finished due to the existence of the deformation rebound quantity of the material;
4.4, during the second-pass spinning, because the final product curved bus section is provided with a circumferential reinforcing rib structure with the average thickness of about 12mm, a thickening forming section with the thickness of 9mm needs to be reserved for the subsequent closing-in spinning, the remaining thickening forming section with the thickness of about 200mm is designed by referring to the processing capacity of closing-in spinning equipment to realize the accumulation and thickening of materials, so that the setting of the spinning length of the second pass needs to be 200mm shorter than the length of the tube blank after the first pass is finished, a powerful spinning program is compiled by combining the parameters of the step A4.2 to finish the powerful spinning of the second pass, and the wall thickness of the tube blank after the deformation is finished is about 6 mm;
4.5, setting the length of the third-pass spinning to be the length corresponding to the 6mm wall thickness of the tube blank after the second-pass spinning is finished, compiling a power spinning program by combining the parameters in the step A4.2, finishing the third-pass power spinning, and obtaining a closed-up tube blank with the wall thickness of about 4.2mm after the deformation is finished, wherein the size structure of the finally obtained closed-up tube blank is shown in a figure 4;
and 4.6, the wall thickness precision is obtained by estimating the deformation rebound quantity of the material and controlling the gap between the rotary wheel and the die, and the inner diameter, the roundness, the straightness accuracy and other precisions are obtained by ensuring that each section of the material is uniformly and continuously deformed and combining the molded surface of the die.
5. Closing-in spinning
Clamping and fixing the tube blank shown in the figure 4 by using a clamping tool of a closing-up spinning device, and designing a closing-up spinning program on the basis of the outer molded surface of a curved bus tube section. Starting a closing spinning program to enable the tube blank to rotate, preheating the tube blank to a set temperature by using a heating system and starting closing spinning, and keeping the temperature of a product and heating the product all the time in the whole closing spinning process. The specific process of heating, closing and spinning is as follows:
5.1, hoisting the powerful spinning tube blank to enable the height of the powerful spinning tube blank to be basically consistent with that of a clamping device of closing-in spinning equipment, then sending the straight tube section of the tube blank for forming a final product into the clamping device, starting a clamping starting switch, and finishing fixing the tube blank;
5.2, compiling a closing-up spinning program on the basis of the outer molded surface of the curved bus tube section, and automatically executing actions such as pre-rotation, spinning closing-up along a preset track, stopping and the like, wherein basic process parameters are as follows:
main shaft rotating speed: 180 r/min;
feeding speed: 200 mm/min;
5.3, pre-heating the part to be closed of the tube blank to be processed by pre-rotating the main shaft to enable the surface temperature of the part to be closed to reach 380 ℃, and controlling the temperature by real-time monitoring of an infrared thermometer and real-time regulation and control of a heating system;
5.4, heating the area to be closed through a heating system all the time during closing and spinning, and keeping the temperature of the tube blank in the area in accordance with the preset requirement; the rotary wheel gradually moves from the large-diameter end to the small-diameter end of the product along the axis, the outer profile meets the requirement through closing-up spinning of two passes, and the forming process of the closing-up spinning outer profile is schematically shown in FIG. 5;
5.5, the curved bus section is provided with a circumferential reinforcing rib structure, when each pass of closing-up and spinning, the rotary wheel moves to the tail end of the thickening forming section L4 from the large end according to a preset track, then reversely moves, reversely extrudes redundant materials to the position of the reinforcing rib, then the rotary wheel is lifted, continuously reversely moves to the starting end of the thickening forming section L4, and the 1 st forward-rotation and reverse-rotation thickening forming is completed; then, the rotating wheel is screwed in from the starting end of the thickening forming section L4, the rotating wheel moves to the tail end of the thickening forming section L4 according to a preset track, redundant materials are extruded into the position of the reinforcing rib, and then the reverse operation process is repeated to finish the 2 nd forward-rotation and reverse-rotation thickening forming; the 3 rd forward and backward thickening formation is similar to the 2 nd. After 2-3 times of forward-rotation and backward-rotation thickening forming, the reserved material can be sufficiently accumulated to the position of the reinforcing rib, so that the reinforcing rib forming in the subsequent machining (only small cutting amount processing is carried out on the basis of spinning) link is realized, and a spinning finished product obtained after closing-up spinning is shown in fig. 6.
6. Thermal treatment
According to the relevant standard specification of 2A12 aluminum alloy heat treatment, the following heat treatment system is adopted to carry out heat treatment on the closed spinning finished product so as to improve the mechanical property of the material and reduce the residual stress:
and (3) heat treatment equipment: controlling the temperature of an aluminum alloy quenching furnace to be not more than +/-5 ℃;
a heating mode: heating along with the furnace;
and (3) heat preservation temperature: 495 ℃;
and (3) heat preservation time: 1 h;
a cooling mode: and naturally aging for 72 hours after water cooling.
7. Turning process
Compiling a turning program, turning the inner surface of the closing spinning semi-finished product (only processing small cutting amount on the basis of spinning), and ensuring that the shape, size, surface smoothness and the like of the inner surface meet the requirements; finally, cutting off the allowance in the length direction to enable the product to meet the design requirement.
From the above description, it can be seen that the above-described embodiments of the present invention achieve the following technical effects:
the integral spinning forming method combines two spinning processes of powerful spinning and closing-in spinning, and includes the steps of preparing pipe blank, stress eliminating treatment, powerful spinning, closing-in spinning, heat treatment, turning and other steps.
(1) The invention adopts the composite spinning technology of combining the powerful spinning and the closing spinning, and directly forms the thick-wall tube blank into the curved bus thin-wall shell with the annular reinforcing ribs by using only one powerful spinning die, thereby greatly saving the cost of die investment, maintenance and the like and reducing the production cost;
(2) according to the invention, through repeated forward and backward spinning forming of the local area in the closing-up spinning process, the integrated forming of the annular reinforcing rib and the shell is realized, compared with the traditional spinning process for forming the annular reinforcing rib by using a split die method, the method has the obvious advantages of low cost, high efficiency, simplicity and convenience in operation and the like;
(3) the forming product has strong interchangeability, can be used for forming curved bus shells with various similar structures, can integrally form the curved bus shells by the process, and has good comprehensive performance, high forming precision and high reliability;
(4) the invention has high forming precision, the size of the straight cylinder section of the shell can be directly forced to the design size without turning, the quality of the inner surface is ensured by a forced spinning die, the design requirement is directly met after the closing-up and spinning of the outer molded surface of the curved bus section, a small machining allowance is left on the inner molded surface, and the size precision can be ensured by simple turning subsequently.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (9)
1. The integral spinning forming method of the curved bus thin-wall shell with the annular reinforcing ribs is characterized in that the forming method comprises the following steps:
1) preparing a tube blank, preparing the tube blank,
preparing a tube blank according to design requirements;
2) the stress-removing treatment is carried out on the alloy,
carrying out heat treatment on the tube blank prepared in the step 1) to eliminate the processing internal stress of the tube blank;
3) the spinning is carried out by a strong force,
3.1 determining the starting rotation position and the final rotation position on the tube blank;
3.2 determining the times of the powerful spinning, and completing the design of the powerful spinning track;
3.3, installing the tube blank;
3.4 designing a power spinning program based on the power spinning track, starting the power spinning program to start power spinning until the power spinning of the pass is finished;
3.5, repeating the step 3.4, and completing a powerful spinning forming process after multi-pass powerful spinning to obtain a semi-finished product of the tube blank with the step thickness, wherein the semi-finished product of the tube blank with the step thickness comprises a thickened forming section and a thin-wall section, the thickened forming section is used for forming a part of curved bus tube sections and annular reinforcing ribs, and the thin-wall section is used for forming a straight tube section of a product and the rest of curved bus tube sections;
4) closing in and spinning,
4.1 according to the molded surface of the final curved busbar barrel section of the shell and the requirement of the annular reinforcing rib structure, setting a closing-up spinning track, matching reasonable rotating speed and feeding related parameters, and adding 2-3 times of forward spinning and reverse spinning before and after the annular reinforcing rib position for the curved busbar barrel section with the requirement of the annular reinforcing rib structure, so that materials are accumulated to the annular reinforcing rib position and sufficient allowance is reserved for the turning forming of the subsequent annular reinforcing rib; wherein,
the 2-3 times of normal rotation and reverse rotation refer to that: the curved bus section is provided with a circumferential reinforcing rib structure, when each pass of closing up and spinning, the rotary wheel moves from the large end to the tail end of the thickening forming section according to a preset track, then reversely moves, reversely extrudes redundant materials to the position of the reinforcing rib, then the rotary wheel is lifted, continuously reversely moves to the initial end of the thickening forming section, and the 1 st forward-rotation thickening and reverse-rotation thickening forming is completed; then, the rotating wheel is screwed in from the initial end of the thickening forming section, the rotating wheel moves to the tail end of the thickening forming section according to a preset track, redundant materials are extruded into the position of the reinforcing rib, and then the reverse operation process is repeated to finish the 2 nd forward-rotation thickening forming and the reverse-rotation thickening forming; the 3 rd forward-rotation thickening and reverse-rotation thickening formation is similar to the 2 nd time;
4.2 designing a closing spinning program based on the closing spinning track in the step 4.1;
4.3, clamping the semi-finished product of the tube blank obtained in the step 3) by a clamping tool of a closing-up spinning device, preheating part of the tube blank of the formed curved bus tube section, and then starting the closing-up spinning procedure in the step 4.2 until closing-up forming of the pass is completed;
4.4 repeating the step 4.3 until the whole closing-up spinning of the tube blank curved bus tube section is completed, and obtaining the curved bus thin-wall shell with the straight tube section and the curved bus tube section and provided with the annular reinforcing ribs.
2. The forming method according to claim 1,
in the step 1), the tube blank is a cylindrical barrel, the wall thickness of the cylindrical barrel is determined according to the reduction rate of 60% -70%, the length of the tube blank is determined according to the volume invariance principle, and the allowance of the reserved process edge is 18% -22% of the volume of the cylindrical barrel.
3. The forming method according to claim 1,
in the step 3.1, the distance between the start-up position and the end surface of the tube blank is 5-10 mm, the length from the final-rotation position to the start-up position is an effective deformation area of the straight cylinder section, and the final-rotation position is determined according to the length of the straight cylinder section and the wall thickness size and according to the volume invariance principle.
4. The forming method according to claim 3,
in the step 3.1, the tube blank after the final spinning position is used for carrying out the step 4) of closing-up spinning and forming the curved bus tube section.
5. The forming method according to claim 1,
in the step 3.2, determining the times of power spinning according to the initial wall thickness and the limit reduction rate of the tube blank and the final wall thickness of the shell; and distributing the thinning rate of each pass, and setting the rotating speed and the feeding.
6. The forming method according to claim 1,
in the step 3.4, a forward spinning outer spinning process is adopted for spinning.
7. The forming method according to claim 1,
in the step 4.3, the tube blank is subjected to heat supplementing in the process of executing the closing-in spinning program.
8. The forming method according to claim 1, further comprising, after the step 4): step 5), heat treatment;
and carrying out quenching heat treatment on the shell, and then fully releasing the stress in a natural aging mode for 72 hours.
9. The forming method according to claim 8, further comprising, after the step 5): step 6), turning;
and (4) turning and shaping the curved busbar barrel section and the annular reinforcing rib part.
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| CN111256022A (en) * | 2020-01-15 | 2020-06-09 | 芜湖三联锻造股份有限公司 | Large thin-wall part with complex shape and manufacturing process thereof |
| CN112058937A (en) * | 2020-07-29 | 2020-12-11 | 宁波大学 | Long hollow tube inner wall thinning forming method |
| CN113351722B (en) * | 2021-06-23 | 2023-04-07 | 上海交通大学 | Multi-stage expanding spinning forming device and method for processing ribbed long-tube component |
| CN114589467B (en) * | 2022-03-29 | 2023-04-28 | 成都光明派特贵金属有限公司 | Noble metal multi-stage reducing channel and manufacturing method thereof |
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