CN111136104A

CN111136104A - Ultrasonic wave and pulse current mixed auxiliary wedge-shaped cavity profile rolling line and rolling process

Info

Publication number: CN111136104A
Application number: CN202010063342.3A
Authority: CN
Inventors: 王洪博
Original assignee: Acre Coking and Refractory Engineering Consulting Corp MCC
Current assignee: Acre Coking and Refractory Engineering Consulting Corp MCC
Priority date: 2020-01-20
Filing date: 2020-01-20
Publication date: 2020-05-12

Abstract

The invention relates to the technical field of groove profile rolling, in particular to an ultrasonic and pulse current mixed auxiliary wedge-shaped cavity profile rolling line and a rolling process. The device comprises a rolling line, a left horizontal calibration roller, a pre-rolling roller, a left ultrasonic vibration roller, a left electric brush, a roller group, a right electric brush, a right ultrasonic vibration roller, a right height calibration roller and a right horizontal calibration carrier roller, wherein the left horizontal calibration roller and the right horizontal calibration roller are sequentially arranged along the rolling line; the ultrasonic vibration module is connected with the left ultrasonic vibration roller and the right ultrasonic vibration roller and drives the left ultrasonic vibration roller and the right ultrasonic vibration roller to vibrate ultrasonically; the left electric brush and the right electric brush are connected with a pulse current source. The rolling difficulty of the wedge-shaped cavity profile is reduced, the rolling efficiency is improved, and the size precision and the surface finish of the wedge-shaped cavity profile are improved.

Description

Ultrasonic wave and pulse current mixed auxiliary wedge-shaped cavity profile rolling line and rolling process

Technical Field

The invention relates to the technical field of groove profile rolling, in particular to an ultrasonic and pulse current mixed auxiliary wedge-shaped cavity profile rolling line and a rolling process.

Background

The selectable preparation processes of the thin-neck wedge-shaped cavity section made of the metal material mainly comprise a cold/warm/hot extrusion forming process, a cold/warm/hot drawing forming process, a milling process and a wire cut electrical discharge machining process. Common metal material thin neck wedge cavity section bars are mainly prepared from metal materials with low yield strength and low deformation resistance, such as aluminum alloy, copper alloy and low-carbon steel. The thin neck wedge-shaped cavity section is mainly prepared by adopting a cold/warm/hot extrusion forming process or a cold/warm/hot drawing forming process. However, if the metal material thin neck wedge-shaped cavity with higher yield strength, deformation resistance and hardness and lower forming strain limit is prepared, the defects that the die necking part is worn quickly to cause high cost and the transition fillet radius of the finished section is generally larger exist. For metal thin-neck wedge-shaped cavity profiles with higher yield strength and hardness and lower forming strain limit, such as medium/high carbon steel thin-neck wedge-shaped cavity profiles, the milling process and the wire electrical discharge machining process can be selected for machining. However, the common disadvantage of these two processes is that the fiber flow lines of the metal blank are cut off, weakening the overall strength of the formed profile. In addition, in the milling process, the diameter of the milling cutter bar must be smaller than the width of the short side opening of the thin-neck wedge-shaped cavity, and the thin cutter bar reduces the overall rigidity of the cutter in the milling process, so that the processing speed and the stability of the processing process are reduced, and the processing precision is reduced. Moreover, for the section bar with the narrow neck part of the narrow-neck wedge-shaped cavity body with the excessively small position width and height, the section bar can hardly be processed by a milling process. The disadvantage of wire cut electrical discharge machining is that the total length of the profile is limited by the height of the machining equipment, resulting in a limitation of the total length of the profile. In addition, because the formed surface is subjected to electrochemical corrosion to form a surface oxide layer, the surface is rough and loose, and subsequent grinding and polishing treatment is required to reduce the surface roughness so as to improve the size and shape precision. Given the complex geometry of the narrow necked wedge cavity, this process significantly increases the difficulty of improving surface quality. Compared with the first three processes, the linear cutting processing speed is the slowest, and the cost-effectiveness ratio is the lowest. In the process of processing the metal thin-neck wedge-shaped cavity profile with higher yield strength and hardness and lower forming limit, the process has the advantages of low yield, over-quick abrasion of production tools/dies and serious waste of raw materials and energy. Therefore, how to prepare the thin-neck wedge-shaped cavity profile from the medium/high carbon steel strip with high yield strength and hardness by high processing efficiency on the premise of ensuring the dimensional accuracy, geometric accuracy and surface roughness of the thin-neck wedge-shaped cavity profile becomes a difficult problem in the field of plastic processing.

The application of pulse current in the plastic forming process of metal materials can cause the metal to have an electro-plastic effect, a skin effect, and a repairing fusion and crack arrest effect on micro holes and micro cracks. This can reduce the deformation resistance of the metal material in the forming process, and improve the forming limit, thereby improving the formability and the machinability of the metal blank. The advantages enable the pulse current to be widely used in the field of metal rolling and to be developed rapidly. However, if pulse current is directly applied to the strip through the roller, the current density of the surface layer of the roller is obviously higher than that of other parts due to the skin effect of the current, which causes the temperature of the surface layer of the metal roller to be obviously increased, further causes the metal of the surface layer of the roller to be softened and oxidized, reduces the surface strength, hardness, durability, wear resistance and service life of the roller, reduces the processing efficiency of the roller and the like. The frequency of replacing and repairing the roller is increased, so that the production cost is increased, the construction period is delayed, and the efficiency-cost ratio of roller processing is reduced finally. How to further weaken the adverse effect brought by the thermal effect generated by the conduction pulse current, but the forming difficulty can be effectively reduced, which becomes a problem to be solved.

In the current-assisted roll-forming process, in order to reduce the contact resistance between the roll and the blank strip, stably maintain a low contact resistance state, and reduce the risk of corrosion on the surface of the formed part, the roll-forming process is usually performed under the condition that no lubricating liquid/fluid is added. However, in the conventional roll-rolling forming process, it is a common practice in the industry to spray/coat/brush a fluid/liquid having lubricating and cooling functions onto the surface of a blank part at a certain rate to reduce the friction coefficient of the contact surface between a roll and a blank strip, to reduce the wear between a profile and a roll, to improve the heat dissipation efficiency, to reduce the heating temperature rise amplitude, to improve the surface smoothness of the part after roll-rolling forming, to reduce the surface roughness of the formed part, and to reduce the friction heat rise amplitude between the roll and the blank strip, to suppress the adverse effects of the temperature rise on the blank strip, the part and the roll such as large heat load and large thermal deformation during the roll-rolling of the blank strip. Under the condition that fluid/liquid with lubricating and cooling functions appears on the surface of a blank strip in the process of rolling the blank strip, if the liquid/liquid resistivity is low and the contact is poor, the degradation of the insulation performance of an electrified system is generally caused, the insulation difficulty of the system is improved, and the stability of the fluid/liquid chemical components with the lubricating and cooling functions and the stability of the exertion of physical functions can also be influenced by the continuous electric field excitation existing in the electrified state; on the other hand, if the liquid/fluid resistivity is high, this inevitably increases the total contact resistance of the roller and the surface of the blank strip, deteriorates the energization efficiency and effect, increases the heating value and the temperature rise amplitude of the contact surface between the blank strip, the roller and the formed profile, increases the thermal load, thermal deformation and corrosion risk of the roller and the blank strip, and increases the energy loss of energization. Therefore, on the premise that fluid/liquid with lubricating and cooling functions is not applied in the electrified rolling process, the contact friction coefficient between the roller and the strip is reduced, and further the remarkable heating, the remarkable thermal deformation and the severe abrasion of the surface of the profile caused by the higher friction coefficient are reduced, so that the method becomes a prominent difficult problem to be solved in the electrified rolling forming process.

Disclosure of Invention

In order to overcome the defects of the prior art, the invention provides an auxiliary wedge-shaped cavity profile rolling line and a rolling process by mixing ultrasonic waves and pulse current. Firstly, the deformation resistance of the metal blank strip in the rolling forming process of the metal blank strip can be reduced, the forming limit and the process processing forming performance of the metal blank strip are improved, and the rolling process processing forming difficulty of the metal blank strip is reduced; secondly, the geometric and dimensional accuracy of the rolled and rolled formed section strip material and the smoothness of the surface appearance are obviously improved, and the required processing energy consumption is reduced; and thirdly, the precise regulation and control of the thin neck structure of the wedge-shaped cavity profile after the roll forming and the dimensional parameter precision grade of the wedge-shaped cavity of the profile are realized.

In order to achieve the purpose, the invention adopts the following technical scheme:

the ultrasonic and pulse current mixed auxiliary wedge-shaped cavity profile rolling line is sequentially provided with a left horizontal calibration roller, a pre-rolling roller, a left ultrasonic vibration roller, a left electric brush, a roller group, a right electric brush, a right ultrasonic vibration roller, a right height calibration roller and a right horizontal calibration carrier roller along the rolling line, wherein the left and right horizontal calibration rollers consist of a left roller and a right roller which are horizontally arranged; the ultrasonic vibration module is connected with the left ultrasonic vibration roller and the right ultrasonic vibration roller and drives the left ultrasonic vibration roller and the right ultrasonic vibration roller to vibrate ultrasonically; the left electric brush and the right electric brush are connected with a pulse current source.

The left horizontal calibration roller is installed on a left horizontal calibration roller base, the pre-rolling roller is installed on a pre-rolling roller base, the left ultrasonic vibration roller is installed on a left ultrasonic vibration roller base, the right ultrasonic vibration roller is installed on a right ultrasonic vibration roller base, the right height calibration roller is installed on a right height calibration roller base, and the right horizontal calibration roller is installed on a right horizontal calibration roller base.

The left and right rollers of the left horizontal calibration roller are in elastic contact with the left and right sides of the section blank strip material, and the shapes of the left and right rollers correspond to the surfaces of the left and right sides of the section blank strip material; the left and right rollers of the right horizontal calibration roller set are in elastic contact with the left and right sides of the roll-formed section, and the shapes of the left and right rollers correspond to the left and right side surfaces of the wedge-shaped cavity section strip; the left and right rollers of the left horizontal calibration roller set and the right horizontal calibration roller set are cylindrical rollers.

The shapes of the upper roller and the lower roller of the pre-rolling roller are arranged in a profiling way with the shapes of the upper surface and the lower surface of the section blank strip; the shapes of the upper and lower rollers of the right height calibration roller and the shapes of the upper and lower surfaces of the rolled section are arranged in a copying way.

The upper and lower rollers of the left and right height calibration rollers are in elastic contact with the upper and lower surfaces of the section blank strip; the surface of an upper roller of the pre-rolling roller is similar to M shape, and a lower roller of the pre-rolling roller is a cylindrical roller; the upper roller and the lower roller of the right height calibration roller are cylindrical rollers.

The left ultrasonic vibration roller comprises two upper rollers and a lower roller which are arranged up and down; the shape of the two upper rollers is arranged in a shape copying way with the shape of the upper surface of the blank strip material, and the lower roller is a cylindrical flat roller; the right ultrasonic vibration roller comprises two upper rollers and a lower roller which are arranged up and down; the shape of the two upper rollers is arranged in a shape copying way with the shape of the upper surface of the blank strip material, and the lower roller is a cylindrical flat roller.

The roll surface of the upper roll and the lower roll of the roll set is provided with an annular belt, the width of the annular belt corresponds to the width of the thin neck of the wedge-shaped cavity profile, and the thickness of the annular belt corresponds to the depth of the wedge-shaped cavity profile.

The rollers of the left horizontal calibration roller, the pre-rolling roller, the left ultrasonic vibration roller, the roller group, the right ultrasonic vibration roller, the right height calibration roller and the right horizontal calibration roller are ceramic rollers. The ceramic roller with outstanding hardness and toughness balance performance is selected, so that the heat accumulation and the remarkable heating-softening behavior caused by joule heat generated by current flowing through the metal roller can be reduced, the precision and the quality of a rolled finished profile and the service life of the roller during the service period of the roller are ensured, the ceramic roller can be processed into surfaces with different roughness according to the requirements of surface finishment of different grades of thin-neck wedge-shaped cavity profiles, and further the preferred regulation and matching of the contact friction coefficient of the profile and the roller are realized.

The left brush and the right brush comprise at least one of a, b, c and d:

a. two electric brushes in the electric brush group are respectively arranged in front of the roller group and behind the roller group, the lower surface of an upper brush head of a left electric brush arranged in front of the roller group is in contact fit with the upper surface of a profile blank strip material, and the lower surface of a brush head of a right electric brush arranged behind the roller group is in contact fit with the upper surface of a profile after roll forming;

b. two electric brushes in the electric brush group are respectively arranged in front of the roller group and behind the roller group, the upper surface of a brush head of a left electric brush arranged in front of the roller group is in contact fit with the lower surface of a profile blank strip material, and the upper surface of a brush head of a right electric brush arranged behind the roller group is in contact fit with the lower surface of a profile after roll forming;

c. two electric brushes in the electric brush group are respectively arranged in front of the roller group and behind the roller group, the lower surface of a brush head of a left electric brush arranged in front of the roller group is in contact fit with the upper surface of a blank strip of the section bar, and the upper surface of a right brush head of the electric brush arranged behind the roller group is in contact fit with the lower surface of the section bar after roll forming;

d. two electric brushes in the electric brush group are respectively arranged in front of the roller group and behind the roller group, the upper surface of a brush head of a left electric brush arranged in front of the roller group is in contact fit with the lower surface of a blank strip of the section bar, and the lower surface of a brush head of a right electric brush arranged behind the roller group is in contact fit with the upper surface of the section bar after roll forming; one of the electric brushes in the electric brush group is connected with the positive pole of the pulse power supply, the other electric brush is connected with the negative pole of the pulse power supply, and only one group of electric brush group is electrified during rolling, so that a current loop is formed between the electric brush group and the rolled section.

The process for rolling the wedge-shaped cavity profile assisted by mixing ultrasonic waves and pulse current is a continuous process and comprises the following steps:

1) the left horizontal calibration roller is an inlet section of the profile blank strip, the profile blank strip is placed between the left horizontal calibration roller and the right horizontal calibration roller, the profile blank strip is brought into a rolling line by the left horizontal calibration roller and the right horizontal calibration roller, and the problems of overlarge rolling shape deviation, unstable operation process and poor size precision caused by high horizontal error in the rolling forming process of the profile blank strip are solved by the left horizontal calibration roller;

2) the section bar blank area material moves forward through the pre-rolling roll, and the pre-rolling roll promotes and ensures blank area material height direction precision, ensures the size and the geometric accuracy of roll forming wedge chamber section bar, avoids the bad influence to the rolling finished product quality that the precision of feed direction of height is too poor to cause:

3) the sectional material blank strip moves forwards and passes through the left ultrasonic vibration roller, the ultrasonic vibration module is connected with a power supply to generate ultrasonic vibration, the ultrasonic vibration is transmitted to the left ultrasonic vibration roller, further, ultrasonic vibration excitation and energy input to the sectional material blank strip are realized, the frequency of the ultrasonic wave is 22-65 khz, the ultrasonic vibration causes the blank strip to contact with the surface material to generate an ultrasonic softening effect, the surface layer metal material is instantly softened, the yield strength, the deformation resistance and the hardness of the surface layer metal material are reduced, and the forming performance of plastic processing of the surface metal material is improved; the contact friction coefficient between the contact surfaces of the roller and the profile is reduced, the frictional heat generation rate is reduced, the thermal load and the thermal deformation of the roller and the profile are reduced, the dimensional precision and the geometric precision of the roll-formed part are improved, and the frictional wear loss rate caused by the temperature rise of the material is reduced;

4) fixing a left electric brush and a right electric brush at two sides of a section blank strip material, enabling two electrodes to be in contact with the section blank strip material to be rolled, connecting a power line to binding posts arranged on the two electrodes, and switching on the power supply; starting a roller set, and rolling the blank strip of the section into a wedge-shaped cavity section by the roller set; the ring belt controls the height and width amplitude of the thin neck of the wedge-shaped cavity, and ensures that the width and height of the thin neck after molding are within the precision requirement range;

the pulse current source forms a closed loop with the section blank strip through the electric brush, and pulse current is applied in the rolling process; the method has the advantages that the softening of the metal on the shallow surface layer of the section and the repair and healing of the strain damage cavities and microcracks are realized, the deformation resistance of the metal with higher yield strength is reduced, the initiation-expansion of the cavities and microcracks on the shallow surface layer of the section caused by excessive strain is timely inhibited and repaired, the plastic forming performance of the wedge-shaped cavity section with the thin-neck structure of the metal difficult to plastically machine is improved, and the forming efficiency, the energy utilization efficiency, the finished product surface smoothness quality and the finished product quality are remarkably improved;

5) the roll-formed section moves forwards and passes through the right ultrasonic vibration roller, the ultrasonic vibration module is connected with a power supply to generate ultrasonic vibration, the ultrasonic vibration is transmitted to the right ultrasonic vibration roller, so that ultrasonic vibration excitation and energy input to the roll-formed section are realized, the frequency of the ultrasonic wave is 22-65 khz, the ultrasonic vibration causes the contact surface material of the roll-formed section to generate an ultrasonic softening effect, the surface metal material is instantly softened, the yield strength, the deformation resistance and the hardness of the surface metal material are reduced, and the forming performance of plastic processing of the surface metal material is improved; the contact friction coefficient between the contact surfaces of the roller and the profile is reduced, the frictional heat generation rate is reduced, the thermal load and the thermal deformation of the roller and the profile are reduced, the dimensional precision and the geometric precision of the roll-formed part are improved, and the frictional wear loss rate caused by the temperature rise of the material is reduced;

6) the roll-formed section moves forwards to pass through the right height calibration roller, the right height calibration roller lifts and ensures the height and direction precision of the strip material of the wedge-shaped cavity section, the size and the geometric precision of the roll-formed wedge-shaped cavity section are ensured, and the adverse effect on the quality of a roll-formed product caused by the precision in the height direction of the material supply is avoided;

7) the roll-formed section moves forwards and passes through a right horizontal calibration roller set, and the right horizontal calibration roller set solves the problems of overlarge roll shape deviation, unstable operation process and poor size precision caused by high horizontal error in the roll forming process of the wedge-shaped cavity section strip material;

8) the finished product of the wedge-shaped cavity section is taken out by a left roller and a right roller which rotate relatively by a right horizontal calibration roller set, and the whole rolling process is completed;

9) and cutting the rolled wedge-shaped cavity profile according to the use requirement.

Compared with the prior art, the invention has the beneficial effects that:

1. the cross section shape of the strip to be rolled before rolling is designed, and the annular protruding roller with preferred setting and design is matched, so that the wedge-shaped cavity hollow section with the thin neck structure and the cross section being narrow at the top and wide at the bottom can be accurately, simply and quickly processed after rolling, the amplitude and the precision of the height and the width of the thin neck can be ensured, the design and the processing difficulty of production tools and processes are reduced, raw materials are saved, the production cost and the forming difficulty are reduced, and the production efficiency is improved.

2. The comprehensive effects of the electric heating effect, the electro-plastic effect, the eddy current repairing and healing of cavities and microcracks generated by pulse current to large strain and the ultrasonic softening effect can reduce the deformation resistance, the yield strength and the hardness of the strip material in the rolling process in real time, obviously improve the forming limit of the strip material and the plastic deformation capability of the strip material on the premise of not changing the metal type, the heat treatment state and the stress hardening level of blank strip materials, further improve the machinable forming performance of the strip material, improve the machining forming speed and the machining adaptability of the same rolling device to different metal materials, particularly large yield strength, medium-high carbon steel strip materials with low limit strain, and increase the service life and the working life length of the roller.

3. The pulse current is utilized to flow through the strip to cause a heat effect, overcome an energy barrier, improve the diffusion capacity of metal atoms, facilitate the occurrence of metal recovery and recrystallization, facilitate the refinement of metal grains, realize the fine grain strengthening of the microstructure of the formed thin-neck wedge-shaped cavity section bar and improve the comprehensive mechanical property of the rolled finished section bar. Meanwhile, due to the thermal history of the strip material electric heating, the residual stress is favorably reduced, and the warping and deformation degree of the formed section bar are reduced; when pulse current flows through the blank strip and the blank strip is vibrated by ultrasonic waves, the thermal effect, the electro-plasticity and the ultrasonic softening effect are comprehensively acted on the blank strip in the rolling process, so that the plasticity of a metal material is improved, the deformation resistance of a workpiece is reduced, and the energy consumption caused by the plastic deformation forming is reduced; the current density of the surface layer of the steel strip is improved by using the skin effect of the pulse current, so that the temperature rising area of the metal strip is mainly concentrated in the area with larger surface strain, and the energy utilization efficiency is improved; and repairing and healing the microcrack formed by the strain damage of the strain area by using the eddy current effect of the pulse current.

4. The invention relates to a process for roll forming a thin neck wedge-shaped cavity, belonging to a plastic forming process without liquid/fluid lubrication and heat dissipation. Because of the absence of liquid/fluid, the method has the advantages of preventing corrosion and stabilizing the contact resistance of the roller and the blank strip. However, this brings the problems of increased friction coefficient of the contact surface between the rolling and the blank strip, severe heat generation during the rolling process, significant thermal load and deformation of the rolls, and severe wear loss of the surfaces of the rolls and the tapered cavity of the neck after forming. In order to solve the problem, the ultrasonic vibration applying method is adopted, the friction coefficient of the contact surface between the roller and a blank strip material under the conditions of no lubrication and no heat dissipation liquid/fluid is reduced, the functions of reducing the friction heat productivity, reducing the heat accumulation speed of the roller surface, the heat load degree and the heat deformation level are realized, and the purpose of reducing the overhigh wear loss speed caused by temperature rise is further realized. The advantages can improve the processability of rolling the metal blank strip with higher hardness, yield strength and deformation resistance, and also can ensure that the surface of a rolled workpiece has smoother quality, the energy required by processing and forming is lower, and the processing and forming efficiency can be obviously improved.

5. When the blank strip is initially introduced in the rolling process, the contact friction coefficient between the roller and the contact surface of the blank strip is large, namely, the friction force with high amplitude is beneficial to bringing the blank strip into the space between the upper roller and the lower roller for rolling. Thus, the ultrasonic vibrations are not applied at the initial moment of rolling, but are applied with the optimum amplitude, frequency and power of the ultrasonic vibrations, maximizing the ultrasonic softening effect and the effectiveness of the ultrasonic vibrations on the contact friction coefficient, in the condition that the blank strip has been introduced into the rolling rolls and the process of rolling the blank strip has been operating normally.

Drawings

FIG. 1 is a schematic diagram of the structure and process flow of the present invention.

FIG. 2 is a schematic cross-sectional view of a wedge cavity profile of the present invention.

Fig. 3 is a sectional view taken along the line a of fig. 1.

Fig. 4 is a sectional view taken along line B of fig. 1.

Fig. 5 is a schematic diagram of the cross-sectional structural parameters of the profile blank strip of fig. 4, including specific structural parameters α 1: blank-profile strip draft angle, h 1: blank height, w1 blank-profile strip width, and r 1: top fillet radius.

Fig. 6 is a cross-sectional view taken along line C of fig. 1.

FIG. 7 is a cross-sectional structural parameter diagram of the blank strip of the profile of FIG. 6, wherein α 2 is the strip draft angle after the blank profile is pre-rolled, h2 is the minor height of the blank strip, h3 is the total height of the blank strip, w2 is the inner width of the blank strip, and w2 is the outer width of the blank strip.

Fig. 8 is a cross-sectional view taken along line D of fig. 1.

Fig. 9 is a cross-sectional view taken along line E of fig. 1.

In the figure: 1-pulse current source 2-blank strip 3-left horizontal calibration roller 4-pre-rolling roller 5-left ultrasonic vibration roller 6-left brush 7-upper roller 8-right brush 9-right ultrasonic vibration roller 10-right height calibration roller 11-right horizontal calibration roller 12-left horizontal calibration roller base 13-pre-rolling roller base 14-left ultrasonic vibration roller base 15-left ultrasonic vibration module 16-lower flat roller 17-right ultrasonic vibration module 18-right ultrasonic vibration roller base 19-right height calibration roller base 20-right horizontal calibration roller base

Detailed Description

The following further describes embodiments of the present invention with reference to the accompanying drawings:

as shown in fig. 1, the ultrasonic wave and pulse current mixed auxiliary wedge-shaped cavity profile rolling line is sequentially provided with a left horizontal calibration roller 3, a pre-rolling roller 4, a left ultrasonic vibration roller 5, a left electric brush 6, a roller group, a right electric brush 8, a right ultrasonic vibration roller 9, a right height calibration roller 10 and a right horizontal calibration carrier roller 11 along the rolling line. The left horizontal calibration roller 3 and the right horizontal calibration roller 11 are composed of a left roller and a right roller which are horizontally arranged, the pre-rolling roller 4 and the right height calibration roller 9 are composed of an upper roller and a lower roller which are vertically arranged, the left ultrasonic vibration roller 5 and the right ultrasonic vibration roller 9 are composed of an upper roller and a lower roller which are vertically arranged, and the roller group is composed of an upper roller 7 and a lower flat roller 16 which are vertically arranged. The left ultrasonic vibration module 15 is connected with the left ultrasonic vibration roller 5 and drives the left vibration roller 5 to vibrate ultrasonically; the right ultrasonic vibration module 17 is connected with the right ultrasonic vibration roller 9 and drives the right ultrasonic vibration roller 9 to vibrate ultrasonically. The left brush 6 and the right brush 8 are connected with the pulse current source 1.

The left horizontal calibration roller 5 is installed on a left horizontal calibration roller base 12, the pre-rolling roller 4 is installed on a pre-rolling roller base 13, the left ultrasonic vibration roller 5 is installed on a left ultrasonic vibration roller base 14, the right ultrasonic vibration roller 9 is installed on a right ultrasonic vibration roller base 18, the right height calibration roller 10 is installed on a right height calibration roller base 19, and the right horizontal calibration roller 11 is installed on a right horizontal calibration roller base 20.

The two brushes form a brush set (a left brush 6 and a right brush 8), and the mounting manner of the brush set on the blank strip material comprises at least one mounting manner of (a), (b), (c) and (d):

(a) two electric brushes in the electric brush group are respectively arranged in front of and behind the roller, the lower surface of an upper brush head of the electric brush arranged in front of the roller is in contact fit with the upper surface of the profile blank strip material 2, and the lower surface of the brush head of the electric brush arranged behind the roller is in contact fit with the upper surface of the roll-formed profile (2);

(b) two electric brushes in the electric brush group are respectively arranged in front of and behind the roller, the upper surface of the brush head of the electric brush arranged in front of the roller is in contact fit with the lower surface of the profile blank strip material 2, and the upper surface of the brush head of the electric brush arranged behind the roller is in contact fit with the lower surface of the roll-formed profile (2);

(c) two electric brushes in the electric brush group are respectively arranged in front of and behind the roller, the lower surface of a brush head of the electric brush arranged in front of the roller is in contact fit with the upper surface of the profile blank strip material 2, and the upper surface of the brush head of the electric brush arranged behind the roller is in contact fit with the lower surface of the roll-formed profile (2);

(d) two electric brushes in the electric brush group are respectively arranged in front of and behind the roller, the upper surface of the brush head of the electric brush arranged in front of the roller is in contact fit with the lower surface of the profile blank strip material 2, and the lower surface of the brush head of the electric brush arranged behind the roller is in contact fit with the upper surface of the profile 2 after the roll forming; one of the electric brushes in the electric brush group is connected with the positive pole of the pulse power supply 1, the other electric brush is connected with the negative pole of the pulse power supply 1, and only one electric brush group is electrified during rolling, so that a current loop is formed between the electric brush group and the rolled section bar (2).

Two ultrasonic vibration modules are including controlling two sets ofly, left side group includes left ultrasonic vibration roll 5, left side ultrasonic vibration module 15 and left ultrasonic vibration roll base 14, right side group includes right ultrasonic vibration roll 9, right side ultrasonic vibration module 17 and right ultrasonic vibration roll base 18, arrange respectively that the business turn over position forms ultrasonic vibration group around thin neck wedge chamber section bar roll forming separately, the realization is to applying ultrasonic excitation to the thin neck wedge chamber section bar in-process of rolling, realize the ultrasonic softening and reduce the effect of metal section bar surface friction coefficient, and the specific details of the mounting means of whole rolling in-process ultrasonic vibration module are as follows:

(a) the left ultrasonic vibration roller 5 is positioned at the inlet stage of rolling the thin-neck wedge-shaped cavity profile blank strip 2, and the two rollers are respectively arranged up and down and respectively in profiling contact with the upper surface and the lower surface of the blank strip 2 in a preferred matching state. The upper roller and the upper surface of the blank belt material 2 are in a shape of a profile modeling and are in profile modeling contact with the upper surface of the blank belt material 2; the lower surface shapes of the lower roller and the blank strip 2 are in a profiling shape, and the lower surface of the blank strip 2 is a plane, so that the lower roller is a cylindrical flat roller in space shape. The upper and lower rollers and the blank strip 2 are in a transition fit adaptive state of a surface elastic deformation contact state, and a preferred fit state. The ultrasonic vibration module 15 is positioned on the left ultrasonic roller base 14, and the generated ultrasonic vibration can be applied to a blank section material strip by driving the upper roller and the lower roller, so that the friction state between the contact surfaces of the blank strip material 2 and the upper flat roller 7 and the lower flat roller 16 is improved, the friction coefficient of the contact roller surface in the rolling forming process of the blank strip material 2 is reduced, and the effect of reducing the energy required by forming and the friction heating degree is achieved.

(b) The right ultrasonic vibration roller 9 is positioned at an outlet section of the thin-neck wedge-shaped cavity profile blank strip 2 after final rolling forming, is arranged in an upper and a lower part and is respectively in copying contact with the upper surface and the lower surface of the blank strip 2, and is in a preferred matching state. The upper roller and the upper surface of the blank strip material 2 are in a shape of a profile modeling, are in profile modeling contact with the upper surface of the blank strip material 2, and are in a preferred matching state; the lower surface shapes of the lower roller and the blank strip 2 are in a profiling shape, and the lower surface of the blank strip 2 is a plane, so that the lower roller is a cylindrical flat roller in space shape. The upper and lower rollers and the blank strip 2 are in a transition fit adaptive state of a surface elastic deformation contact state, and a preferred fit state. The right ultrasonic vibration module 17 is fixed on the right ultrasonic roller base 18, and the generated ultrasonic vibration can be applied to the blank belt material 2 by driving the upper roller and the lower roller, so that the friction state between the blank belt material 2 and the contact surface is improved, the friction coefficient in the rolling forming process of the blank belt material 2 is reduced, and the purpose of reducing the energy required by forming and the friction heating degree is achieved.

The energy in the form of ultrasonic vibration is injected through the action excitation of the left ultrasonic roller group and the right ultrasonic roller group on the profile blank strip 2, and the contact friction coefficient between the contact surfaces of the upper roller 7, the lower flat roller 16 and the blank strip 2 is reduced, so that a series of common problems in the roll forming process caused by high contact friction coefficient, such as high heating value of the profile and the rollers, high abrasion of the surfaces of the profile and the rollers, high surface roughness of the formed blank strip and the like, are relieved/reduced.

The left horizontal calibration roller 3 is fixed on the left horizontal calibration roller base 12, the left horizontal calibration roller 3 and the left horizontal calibration roller base 12 are arranged in the stage before the blank strip 2 is preformed by rolling, the right horizontal calibration roller 11 is fixed on the right horizontal calibration roller base 20, and the right horizontal calibration roller 11 and the right horizontal calibration roller base 20 are respectively arranged in the stage of outlet after the blank strip 2 is formed by rolling and is calibrated in height (10). Two groups of horizontal calibration rollers and horizontal calibration roller bases are arranged before and after the thin-neck wedge-shaped cavity profile is subjected to roll forming, so that the horizontal positioning and calibration accuracy coordination and guarantee of the blank strip 2 to the upper flat roller 7 and the lower flat roller 16 are realized, the pre-roll forming (4) before the final roll forming is also realized, the final roll forming difficulty is reduced, and the roll forming accuracy is improved.

In order to realize the determination of the positioning and calibration precision of the horizontal direction of the blank strip 2 and the thin-neck wedge-shaped cavity section bar supplied to the rolling pair, the left horizontal calibration roller 3 and the right horizontal calibration roller 11 are installed in the following modes in the whole rolling process:

the left horizontal calibration roller 3 is positioned at the entrance section before the blank strip 2 of the tapered cavity profile with the thin neck is pre-roll formed, and the two rollers are respectively arranged at the left and the right relative to the blank strip 2 and are respectively in surface contact with the left and the right side surfaces of the blank strip 2. The left roller and the left surface of the blank strip 2 are in a shape of a profile modeling, and are in profile modeling contact with the left surface of the blank strip 2, and the preferred matching state is selected; the right roller and the right surface of the blank strip 2 are in a shape of a profile, and are in contact with the right surface of the blank strip 2 in a preferred matching state. Because the left and right surfaces of the blank strip 2 are both planes, the space shapes of the left and right rollers are cylindrical flat rollers. The left and right rollers and the left and right side surfaces of the blank belt material 2 are in a transition fit adaptive state with a preferred elastic deformation state in a surface contact state, and the elastic force generated by the contact with the side surface of the blank belt material 2 can be applied to the blank belt material 2, so that support is provided for ensuring the horizontal positioning precision of the blank belt material 2 between the upper flat roller 7 and the lower flat roller 16.

The right horizontal calibration roller 11 is positioned at an outlet section of the blank strip 2 of the tapered cavity profile of the rolling thin neck, and the two rollers are respectively arranged on the left and right sides, are respectively contacted with the left and right side surfaces of the blank strip 2 and are in a preferred matching state. The left roller and the left side surface of the blank strip material 2 are in a shape of a profile modeling and are contacted with the left side surface of the blank strip material 2; the right roller and the right side surface of the blank strip material 2 are in a shape of a profile, and are in contact with the right side surface of the blank strip material 2, and the right roller and the blank strip material are in a preferred matching state. Because the left side surface and the right side surface of the blank strip 2 are both planes, the space shapes of the left roller and the right roller are cylindrical flat rollers. The contact state of the left and right rollers and the left and right side surfaces of the blank belt material 2 is a transition fit adaptive state with elastic deformation of the surfaces, and the elastic force generated by the contact with the side surfaces of the blank belt material 2 can be applied to the blank belt material 2 in a preferred fit state, so that support and guarantee are provided for ensuring the positioning accuracy of the blank belt material 2 in the horizontal direction between the upper flat roller 7 and the lower flat roller 16.

The left horizontal calibration roller 3 and the right horizontal calibration roller 11 ensure the positioning and calibration precision of the running horizontal direction of the blank strip 2, and reduce the horizontal movement error of the running of the blank strip 2 and the thin-neck wedge-shaped cavity profile, thereby alleviating a series of problems such as overlarge rolling shape deviation, unstable running process, over-tolerance of size precision and the like caused by the higher horizontal error of the blank strip 2 and the thin-neck wedge-shaped cavity profile in the rolling forming process.

The pre-rolling roller 4 is fixed on the pre-rolling roller base 13, the pre-rolling roller 4 and the pre-rolling roller base 13 are arranged at an entrance section before the blank strip is applied with the ultrasonic vibration, the right height calibration roller 10 is fixed on the right height calibration roller base 19, and the right height calibration roller 10 and the right height calibration roller base 19 are respectively arranged at an exit section after the blank strip is applied with the ultrasonic vibration. Two sets of rollers and roller bases are arranged before and after the thin-neck wedge-shaped cavity profile is subjected to ultrasonic vibration, so that coordination and guarantee of height positioning and calibration accuracy of the blank strip 2 introduced into the upper roller 7 and the lower flat roller 16 are achieved.

The positioning and calibration precision in the height direction of the blank strip 2 supplied to the roll rolling is determined, and the installation modes of the pre-rolling roller 4 and the right height calibration roller 10 in the whole rolling process are as follows:

the pre-rolling rollers 4 are located at the inlet section of the blank section strip 2 excited by ultrasonic vibration, and the two rollers are respectively arranged up and down relative to the blank strip and are respectively contacted with the upper surface and the lower surface of the blank strip 2. The upper roller and the upper surface of the blank belt material 2 are in a shape of a profile modeling and are contacted with the upper surface of the blank belt material 2; the shape of the lower roller and the lower surface of the blank strip 2 is in a copying shape and is contacted with the lower surface of the blank strip 2. Because the upper surface of the blank strip 2 is in a shape close to C, the space shape of the upper roller is a special-shaped roller similar to M. The lower surface of the blank strip 2 is a plane, so that the space shape of the lower rolling roll is a cylindrical flat roll. The upper and lower rollers and the upper and lower surfaces of the blank belt material 2 are in surface contact state, namely in elastic deformation state, in a preferred transition fit adaptation state, and the elastic force generated by the surface contact with the blank belt material 2 can be applied to the blank belt material 2, so that support is provided for ensuring the positioning precision of the blank belt material 2 in the height direction between the upper roller 7 and the lower flat roller 16.

The right height calibration roller 10 is located at the outlet section of the blank strip 2 after being ultrasonically excited, and the two rollers are respectively arranged up and down and are respectively in contact with the upper surface and the lower surface of the blank strip 2. The upper roller and the upper surface of the blank belt material 2 are in a shape of a profile modeling and are contacted with the upper surface of the blank belt material 2; the shape of the lower roller and the lower surface of the blank strip 2 is in a copying shape and is contacted with the lower surface of the blank strip 2. Because the upper and lower surfaces of the blank strip 2 are both planes, the upper and lower rollers are flat rollers with cylindrical space shapes. The upper and lower rollers are in surface elastic deformation and in a preferred transition fit adaptation state with the upper and lower surfaces of the blank belt material 2, and the elastic force generated by the contact with the upper and lower surfaces of the blank belt material 2 can be applied to the blank belt material 2, so that support is provided for ensuring the positioning precision of the blank belt material 2 in the height direction between the upper roller 7 and the lower flat roller 16.

The pre-rolling roller 4 and the right height calibration roller 10 ensure the positioning and calibration precision of the running height direction of the blank strip 2, and reduce the height motion error of the feeding running of the blank strip 2, thereby alleviating a series of problems such as overlarge rolling shape error, unstable rolling running process, and out-of-tolerance of the dimension precision of the formed narrow-neck wedge-shaped cavity caused by the high positioning error of the blank strip 2 in the rolling forming process of the upper roller 7 and the lower flat roller 16.

The arrangement positions are based on the fact that rolling of the thin-neck wedge-shaped cavity section bar can be finished in a qualified mode, and the front, back, left and right arrangement of the relative positions of the devices is not fixed uniquely.

In the invention, the installation mode of the electric brush group on the rolling mill comprises at least one of the installation modes. If more than two mounting methods are adopted, the brushes between the brush groups can be shared. Four mounting modes are taken as examples, namely, when the left electric brush 6 and the right electric brush 8 are respectively positioned in front of and behind the upper rolling roller 7 and the lower flat roller 16 and are respectively connected with the pulse current source 1, the mounting mode is the (a) mounting mode of the invention; namely, the left electric brush 6 and the right electric brush 8 are respectively positioned in front of the roller of the lower roller group and behind the roller of the lower roller group and are respectively connected with the pulse power supply 1, and the installation mode (b) is adopted; the left electric brush 6 and the right electric brush 8 are respectively positioned in front of and behind the upper rolling roller 7 and the lower flat roller 16 and are respectively connected with the pulse power supply 4, which is the installation mode of the invention (c); the left brush 6 and the right brush 8 are respectively positioned in front of and behind the upper rolling roller 7 and the lower flat roller 16 and are respectively connected with the pulse power supply 4, and the installation mode (d) is the installation mode of the invention. Whatever the installation mode of the brush set, a current loop can be formed between the current of the pulse power supply 4 and the rolled blank strip 2. And only one set of brush sets is connected to the pulsed power supply 4 during rolling. In the rolling process, the upper roll group and the lower roll group rotate and do not generate displacement change, the working electric brush group does not generate displacement change, but the section blank strip 2 runs from the front of the upper roll 7 to the rear of the lower flat roll 16 under the driving of the relative rotation of the upper roll 7 and the lower flat roll 16 to be formed.

Fig. 2 is a schematic diagram of a cross-sectional geometry of a specific formed narrow-neck wedge-shaped cavity profile shown in an embodiment, the cross-sectional geometry of the formed profile includes not only a hollow wedge-shaped cavity shape, but also a width and a height of a narrow-neck structure, and specific parameters need to be obtained with a certain level of precision through forming control. In the figure L represents the inner width, D the outer width and H the profile height. Due to the small width value of the thin neck in the thin neck structure, the traditional milling processing of the wedge-shaped cavity hollow section is difficult to implement. Fig. 3 is a schematic sectional view of a left horizontal calibration roll a-a according to an embodiment, which shows a functional link of horizontal positioning and calibration of a blank strip profile to be rolled before a link of final roll forming of a thin-necked wedge-shaped cavity profile, and shows cross-sectional shape structures of a blank strip profile to be roll formed and the left horizontal calibration roll, and schematic diagrams of mutual matching, corresponding to the section a-a in the general flow diagram of fig. 1. Fig. 4 is a schematic diagram of the relationship between the blank strip and the corresponding rolls in the entering state of the functional links of pre-roll forming, height positioning and alignment of the strip to be rolled before rolling the thin-neck wedge-shaped cavity profile in accordance with the embodiment.

Fig. 5 is a schematic diagram of specific cross-sectional structural parameters of a blank profile before pre-rolling, which includes α 1: draft angle of blank profile strip, h 1: height of blank, w1 width of blank profile strip, and r 1: top fillet radius, according to an embodiment.

Fig. 6 is a schematic cross-sectional view of a blank strip at the rolling entry end C-C after the particular pre-rolling and before the final rolling step, and a pre-roll formed blank strip before the thin neck wedge shaped cavity profile is rolled, showing the cross-sectional shape configuration and matching of the strip including the pre-roll formed thin neck wedge shaped cavities, the upper roll and the lower flat roll, which corresponds to the C-C cross-section of fig. 1. Wherein, the upper roller and the geometric shape of the upper end of the blank strip material after the pre-rolling forming are profiled, and the upper roller and the blank strip material are preferentially matched.

FIG. 7 is a schematic diagram of cross-sectional structural parameters of a strip of a blank profile after pre-rolling and before final rolling, wherein α 2 is a strip draft angle after the pre-rolling of the blank profile, h2 is a minor height of the strip of the blank, h3 is a total height of the strip of the blank, w2 is an inner width of the strip of the blank, and w2 is an outer width of the strip of the blank.

As shown in fig. 4 and 5. After rolling and rolling in advance, the C-shaped structural section material with the top of a sharp-angled structure and the left side and the right side with the slight upsetting characteristic is formed, and as shown in fig. 6 and 7, the precision grade regulation is realized through the magnitude of relevant geometric parameters. The C-shaped profile is geometrically provided with a demoulding angle before and after pre-rolling, so that the roller enters before the face rolling and the roller is separated and pulled out after the rolling. The geometrical structure size of the cross section of the blank strip after pre-roll forming is optimized, and a preferred geometrical shape and size parameters with high enough precision grade are provided for subsequent final roll forming.

Fig. 8 is a schematic cross-sectional structure of a blank section strip before finish rolling, corresponding to the view of section D-D in fig. 1, where 2 is the blank section strip, 7 is the upper roll (profile roll with protruding ring belt), and 16 is the lower flat roll. The geometric parameters of the upper roller and the lower flat roller and the center distance between the two rollers are preferably designed, so that after roll forming, the upper sharp corner of the blank section strip material is plastically deformed towards the center line. Under the action of the protruding ring belt arranged in the middle of the upper roller, the structural parameters of the roller and the center distance of the roller in the rolling process are selected preferentially to form a thin neck structure and ensure that the parameters of the thin neck structure are kept at a certain precision level.

Fig. 9 is a schematic cross-sectional view corresponding to E-E in fig. 1 before finish rolling, where 2 is a blank profile strip, 7 is an upper roll (profile roll with protruding ring belt), and 16 is a lower flat roll. As can be seen, after roll forming, a hollow structure with a wedge-shaped cavity and a thin neck structure are formed.

At the roll entry end, the cross section of the blank strip 2 to be rolled overall exhibits an approximately "U" -shaped profile shape with a "concave middle and convex sides". The left side and the right side are provided with sharp-angle bulges, and the pointed ends of the bulges are respectively deviated to the middle line position. In the rolling process of the cylindrical flat roller, the metal material is subjected to plastic deformation, and the projections at the sharp corners at two sides deform towards the hollow part. By precisely optimizing and designing and controlling the geometric shapes of the sharp-horn-shaped convex parts at the left side and the right side, the volume of plastic deformation caused by the pressing amount in the rolling process and the upper roller 7 with the annular convex in the middle, the upper part of the hollow part of the original blank strip material after rolling is not sealed by metal at the sharp-horn parts at the left side and the right side which are rolled and deformed as shown in figures 8 and 9 before and after final rolling, the width and the height of a thin neck are precisely controlled by the annular belt which protrudes from the roller, and the hollow cavity after rolling forming is ensured to form a narrow-lower-wide wedge-shaped cavity shape with a thin neck structure. And the upward sharp-angle-shaped bulges at the left and right sides of the original cross section are rolled and flattened by flat rollers which are rolled and protrude out of the two sides of the ring belt.

The process flow of the invention is as follows: the sectional material blank strip 2 to be rolled is placed between the left horizontal calibration roller 3 and the pre-rolling roller 4 which enter the guide rollers arranged in pairs, and the sectional material blank strip 2 runs from the front of the rollers to the back of the rollers under the driving of the relative rotation of the paired roller sets. Fixing electric brushes on two sides of a section blank strip material 2, enabling the two electrodes to be in contact with the section blank strip material 2 to be rolled, connecting a power line to binding posts arranged on the two electrodes, switching on the power supply, starting an upper roller 7 and a lower flat roller 16 to enable the section blank strip material 2 to move from left to right in the horizontal direction, and rolling and forming the section blank strip material 2, so that bulges on the left side and the right side of the cross section of the blank strip material are rolled and deformed by the rollers, and strain towards the middle is generated, thereby not only forming the section material with a hollow thin neck wedge-shaped cavity structure with a narrow upper part and a wide lower part of the cross section, but also precisely controlling the width and the height of the thin neck after the section material with the thin neck wedge-shaped cavity due to the self width of a bulge girdle on the upper roller 7, and with the help of the optimized geometrical shape of the cross section of the section blank. Because the blank strip 2 is always contacted with the left electric brush 6 and the right electric brush 8 in the rolling forming process, the serious consequence that the size error of the workpiece is overlarge due to the matching interference between the workpiece and the electrode can be avoided. The left ultrasonic roller 6 is in elastic contact with the upper surface and the lower surface of the blank belt material 2, and the right ultrasonic roller 8 is in elastic contact with the upper surface and the lower surface of the blank belt material 2. Ultrasonic vibration is differently applied in the initial stage of rolling, and after the blank strip 2 is rolled and formed by the upper roller 7 and the lower flat roller 16 for a period of time, the ultrasonic vibration is applied, so that the problem that the blank strip 2 is difficult to be introduced due to the fact that the friction coefficient of the contact surface between the guide roller and the blank strip 2 is reduced by applying the ultrasonic vibration in the initial stage is avoided.

The working rolling roller for rolling the profile blank strip 2 can be a ceramic roller. Preferably the fracture strength, bending strength, hardness, toughness and ultimate strain are sufficient to meet the ceramic work rolls used in the production of rolling mills. The ceramic roller is selected as the working roller of the rolling mill, so that the insulating property of the roller can be ensured, the heat energy and the electro-plasticity generated when pulse current passes through the roller can be avoided, the defect that the softening of the metal roller is obvious due to obvious temperature rise is overcome, the ceramic roller has stable mechanical property due to the lower production temperature, the abrasion rate of the roller is reduced, and the electric energy is saved.

The ultrasonic-assisted metal plastic forming process has two significant advantages: firstly, the ultrasonic action metal material has an ultrasonic softening effect with good instantaneity, can reduce the deformation resistance and the yield strength of the metal material in the forming process in real time, has insignificant heating and temperature rise and thermal deformation, and has the advantages of lower thermal effect and thermal load of the metal; secondly, the vibration can cause the reduction of the contact friction coefficient of the metal surface, the ultrasonic vibration has a particularly outstanding effect on reducing the friction coefficient of the metal contact surface, the application of the ultrasonic vibration in the plastic deformation process of the metal is beneficial to improving the finish quality of the metal surface of the formed part, the requirement that the surface finish is improved by further grinding and polishing after the part is formed is reduced, the environmental pollution and the production cost caused by grinding and polishing are reduced, and the production efficiency is improved. Therefore, the ultrasonic vibration is introduced into the electrically-assisted rolling process, and the ceramic roller with balanced hardness and toughness is adopted, so that the method becomes a very feasible solution to the problems of reducing the contact friction coefficient between the roller and the strip material, inhibiting the electrothermal effect from causing remarkable heating-softening behaviors of the roller and the profile and the like on the premise of not applying a fluid/liquid with lubricating and cooling functions in the electrified rolling process.

The invention utilizes the skin effect of the electro-plasticity effect and the current density when the pulse current acts on the metal, the efficacy of the pulse current for repairing and healing the eddy current formed by holes/microcracks generated by overlarge plastic strain damage, the efficacy of ultrasonic softening effect and reduction of the metal surface contact friction coefficient of the ultrasonic-assisted plastic deformation, and the two types of energy are applied to the thin-neck wedge-shaped cavity section rolling forming process aiming at the metal with higher deformation resistance, yield strength and hardness and lower forming limit. In addition, the ceramic roller is adopted in the process, and liquid cooling lubricating liquid is not adopted, so that the processing cost-effectiveness ratio of the traditional rolling method to the rolling process of the section bar with the complicated cross section shape of the low/difficult-to-form metal is obviously improved.

The invention provides a processing method which can firstly reduce the deformation resistance of a section bar strip material in the rolling forming process of a metal blank strip material, improve the forming limit and the process processing forming performance of the metal blank strip material and reduce the processing forming difficulty of the rolling process of the metal section bar strip material; and secondly, the friction coefficient between the contact performance of the roller and the strip in the rolling process under the lubrication state of no/little lubricating liquid can be reduced, so that the large heat accumulation temperature rise and heating temperature rise amplitude, the severe abrasion degree of the surface of the section, the obvious heat load and thermal deformation of the roller and the section, which are caused by the higher friction coefficient, are reduced, the geometric and dimensional precision of the formed section strip after the rolling and rolling forming and the smoothness of the surface appearance are obviously improved, and the required processing energy consumption is reduced. And thirdly, realizing accurate regulation and control of the thin neck structure of the wedge-shaped cavity profile after the profile is formed by rolling and the precision grade of the wedge-shaped cavity parameter of the profile through the optimization design of the geometric parameters of the roller represented by the geometric dimension of the protruding ring belt on the special-shaped roller and the parameters of the rolling process. The processing method provided by the invention has the capability of improving the rolling forming process capability and the quality of the formed part.

Under the assistance of pulse current and ultrasonic vibration dual energy excitation with preferred characteristic parameters, the width size of the thin neck part can be regulated and controlled by adopting a roller with a protruding ring belt through an initial blank sectional material with an optimally designed C-like cross section shape, and the regulation and calibration of the related size and precision are realized. The method comprises the steps of realizing the regulation and the precision calibration of the height of the thin neck and quickly preparing the wedge-shaped cavity section with a smooth whole surface and a thin neck local structure through the optimization of the geometric shape of the initial cross section of a blank strip (2) and related structural dimension parameters and the optimization of the center distance of a pair of rollers formed in the rolling process and the geometric dimension parameters of a protruding ring belt.

The invention mainly designs the initial blank belt material with a preferred cross section geometric shape under the combined excitation action of pulse current technology and ultrasonic wave dual energy preferred parameters in the process of rolling the thin neck wedge-shaped cavity, and can obviously improve the forming quality, cost effectiveness ratio and processing capacity of the rolling processing forming technology of the thin neck wedge-shaped cavity section bar, obviously improve the surface finish of the section bar after the rolling forming, reduce the heating range of friction heat generation in the production process and reduce the heat load and heat strain level of related rollers and the section bar.

The invention relates to a pulse current and ultrasonic double-auxiliary rolling processing method which can improve the processability, the formability and the usability of a metal blank strip material with high hardness and strength and low forming limit. In order to enable the section to have higher formability and processing cost ratio, better processability, higher geometric and dimensional precision after forming, more stable, uniform and optimized overall mechanical property, smaller grain size and smaller residual stress, the invention provides the thin-neck wedge-shaped cavity section which is produced by applying pulse current and ultrasonic vibration to the rolling process together to roll the thin-neck wedge-shaped cavity section.

Aiming at different rolling materials, sectional material cross section shapes and processing technologies, by adjusting the upper roller, the lower roller, the left roller, the right roller and a blank sectional material strip to be matched with the geometric shape of a contact surface, the center distance between the rollers or/and the rollers with different diameters and geometric shapes, and adopting proper optimization on the ultrasonic vibration frequency, the amplitude and the power, preferential preparation production conditions for metal sectional materials with different types and sectional material geometric shapes and heat treatment and strain states are obtained, and the ultrasonic softening efficiency of ultrasonic vibration on metal is maximally improved, and the efficiency of the contact surface friction coefficient of the blank sectional material is reduced.

By adjusting characteristic parameters of a pulse power supply, including power, voltage/current amplitude, pulse frequency, duty ratio and pulse width of the current source, the skin effect and the electroplasticity of the pulse current flowing through the metal and the capability of repairing and healing cavities and microcracks caused by strain damage are utilized, the current density amplitude, the heating and temperature rise amplitude and the strain damage repairing capability of the surface layer of the metal section with obvious deformation are improved, the yield strength, the deformation resistance and the forming difficulty of the surface layer metal are reduced, and the processing efficiency, the quality, the machinability and the processing cost ratio of the section are improved.

By optimizing and adjusting characteristic parameters of the ultrasonic vibration module, including vibration output power, vibration amplitude, vibration frequency and phase, by utilizing the ultrasonic softening effect of ultrasonic vibration on metal and the effect of reducing the friction coefficient of the metal contact surface, the forming and forming difficulty of the metal profile with higher yield strength and hardness is reduced, the surface smoothness after roll forming is improved, and the machinability, the processing efficiency, the quality and the cost effectiveness ratio of the profile are improved.

The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.

Claims

1. The ultrasonic and pulse current mixed auxiliary wedge-shaped cavity profile rolling line is characterized in that a left horizontal calibration roller, a pre-rolling roller, a left ultrasonic vibration roller, a left electric brush, a roller group, a right electric brush, a right ultrasonic vibration roller, a right height calibration roller and a right horizontal calibration carrier roller are sequentially arranged along the rolling line, the left horizontal calibration roller and the right horizontal calibration roller are composed of a left roller and a right roller which are horizontally arranged, the pre-rolling roller and the right height calibration roller are composed of an upper roller and a lower roller which are vertically arranged, the left ultrasonic vibration roller and the right ultrasonic vibration roller are composed of an upper roller and a lower roller which are vertically arranged, and the roller group is composed of an upper roller and a lower roller; the ultrasonic vibration module is connected with the left ultrasonic vibration roller and the right ultrasonic vibration roller and drives the left ultrasonic vibration roller and the right ultrasonic vibration roller to vibrate ultrasonically; the left electric brush and the right electric brush are connected with a pulse current source.

2. The ultrasonic and pulse current hybrid assisted wedge cavity profile rolling line of claim 1, wherein said left horizontal calibration roll is mounted on a left horizontal calibration roll base, the pre-rolling roll is mounted on a pre-rolling roll base, the left ultrasonic vibrating roll is mounted on a left ultrasonic vibrating roll base, the right ultrasonic vibrating roll is mounted on a right ultrasonic vibrating roll base, the right height calibration roll is mounted on a right height calibration roll base, and the right horizontal calibration idler is mounted on a right horizontal calibration idler base.

3. The ultrasonic and pulsed current hybrid assisted wedge cavity profile pass line of claim 1, wherein the left and right rolls of the left horizontal alignment roll set are in elastic contact with the left and right sides of the profile blank strip, and the left and right rolls of the right horizontal alignment roll set are in elastic contact with the left and right sides of the roll formed profile; the left and right rollers of the left horizontal calibration roller set and the right horizontal calibration roller set are cylindrical rollers.

4. The ultrasonic vibration assisted wedge cavity profile rolling line of claim 1, wherein the shape of the upper and lower rolls of the pre-rolling roll is contoured to the shape of the upper and lower surfaces of the profile blank strip; the shapes of the upper and lower rollers of the right height calibration roller and the shapes of the upper and lower surfaces of the rolled section are arranged in a copying way.

5. The ultrasonic vibration assisted wedge cavity profile rolling line of claim 4, wherein said left and right elevation calibration rolls upper and lower rolls are in elastic contact with upper and lower surfaces of the profile blank strip; the surface of an upper roller of the pre-rolling roller is similar to M shape, and a lower roller of the pre-rolling roller is a cylindrical roller; the upper roller and the lower roller of the right height calibration roller are cylindrical rollers.

6. The ultrasonic vibration assisted wedge cavity profile rolling line according to claim 1, wherein the left ultrasonic vibration roll comprises two upper rolls and one lower roll which are arranged up and down; the shape of the two upper rollers is arranged in a shape copying way with the shape of the upper surface of the blank strip material, and the lower roller is a cylindrical flat roller; the right ultrasonic vibration roller comprises two upper rollers and a lower roller which are arranged up and down; the shape of the two upper rollers is arranged in a shape copying way with the shape of the upper surface of the blank strip material, and the lower roller is a cylindrical flat roller.

7. The ultrasonic vibration assisted wedge cavity profile rolling line according to claim 1, wherein the upper and lower rolls of the roll set are provided with ring belts on the roll surfaces, the width of the ring belts corresponds to the width of the thin neck of the wedge cavity profile, and the thickness of the ring belts corresponds to the depth of the wedge cavity profile.

8. The ultrasonic vibration assisted wedge cavity profile rolling line according to claim 1, wherein the rollers of the left horizontal calibration roller, the pre-rolling roller, the left ultrasonic vibration roller, the roller group, the right ultrasonic vibration roller, the right height calibration roller and the right horizontal calibration idler are ceramic rollers.

9. The ultrasonic vibration assisted wedge cavity profile mill pass line of claim 1, wherein the left and right brushes comprise at least one of a, b, c and d:

10. A rolling process based on the pass line of claim 1, wherein the rolling process is a continuous process, and the method comprises the following steps:

1) the left horizontal calibration roller is an inlet section of the section blank strip, the section blank strip is placed between the left horizontal calibration roller and the right horizontal calibration roller, the section blank strip is brought into a rolling line by the left horizontal calibration roller and the right horizontal calibration roller, and the left horizontal calibration roller controls the horizontal error of the section blank strip in the rolling forming process;

2) the sectional material blank strip moves forwards and passes through a pre-rolling roller, and the pre-rolling roller controls the height and orientation precision of the sectional material blank strip in the roll forming process;

3) the section blank strip moves forwards and passes through the left ultrasonic vibration roller, the ultrasonic vibration module is connected with a power supply to generate ultrasonic vibration, and the ultrasonic vibration is transmitted to the left ultrasonic vibration roller, so that ultrasonic vibration excitation and energy input on the section blank strip are realized, and the frequency of the ultrasonic wave is 22-65 khz;

5) the roll-formed section moves forwards and passes through the right ultrasonic vibration roller, the ultrasonic vibration module is connected with a power supply to generate ultrasonic vibration, and the ultrasonic vibration is transmitted to the right ultrasonic vibration roller, so that ultrasonic vibration excitation and energy input on the roll-formed section are realized, and the frequency of the ultrasonic wave is 22-65 khz;

6) the roll-formed section moves forwards to pass through a right height calibration roller, and the right height calibration roller controls the height and orientation precision of the roll-formed section in the roll forming process;

7) the roll-formed section moves forwards and passes through a right horizontal calibration roller set, and the right horizontal calibration roller set controls the horizontal direction precision of the roll-formed section in the roll forming process;