CN111633103A - Electro-hydraulic-electromagnetic composite forming system and forming method - Google Patents
Electro-hydraulic-electromagnetic composite forming system and forming method Download PDFInfo
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- CN111633103A CN111633103A CN202010449030.6A CN202010449030A CN111633103A CN 111633103 A CN111633103 A CN 111633103A CN 202010449030 A CN202010449030 A CN 202010449030A CN 111633103 A CN111633103 A CN 111633103A
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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
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/06—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves
- B21D26/10—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves generated by evaporation, e.g. of wire, of liquids
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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
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/14—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces applying magnetic forces
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Abstract
The invention discloses an electro-hydraulic-electromagnetic composite forming system, belonging to the field of metal forming and manufacturing, comprising: a metal pipe to be formed, which is placed in a mold with both ends closed, and in which a liquid medium is stored; the wire is immersed in a liquid medium; the first power supply module is connected with the metal and used for discharging the metal wire to generate shock waves in the metal pipe fitting; the two boosting coils are respectively arranged at the top end and the bottom end of the metal pipe fitting; the second power supply module is connected with both the two boosting coils and is used for discharging electricity to the two boosting coils so as to generate boosting electromagnetic force in the metal pipe fitting; the discharge control module is connected with the two power supply modules and is used for controlling the discharge time sequence of the two power supply modules, so that plastic deformation processing of the metal pipe fitting is realized under the synergistic effect of the shock wave and the boosting electromagnetic force. The invention can effectively solve the problems of workpiece thinning, cracking and the like caused by poor material flowability in the prior electro-hydraulic forming technology and improve the die attaching performance of the workpiece.
Description
Technical Field
The invention belongs to the field of metal forming and manufacturing, and particularly relates to an electro-hydraulic-electromagnetic composite forming system and a forming method.
Background
The light aluminum alloy material is widely applied to the fields of automobile manufacturing, aerospace and the like due to the excellent mechanical property of the material. However, the effect of plastic working of aluminum alloy by using the traditional processing technology is not ideal, mainly because the aluminum alloy has poor plasticity and is difficult to form.
Research shows that the forming performance of the material can be obviously improved by high-speed forming. Electro-hydraulic forming is a manufacturing technology for processing a workpiece by using shock waves generated by explosion of metal wires, belongs to high-speed forming, and can greatly improve the forming performance of materials. However, in the electro-hydraulic forming manufacturing process, due to the insufficient flowability of the material at the end of the workpiece to be processed, the workpiece to be processed is subject to thinning and even cracking, and on the other hand, for complex workpieces, the die attaching performance of the workpiece under the electro-hydraulic forming technology needs to be improved.
Disclosure of Invention
Aiming at the defects and improvement requirements of the prior art, the invention provides an electro-hydraulic-electromagnetic composite forming system and a forming method, aiming at solving the problems of workpiece thinning, cracking and the like caused by poor material flowability in the prior electro-hydraulic forming technology and improving the die attaching performance of the workpiece.
To achieve the above object, according to one aspect of the present invention, there is provided an electro-hydraulic-electromagnetic composite forming system including: the device comprises a metal pipe fitting to be formed, a die, a metal wire, a liquid medium, two boosting coils, a first power supply module, a second power supply module and a discharge control module;
the shape of the inner wall of the mould is matched with the shape to be formed; the metal pipe fitting is arranged in the die, and two ends of the metal pipe fitting are sealed; the liquid medium is stored in the metal pipe fitting;
the metal wire is immersed in the liquid medium and is connected with the first power supply module through two metal electrodes; the first power supply module is used for discharging the metal wire, so that plasma is generated after the metal wire is gasified and exploded, and shock waves are generated on the metal pipe fitting;
the two boosting coils are respectively arranged at the top end and the bottom end of the metal pipe fitting and are connected with the second power supply module; the second power supply module is used for discharging the two boosting coils to generate boosting electromagnetic force in the direction consistent with that of the pipe fitting in the metal pipe fitting, so that the flowability of the material at the end part of the metal pipe fitting is improved;
the discharge control module is connected with the first power supply module and the second power supply module and used for controlling the discharge time sequence of the first power supply module and the second power supply module according to the shape to be formed, so that plastic deformation machining of the metal pipe fitting is achieved under the synergistic effect of the shock waves and the boosting electromagnetic force.
The metal wire is discharged by utilizing the first power supply module, pulse heavy current is generated in the metal wire, the temperature of the metal wire is rapidly increased, gasification explosion is generated, severe chemical reaction is generated between the metal wire and surrounding liquid media, plasma is generated, and high-speed shock waves are generated on a metal pipe fitting to be formed along with expansion of gas; meanwhile, the second power supply module is used for discharging electricity to the boosting coil, the boosting coil generates an induced eddy current and a pulse magnetic field at the end part of the metal pipe fitting, so that a boosting electromagnetic force consistent with the direction of the pipe fitting is generated in the metal pipe fitting, and the material flowability at the end part of the metal pipe fitting to be formed is improved under the action of the boosting electromagnetic force, so that the problems of workpiece thinning, cracking and the like can be effectively solved; under the synergistic action of high-speed shock waves and boosting electromagnetic force, the plastic deformation processing of the metal pipe fitting to be formed is realized, and the forming performance is improved.
The invention realizes radial (central region of the workpiece) loading by discharging the metal wire by the first power supply module, realizes axial (end region of the workpiece) loading by discharging the boosting coil by the second power supply module, controls the discharging time sequence of the first power supply module and the second power supply module by the discharging control module, realizes accurate matching of axial and radial loading, and can effectively improve the die attaching performance of the workpiece.
Further, if the shape of the inner wall of the mold is symmetrical up and down, the second power supply module comprises a set of power supply, and the two boosting coils are connected in series or in parallel and then connected with the power supply in the second power supply module;
if the shape of the inner wall of the mold is asymmetrical up and down, the second power supply module comprises two sets of power supplies, and each boosting coil is connected with one set of power supply respectively.
When the inner wall shape (namely the shape to be formed) of the mold is vertically symmetrical, the two boosting coils are connected in series or in parallel and then connected to the same set of power supply, so that the number of the power supplies can be reduced.
Further, the centers of the wire areas of the two boosting coils are both positioned on the axis of the pipe wall of the metal pipe fitting.
According to the invention, the centers of the wire areas of the two boosting coils are both positioned on the axis of the pipe wall of the metal pipe fitting, and the material area of the metal pipe fitting is just positioned between the wire areas of the two boosting coils, so that the electromagnetic force provided by the boosting coils to the metal pipe fitting can be maximized.
Further, the mold is provided with vent holes for balancing the internal and external air pressure of the mold during the forming process.
Furthermore, the first ends of the two metal electrodes are inserted into the metal pipe fitting and immersed in the liquid medium, and the metal wires are wound on the first ends of the two metal electrodes; the second ends of the two metal electrodes are exposed outside, and the second ends of the two metal electrodes are respectively connected to the positive electrode and the negative electrode of the first power supply module.
Furthermore, the boosting coil arranged at the top end of the metal pipe fitting is an air coil.
The hollow coil is used as the boosting coil arranged at the top end of the metal pipe fitting, so that the metal electrode can be conveniently inserted into the metal pipe fitting.
According to another aspect of the invention, a forming method based on the electro-hydraulic-electromagnetic composite forming system provided by the invention is provided, and comprises the following steps:
determining the discharge time sequence of the first power supply module and the second power supply module according to the shape to be formed;
when the discharge time sequence of the first power supply module arrives, generating a corresponding control signal to enable the power supply in the first power supply module to discharge to the metal wire, so that the metal wire generates plasma after gasification and explosion, and shock waves are generated on the metal pipe fitting;
when the discharge time sequence of the second power supply module arrives, a corresponding control signal is generated, so that the power supply in the second power supply module discharges to the boosting coil, boosting electromagnetic force consistent with the direction of the pipe fitting is generated in the metal pipe fitting, and the flowability of the end material of the metal pipe fitting is improved.
Further, the discharge timing t of the first power supply module0At the moment t of the peak current value of the booster coilpDifference between | t0-tp|≤;
Where > 0.
The invention sets the discharge time sequence of the first power supply module near the current peak time of the boosting coil, thereby ensuring the maximum boosting electromagnetic force.
Generally, by the above technical solution conceived by the present invention, the following beneficial effects can be obtained:
(1) according to the invention, the boosting coils are respectively arranged at two ends of the metal pipe fitting to be formed, and the boosting coils are discharged through the second power supply module, so that the boosting electromagnetic force consistent with the direction of the pipe fitting is generated in the metal pipe fitting, the fluidity of the end material of the metal pipe fitting is improved, and the problems of workpiece thinning and cracking are effectively avoided.
(2) According to the invention, the first power supply module is used for discharging the metal wire to realize radial loading, the second power supply module is used for discharging the boosting coil to realize axial loading, and the discharge control module is used for controlling the discharge time sequence of the first power supply module and the second power supply module, so that the accurate matching of the axial loading and the radial loading is realized, and the die attaching performance of the workpiece can be effectively improved.
Drawings
Fig. 1 is a schematic structural diagram of an electro-hydraulic-electromagnetic composite forming apparatus provided in an embodiment of the present invention;
fig. 2 is a schematic diagram of induced eddy currents and a pulse electromagnetic force generated by a boosting coil at an end of a metal pipe to be formed according to an embodiment of the invention;
fig. 3 is a schematic diagram of discharge timing sequences of a first power module and a second power module according to an embodiment of the invention;
FIG. 4 is a schematic diagram illustrating the effect of the early-stage boosting electromagnetic force provided by the embodiment of the present invention;
FIG. 5 is a schematic diagram of the boosting electromagnetic force and high-speed shockwave effect provided by the embodiment of the invention;
the same reference numbers will be used throughout the drawings to refer to the same or like elements or structures, wherein:
the device comprises a power supply module, a power module, a discharge control module, a power module and a power module, wherein the power module is 1, the power module is 2, the power module is 3, a metal wire is 4, the power module is 5, the power module is 6, the power module is 7, 8.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
In the present application, the terms "first," "second," and the like (if any) in the description and the drawings are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order.
In order to solve the problems of workpiece thinning, cracking and the like caused by poor material flowability in the prior electro-hydraulic forming technology and improve the die attaching performance of the workpiece, in one embodiment of the invention, an electro-hydraulic-electromagnetic composite forming system is provided, as shown in fig. 1, and comprises: the device comprises a metal pipe fitting 8 to be formed, a die 7, a metal wire 3, a liquid medium 4, two boosting coils 5, a first power supply module 1, a second power supply module 6 and a discharge control module 10;
the shape of the inner wall of the mould 7 is matched with the shape to be formed; the metal pipe fitting 8 is arranged in the die 7, and two ends of the metal pipe fitting are respectively sealed by a sealing ring 9; the liquid medium 4 is stored in the metal pipe 8;
the metal wire 3 is immersed in a liquid medium 4 and is connected with the first power supply module 1 through two metal electrodes 2; the first power supply module 1 is used for discharging the metal wire 3, so that plasma is generated after the metal wire 3 is gasified and exploded, and shock waves are generated on the metal pipe fitting 8;
the two boosting coils 5 are respectively arranged at the top end and the bottom end of the metal pipe fitting 8 and are connected with the second power supply module; the second power supply module 6 is used for discharging electricity to the two boosting coils 5 to generate boosting electromagnetic force in the direction consistent with the direction of the metal pipe fitting 8, as shown in fig. 2, so that the flowability of the material at the end part of the metal pipe fitting 8 is improved, and the material of the metal pipe fitting 8 is promoted to flow into the cavity of the die 7;
the discharge control module 10 is connected with the first power module 1 and the second power module 6, and is used for controlling the discharge time sequence of the first power module 1 and the second power module 6 according to the shape to be formed, so that plastic deformation processing of the metal pipe fitting 8 is realized under the synergistic effect of the shock wave and the boosting electromagnetic force.
In the present embodiment, as shown in fig. 2, the shape of the inner wall of the mold 7, i.e. the shape to be formed, is symmetrical up and down, wherein the second power module 6 includes a set of power sources, and the two boosting coils 5 can be connected in series or in parallel to be connected with the power source in the second power module 6, thereby reducing the number of power sources; it should be noted that the description is only a preferred embodiment of the present invention, and should not be construed as the only limitation to the present invention, in other embodiments of the present invention, in the case that the inner wall shape of the mold 7 is symmetrical up and down, two sets of power supplies may be used to separately supply power to the two boosting coils;
in other embodiments of the present invention, if the mold 7 is complex, for example, the shape of the inner wall of the mold 7 is asymmetric from top to bottom, the second power module 6 should include two sets of power supplies, and each boosting coil 5 is connected to one set of power supply respectively to supply power to each boosting coil separately;
as shown in fig. 1, in this embodiment, each of the first power module 1 and the second power module 6 includes a switching device for turning on or off the power supply, and the discharge control module 10 controls the discharge timing of each power module by turning on or off the switching device; in other embodiments of the present invention, the discharge timing of the power supply may be controlled in other manners.
In the present embodiment, the radii, winding directions and turns of the two boosting coils 5 are the same; the specific radius and the number of turns of the boosting coil 5 are determined according to the size of the pipe fitting;
in the present embodiment, the center of the wire area of the two boosting coils 5 is located on the axis of the pipe wall of the metal pipe 8, and accordingly, the material area of the metal pipe is located right between the wire areas of the two boosting coils as shown in fig. 2, thereby maximizing the electromagnetic force provided by the boosting coils to the metal pipe.
In this embodiment, the mold 7 is further provided with an exhaust hole for balancing the internal and external air pressures of the mold 7 during the molding process;
specifically, the air holes can be distributed along the circumferential direction at equal intervals, and generally 4 air holes are arranged to be enough for exhausting air between the mold 7 and the metal pipe fitting 8 in the forming process and balancing the internal and external air pressure of the mold 7; it should be noted that the present invention is only exemplary described herein, and should not be construed as the only limitation of the present invention, and other ways of providing the air holes can be equally applied to the present invention as long as the effect of balancing the internal and external air pressures of the mold 7 can be achieved.
As shown in fig. 1, in the present embodiment, first ends of two metal electrodes 2 are inserted into a metal pipe 8 and are immersed in a liquid medium 4, and a metal wire 3 is wound around the first ends of the two metal electrodes 2; the second ends of the two metal electrodes 2 are exposed outside, and the second ends of the two metal electrodes 2 are respectively connected to the positive electrode and the negative electrode of the first power module 1; correspondingly, the boosting coil 5 arranged at the top end of the metal pipe fitting 8 is an air coil so as to facilitate the insertion of the metal electrode 2 into the metal pipe fitting 8.
In practical application, the electro-hydraulic-electromagnetic composite forming system shown in fig. 1 can be assembled according to the following steps:
(1) placing a metal pipe fitting 8 to be formed in a mould 7;
(2) storing the liquid medium 4 in the metal pipe 8, and respectively sealing two ends of the metal pipe 8 by using two sealing rings 9;
(3) winding a metal wire 3 at one end of the two metal electrodes 2;
(4) inserting one end of the two metal electrodes 2 wound with the metal wires 3 into the metal pipe fitting 8;
(5) placing two boosting coils 5 at the end parts of two ends of a metal pipe fitting 8 to be formed;
(6) connecting a first power supply module 1 with a metal electrode 2;
(7) connecting a second power supply module 6 to the boosting coil;
(8) the discharge control module 10 connects the first power module 1 and the second power module 6.
In another embodiment of the present invention, there is provided a forming method based on the above-described electro-hydraulic-electromagnetic composite forming system, including:
determining the discharge time sequence of the first power supply module 1 and the second power supply module 6 according to the shape to be formed;
when the discharging time sequence of the first power supply module 1 is reached, generating a corresponding control signal to enable the power supply in the first power supply module 1 to start discharging to the metal wire 3, enabling the metal wire 3 to generate plasma after gasification and explosion, and generating shock waves on the metal pipe 8 so as to enable the metal pipe 8 to generate plastic deformation;
when the discharge time sequence of the second power supply module 6 is reached, a corresponding control signal is generated, so that the power supply in the second power supply module 3 starts to discharge to the boosting coil 5, boosting electromagnetic force which is consistent with the direction of the pipe fitting is generated in the metal pipe fitting 8, and the flowability of the end material of the metal pipe fitting 8 is improved.
In this embodiment, the determined discharge timing of the first power module 1 and the second power module 6 is shown in fig. 3, the first power supplyDischarge timing t of module0At the time t of the peak current value of the booster coil 5pThereby enabling the maximum assist electromagnetic force to be used; in the actual control process, the discharge time sequence t of the first power module 1 can be set0At the time t of the peak current value of the booster coil 5pDifference between | t0-tpThe discharge time sequence t of the first power supply module is ensured to be less than or equal to (greater than 0)0At the time t of the peak current value of the booster coil 5pNearby;
in some other embodiments of the present invention, the discharging time sequence of the first power module 1 may be prior to the discharging time sequence of the second power module 6, and the first power module 1 and the second power module 6 may also discharge simultaneously; through the flexible arrangement of the discharge time sequence of the first power supply module 1, the flexible matching of high-speed shock waves and boosting electromagnetic force is realized, and further the effective regulation and control of the deformation behavior of the metal pipe fitting 8 to be formed are realized.
According to the discharge sequence shown in fig. 3, when the metal pipe 8 to be formed is subjected to plastic deformation processing by using the forming method provided in the above embodiment, as shown in fig. 4, at time 0, the second power module 6 discharges the boost coil 5, and an induced eddy current and a pulse electromagnetic force are generated in the metal pipe 81 in an initial state, and the pulse electromagnetic force is loaded on the end of the metal pipe 8 in advance (time 0 to t 0); at the time t0, the first power module 1 discharges the metal wire 3 to generate a pulse large current, the metal wire 3 is heated, and the temperature of the metal wire 3 rises rapidly (at the time t 0-t 1); at the time of t1, the metal wire 3 is gasified and exploded, and has violent chemical reaction with the surrounding liquid medium 4 to generate plasma, and high-speed shock waves are generated on the metal pipe fitting to be formed along with the expansion of the gas; as shown in fig. 5, plastic deformation processing of the metal pipe 8 is realized under the synergistic effect of the boosting electromagnetic force and the high-speed shock wave, and a processed metal pipe 82 is obtained.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (8)
1. An electro-hydraulic-electromagnetic composite forming system, comprising: the device comprises a metal pipe fitting (8) to be formed, a die (7), a metal wire (3), a liquid medium (4), two boosting coils (5), a first power supply module (1), a second power supply module (6) and a discharge control module (10);
the shape of the inner wall of the mould (7) is matched with the shape to be formed; the metal pipe fitting (8) is arranged in the die (7), and two ends of the metal pipe fitting are sealed; the liquid medium (4) is stored inside the metal pipe (8);
the metal wire (3) is immersed in the liquid medium (4) and is connected with the first power supply module (1) through two metal electrodes (2); the first power supply module (1) is used for discharging the metal wire (3), so that plasma is generated after the metal wire (3) is gasified and exploded, and shock waves are generated on the metal pipe fitting (8);
the two boosting coils (5) are respectively arranged at the top end and the bottom end of the metal pipe fitting (8) and are connected with the second power supply module; the second power supply module (6) is used for discharging the two boosting coils (5) to generate boosting electromagnetic force in the direction consistent with that of the metal pipe fitting (8), so that the flowability of the material at the end part of the metal pipe fitting (8) is improved;
the discharge control module (10) is connected with the first power supply module (1) and the second power supply module (6) and is used for controlling the discharge time sequence of the first power supply module (1) and the second power supply module (6) according to the shape to be formed, so that plastic deformation machining of the metal pipe fitting (8) is achieved under the synergistic effect of shock waves and boosting electromagnetic force.
2. The electro-hydraulic-electromagnetic composite forming system according to claim 1, wherein if the inner wall of the mold (7) is vertically symmetrical, the second power module (6) comprises a set of power source, and the two boosting coils (5) are connected in series or in parallel and then connected with the power source in the second power module (6);
if the shape of the inner wall of the mold (7) is asymmetric from top to bottom, the second power supply module (6) comprises two sets of power supplies, and each boosting coil (5) is connected with one set of power supply respectively.
3. Electro-hydraulic-electromagnetic composite forming system according to claim 1, characterized in that the wire areas of both booster coils 5 are centered on the axis of the wall of the metal tube (8).
4. The electro-hydraulic-electromagnetic composite forming system according to claim 1, wherein the mold (7) is provided with vent holes for equalizing internal and external air pressures of the mold (7) during forming.
5. The electro-hydraulic-electromagnetic composite forming system according to claim 1, characterized in that first ends of two metal electrodes (2) are inserted into the metal pipe (8) and immersed in the liquid medium (4), the metal wire (3) being wound around the first ends of the two metal electrodes (2); the second ends of the two metal electrodes (2) are exposed outside, and the second ends of the two metal electrodes (2) are respectively connected to the positive electrode and the negative electrode of the first power supply module (1).
6. The electro-hydraulic-electromagnetic composite forming system according to claim 5, wherein the booster coil (5) disposed at the top end of the metal pipe (8) is an air coil.
7. A forming method based on the electro-hydraulic-electromagnetic composite forming system according to any one of claims 1 to 6, characterized by comprising:
determining the discharge timing of the first power module (1) and the second power module (6) according to the shape to be formed;
when the discharge time sequence of the first power supply module (1) is reached, generating a corresponding control signal to enable a power supply in the first power supply module (1) to discharge to the metal wire (3), so that the metal wire (3) generates plasma after gasification and explosion, and shock waves are generated on the metal pipe fitting (8);
when the discharge time sequence of the second power supply module (6) arrives, a corresponding control signal is generated, the power supply in the second power supply module (3) discharges to the boosting coil (5), boosting electromagnetic force consistent with the direction of the pipe fitting is generated in the metal pipe fitting (8), and therefore the flowability of the end material of the metal pipe fitting (8) is improved.
8. Forming method according to claim 7, characterised in that the discharge timing t of the first power supply module (1)0With the current peak time t of the boost coil (5)pDifference between | t0-tp|≤;
Where > 0.
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