CN111659786B - Ultrasonic vibration assisted electromagnetic lock welding device and method - Google Patents
Ultrasonic vibration assisted electromagnetic lock welding device and method Download PDFInfo
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- CN111659786B CN111659786B CN202010533585.9A CN202010533585A CN111659786B CN 111659786 B CN111659786 B CN 111659786B CN 202010533585 A CN202010533585 A CN 202010533585A CN 111659786 B CN111659786 B CN 111659786B
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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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- 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
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/03—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal otherwise than by folding
- B21D39/031—Joining superposed plates by locally deforming without slitting or piercing
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Abstract
The invention provides an ultrasonic vibration assisted electromagnetic lock welding device and method, which comprises the following steps: the ultrasonic auxiliary device is arranged in the lower die, and a first metal plate and a second metal plate are placed at the top of the lower die; the upper die is fixedly arranged above the lower die and is coaxially arranged with the lower die; the controller is arranged at the top of the upper die. The ultrasonic vibration assisted electromagnetic lock welding device and the method provided by the invention have the advantages that rivets are not needed, pre-punching is not needed, the sheet material is processed by utilizing the force of a pulse magnetic field, the plastic deformation capacity of the material in the connecting process is enhanced by ultrasonic vibration assistance, the tension crack defect caused by the concentrated tensile stress of the neck part of the joint is avoided by using electromagnetic pulse welding, the mechanical property of the joint is obviously improved, the connecting strength is high, the control is easy, the efficiency is higher, and the operation is simple.
Description
Technical Field
The invention relates to the technical field of electromagnetic forming connection, in particular to an ultrasonic vibration assisted electromagnetic lock welding device and method.
Background
With the development of aviation industry and automobile industry, the requirements for connection of mechanical parts are higher and higher, and the requirements for riveting technology are also higher and higher. As a novel connection process, the electromagnetic riveting technology is paid more and more attention by research institutions and manufacturing enterprises. The electromagnetic riveting is a riveting process for plastically deforming a rivet by using eddy repulsion generated between two stages of coils. Because of high loading rate, large strain rate, uniform deformation of rivet stem, and effective prevention of damage to composite materials, they have been used in the joining of titanium alloy and composite material structures and in the forming of large diameter rivets and difficult-to-form rivets.
However, in the electromagnetic riveting process, the deformation mechanism of the rivet under the pulse electromagnetic force is very complex, and the mutual influence of the riveting process and the high-speed deformation process of the rivet makes the plate forming control very difficult. The introduction of the external rivet certainly increases the mass and cost of the connected parts, which is very disadvantageous for the lightweight of the connection structure. In addition to the increased cost and complexity of the process due to the pre-piercing, the strain rate of the rivet during high voltage riveting can lead to micro-cracks and shear failure of the rivet head.
At present, an electromagnetic forming connection technology without rivets is urgently needed in the field of plate connection, metal plates can be connected with high strength, in the connection process, the forming of the plates is easy to control, and damage phenomena such as cracks are not generated.
Disclosure of Invention
The invention provides an ultrasonic vibration assisted electromagnetic lock welding device and method, and aims to solve the problems that the forming control of a plate is very difficult and cracks are easily generated in the traditional electromagnetic riveting process.
In order to achieve the above object, an embodiment of the present invention provides an ultrasonic vibration assisted electromagnetic lock welding apparatus, including:
the ultrasonic auxiliary device is arranged in the lower die, and a first metal plate and a second metal plate are placed at the top of the lower die;
the upper die is fixedly arranged above the lower die and is coaxially arranged with the lower die;
the controller is arranged at the top of the upper die;
the blank holder electromagnetic circuit is integrated on a circuit board of the controller and is electrically connected with the first end of the controller;
the forming electromagnetic circuit set is integrated on a circuit board of the controller, the forming electromagnetic circuit set is electrically connected with the second end of the controller, and the forming electromagnetic circuit set comprises a first forming electromagnetic circuit, a second forming electromagnetic circuit, a third forming electromagnetic circuit, a fourth forming electromagnetic circuit and a fifth forming electromagnetic circuit.
Wherein, go up the mould and include:
a plurality of first forming coils, each of which is embedded above the concave part of the upper die;
the second forming coil is embedded below the middle of the upper die;
and the blank holder coil is embedded at the lower edge of the upper die.
Wherein the ultrasonic wave assisting device includes:
the energy converter is arranged in the circular ring hole of the lower die, is electrically connected with the third end of the controller, and is used for converting electric energy into ultrasonic mechanical vibration;
and the amplitude variation ring is arranged at the top of the transducer and is used for enhancing the ultrasonic mechanical vibration amplitude.
Wherein, blank holder electromagnetic circuit includes:
a first switch, wherein a first end of the first switch is electrically connected with a first end of the blank holder coil;
a first end of the first capacitor is electrically connected with a second end of the first switch;
a first end of the first inductor is electrically connected with a second end of the first capacitor;
and a first end of the first resistor is electrically connected with a second end of the first inductor, and a second end of the first resistor is electrically connected with a second end of the blank holder coil.
Wherein the first shaped electromagnetic circuit comprises:
a second switch, a first end of the second switch being electrically connected to a first end of the second shaped coil;
a first end of the second capacitor is electrically connected with a second end of the second switch;
a first end of the second inductor is electrically connected with a second end of the second capacitor;
and a second resistor, wherein a first end of the second resistor is electrically connected with a second end of the second inductor, and a second end of the second resistor is electrically connected with a second end of the second forming coil.
Wherein the second, third, fourth, and fifth shaped electromagnetic circuits comprise:
a third switch, a first end of the third switch being electrically connected to a corresponding first end of the first forming coil;
a first end of the third capacitor is electrically connected with a second end of the third switch;
a first end of the fourth capacitor is electrically connected with a first end of the third capacitor, and a second end of the fourth capacitor is electrically connected with a second end of the third capacitor;
a first end of the third inductor is electrically connected with a second end of the fourth capacitor;
and a first end of the third resistor is electrically connected with the second end of the third inductor, and a second end of the third resistor is electrically connected with the second end of the corresponding first forming coil.
The coil sections of the first forming coil, the second forming coil and the blank holder coil are all spiral tube coils formed by winding round or rectangular red copper wires.
The embodiment of the invention also provides an ultrasonic vibration assisted electromagnetic lock welding connection method, which comprises the following steps:
The scheme of the invention has the following beneficial effects:
according to the ultrasonic vibration assisted electromagnetic lock welding device and method, the plastic deformation capacity of materials in the connecting process is enhanced through ultrasonic vibration assistance, the tension crack defect caused by the concentrated tensile stress of the joint neck is avoided, locking and welding are ingeniously completed in the forming process, mechanical lock interlocking is achieved, interface combination is achieved, the connecting strength is greatly improved through double effects, the defects that punching is needed in the traditional electromagnetic riveting process and rivets are needed are overcome, and the ultrasonic vibration assisted electromagnetic lock welding device and method have the advantages of being high in connecting strength, easy to control, high in efficiency, simple to operate and the like.
Drawings
FIG. 1 is a schematic diagram of the general structure of the present invention;
FIG. 2 is a schematic specific circuit diagram of a second, third, fourth and fifth shaped electromagnetic circuits of the present invention;
FIG. 3 is a positioning diagram of the present invention;
FIG. 4 is a molding diagram of the present invention;
FIG. 5 is an electromagnetic welding diagram of the present invention;
fig. 6 is a final connection diagram of the present invention.
[ description of reference ]
1-upper mould; 2-a first forming coil; 3-a second shaped coil; 4-a first metal sheet; 5-a second metal sheet; 6-lower die; 7-a transducer; 8-a variable amplitude ring; 9-blank holder coil; 10-a blank holder electromagnetic circuit; 11-forming the set of electromagnetic circuits; 12-a controller; 13-a mechanical lock; 14-a welded structure; 15-a third switch; 16-a third capacitance; 17-a fourth capacitance; 18-a third inductance; 19-third resistance.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following detailed description is given with reference to the accompanying drawings and specific embodiments.
The invention provides an ultrasonic vibration assisted electromagnetic lock welding device and method, aiming at the problems that the forming control of a plate is very difficult and cracks are easily generated in the traditional electromagnetic riveting process.
As shown in fig. 1 to 6, an embodiment of the present invention provides an ultrasonic vibration assisted electromagnetic lock welding apparatus, including: the ultrasonic auxiliary device comprises a lower die 6, wherein an ultrasonic auxiliary device is arranged in the lower die 6, and a first metal plate 4 and a second metal plate 5 are placed at the top of the lower die 6; the upper die 1 is fixedly arranged above the lower die 6, and the upper die 1 and the lower die 6 are coaxially arranged; a controller 12, wherein the controller 12 is arranged at the top of the upper die 1; the blank holder electromagnetic circuit 10 is integrated on a circuit board of the controller 12, and the blank holder electromagnetic circuit 10 is electrically connected with a first end of the controller 12; a forming electromagnetic circuit set 11, the forming electromagnetic circuit set 11 being integrated on a circuit board of the controller 12, the forming electromagnetic circuit set 11 being electrically connected to a second end of the controller 12, the forming electromagnetic circuit set 11 including a first forming electromagnetic circuit, a second forming electromagnetic circuit, a third forming electromagnetic circuit, a fourth forming electromagnetic circuit, and a fifth forming electromagnetic circuit.
In the ultrasonic vibration assisted electromagnetic lock welding device and method according to the above embodiment of the present invention, the lower die 6 and the upper die 1 are fixedly disposed, the first metal plate 4 and the second metal plate 5 are stacked on the top of the lower die 6, the upper die 1 is located above the second metal plate 5, the upper die 1 is overlapped with the central axis of the lower die 6, the first forming electromagnetic circuit, the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit and the fifth forming electromagnetic circuit are disposed in the forming electromagnetic circuit group 11, the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit and the fifth forming electromagnetic circuit are respectively provided with the corresponding first forming coils 2, the second forming coils 3 correspond to the first forming electromagnetic circuits, and the blank holder electromagnetic circuit 10 corresponds to the blank holder coil 9, the blank holder coil 9, each of the first forming coils 2 and the second forming coils 3 are helical coils formed by winding round or rectangular red copper wires, the blank holder coil 9, each of the first forming coils 2 and the second forming coils 3 can be formed by combining more than one sub-coils, the blank holder electromagnetic circuit 10 and the forming electromagnetic circuit group 11 are integrated on a circuit board of the controller 12, capacitors in the blank holder electromagnetic circuit 10 and the forming electromagnetic circuit group 11 are powered by the controller 12, charging circuits are not interfered with each other, and the controller 12 controls the closing of switches in the blank holder electromagnetic circuit 10 and the forming electromagnetic circuit group 11.
Wherein, go up mould 1 and include: a plurality of first forming coils 2, wherein each first forming coil 2 is embedded above the concave part of the upper die 1; the second forming coil 3 is embedded below the middle of the upper die 1; and the blank holder coil 9 is embedded at the lower edge of the upper die 1, and the blank holder coil 9 is embedded at the lower edge of the upper die 1.
In the ultrasonic vibration assisted electromagnetic lock welding device and method according to the above embodiment of the present invention, the upper die 1 includes the first forming coil 2, the second forming coil 3, and the blank holder coil 9, which are annularly arranged.
Wherein the ultrasonic wave assisting device includes: the transducer 7 is arranged in the circular ring hole of the lower die 6, the transducer 7 is electrically connected with a third end of the controller 12, and the transducer 7 is used for converting electric energy into ultrasonic mechanical vibration; the amplitude variation ring 8 is arranged at the top of the transducer 7, and the amplitude variation ring 8 is used for enhancing the ultrasonic mechanical vibration amplitude.
In the ultrasonic vibration assisted electromagnetic lock welding device and method according to the above embodiments of the present invention, the lower die 6 includes the ultrasonic auxiliary device annularly disposed, the ultrasonic auxiliary device includes the transducer 7 and the amplitude variation ring 8, the transducer 7 is connected to the amplitude variation ring 8 and is installed in the circular ring hole of the lower die 6, the ultrasonic power source of the transducer 7 is provided by the controller 12, the transducer 7 converts electric energy into ultrasonic mechanical vibration, and the amplitude of the ultrasonic mechanical vibration is enhanced by the amplitude variation ring 8, so that the workpiece at the end of the amplitude variation ring 8 generates ultrasonic vibration.
Wherein, blank holder electromagnetic circuit 10 includes: a first switch, a first end of which is electrically connected with a first end of the blank holder coil 9; a first end of the first capacitor is electrically connected with a second end of the first switch; a first end of the first inductor is electrically connected with a second end of the first capacitor; and a first end of the first resistor is electrically connected with a second end of the first inductor, and a second end of the first resistor is electrically connected with a second end of the blank holder coil 9.
Wherein the first shaped electromagnetic circuit comprises: a second switch, a first end of the second switch is electrically connected with a first end of the second forming coil 3; a first end of the second capacitor is electrically connected with a second end of the second switch; a first end of the second inductor is electrically connected with a second end of the second capacitor; and a second resistor, wherein a first end of the second resistor is electrically connected with a second end of the second inductor, and a second end of the second resistor is electrically connected with a second end of the second forming coil 3.
Wherein the second, third, fourth, and fifth shaped electromagnetic circuits comprise: a third switch 15, a first end of the third switch 15 is electrically connected with a first end of the corresponding first forming coil 2; a third capacitor 16, wherein a first terminal of the third capacitor 16 is electrically connected to a second terminal of the third switch 15; a fourth capacitor 17, wherein a first end of the fourth capacitor 17 is electrically connected to a first end of the third capacitor 16, and a second end of the fourth capacitor 17 is electrically connected to a second end of the third capacitor 16; a third inductor 18, wherein a first end of the third inductor 18 is electrically connected with a second end of the fourth capacitor 17; a third resistor 19, a first end of the third resistor 19 is electrically connected to the second end of the third inductor 18, and a second end of the third resistor 19 is electrically connected to the corresponding second end of the first forming coil 2.
The coil sections of the first forming coil 2, the second forming coil 3 and the blank holder coil 9 are all helical tube coils formed by winding round or rectangular red copper wires.
The embodiment of the invention also provides an ultrasonic vibration assisted electromagnetic lock welding connection method, which comprises the following steps: step 1, horizontally stacking a first metal plate 4 and a second metal plate 5 on the top of a lower die 6; step 2, starting the controller 12 to charge a second capacitor and a third capacitor 16 in the forming electromagnetic loop group 11 and a first capacitor in the blank holder electromagnetic loop group 10, controlling switches in the blank holder electromagnetic loop group 10 and the forming electromagnetic loop group 11 to be closed by the controller 12, controlling each first forming coil 2, each second forming coil 3 and each blank holder coil 9 by the controller 12, and stopping charging after the second capacitor and the third capacitor 16 in the forming electromagnetic loop group 11 and the first capacitor in the blank holder electromagnetic loop group 10 reach a specified voltage; step 3, the controller 12 controls switches in the blank holder electromagnetic circuit 10 and the forming electromagnetic circuit group 11 to be closed, a first capacitor in the blank holder electromagnetic circuit 10 and a second capacitor and a third capacitor 16 in the forming electromagnetic circuit group 11 start to discharge, a magnetic field is formed between the upper die 1 and the lower die 6, the first metal plate 4 and the second metal plate 5 generate plastic deformation under the action of the magnetic field force, the first metal plate 4 and the second metal plate 5 are tightly pressed by the electromagnetic force on the periphery of the upper die 1, the first metal plate 4 and the second metal plate 5 flow along the oblique conical surface of the lower die 6 by the magnetic field force under the second forming coil 3, and the first metal plate 4 and the second metal plate 5 are compressed by the magnetic field force under the first forming coil 2; step 4, the plastic deformation of the first metal plate 4 and the second metal plate 5 is gradually increased, the first metal plate 4 is in contact with the end part of the amplitude-variable ring 8, the controller 12 controls the transducer 7 to be electrified, the transducer 7 converts electric energy into ultrasonic mechanical vibration, the amplitude of the ultrasonic mechanical vibration is enhanced through the amplitude-variable ring 8, so that the workpiece on the end part of the amplitude-variable ring 8 generates ultrasonic vibration, the ultrasonic vibration enhances the plastic deformation capability of the two metal plates, the magnetic field force under the first forming coil 2 enables the first metal plate 4 and the second metal plate 5 to be remarkably thinned, the materials of the first metal plate 4 and the second metal plate 5 under the first forming coil 2 move outwards along the radial direction, the first metal plate is embedded into the second metal plate under the action of the magnetic field force and the lower die 6, and an S-shaped mechanical lock 13 is gradually formed between the first metal plate 4 and the second metal plate 5; step 5, finishing discharging a first capacitor in the blank holder electromagnetic loop 10 and a second capacitor and a third capacitor 16 in the forming electromagnetic loop group 11, automatically opening switches in the blank holder electromagnetic loop 10 and the forming electromagnetic loop group 11, losing power of each first forming coil 2, each second forming coil 3 and each blank holder coil 9, and controlling the power supply of the transducer 7 to be disconnected by the controller 12; step 6, starting the controller 12 to charge a third capacitor 16 and a fourth capacitor 17 in the second forming electromagnetic loop, the third forming electromagnetic loop, the fourth forming electromagnetic loop and the fifth forming electromagnetic loop and a first capacitor in the blank holder electromagnetic loop 10; step 7, completing charging of a third capacitor 16 and a fourth capacitor 17 in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit and a first capacitor in the binder ring electromagnetic circuit 10, closing switches in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit and the binder ring electromagnetic circuit 10 by the controller 12, starting discharging of the third capacitor 16 and the fourth capacitor 17 in the second forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit and the first capacitor in the binder ring electromagnetic circuit 10, impacting the second metal plate 5 to the first metal plate 4 at a high speed under the action of electromagnetic force, gradually forming a solid-state welding structure 14 at the overlapping position of the centers of the first metal plate 4 and the second metal plate 5, an S-shaped mechanical lock 13 with a solid-state welding structure 14 is formed on the lower die 6, the discharge of the third capacitor 16 and the fourth capacitor 17 in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit and the fifth forming electromagnetic circuit is completed, and the first capacitor in the blank holder electromagnetic circuit 10 is completed, and the controller 12 controls the switch in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit and the blank holder electromagnetic circuit 10 to be disconnected.
In the ultrasonic vibration assisted electromagnetic lock welding device and method according to the above embodiment of the present invention, the controller 12 is started to charge the second capacitor and the third capacitor 16 in the forming electromagnetic loop group 11 and the first capacitor in the blank holder electromagnetic loop 10 for the first time, the controller 12 controls the switches in the blank holder electromagnetic loop 10 and the forming electromagnetic loop group 11 to be closed, the controller 12 controls each of the first forming coil 2, the second forming coil 3 and the blank holder coil 9, the second capacitor and the third capacitor 16 in the forming electromagnetic loop group 11 and the first capacitor in the blank holder electromagnetic loop 10 to reach a specified voltage, the charging is stopped, the controller 12 controls the switches in the blank holder electromagnetic loop group 10 and the forming electromagnetic loop group 11 to be closed, and the first capacitor in the blank holder electromagnetic loop group 10 and the second capacitor and the first capacitor in the forming electromagnetic loop group 11 and the blank holder electromagnetic loop group 11 are closed The third capacitor 16 starts to discharge, a magnetic field is formed between the upper die 1 and the lower die 6, the first metal plate 4 and the second metal plate 5 are plastically deformed under the action of the magnetic field force above the horn 8, the electromagnetic force at the periphery of the upper die 1 mainly acts to press the first metal plate 4 and the second metal plate 5, the magnetic field force under the second forming coil 3 causes the first metal plate 4 and the second metal plate 5 to flow along the oblique conical surface of the lower die 6, the magnetic field force under the first forming coil 2 causes the first metal plate 4 and the second metal plate 5 to be compressed, and the electromagnetic force under each first forming coil 2 causes the first metal plate 4 and the second metal plate 5 under the concave portion of the upper die 1 to be subjected to a uniform downward magnetic field force, the plastic deformation of the first metal plate 4 and the second metal plate 5 is gradually increased, the first metal plate 4 is in contact with the end portion of the amplitude-changing ring 8, the controller 12 starts to energize the transducer 7, the transducer 7 converts electric energy into ultrasonic mechanical vibration, the amplitude of the ultrasonic mechanical vibration is enhanced through the amplitude-changing ring 8, so that the workpiece on the end portion of the amplitude-changing ring 8 generates ultrasonic vibration, the ultrasonic vibration enhances the plastic deformation capability of the two metal plates, the magnetic field force under the first forming coil 2 enables the first metal plate 4 and the second metal plate 5 to be remarkably thinned, the materials of the first metal plate 4 and the second metal plate 5 under the first forming coil 2 move outwards in the radial direction, the first metal plate 4 is embedded into the second metal plate 5 under the action of the magnetic field force and the lower die 6, an S-shaped mechanical lock 13 is gradually formed between the first metal plate 4 and the second metal plate 5, after the capacitor discharge in the blank holder electromagnetic circuit 10 and the forming electromagnetic circuit group 11 is finished, the switches in the blank holder electromagnetic circuit 10 and the forming electromagnetic circuit group 11 are automatically turned on, each of the first forming coil 2, the second forming coil 3 and the blank holder coil 9 is de-energized, and meanwhile, the controller 12 controls the power supply of the transducer 7 to be turned off. And charging for the second time, starting the controller 12 to charge the third capacitor 16 and the fourth capacitor 17 in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit and the first capacitor in the binder ring electromagnetic circuit 10, after the charging of the third capacitor 16 and the fourth capacitor 17 in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit and the fifth forming electromagnetic circuit and the first capacitor in the binder ring electromagnetic circuit 10 is completed, controlling the switches in the charged second forming electromagnetic circuit, third forming electromagnetic circuit, fourth forming electromagnetic circuit, fifth forming electromagnetic circuit and binder ring electromagnetic circuit 10 to be closed by the controller 12, and closing the switches in the second forming electromagnetic circuit, third forming electromagnetic circuit, fourth forming electromagnetic circuit, fifth forming electromagnetic circuit and the binder ring electromagnetic circuit 10, The third capacitor 16 and the fourth capacitor 17 in the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, and the fifth forming electromagnetic circuit, and the first capacitor in the blankholder electromagnetic circuit 10 start discharging, each of the first forming coils 2 and the blankholder coil 9 are energized for the second time, the electromagnetic force of the outer ring of the upper die 1 mainly acts to press the first metal plate 4 and the second metal plate 5, the second energization of each of the first forming coils 2 is compared with the first energization of each of the first forming coils 2, because each of the first forming coils 2 is connected with two capacitors when energized for the second time, the instantaneous energization amount of each of the first forming coils 2 when energized for the second time becomes twice that when each of the first forming coils 2 is energized for the first time, at this time, the electromagnetic force under each of the first forming coils 2 becomes large, the second metal plate 5 is impacted against the first metal plate 4 at a high speed by an electromagnetic force, a solid-state welded structure 14 is formed at the center of the first metal plate 4 and the second metal plate 5, and an S-shaped mechanical lock 13 having a solid-state welded structure 14 is formed on the lower die 6. The third capacitor 16 and the fourth capacitor 17 in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, and the fifth forming electromagnetic circuit, and the first capacitor in the blank holder electromagnetic circuit 10 are discharged, and the controller 12 controls the switches in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit, and the blank holder electromagnetic circuit 10 to be turned off.
In the ultrasonic vibration assisted electromagnetic lock welding device and method according to the above embodiments of the present invention, the solid-state welding structure 14 is formed at the center overlapping position of the first metal plate 4 and the second metal plate 5, and the S-shaped mechanical lock 13 having the solid-state welding structure 14 is formed on the lower die 6, so that the mechanical lock interlocking is realized, and the interface combination is realized, thereby greatly improving the connection strength between the plates through the dual functions, overcoming the defects that the traditional electromagnetic riveting needs to be punched and needs to be riveted, and having the characteristics of high connection strength, easy control, high efficiency, simple operation, etc.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (8)
1. An ultrasonic vibration assisted electromagnetic lock welding device, comprising:
the ultrasonic auxiliary device is arranged in the lower die, and a first metal plate and a second metal plate are placed at the top of the lower die;
the upper die is fixedly arranged above the lower die and is coaxially arranged with the lower die;
the controller is arranged at the top of the upper die;
the blank holder electromagnetic circuit is integrated on a circuit board of the controller and is electrically connected with the first end of the controller;
the forming electromagnetic circuit set is integrated on a circuit board of the controller, the forming electromagnetic circuit set is electrically connected with the second end of the controller, and the forming electromagnetic circuit set comprises a first forming electromagnetic circuit, a second forming electromagnetic circuit, a third forming electromagnetic circuit, a fourth forming electromagnetic circuit and a fifth forming electromagnetic circuit.
2. The ultrasonic vibration assisted electromagnetic lock welding apparatus of claim 1, wherein the upper die comprises:
a plurality of first forming coils, each of which is embedded above the concave part of the upper die;
the second forming coil is embedded below the middle of the upper die;
and the blank holder coil is embedded at the lower edge of the upper die.
3. The ultrasonic vibration assisted electromagnetic lock welding apparatus of claim 2, wherein the ultrasonic assist apparatus comprises:
the energy converter is arranged in the circular ring hole of the lower die, is electrically connected with the third end of the controller, and is used for converting electric energy into ultrasonic mechanical vibration;
and the amplitude variation ring is arranged at the top of the transducer and is used for enhancing the ultrasonic mechanical vibration amplitude.
4. The ultrasonic vibration assisted electromagnetic lock welding apparatus of claim 3, wherein the binder ring electromagnetic circuit comprises:
a first switch, wherein a first end of the first switch is electrically connected with a first end of the blank holder coil;
a first end of the first capacitor is electrically connected with a second end of the first switch;
a first end of the first inductor is electrically connected with a second end of the first capacitor;
and a first end of the first resistor is electrically connected with a second end of the first inductor, and a second end of the first resistor is electrically connected with a second end of the blank holder coil.
5. The ultrasonic vibration assisted electromagnetic lock welding apparatus of claim 4, wherein the first forming electromagnetic circuit comprises:
a second switch, a first end of the second switch being electrically connected to a first end of the second shaped coil;
a first end of the second capacitor is electrically connected with a second end of the second switch;
a first end of the second inductor is electrically connected with a second end of the second capacitor;
and a second resistor, wherein a first end of the second resistor is electrically connected with a second end of the second inductor, and a second end of the second resistor is electrically connected with a second end of the second forming coil.
6. The ultrasonic vibration assisted electromagnetic lock welding apparatus of claim 5, wherein the second, third, fourth, and fifth forming electromagnetic circuits comprise:
a third switch, a first end of the third switch being electrically connected to a corresponding first end of the first forming coil;
a first end of the third capacitor is electrically connected with a second end of the third switch;
a first end of the fourth capacitor is electrically connected with a first end of the third capacitor, and a second end of the fourth capacitor is electrically connected with a second end of the third capacitor;
a first end of the third inductor is electrically connected with a second end of the fourth capacitor;
and a first end of the third resistor is electrically connected with the second end of the third inductor, and a second end of the third resistor is electrically connected with the second end of the corresponding first forming coil.
7. The ultrasonic-vibration-assisted electromagnetic lock welding device according to claim 6, wherein the coil sections of the first forming coil, the second forming coil and the blankholder coil are all round or rectangular copper wire-wound helical tube coils.
8. An ultrasonic vibration assisted electromagnetic lock welding connection method, comprising:
step 1, horizontally stacking a first metal plate and a second metal plate on the top of a lower die;
step 2, starting the controller to charge a second capacitor and a third capacitor in the forming electromagnetic loop group and a first capacitor in the blank holder electromagnetic loop, controlling switches in the blank holder electromagnetic loop and the forming electromagnetic loop group to be closed by the controller, controlling each first forming coil, each second forming coil, each blank holder coil and each transducer to be electrified by the controller, and stopping charging after the second capacitor and the third capacitor in the forming electromagnetic loop group and the first capacitor in the blank holder electromagnetic loop reach specified voltage;
step 3, a controller controls switches in the blank holder electromagnetic circuit and the forming electromagnetic circuit group to be closed, a first capacitor in the blank holder electromagnetic circuit and a second capacitor and a third capacitor in the forming electromagnetic circuit group start to discharge, a magnetic field is formed between the upper die and the lower die, the first metal plate and the second metal plate generate plastic deformation under the action of the magnetic field force, the first metal plate and the second metal plate are tightly pressed by the electromagnetic force on the periphery of the upper die, the first metal plate and the second metal plate flow along the oblique conical surface of the lower die by the magnetic field force under the second forming coil, and the first metal plate and the second metal plate are compressed by the magnetic field force under the first forming coil;
step 4, the plastic deformation of the first metal plate and the second metal plate is gradually increased, the first metal plate is in contact with the end part of the amplitude-variable ring, the controller controls the transducer to be electrified, the transducer converts electric energy into ultrasonic mechanical vibration, the amplitude of the ultrasonic mechanical vibration is enhanced through the amplitude-variable ring, a workpiece on the end part of the amplitude-variable ring generates ultrasonic vibration, the ultrasonic vibration enhances the plastic deformation capacity of the two metal plates, the first metal plate and the second metal plate are remarkably thinned through magnetic field force under the first forming coil, the materials of the first metal plate and the second metal plate under the first forming coil move outwards along the radial direction, the first metal plate is embedded into the second metal plate under the action of the magnetic field force and the lower die, and an S-shaped mechanical lock is gradually formed between the first metal plate and the second metal plate;
step 5, discharging of the first capacitor in the blank holder electromagnetic loop and the second capacitor and the third capacitor in the forming electromagnetic loop group is finished, switches in the blank holder electromagnetic loop and the forming electromagnetic loop group are automatically opened, each of the first forming coil, the second forming coil and the blank holder coil loses power, and the controller controls the power supply of the transducer to be disconnected;
step 6, starting the controller to charge a third capacitor and a fourth capacitor in the second forming electromagnetic loop, the third forming electromagnetic loop, the fourth forming electromagnetic loop and the fifth forming electromagnetic loop and a first capacitor in the blank holder electromagnetic loop;
step 7, a third capacitor and a fourth capacitor in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit and a first capacitor in the blank holder electromagnetic circuit are charged, the controller controls the switches in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit and the blank holder electromagnetic circuit to be closed, the third capacitor and the fourth capacitor in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit and the fifth forming electromagnetic circuit and the first capacitor in the blank holder electromagnetic circuit start to discharge, the second metal plate collides with the first metal blank plate at a high speed under the action of electromagnetic force, a solid welding structure is gradually formed at the central superposed position of the first metal plate and the second metal plate, and an S-shaped mechanical lock with a solid welding structure is formed on the lower die, and the controller controls the switches in the second forming electromagnetic circuit, the third forming electromagnetic circuit, the fourth forming electromagnetic circuit, the fifth forming electromagnetic circuit, the blank holder electromagnetic circuit to be disconnected after the third capacitor and the fourth capacitor in the second forming electromagnetic circuit and the first capacitor in the blank holder electromagnetic circuit are discharged.
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