CN112427556B - Self-resistance heating forming device and method for large metal plate - Google Patents

Self-resistance heating forming device and method for large metal plate Download PDF

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CN112427556B
CN112427556B CN202011044291.6A CN202011044291A CN112427556B CN 112427556 B CN112427556 B CN 112427556B CN 202011044291 A CN202011044291 A CN 202011044291A CN 112427556 B CN112427556 B CN 112427556B
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metal plate
temperature
plate
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large metal
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CN112427556A (en
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易卓勋
王博
刘淑芬
赖小明
黄鑫
毛雷
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Beijing Satellite Manufacturing Factory Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00Tools as parts of machines covered by this subclass
    • B21D37/16Heating or cooling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02Stamping using rigid devices or tools
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/34Methods of heating
    • C21D1/40Direct resistance heating
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Control Of Resistance Heating (AREA)

Abstract

The invention relates to a self-resistance heating forming device and method for a large-sized metal plate, belonging to the technical field of rapid heating and forming of the large-sized metal plate, wherein the large-sized metal plate means that the length of the metal plate is not less than 2 m. The device solves the problem of overlarge temperature difference in the self-resistance heating process of the large-sized metal plate, and can meet the requirements of hot forming or heat treatment of a local area of the large-sized metal plate. The device is simple and flexible, can be independently used for heat treatment of the metal plate blank, can be effectively integrated with a forming system, and realizes in-situ heating forming of large-size parts, so that the problems of high heat dissipation speed, difficulty in operation and the like in the transfer process of the large-size plate blank after heating are solved, and the device has great advantages in the aspects of integration, automation and digital upgrading of equipment in the forming and heat treatment processes of large-size complex thin-wall parts.

Description

Self-resistance heating forming device and method for large metal plate
Technical Field
The invention relates to a self-resistance heating forming device and method for a large-sized metal plate, belonging to the technical field of rapid heating and forming of the large-sized metal plate, wherein the length of the large-sized metal plate is not less than 2 m.
Background
With the continuous increase of the size of aerospace vehicles, the demand on large thin-wall structural members is gradually highlighted, and a series of problems of large volume of heating equipment, difficulty in inter-process transfer and the like must be faced when the large thin-wall structural members are formed by adopting the traditional hot forming method.
The self-resistance heating technology of the metal plate directly heats the metal material by using joule heat generated by pulse current in the metal, has rapid and efficient energy conversion, and is an ideal auxiliary hot forming method. However, there are also major difficulties in self-resistance thermoforming of large sheet metal materials: firstly, due to the cumulative effect of the size increase of the metal plate in the self-resistance heating process, the small differences of the heat dissipation conditions of all parts of the plate can accumulate larger temperature differences, and if the temperature differences are not controlled, the part forming can fail; secondly, the pulse current required for realizing rapid heating and temperature maintenance of the large-scale metal plate is very large, and the output power of a single power supply cannot meet the requirement easily; in addition, hot forming or heat treatment of local areas of large metal sheets is currently difficult to achieve.
Disclosure of Invention
The technical problem solved by the invention is as follows: the method comprises the steps of firstly, controlling the size and the position of energy input in real time by using a multi-power supply cooperative power supply, multipoint temperature measurement feedback and centralized control mode, and ensuring the temperature rise of the sheet to be rapid and accurate by adopting an optimal control strategy; secondly, the shape and the size of the clamping electrode are optimally designed to ensure stable and reliable energy input; in addition, a temperature compensation device is designed in the electrode, so that the heat loss through the electrode is reduced, and the temperature uniformity of the plate in the current passing direction is improved.
The technical solution of the invention is as follows:
a self-resistance heating forming device for large metal plates comprises n temperature sensors, n direct-current pulse power supplies, 2n clamping electrodes and a control system; n is a natural number, and n is not less than 5;
the clamping electrode comprises a conductive plate, a temperature compensation plate and a base; the material of current conducting plate is red copper, and temperature compensation plate material requirement does: the electric conductivity coefficient is less than that of the large metal plate to be formed, the large metal plate to be formed is aluminum alloy, titanium alloy or high-strength steel, and when the large metal plate to be formed is aluminum alloy, the temperature compensation plate can be preferably made of stainless steel;
the 2n clamping electrodes are clamped at the top end and the bottom end of the large metal plate to be formed in pairs, and the 2n clamping electrodes are divided into n pairs and uniformly distributed at the top end and the bottom end of the large metal plate to be formed;
the n temperature sensors are uniformly distributed on the upper surface of the large metal plate to be formed (the upper surface of the large metal plate to be formed refers to a surface formed by the length and the width of the metal plate), and are positioned in the middle of each pair of clamping electrodes, namely the center of each pair of clamping electrodes and the center of one temperature sensor are positioned on the same straight line; a large metal plate to be formed is arranged above the base in each clamping electrode, a temperature compensation plate is arranged above the large metal plate to be formed, and a conductive plate is arranged above the temperature compensation plate; applying an external force above the conductive plate to ensure that the pressure intensity transmitted to the upper surface of the large metal plate to be formed after the external force passes through the temperature compensation plate is 30-50MPa, and the temperature compensation plate is tightly attached to the upper surface of the large metal plate to be formed; the temperature sensor is used for measuring the temperature of the upper surface of the large metal plate to be formed; the output end of the temperature sensor is connected with the control system;
the positive output end of the direct current pulse power supply is connected with the clamping electrode at the top end of the large metal plate to be formed in the paired clamping electrodes;
the negative output end of the direct current pulse power supply is connected with the clamping electrode at the bottom end of the large metal plate to be formed in the paired clamping electrodes;
the control input end of the direct current pulse power supply is connected with the control system;
the control system stores the target temperature T of the upper surface of the large-scale metal plate to be formed 0 The control system is used for receiving temperature data T of the upper surface of the large metal plate to be formed, which is measured by the temperature sensor, and the control system obtains a real-time output current value I according to the control strategy as the output of the direct-current pulse power supply;
the control strategy is
Figure BDA0002707533040000031
Wherein: i is the real-time output current, T 0 Is a target temperature, T is a measured temperature of the temperature sensor, I e (t) is a current reference value determined by the following method:
Figure BDA0002707533040000032
I 0 and (c) initially setting a current value, wherein I (t) is the output current value of the direct current pulse power supply recorded at the time t of the control system, and t is the recording time.
A self-resistance heating forming method for large-scale metal plates comprises the following steps:
polishing the clamping position of the upper surface of the large metal plate to be formed to remove an oxide layer on the surface, so that the primary color of the metal at the clamping position of the upper surface of the large metal plate to be formed is exposed;
placing the large metal plate to be formed obtained in the step one on a base, tightly attaching the current-conducting plate, the temperature compensation plate and the large metal plate to be formed through external force, and applying pressure, wherein the preferable pressure is 30 Mpa;
inputting the control strategy and the target temperature of each part of the large-sized metal plate into a control system;
step four, starting a direct-current pulse power supply, heating the large metal plate by the direct-current pulse power supply according to a control strategy, raising the temperature to a target temperature, and keeping the temperature stable;
and step five, after the temperature reaches the target temperature and is stable, carrying out forming or heat treatment operation on the large metal plate.
Compared with the prior art, the invention has the beneficial effects that:
(1) the invention aims at the high-efficiency heating of large-size metal plates, the electric energy can be fully utilized by heating the metal plates by the Joule heat effect of the current passing through the metal, and compared with the traditional radiation type heating or contact type heating, the heat transfer efficiency can be greatly improved, so that the heating rate and the energy utilization rate are very high, the use of a large-size heating furnace can be effectively reduced, and the energy waste is reduced.
(2) The device is simple and flexible, can be independently used for heat treatment of the metal plate blank, can be effectively integrated with a forming system, and realizes in-situ heating forming of the large-size part, so that the problems of quick heat dissipation, difficult operation and the like in the transfer process of the large-size plate blank after heating are solved, and the device has great advantages in the aspects of integration, automation and digital upgrading of equipment in the forming and heat treatment processes of the large-size complex thin-wall part.
(3) The invention effectively solves the problems of uneven temperature and incapability of controlling the heating temperature in different areas in the process of electrifying and heating the large-scale metal plate. When the plate is heated, the required temperature of each part of the plate is set through a control system, and a control strategy is input; the control system starts each direct current pulse power supply to output current, the current is input into the plate from the clamping electrode, joule heat generated by the current heats the plate and the temperature compensation plate simultaneously, and because the resistance of the temperature compensation plate is greater than that of the plate, part of the generated heat is dispersed into the conductive plate, and the other part of the generated heat raises the temperature of the plate to reduce the heat loss of the plate, thereby ensuring the temperature uniformity of the plate in the current passing direction; meanwhile, energy input at each part of the plate in the direction perpendicular to the current is accurately controlled in a multi-power supply and multi-electrode dynamic heating mode; the temperature of each part can be compared in real time by arranging a plurality of temperature measuring points, the temperature difference is used as the input of a control strategy, the output power of each pulse power supply is adjusted according to a preset strategy, and finally the high-efficiency, partition and dynamic temperature control of the plate blank is realized.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the invention without limiting the invention. In the drawings:
FIG. 1 is a schematic diagram of the basic components of the present invention;
FIG. 2 is a schematic view of a clamping electrode assembly according to the present invention;
FIG. 3 is a partial schematic view of the present invention.
Detailed Description
Embodiments of the method are described in detail below with reference to fig. 1, 2 and 3.
The heating device adopted in the embodiment is shown in fig. 1, and mainly comprises a clamping electrode 1, an infrared temperature measuring probe 2, a plate 3, a pulse power supply 4 and a control system 5;
the clamping electrode 1 is schematically composed as shown in fig. 2, and mainly includes a conductive plate 6, a temperature compensation plate 7 and a base 8. In operation, the sheet metal blanks are clamped to the sheet metal blanks 3 and are each connected in pairs to a separate pulse current source 4 for the introduction of pulse currents into the sheet metal blanks 3.
And the infrared temperature measuring probes 2 are respectively arranged right above each pair of clamping electrodes 1, are used for measuring the temperature distribution condition of the plate blank 3 in real time and send the temperature distribution condition to the control system 5.
The sheet 3 is a metal sheet or part to be formed or heat treated.
And the pulse power supply 4 is used for outputting pulse current, and the output power is controlled by the control system 5.
And the control system 5 is used for storing a target temperature and a control strategy, receiving temperature data of the infrared temperature measurement probe 2, controlling the output of the pulse power supply 4 and recording the output data of the pulse power supply 4. The preferred control strategy is as follows:
Figure BDA0002707533040000051
wherein: i is the real-time output power, T 0 Is a target temperature, T is a feedback temperature of the infrared temperature measuring probe, I e (t) is a current reference value, and the calculation method is as follows:
Figure BDA0002707533040000052
I 0 and (c) initially setting a current value, wherein I (t) is a current value recorded by the control system in real time, and t is a recording time value.
And the conductive plate 6 is used for uniformly guiding current to the temperature compensation plate.
The temperature compensation plate 7 is made of 1/2 materials with the conductivity coefficient smaller than that of the plate, and if the plate is an aluminum plate, the temperature compensation plate can be made of a stainless steel plate; the thickness of the plate is larger than that of the plate, one corner of the cross section of the plate, which is in contact with the plate, needs to be rounded, and the round angle b needs to be larger than the thickness of the plate.
And the base 8 is used for bearing the plate and is made of insulating and high-temperature-resistant materials.
The invention provides a large-scale metal plate self-resistance heating forming temperature field control method, which mainly comprises the following steps:
step one, a plate is placed on a base, the conductive plate, the temperature compensation plate and the plate are tightly attached through external force, certain pressure is applied, and the preferred pressure is 30 MPa.
Step two, the control system checks the resistance value of each circuit and judges whether the resistance value is in a reasonable range; if the resistance value of each part deviates from the reasonable range, the first step is repeated.
Inputting the heating strategy and the target temperature of the plate into a control system;
starting heating, and automatically raising the temperature of the control system to a target temperature according to a heating strategy and keeping the temperature stable;
and step five, after the temperature meets the forming requirement, loosening the clamping electrode and forming the plate.
The effect of the embodiment is as follows: the equipment can solve the problem of non-uniform self-resistance heating forming temperature field of large metal plates made of difficult-to-deform materials such as metal matrix composite materials, titanium alloys, magnesium alloys, aluminum lithium alloys and the like, and can effectively improve the forming success rate and the qualification rate of large-size products; by adopting an optimal control strategy, the output current can be adjusted in real time according to the difference value with the target temperature, and efficient and stable heating for large-size plates can be realized; the temperature compensation plate is added in the clamping electrode, so that the heat loss of the plate to the electrode is effectively prevented, and the problem of uneven temperature field distribution of the plate in the current direction is solved;
the second embodiment is as follows: the difference between this embodiment and the first embodiment is that the target temperature of the plate in this embodiment is distributed in a curve, and the local heating temperature of the large plate can be controlled according to the preferred heating strategy, so as to realize the local hot forming/heat treatment of the large plate.
Examples
Forming a 5A90 aluminum lithium alloy plate with the length of 2m, wherein the aluminum lithium alloy plate comprises 5 temperature sensors, 5 direct current pulse power supplies and 5 pairs of clamping electrodes, the 5 temperature sensors are a, b, c, d and e respectively, the 5 direct current pulse power supplies are u1, u2, u3, u4 and u5 respectively, and the 10 pairs of clamping electrodes are v1, v2, v3, v4 and v5 respectively, as shown in FIG. 3;
the conductive plate is made of red copper;
the temperature compensation plate is made of stainless steel;
the control strategy is
Figure BDA0002707533040000061
Wherein: i is the real-time output current, T 0 Is a target temperature, T is a measured temperature of the temperature sensor, I e (t) is a current reference value, and the determination method is as follows:
Figure BDA0002707533040000062
I 0 and (c) initially setting a current value, wherein I (t) is the output current value of the direct current pulse power supply recorded at the time t of the control system, and t is the recording time.
A self-resistance heating forming method for large-scale metal plates comprises the following steps:
polishing the clamping position of the upper surface of the large metal plate to be formed to remove an oxide layer on the surface, so that the primary color of the metal at the clamping position of the upper surface of the large metal plate to be formed is exposed;
placing the large metal plate to be formed obtained in the step one on a base, tightly attaching the current-conducting plate, the temperature compensation plate and the large metal plate to be formed through external force, and applying pressure, wherein the preferable pressure is 30 Mpa;
inputting the control strategy and the target temperature of the plate to be formed into a control system, wherein the target temperature T is obtained in the step 0 Initial set current I at 360 DEG C 0 =3000A;
Step four, starting a direct-current pulse power supply, heating the plate to be formed by the direct-current pulse power supply according to a control strategy, raising the temperature to a target temperature, keeping the temperature for 20min after the temperature is stable, and carrying out solution treatment on the plate;
and fifthly, loosening the clamping electrode and forming the large metal plate to be formed.
Adjusting the position of the electrode, re-clamping the formed part, tightly attaching the conductive plate and the temperature compensation plate to the formed part through external force, and applying pressure, wherein the preferable pressure is 30 Mpa;
step seven, inputting the control strategy and the target temperature of the plate to be formed into a control system, wherein the target temperature T is 0 160 ℃, initial set current I 0 =1000A;
Step eight, starting a direct-current pulse power supply, heating the formed part by the direct-current pulse power supply according to a control strategy, raising the temperature to a target temperature, keeping the temperature for 8 hours after the temperature is stable, and carrying out aging treatment on the part;
the obtained part is subjected to dimensional precision measurement and sampling for room-temperature unidirectional tensile test, the precision of the part profile is better than +/-0.2 mm, the tensile strength of the sampling part is better than 490MPa, and the yield strength is better than 300 MPa. According to the test result, the device and the method can be used for efficiently and precisely forming the large-size metal thin-wall part, so that the production field and equipment are saved, and the problem of forming failure caused by overlarge temperature difference due to the scale effect in the self-resistance heating process of the large-size metal plate is effectively solved.

Claims (9)

1. A self-resistance heating forming device for large metal plates is characterized in that: the self-resistance heating forming device comprises n temperature sensors, n direct current pulse power supplies, 2n clamping electrodes and a control system; n is a natural number;
the clamping electrode comprises a conductive plate, a temperature compensation plate and a base;
the 2n clamping electrodes are divided into n pairs and are uniformly clamped at the top end and the bottom end of the large metal plate to be formed in pairs;
the n temperature sensors are uniformly distributed on the upper surface of the large metal plate to be formed and are positioned in the middle of each pair of clamping electrodes, the large metal plate to be formed is arranged above the base in each clamping electrode, the temperature compensation plate is arranged above the large metal plate to be formed, and the current conducting plate is arranged above the temperature compensation plate;
the temperature sensor is used for measuring the temperature of the upper surface of the large metal plate to be formed;
the output end of the temperature sensor is connected with the control system;
the positive output end of the direct current pulse power supply is connected with the clamping electrode at the top end of the large metal plate to be formed in the paired clamping electrodes;
the negative electrode output end of the direct current pulse power supply is connected with the clamping electrode at the bottom end of the large metal plate to be formed in the paired clamping electrodes;
the control input end of the direct current pulse power supply is connected with the control system;
the control system stores the target temperature T of the upper surface of the large-scale metal plate to be formed 0 The control system is used for receiving temperature data T of the upper surface of the large metal plate to be formed, which is measured by the temperature sensor, and the control system obtains a real-time output current value I according to the control strategy as the output of the direct-current pulse power supply;
the control strategy is
Figure FDA0003677322930000011
Wherein: i is the real-time output current, T 0 Is a target temperature, T is a measured temperature of the temperature sensor, I e (t) is a current reference value determined by the following method:
Figure FDA0003677322930000012
I 0 initial set Current value, I (t)The output current value of the direct current pulse power supply recorded at the time t of the control system is recorded, and t is the recording time.
2. The large-sized metal plate self-resistance thermoforming device as claimed in claim 1, wherein: n is not less than 5.
3. The large-sized metal plate self-resistance thermoforming device as claimed in claim 1, wherein: the conductive plate is made of red copper.
4. The large-sized metal plate self-resistance thermoforming device as claimed in claim 1, wherein: the temperature compensation plate has the following requirements: the electrical conductivity is less than that of the large metal sheet to be formed.
5. The large-sized metal plate self-resistance thermoforming device as claimed in claim 4, wherein: the large metal plate to be formed is aluminum alloy, titanium alloy or high-strength steel.
6. The large-sized metal plate self-resistance thermoforming device as claimed in claim 5, wherein: the large metal plate to be formed is aluminum alloy, and the temperature compensation plate is made of stainless steel.
7. The large-sized metal plate self-resistance thermoforming device as claimed in claim 1, wherein: and applying external force above the conductive plate to enable the temperature compensation plate to be tightly attached to the upper surface of the large metal plate to be formed.
8. The large-sized metal plate self-resistance thermoforming device as claimed in claim 7, wherein: the pressure intensity of the external force transmitted to the upper surface of the large-scale metal plate to be formed after passing through the temperature compensation plate is 30-50 MPa.
9. A large-sized metal plate self-resistance heating forming method using the large-sized metal plate self-resistance heating forming device according to any one of claims 1 to 8, characterized by comprising the steps of:
polishing the clamping position of the upper surface of the large metal plate to be formed to remove an oxide layer on the surface, so that the primary color of the metal at the clamping position of the upper surface of the large metal plate to be formed is exposed;
placing the large metal plate to be formed obtained in the step one on a base, and tightly attaching the current conducting plate, the temperature compensation plate and the large metal plate to be formed through external force;
inputting the control strategy and the target temperature of each part of the large-scale metal plate to be formed into a control system;
step four, starting a direct-current pulse power supply, heating the large metal plate to be formed by the direct-current pulse power supply according to a control strategy, raising the temperature to a target temperature, and keeping the temperature stable;
and fifthly, after the temperature reaches the target temperature and is stable, carrying out forming or heat treatment operation on the large metal plate to be formed.
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CN113000667B (en) * 2021-03-12 2022-06-03 上海交通大学 Electric-assisted superplastic forming and aging treatment full-flow manufacturing method for aluminum-lithium alloy thin-wall component
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