CN112440081A - Integrally formed large-scale product and manufacturing method thereof - Google Patents
Integrally formed large-scale product and manufacturing method thereof Download PDFInfo
- Publication number
- CN112440081A CN112440081A CN202011339551.2A CN202011339551A CN112440081A CN 112440081 A CN112440081 A CN 112440081A CN 202011339551 A CN202011339551 A CN 202011339551A CN 112440081 A CN112440081 A CN 112440081A
- Authority
- CN
- China
- Prior art keywords
- foam
- rectangular
- product
- beams
- integrally formed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q3/00—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine
- B23Q3/02—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine for mounting on a work-table, tool-slide, or analogous part
- B23Q3/06—Work-clamping means
Abstract
The invention relates to an integrally formed large-scale product and a manufacturing method thereof, wherein the product comprises the following components: the beam comprises a lower skin, foam outside the beam, foam inside the beam, a metal block, a beam shaped like a Chinese character 'ji', a rectangular beam, a connecting sheet and an upper skin; the upper skin, the lower skin and the rectangular beam are made into the outer surface of the product, and criss-cross crossed beams are arranged inside the product; a plurality of rectangular beams form a frame, and the rectangular beams are connected by connecting sheets; the foam outside the beam and the foam inside the beam are provided with a n-shaped beam groove, and after the foam outside the beam and the foam inside the beam are attached, the n-shaped beam groove is embedded with a n-shaped beam; and the foam outside the beam and the foam inside the beam are both provided with metal block grooves, and the metal blocks are fixed in the metal block grooves. The forming die of the product has a simple structure; the rectangular beam is formed independently, so that the integral strength of the product is ensured; the one-time molding of the large-scale product improves the production efficiency and the product quality of the product; the use of laser projection can improve the product size machining precision and improve the machining efficiency.
Description
Technical Field
The invention relates to a large product and a manufacturing method thereof, in particular to an integrally formed large product and a manufacturing method thereof, wherein a forming die of the product has the advantages of simple structure, low manufacturing cost, high die machining efficiency, overlapping use of a tool and laser projection, and capability of improving the size machining precision and the machining efficiency of the large product.
Background
With the development of the rail transit industry, the light weight of the train becomes an important development direction. With the increasing application rate of composite materials on trains, in order to meet the strength design requirement, the integral one-step forming of members such as floors becomes a research hotspot and direction. The invention can well solve the problems and difficulties of low processing precision, high processing equipment requirement, high molding equipment requirement, complex processing technology, low processing efficiency and the like of large products.
Disclosure of Invention
In view of the above problems, the present invention provides an integrally formed large product and a manufacturing method thereof, wherein the product forming mold has a simple structure, a low manufacturing cost, a high mold processing efficiency, and a tool and a laser projection are used in a superposition manner, so that the size processing precision and the processing efficiency of the large product can be improved.
The invention solves the technical problems through the following technical scheme: an integrally formed large product comprising: the beam comprises a lower skin, foam outside the beam, foam inside the beam, a metal block, a beam shaped like a Chinese character 'ji', a rectangular beam, a connecting sheet and an upper skin; the upper skin, the lower skin and the rectangular beam are made into the outer surface of the product, and criss-cross crossed beams are arranged inside the product;
a plurality of rectangular beams form a frame, and the rectangular beams are connected by connecting sheets; the foam outside the beam and the foam inside the beam are provided with a n-shaped beam groove, and after the foam outside the beam and the foam inside the beam are attached, the n-shaped beam groove is embedded with a n-shaped beam; and the foam outside the beam and the foam inside the beam are both provided with metal block grooves, and the metal blocks are fixed in the metal block grooves.
In a specific implementation example of the invention, the connecting pieces are a plurality of connecting pieces in flat plate shapes and L shapes, and the flat plate shapes are connected with two rectangular beams on the same straight line; the "L" shape connects two rectangular beams arranged vertically.
In an embodiment of the present invention, the connecting sheet made of the connecting sheet carbon fiber material has a thickness range of: 3-5 mm.
In the specific implementation example of the invention, the rectangular beam is of a hollow structure inside, and two ends of the rectangular beam are tightly sealed by flat plates.
In a specific embodiment of the invention, the thickness of the plate is in the range of 0.8-1.5 mm.
In the embodiment of the invention, before the metal block is placed in the groove of the metal block, a layer of sheet rubber for ensuring the connection strength of the metal block and the foam is coated on the surface of the metal block.
In an embodiment of the present invention, the extrabeam foam and the intrabeam foam are both Polymethacrylimide (PMI) foams having a density of 75kg/m3And the outer beam foam and the inner beam foam are provided with through holes with the diameter of 2-5mm in the area of 40-60 mm, so that the resin can smoothly flow in the product.
A manufacturing method of an integrally formed large product comprises the following steps:
step (1), paving and pasting a lower skin;
step (2), paving and forming a rectangular beam;
step (3), paving and forming connecting sheets;
step (4), assembling the rectangular beams;
step (5), placing the foam and the metal piece in the beam for positioning;
step (6), paving and pasting a rectangular beam;
step (7), installing the foam outside the beam and polishing the foam to be smooth;
step (8), paving and pasting an upper skin;
step (9), after resin is poured, vacuumizing and integrally forming;
and (10) processing a threaded hole interface by using a forming die, a processing tool and laser projection.
In the embodiment of the invention, when two rectangular beams are spliced, the four peripheral surfaces are firstly bonded by structural adhesive by connecting sheets and then fixed by rivets.
In the concrete implementation example of the invention, when the longitudinal inverted V-shaped beams are laid and pasted, the longitudinal inverted V-shaped beams are firstly laid and are in lap joint with the outer frame of the rectangular beam in the length of 50-100mm, and then the transverse inverted V-shaped beams are laid and pasted to be firmly lap joint with the longitudinal beams and the rectangular beam.
The positive progress effects of the invention are as follows: the integrally formed large-scale product and the manufacturing method thereof provided by the invention have the following advantages: (1) the forming die of the product has simple structure, low manufacturing cost and high die processing efficiency;
(2) the rectangular beam is formed independently, so that the integral strength of the product is ensured;
(3) the production efficiency and the product quality of the large-scale product are improved by one-step molding of the large-scale product;
(4) the tool and the laser projection are overlapped for use, so that the size processing precision of large products can be improved, and the processing efficiency can be improved.
Drawings
FIG. 1 is a schematic structural diagram of the present invention.
The following are the names corresponding to the reference numbers in the invention:
the structure comprises a lower skin 1, outer beam foam 2, inner beam foam 3, a metal block 4, a beam 5 shaped like a Chinese character 'ji', a rectangular beam 6, a connecting sheet 7 and an upper skin 8.
Detailed Description
The following provides a detailed description of the preferred embodiments of the present invention with reference to the accompanying drawings. Fig. 1 is a schematic structural diagram of the present invention, as shown in the above figures: the integrally formed large-sized product provided by the invention comprises: the structure comprises a lower skin 1, outer beam foam 2, inner beam foam 3, a metal block 4, a beam 5 shaped like a Chinese character 'ji', a rectangular beam 6, a connecting sheet 7 and an upper skin 8.
The upper skin 8, the lower skin 1 and the rectangular beam 6 are made into the outer surface of the product, and criss-cross inverted V-shaped beams 5 are arranged inside the product. A plurality of rectangular beams 6 form a frame, and the rectangular beams 6 are connected by connecting sheets 7; be provided with a few word roof beam recesses on foam 2 outside the roof beam and the roof beam in the foam 3, the foam 2 outside the roof beam and the 3 laminating backs of foam in the roof beam, a few word roof beam recesses are embedded to have a few word roof beams 5, all are provided with the metal block recess on foam 2 outside the roof beam and the roof beam in the foam 3, and metal block 4 is fixed in the metal block recess.
The connecting pieces 7 in the invention are a plurality of connecting pieces in flat plate shape and L shape, and the flat plate shape is connected with two rectangular beams 6 on the same straight line; the "L" shape connects two rectangular beams 6 arranged vertically.
The connecting sheet in the invention can be made of carbon fiber, and the thickness range is as follows: 3-5 mm.
The rectangular beam 6 in the invention has a hollow structure inside, and two ends are tightly sealed by flat plates. The structure prevents resin in skin forming from being poured into the rectangular beam to increase the weight of a product; the thickness of the plate is in the range of 0.8-1.5mm, preferably 1 mm.
Before the metal block 4 is placed in the groove, a layer of sheet rubber for ensuring the connection strength of the metal block 4 and the foam is wrapped on the surface of the metal block 4.
The foam 2 outside the beam and the foam 3 inside the beam are both made of Polymethacrylimide (PMI) and have the density of 75kg/m3And the outer beam foam 2 and the inner beam foam 3 are provided with through holes with the diameter of 2-5mm in the area of 40-60 mm, so that the resin can smoothly flow in the product.
The manufacturing method of the integrally formed large-scale product comprises the following steps:
step (1), paving and pasting a lower skin;
step (2), paving and forming a rectangular beam;
step (3), paving and forming connecting sheets;
step (4), assembling the rectangular beams;
step (5), placing the foam and the metal piece in the beam for positioning;
step (6), paving and pasting a rectangular beam;
step (7), installing the foam outside the beam and polishing the foam to be smooth;
step (8), paving and pasting an upper skin;
step (9), after resin is poured, vacuumizing and integrally forming;
and (10) processing a threaded hole interface by using a forming die, a processing tool and laser projection.
When the two rectangular beams 6 are spliced, the four peripheral surfaces are bonded by the connecting sheets by structural adhesive and then fixed by rivets.
When the rectangular beams are laid and pasted, the longitudinal rectangular beams are firstly laid and pasted, the 80 mm-length lap joint with the outer frame of the rectangular beam is well made, and then the transverse rectangular beams are laid and pasted, and the lap joint with the longitudinal beams and the rectangular beams is firm.
The invention has more metal blocks and types, some of the metal blocks are arranged above the foam and some of the metal blocks are arranged below the foam, and the foam is reserved with corresponding pits corresponding to the metal blocks. When the metal block is placed, laser projection is used for assisting positioning, and the correctness of the position of the metal piece is ensured. The metal block is made of aluminum alloy, and the threaded hole is machined after the metal block is formed, and then the steel wire tooth socket with the corresponding model is installed. After the rectangular beam is formed, two ends of the rectangular beam are tightly sealed by carbon sheets, or the rectangular beam is internally filled with filling materials with lower density.
Need last lower surface processing screw hole after the product shaping is accomplished, use the simple and easy frock of suggestion earlier in this time to guarantee that the hickey relative position precision of some part is within 0.2mm, and the position of simple and easy frock relies on laser projection to fix a position on the product and guarantees that the position precision is within 2 mm. Some equipment interfaces have requirements on the flatness of the installation surface, the non-mold surface of a product is uneven, glass powder and resin are required to be filled between the tool surface and the product gap, and the flatness of the installation surface is guaranteed to meet the use requirements of the product.
The following is a specific example of implementation: the upper and lower skins and the rectangular beam cover the outer surface of the product, criss-cross beams are designed inside, the inner structure and the outer structure are closely connected and overlapped, and the overall strength of the product is guaranteed by changing the structure.
The upper skin, the lower skin and the n-shaped beams are all paved and pasted by carbon fiber dry cloth, the length of a product is more than 20 meters, the width of the product is more than 3 meters, each part of the product is formed by splicing a plurality of pieces of cut dry cloth, and the dry cloth paving and pasting are very easy and quick when the curvature of the surface of each paving and pasting is changed slightly.
PMI material for inner and outer foams of beam with density of 75kg/m3All foams require a 3-diameter through hole inside the 50 x 50 area to ensure that the resin can flow smoothly inside the product.
The rectangular beam is internally of a hollow structure, the two ends of the rectangular beam are tightly sealed by using a 1mm flat plate, and resin is prevented from being poured into the rectangular beam when the skin is formed to increase the weight of a product.
The metal blocks are arranged in the inner and outer foam grooves of the beam, and a layer of glue is required to wrap the surface of the metal blocks to ensure the connection strength between the metal blocks and the foam when the metal blocks are placed. The metal blocks are more in quantity and variety, and the problem that the positions of metal pieces are misplaced or missed can be solved by using laser projection auxiliary positioning.
The connecting piece is made of carbon fiber, the thickness is designed to be 4mm, the appearance is flat and L-shaped, the connecting piece is formed by an autoclave process, and the connecting piece is high in performance stability and strength.
According to the invention, the lower skin is paved on the upper surface of the mold, and the paving boundary of a single material sheet is numbered and positioned through the laser projector, so that the paving speed and the accuracy are improved.
In the specific implementation process of the invention, a plurality of inserts are placed on the single-side forming die to position the outer edge of the product, and the rectangular beam with two sealed ends is placed to be spliced and positioned along the edges of the inserts. The connecting sheet is firstly bonded by structural adhesive at the connecting part of the rectangular beam, then the hole on the connecting sheet is matched with the hole of the rectangular beam, and 4 rivets are fixed on the single side for reinforcing connection.
In the specific implementation process of the invention, foam edges in the beam are positioned through a laser projector, the foam is placed in the beam, the beam is laid and pasted, the outer edge of the laid and pasted is aligned with a projection line, and excess materials are cut off. All the transverse and longitudinal beams and the rectangular beams are connected by at least two surfaces with the length of more than 80 mm. The top width of the longitudinal n-shaped beam is designed to be 150mm, the bottom flanging width is designed to be 80mm, the whole thickness is uniform to be 2.8mm, and the cross section size can be properly reduced when the stress of the transverse n-shaped beam is small.
In the specific implementation process of the invention, foam outside the beam is matched with the paved beam in the shape of a Chinese character 'ji', the position with interference is ground, the position with large gap is filled with thinner foam, the position is prevented from being filled with redundant resin during molding, and the volume ratio of the foam is improved on the premise of ensuring the strength, so that the weight of the product is greatly reduced.
The foregoing shows and describes the general principles and broad features of the present invention and advantages thereof. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are merely illustrative of the principles of the present invention, but that various changes and modifications may be made without departing from the spirit and scope of the invention, which is defined by the appended claims and their equivalents.
Claims (10)
1. An integrated large-scale product, which is characterized in that: the integrally formed large-sized product includes: the beam comprises a lower skin, foam outside the beam, foam inside the beam, a metal block, a beam shaped like a Chinese character 'ji', a rectangular beam, a connecting sheet and an upper skin; the upper skin, the lower skin and the rectangular beam are made into the outer surface of the product, and criss-cross crossed beams are arranged inside the product;
a plurality of rectangular beams form a frame, and the rectangular beams are connected by connecting sheets; the foam outside the beam and the foam inside the beam are provided with a n-shaped beam groove, and after the foam outside the beam and the foam inside the beam are attached, the n-shaped beam groove is embedded with a n-shaped beam; and the foam outside the beam and the foam inside the beam are both provided with metal block grooves, and the metal blocks are fixed in the metal block grooves.
2. The integrally formed large product according to claim 1, characterized in that: the connecting pieces are in the shape of a plurality of flat plates and L-shaped connecting pieces, and the flat plates are connected with two rectangular beams on the same straight line; the "L" shape connects two rectangular beams arranged vertically.
3. The integrally formed large product according to claim 2, characterized in that: the connection piece of connection piece carbon fiber material, the thickness scope is: 3-5 mm.
4. The integrally formed large product according to claim 1, characterized in that: the rectangular beam is internally of a hollow structure, and two ends of the rectangular beam are of a structure tightly sealed by flat plates.
5. The integrally formed large product according to claim 4, characterized in that: the thickness of the flat plate ranges from 0.8 mm to 1.5 mm.
6. The integrally formed large product according to claim 1, characterized in that: before the metal block is placed in the metal block groove, a layer of sheet rubber for ensuring the connection strength of the metal block and the foam is wrapped on the surface of the metal block.
7. The integrally formed large product according to claim 1, characterized in that: the foam outside the beam and the foam inside the beam are both made of polymethacrylimide, and the density is 75kg/m3And the outer beam foam and the inner beam foam are provided with through holes with the diameter of 2-5mm in the area of 40-60 mm, so that the resin can smoothly flow in the product.
8. A manufacturing method of an integrally formed large-scale product is characterized in that: the manufacturing method comprises the following steps:
step (1), paving and pasting a lower skin;
step (2), paving and forming a rectangular beam;
step (3), paving and forming connecting sheets;
step (4), assembling the rectangular beams;
step (5), placing the foam and the metal piece in the beam for positioning;
step (6), paving and pasting a rectangular beam;
step (7), installing the foam outside the beam and polishing the foam to be smooth;
step (8), paving and pasting an upper skin;
step (9), after resin is poured, vacuumizing and integrally forming;
and (10) processing a threaded hole interface by using a forming die, a processing tool and laser projection.
9. The method for manufacturing an integrally formed large product according to claim 8, wherein: when two rectangular beams are spliced, the four peripheral surfaces of the rectangular beams are bonded by the connecting sheets by structural adhesive and then fixed by rivets.
10. The method for manufacturing an integrally formed large product according to claim 8, wherein: when the inverted V-shaped beams are laid and pasted, the longitudinal inverted V-shaped beams are firstly laid and pasted, the lap joint with the rectangular beam outer frame in the length of 50-100mm is well made, and then the transverse inverted V-shaped beams are laid and pasted, and the lap joint with the longitudinal beams and the rectangular beams is firm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011339551.2A CN112440081A (en) | 2020-11-25 | 2020-11-25 | Integrally formed large-scale product and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011339551.2A CN112440081A (en) | 2020-11-25 | 2020-11-25 | Integrally formed large-scale product and manufacturing method thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN112440081A true CN112440081A (en) | 2021-03-05 |
Family
ID=74738359
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202011339551.2A Pending CN112440081A (en) | 2020-11-25 | 2020-11-25 | Integrally formed large-scale product and manufacturing method thereof |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN112440081A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114704308A (en) * | 2022-04-06 | 2022-07-05 | 常州市新创智能科技有限公司 | Composite material side protection plate and processing technology thereof |
-
2020
- 2020-11-25 CN CN202011339551.2A patent/CN112440081A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114704308A (en) * | 2022-04-06 | 2022-07-05 | 常州市新创智能科技有限公司 | Composite material side protection plate and processing technology thereof |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN101269553A (en) | Magnesium alloy cellular board and manufacturing technique | |
| CN106827557A (en) | Composite is glued reinforced structure and is glued face compensation method altogether | |
| CN106985413B (en) | A kind of forming frock for foam core filled composite material structure winglet | |
| CN107139503A (en) | The forming method of composite cylinder component partial honeycomb sandwich construction | |
| CN111070724B (en) | Integral forming method and tool for composite material U-shaped stringer wallboard | |
| CN112440081A (en) | Integrally formed large-scale product and manufacturing method thereof | |
| CN112537047A (en) | Forming and assembling method for composite material reflector | |
| CN114953506B (en) | Co-curing forming method for composite material I-shaped reinforced wallboard | |
| CN101938041B (en) | High-accuracy antenna reflecting surface panel and manufacturing method thereof | |
| CN213888920U (en) | Integrally formed large-scale product | |
| CN103612441B (en) | Composite Sandwich Plates, mould and preparation method | |
| CN107599452A (en) | A kind of combining structure technique cover plate and preparation method | |
| US6797364B2 (en) | Composite panel | |
| CN109203516A (en) | A kind of manufacturing method of wind electricity blade | |
| CN111923443A (en) | Wind power blade and forming method thereof | |
| CN112537050A (en) | Manufacturing method of wind power blade main beam | |
| CN115822867A (en) | Modularized wind power blade structure and manufacturing method thereof | |
| CN109291465B (en) | Forming method of metal panel sandwich structure product | |
| CN110587868B (en) | Method for manufacturing vertical edge of main beam mold | |
| CN203957426U (en) | Spliced large scale stretching aramid fiber cellular board | |
| CN207128300U (en) | Mould for the I-shaped web of blade | |
| CN212920524U (en) | Wind power blade | |
| CN210911223U (en) | Auxiliary die device for blade web | |
| CN114228199B (en) | Wing skin forming tool and forming method | |
| CN215943515U (en) | Special-shaped top cover laminating foaming tool |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |