CN112808849A - Double-sided flexible force control and auxiliary heating forming equipment and method - Google Patents
Double-sided flexible force control and auxiliary heating forming equipment and method Download PDFInfo
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- CN112808849A CN112808849A CN202011328067.XA CN202011328067A CN112808849A CN 112808849 A CN112808849 A CN 112808849A CN 202011328067 A CN202011328067 A CN 202011328067A CN 112808849 A CN112808849 A CN 112808849A
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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
- B21D31/00—Other methods for working sheet metal, metal tubes, metal profiles
- B21D31/005—Incremental shaping or bending, e.g. stepwise moving a shaping tool along the surface of the workpiece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
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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
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/16—Heating or cooling
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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
- B21D43/00—Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
- B21D43/003—Positioning devices
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Abstract
The invention provides a double-sided flexible force control and auxiliary heating forming device and a method, wherein the double-sided flexible force control and auxiliary heating forming device comprises a fixed rack, a pressure forming device, an electric heating device, a fixed clamp and a control device, the pressure forming device comprises two mechanical arms and a force detection device, the first end of each mechanical arm can be rotatably connected with the fixed rack, and the second end of each mechanical arm is connected with a cutter; the electric heating device is provided with a positive electrode connecting end and a negative electrode connecting end, and the positive electrode connecting end and the negative electrode connecting end are respectively connected with the two cutters; the fixed clamp is connected to the fixed rack and can limit the sheet metal between the two mechanical arms in a vertical state; the control device is electrically connected with the pressing forming device and the electric heating device and can control the action of the pressing forming device and adjust the heating temperature of the electric heating device. The invention can reduce the defects and flaws in the sheet metal forming process and improve the processing quality and efficiency.
Description
Technical Field
The invention relates to the technical field of sheet metal processing and forming, in particular to double-sided flexible force control and auxiliary heating forming equipment and a surface flexible force control and auxiliary heating forming method.
Background
In the prior art, the production of small series of sheet metal prototypes or parts is commonly performed using a stamping process. However, such a process is not economical due to the high cost of developing suitable molds and the long time to produce the molds. The traditional stamping and forming process needs larger equipment (a punch) to realize the forming process when producing large parts, and the use of the larger equipment needs to occupy larger factory space to store the required equipment, so that the cost is high and visible.
On the other hand, the requirements of different industries on the weight reduction and the customization of products are on the obvious rising trend, and the requirements on the sheet metal parts with complex forming are also increased. Because traditional stamping process often needs a plurality of steps when some complicated parts are formed, produce the cooperation that a part just needs many punch presses and whole strip production line, shared space and high cost do not in fact vary a little, moreover because can not accurately control local deformation stress, plastic deformation stress does not distribute on the panel beating uniformly, in addition residual stress's problem, the problem that the fracture appears in the panel beating is serious, leads to the shaping quality of panel beating not good.
While coordinating the quality and complexity of sheet metal forming, conventional stamping techniques limit the possibility of producing geometrically complex parts. Even if this drawback can be compensated for in the design of the production process, the time and cost of development are generally quite significant. To survive in intense market competition, several factors are crucial to create product uniqueness, shorten product development cycles, and reduce production costs. In some industries, such as automobiles, airplanes, and buildings, the size of the molds used is generally very large, the structures of the molds are also very complex, and the cost for storing and managing the molds is very expensive. Although the emerging three-dimensional metal printing technology is a process suitable for rapidly producing various complex hollow parts in small batches and has a good prospect, the existing three-dimensional printing machine is not suitable for producing sheet metal parts because the working platform is small, the material selection is limited, the cost of raw materials (metal powder) is high, and the workload of post-treatment processes (such as removing a supporting structure and polishing a surface) is large.
The mechanical local metal plate deformation forming technology is one kind of machining process for prototype manufacture and small batch production. In this process, a tool progressively deforms the sheet metal along a predetermined path into a desired shape. The process is characterized in that: at any time, only a small portion of the product is being formed. In other words, it is a process of local deformation. The mechanical local metal plate deformation forming technology can be divided into two types, one type is single-point mechanical local metal plate deformation forming, namely, a single-needle cutter is used for pressing and deforming one side of a metal plate; the other method is mechanical local sheet metal deformation forming based on a mold, wherein the mold is arranged below a metal plate, and a cutter is used for pressing the upper part of the metal plate to form the metal plate on the mold. However, both existing processes have their own disadvantages. Single point progressive forming lacks a supporting die structure, resulting in poor dimensional accuracy of formed parts, while mechanical local sheet metal deformation forming based on a die increases the cost of manufacturing the die and the time of die production. In addition, both processes are usually implemented in a three-coordinate numerical control machine, which limits the requirement of versatility and complexity of the geometric design of the parts.
However, the mechanical local sheet metal deformation forming technique is difficult to form a metal material having a high thickness. Sheet metal of high thickness requires more deformation pressure to be formed, but the difficulty with this technique is that the force applied by the mechanical part is limited.
Disclosure of Invention
One object of the present invention is to provide a double-sided flexible force-controlled and assisted heat forming apparatus that reduces defects and flaws that occur during sheet metal forming.
Another object of the present invention is to provide a double-sided flexible force-controlled and assisted thermoforming method that improves the quality and efficiency of the process.
In order to achieve the above object, the present invention provides a double-sided flexible force control and auxiliary heating forming apparatus, comprising:
fixing the frame;
the pressing forming device comprises a force detection device and two opposite mechanical arms arranged at intervals, wherein the first end of each mechanical arm is rotatably connected with the fixed rack, the second end of each mechanical arm is connected with a cutter, and the force detection device is used for detecting the force application magnitude of the cutter;
the electric heating device is provided with a positive electrode connecting end and a negative electrode connecting end, and the positive electrode connecting end and the negative electrode connecting end are respectively connected with the two cutters;
the fixed clamp is connected to the fixed rack and positioned between the two mechanical arms, and the fixed clamp can limit the sheet metal between the two mechanical arms in a vertical state;
and the control device is electrically connected with the pressure forming device and the electric heating device, can adjust the pressure applying force of the two mechanical arms according to the detection result of the force detection device, and can adjust the heating temperature of the electric heating device.
The double-sided flexible force control and auxiliary heating forming equipment comprises a first mechanical arm, a second mechanical arm, a force detection device and a control device, wherein the force detection device is connected to the second end of one of the two mechanical arms.
The double-sided flexible force control and auxiliary heating forming equipment comprises a pressing forming device, a control device and a pressure forming device, wherein the pressure forming device is connected with the control device, and the pressure forming device is connected with the control device.
The double-sided flexible force control and auxiliary heating forming equipment comprises a mechanical arm, a cutter, a force adjusting device, a control device and a power control device, wherein the cutter is connected with the mechanical arm through the force adjusting device, the force adjusting device is electrically connected with the control device, and the control device can control the action of the force adjusting device.
The double-sided flexible force control and auxiliary heating forming equipment comprises a control device, wherein the control device is provided with an operation panel.
The invention also provides a double-sided flexible force control and auxiliary heating forming method, which adopts the double-sided flexible force control and auxiliary heating forming equipment, and comprises the following steps:
the controller obtains the running paths of the two cutters of the double-sided flexible force control and auxiliary heating forming equipment according to the 3D model of the target shape;
the controller adjusts the pressure applying force of the two mechanical arms of the double-sided flexible force control and auxiliary heating forming equipment according to the material thickness and the shape of the plate to be processed;
the controller adjusts the heating temperature of the electric heating device of the double-sided flexible force control and auxiliary heating forming equipment according to the material of the sheet metal to be processed;
and the controller drives the two mechanical arms of the double-sided flexible force control and auxiliary heating forming equipment to synchronously move according to the acquired running path and the set running speed.
The double-sided flexible force control and auxiliary heating forming method as described above, wherein when a temperature sensor is connected to the pressing and forming device of the double-sided flexible force control and auxiliary heating forming apparatus, the double-sided flexible force control and auxiliary heating forming method further includes:
and the controller adjusts the heating temperature of the electric heating device according to the feedback signal of the temperature sensor.
According to the double-sided flexible force control and auxiliary heating forming method, the controller is provided with an alarm, and when a feedback signal of the temperature sensor is larger than a first preset value, the controller controls the alarm to give an alarm;
and when the feedback signal of the temperature sensor is greater than a second preset value, the controller controls the two mechanical arms to stop moving.
The double-sided flexible force control and auxiliary heating forming method as described above, wherein when the pressing forming device of the double-sided flexible force control and auxiliary heating forming apparatus is connected with the force detecting device, the double-sided flexible force control and auxiliary heating forming method further includes:
and the controller judges the moving direction of the cutter according to the feedback signal of the force detection device.
The double-sided flexible force control and auxiliary heating forming method comprises the following steps that when the cutter is connected with the mechanical arm through a force adjusting device, the double-sided flexible force control and auxiliary heating forming method further comprises the following steps:
and the controller controls the force adjusting device to drive the cutter to move towards or away from the sheet metal according to the feedback signal of the force detecting device.
Compared with the prior art, the invention has the following advantages:
the double-sided flexible force control and auxiliary heating forming equipment and the method can keep twelve shafts of two mechanical arms to move simultaneously by controlling the action of the pressure forming device through the control device, thereby realizing the processing of the undercut and deep taper characteristics, and can directly form;
according to the double-sided flexible force control and auxiliary heating forming equipment and method, the plate is pressed and processed by the two cutters at the same time, so that the dimensional accuracy of a formed part is superior to that of the traditional single-point incremental forming;
the double-sided flexible force control and auxiliary heating forming equipment and the method of the invention have the advantages that the sheet metal is instantaneously heated by the electric heating device, the dislocation of atoms in the microstructure of the sheet metal material can be promoted by the current to generate the electro-plasticity, so that the deformation force is reduced, the plastic deformation is increased, the residual stress and the forming load of the material are reduced, the yield strength of the sheet metal is reduced, namely the force applied by forming is reduced, the expected deformation effect is more easily generated, the accuracy of controlling the size of the sheet metal is improved, and the defects and flaws in the forming process of the sheet metal are reduced
The double-sided flexible force control and auxiliary heating forming equipment and the method can overcome the defects of the traditional stamping process, namely, the mould with high production cost in large batch and high cost, can deal with complex shapes, and realize the processing of the characteristics of the undercut and the deep cone through the combined action of the control device, the force detection device, the force adjusting device, the electric heating device and the temperature sensor, thereby efficiently realizing the light weight and customized production, realizing the unique shape design of metal parts, and having the characteristics of excellent quality of processed products, high efficiency and easy realization of vivid characteristics.
Drawings
The drawings are only for purposes of illustrating and explaining the present invention and are not to be construed as limiting the scope of the present invention. Wherein:
FIG. 1 is a schematic structural view of a double-sided flexible force-controlled and assisted thermoforming apparatus of the present invention;
FIG. 2 is a schematic view of a first installation structure of the pressing and forming device, the force detecting device and the force adjusting device;
FIG. 3 is a schematic view of a second installation structure of the pressing forming device, the force detecting device and the force adjusting device
FIG. 4 is a flow chart of the double-sided flexible force-controlled and assisted thermoforming method of the present invention;
FIG. 5 is another flow chart of the double-sided flexible force-controlled and assisted thermoforming method of the present invention;
FIG. 6 is a diagram of a relationship between two tools;
fig. 7 is a control schematic of the controller.
The reference numbers illustrate:
1. fixing the frame;
2. a pressure forming device; 21. a mechanical arm; 22. a cutter;
3. an electric heating device; 31. a positive electrode connecting end; 32. a negative electrode connecting end;
4. fixing the clamp;
5. a temperature sensor;
6. a force detection device;
7. a force adjusting device;
8. a control device;
10. and (5) sheet metal.
Detailed Description
In order to clearly understand the technical solution, the purpose and the effect of the present invention, a detailed description of the present invention will be described with reference to the accompanying drawings. Where the adjective or adverbial modifiers "center," "horizontal," and "vertical" are used merely to facilitate relative reference between groups of terms, and do not describe any particular directional limitation on the modified terms. Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated, whereby a feature defined as "first", "second", etc. may explicitly or implicitly include one or more of such features.
Implementation mode one
As shown in fig. 1, the present invention provides a double-sided flexible force control and auxiliary heating forming apparatus, which comprises a fixed frame 1, a pressing forming device 2, an electric heating device 3, a fixed clamp 4 and a control device 8, wherein:
the fixed rack 1 is flat, the bottom surface of the fixed rack 1 is provided with a cushion block, and the cushion block can enable the fixed rack 1 to be stably placed on the ground or a table top;
the pressure forming device 2 comprises two opposite mechanical arms 21 and a force detection device 6 which are arranged at intervals, wherein a first end of each mechanical arm 21 can be rotatably connected with the fixed rack 1, a second end of each mechanical arm 21 is connected with a cutter 22, the mechanical arms 21 can drive the cutters 22 to move relative to the fixed rack 1, because the pressure applied by deformation is regional deformation in the traditional sheet metal forming process, the strain force in the microstructure of the sheet metal is unevenly concentrated on a shearing band, most of the fracture can occur at the middle position of the pressure applied by the sheet metal, the two cutters 22 of the pressure forming device can simultaneously press two sides of a sheet metal, one of the two cutters 22 is a main cutter which is used for applying force, the other cutter is an auxiliary cutter which is used for supporting the applied force, and the local deformation can be rapidly and stably carried out at the contact area between the cutter 22 and the sheet metal 10, therefore, the traditional larger deformation is evenly distributed on the whole sheet metal 10, so that the plate is deformed to form a required shape, unnecessary bending at the forming edge position of the sheet metal 10 is reduced, defects and flaws in the forming process are reduced, the size precision of a formed part is further improved, the plasticity and the complexity of the material are improved, and the force detection device 6 can detect the magnitude of the force applied by the cutter 22 so as to adjust the force applied by the pressure forming device 2 in real time;
the electric heating device 3 is provided with an anode connecting end 31 and a cathode connecting end 32, the anode connecting end 31 and the cathode connecting end 32 are respectively connected with the two cutters 22, the electric heating device 3 can enable current to pass through a contact point of the sheet metal 10 and the cutters 22, so that the sheet metal 10 can generate heat instantly, the physical properties of the material of the sheet metal 10 are changed locally, the sheet metal 10 is softened, and expected deformation effects can be generated more easily;
the fixed clamp 4 is connected to the fixed rack 1 and located between the two mechanical arms 21, namely the two mechanical arms 21 are respectively located at two sides of the fixed clamp 4, the fixed clamp 4 can limit the sheet metal 10 between the two mechanical arms 21 in a vertical state, namely the sheet metal 10 can be clamped on the fixed clamp 4 in a vertical state, and the sheet metal 10 is limited between the two mechanical arms 21 through the fixed clamp 4;
the control device 8 is electrically connected with the pressure forming device 2 and the electric heating device 3, the control device 8 can control the pressure applying force of the two mechanical arms 21 according to the detection result of the force detection device 6, and the control device 8 can adjust the heating temperature of the electric heating device 3, specifically, the control device 8 can control the motion tracks of the two mechanical arms 21, keep the synchronization of twelve shafts (the twelve shafts are the X shaft, the Y shaft, the Z shaft of the two mechanical arms, the A shaft rotating around the X shaft, the B shaft rotating around the Y shaft and the C shaft rotating around the Z shaft), the control device 8 can judge the adjustment direction of the cutter 22 according to the feedback of the force detection device 6, the force detection device 6 can detect the force from several newtons (N) to one thousand newtons (N), when the difference between the actual force and the preset force is positive, namely the actual force is greater than the set force, the contact force at the moment is over large, the control device 8 judges and drives the mechanical arm 21 to drive the cutter 22 to move in a direction away from the sheet metal 10 or increase the feeding speed so as to change the contact force at the moment and reduce the pressure between the cutter 22 and the sheet material; when the difference between the actual force and the preset force is negative, that is, the actual force is smaller than the preset force, which indicates that the contact force is too small, the control device 8 judges and drives the mechanical arm 21 to drive the cutter 22 to move towards the direction close to the sheet metal 10 or reduce the feeding speed, so as to change the contact force at the moment and increase the pressure between the cutter and the sheet material; the adjustment is repeatedly, quickly and high-frequency carried out in the whole movement process, so that the detection force can reach or approach a preset value, and the stability and the adjustability of the contact force between the workpiece and the tool are ensured; the control device 8 can adjust the heating temperature of the electric heating device 3 according to the material of the sheet metal 10, so that the electric heating device 3 can heat different materials.
It should be noted that, the tool 22 is driven to move by the motion track of the mechanical arm 21 itself to achieve the purpose of adjusting the force, and in order to ensure the accuracy of adjusting the force application, the following conditions should be satisfied:
firstly, the control device 8 has rich programming functions and can allow real-time modification on the set motion track of the mechanical arm 21;
secondly, the difference between the feedback value of the force detection device 6 and the preset force is small, so as to avoid the situation that if the required adjustment amount of the current processing point is large, the target adjustment amount may not be reached due to the limitation of the response speed of the mechanical arm 21 (namely the highest speed of the mechanical arm 21), and the position precision of the next processing point is affected by the large adjustment amount of the processing point, and when the adjustment amount of the next processing point is opposite to the adjustment amount direction of the current processing point, the force adjustment effect is difficult to ensure;
thirdly, heating is not started or heating time is slightly increased so as to avoid damaging the plate.
The tool 22 is driven to move by the motion track of the mechanical arm 21 to achieve a force adjusting mode, so that the whole structure of the double-sided flexible force control and auxiliary heating forming equipment is simple and low in cost.
The double-sided flexible force control and auxiliary heating forming equipment disclosed by the invention has the advantages that the action of the pressure forming device 2 is controlled by the control device 8, the twelve shafts of the two mechanical arms 21 can be kept to move synchronously, so that the machining of the undercut and deep taper characteristics is realized, the direct forming is realized, the light application is enabled to realize stronger design property through a manufacturing method for enhancing the forming property and the flexibility, the machining of metal parts with unique design is realized, and the double-sided flexible force control and auxiliary heating forming equipment is particularly suitable for prototype manufacturing and small-batch production; the sheet metal 10 is pressed and processed by the two cutters 22, so that the dimensional accuracy of a formed piece is superior to that of the traditional single-point progressive forming; the electric heating device 3 can make the sheet metal 10 instantaneously generate heat, and the current can promote the dislocation of atoms in the microstructure of the sheet metal 10 material to generate electric plasticity, thereby reducing the deformation force, increasing the plastic deformation, reducing the residual stress and the forming load of the material, reducing the yield strength of the sheet metal 10, namely reducing the force applied by forming, more easily generating the expected deformation effect, improving the accuracy of controlling the size of the sheet metal 10, and reducing the defects and flaws generated in the forming process of the sheet metal 10.
Further, as shown in fig. 1, the press forming device 2 is further connected to a temperature sensor 5 for detecting a temperature of the sheet metal 10, specifically, the temperature sensor 5 is an infrared temperature sensor, the infrared temperature sensor is connected to one of the two mechanical arms 21, the infrared temperature sensor can detect a real-time temperature of a contact point between a cutter and a sheet metal on the sheet metal 10, and the control device 8 can adjust a current output by the electric heating device 3 in real time according to the detected temperature of the infrared temperature sensor 5, so as to ensure that the current output by the electric heating device 3 can meet requirements of materials of different sheet metals 10.
Further, as shown in fig. 1 and 2, the force detection device 6 is connected to the second end of one of the two mechanical arms 21, so that the detection result is more accurate.
Still further, the tool 22 is connected with the mechanical arm 21 through the force adjusting device 7, the force adjusting device 7 can push the tool 22 to move towards or away from the sheet metal 10, the force adjusting device 7 is electrically connected with the control device 8, the control device 8 can control the action of the force adjusting device 7 according to the feedback of the force detecting device 6, when the control device 8 judges that the tool 22 should move towards the direction away from the sheet metal 10, the control device 8 controls the force adjusting device 7 to drive the two tools to move towards the sheet metal 10, when the control device 8 judges that the tool 22 should move towards the direction close to the sheet metal 10, the control device 8 controls the force adjusting device 7 to drive the two tools to move towards the sheet metal 10, in addition, in the machining process, the force adjusting device 7 can also achieve the purpose of adjusting the force, so that each moving process of the tool 22 has independent force parameters, for example, the force of the arc motion can be preset to a value slightly smaller than that of the linear motion, otherwise, the processed material is easy to puncture at the arc position; in the case of a smaller feed requirement (denser profile), the periphery of some processing points is already stretched, and if the force is not controlled adjustably, these processing points are also very easily punctured, and in addition, if the angle jump between profiles of different levels needs to be shaped, the operation becomes simpler and more convenient after the force adjusting device 7 is adopted.
Specifically, in the embodiment shown in fig. 1 and 3, the force detection device 6 and the force adjustment device 7 are respectively fixed on two mechanical arms 21; the force detection device 6 comprises a force sensor or a torque sensor, such as a common flange type pressure sensor, a rotary type torque sensor or an encoder, and the like, and has a plurality of product types, but the structure adopting an independent detection shaft has higher detection sensitivity and faster response, for example, the force detection device can be composed of (but not limited to) a motor, a coupling and a sensing shaft, wherein the sensing shaft is connected with a main cutter in the pressure forming device 2, when the main cutter is contacted with the processing sheet metal 10, the main cutter is stressed, the stressed force is transmitted to the motor of the force detection device 6 through the sensing shaft, the motor can sense the tiny change of the load force or the moment generated by the force, the change of the load force or the moment before and after the force application is calculated through the control device 8, namely, the process of converting the actual force of the physical quantity into an electric signal, the electric signal of the actual force obtained by the method is compared with the preset value of the force in the control device 8, if the actual dynamics is greater than the dynamics preset value, then will keep away from the instruction of processing the panel beating and send to dynamics adjusting device 7, if the actual dynamics is less than the dynamics preset value, then will be close to the instruction of processing the panel beating and send to dynamics adjusting device 7. The force adjusting device 7 comprises a driving motor, a coupler and a transmission shaft, the motor receives an instruction signal from the control device 8, the instruction signal comprises the speed and the amplitude of the operation of the motor when the motor is far away from or close to the sheet metal 10, the motor can drive the transmission shaft to perform corresponding actions, and the transmission shaft is connected with an auxiliary cutter in the pressure forming device 2, so that the supporting force of the auxiliary cutter can be adjusted, and the purpose of controlling the contact force between the cutter and the processed sheet metal is achieved. The hardware structures of the force detection device 6 and the force adjustment device 7 can be the same or different, but the functions are opposite, the actual contact force is transmitted to the motor through the sensing shaft by the force detection device 6 through hard connection, and the force adjustment device 7 receives an instruction from the control device 8 to drive the motor and drive the transmission shaft to achieve the purpose of being far away from or close to the processed metal plate 10. Another distinct and important characteristic is that the sensing shaft is stationary (only micro-deformations sensed by the motor) while the drive shaft is the movable part. This is an important feature that distinguishes it from other detection and adjustment methods.
It should be noted that, as shown in fig. 2, the force detection device 6 and the force adjustment device 7 may be fixed to the same mechanical arm 21, and the purpose of adjusting the force application may also be achieved.
Further, the control device 8 is provided with an operation panel, and the operation of controlling the actions of the components is simple and convenient due to the arrangement of the operation panel.
Second embodiment
As shown in fig. 4, the present invention further provides a double-sided processing and forming method, which uses the above-mentioned double-sided flexible force control and auxiliary heating and forming apparatus, and comprises the following steps:
and 240, driving the two mechanical arms of the double-sided flexible force control and auxiliary heating forming equipment to synchronously move by the controller according to the acquired running path and the set running speed, and gradually forming the sheet metal into the designed three-dimensional shape according to continuous advanced contour actions until the required final shape is obtained, so that the light weight and customized production is efficiently realized.
The controller may be a PLC controller provided in the control device of the double-sided flexible force control and auxiliary thermoforming apparatus, or may be a CAM (computer Aided Manufacturing) system.
The double-sided flexible force control and auxiliary heating forming method can directly generate functional sheet metal parts from CAD data, can be widely applied to industries such as automobiles, aviation, medical treatment and the like, remarkably shortens delivery time from a design stage to actual forming, and does not need to consider the inventory problem of large dies.
Further, as shown in fig. 5, when the pressing and forming device of the double-sided flexible force control and auxiliary heating and forming apparatus is connected with a temperature sensor, the double-sided flexible force control and auxiliary heating and forming method further includes:
and 231, adjusting the current of the electric heating device by the controller according to a feedback signal of the temperature sensor so that the current output by the electric heating device can be automatically adjusted according to the real-time temperature value of the sheet metal in the machining process, and thus the double-sided flexible force control and auxiliary heating forming method has the advantages of high quality of machined products, high efficiency and easiness in implementation.
Still further, the controller is provided with an alarm, when the feedback signal of the temperature sensor is greater than a first preset value (such as 100-300 degrees), the controller controls the alarm to give an alarm, wherein the alarm can be a warning lamp or a warning sound to prompt a worker that the current temperature of the sheet metal is higher;
when the feedback signal of the temperature sensor is larger than a second preset value (such as 500-800 degrees), the controller controls the two mechanical arms to stop moving, namely when the temperature of the sheet metal is too high, the controller commands the mechanical arms to stop moving so as to ensure the processing safety.
Further, as shown in fig. 5, when the pressing and forming device of the double-sided flexible force control and auxiliary heating and forming apparatus is connected with the force detection device, the double-sided flexible force control and auxiliary heating and forming method further includes:
Further, as shown in fig. 5, when the tool is connected to the mechanical arm through the force adjusting device, the double-sided flexible force control and auxiliary heating forming method further includes:
There are inevitable errors between the design model and the actual processing equipment, and there are various factors (and not limited thereto): the assembling error of the mechanical arm, the processing and assembling error of the main cutter and the auxiliary cutter, the processing and assembling error of raw materials and the like. Therefore, environmental calibration is required, but the environmental calibration technology in the industry is not perfect at present, and cannot be calibrated to the high precision requirement, and in the case of a small feed depth (i.e. the feed amount of the profile per circle), the error which cannot be calibrated to be completely consistent with the model affects the machining effect. In addition, the flatness of the processed material also influences the processing effect, any degree of distortion can cause insufficient or excessive contact between the tool and the material, the insufficient contact can not achieve the purpose of pressurization deformation, the excessive contact can damage the material, and the loss of time and cost is caused.
The technical process of processing sheet metal by adopting the double-sided flexible force control and auxiliary heating forming equipment and method is described by combining the specific embodiment as follows:
1. determining the material of the processed sheet metal and the thickness of the sheet metal, wherein 6061 aluminum alloy/304 steel is selected in the embodiment, and the thickness of the sheet metal is 0.5-1.5 mm;
2. selecting a corresponding cutter material, wherein in the embodiment, XW-5 steel is selected, the radius range of the main cutter is 2.5 mm-12.5 mm, and the radius range of the auxiliary cutter is 2.5 mm-12.5 mm;
3. determining the agreed relationship between the main tool and the auxiliary tool, in this embodiment, as shown in fig. 6, D is 0, S is 0 or D is 0.5-5 mm, and S is 0.1-1 mm, where D is a radial distance and S is an axial distance;
4. determining the feeding depth, namely the feeding amount of each circle of contour is 0.1-1 mm according to the material of the sheet metal and the two cutters;
5. the controller obtains the running paths of the two cutters of the double-sided flexible force control and auxiliary heating forming equipment according to the 3D model of the target shape;
6. feeding;
7. setting the current of the electric heating device to be 0-160A;
8. setting the contact force of the cutter to be 0-100N;
9. setting the motion speed of the mechanical arm, such as the linear speed of 0.1 mm/s-1500 mm/s, and the speed proportion of 0.01-100%;
10. setting a first preset value and a second preset value;
11. coating lubricating oil of copper-based anti-sticking agent on the sheet metal material to be processed (preventing noise in the processing process and electric arc when power is supplied);
12. the controller sends out a starting instruction to start machining;
13. in the machining process, as shown in fig. 7, the controller adjusts the current of the electric heating device in real time according to the feedback of the temperature sensor, and controls the force adjusting device to drive the tool to move towards or away from the sheet metal in real time according to the feedback of the force detecting device and the running path.
14. And (5) blanking after the processing is finished.
In summary, the double-sided flexible force control and auxiliary heating forming equipment and method provided by the invention can keep the twelve shafts of the two mechanical arms moving simultaneously by controlling the action of the pressure forming device through the control device, so that the machining of the undercut and deep taper characteristics can be realized, the direct forming can be realized, the light application can realize stronger designability through the manufacturing method for enhancing the formability and the flexibility, the machining of metal parts with unique design can be realized, and the double-sided flexible force control and auxiliary heating forming equipment and method are particularly suitable for prototype manufacturing and small-batch production;
according to the double-sided flexible force control and auxiliary heating forming equipment and method, the plate is pressed and processed by the two cutters at the same time, so that the dimensional accuracy of a formed part is superior to that of the traditional single-point incremental forming;
the double-sided flexible force control and auxiliary heating forming equipment and the method of the invention have the advantages that the sheet metal is instantaneously heated by the electric heating device, the dislocation of atoms in the microstructure of the sheet metal material can be promoted by the current to generate the electro-plasticity, so that the deformation force is reduced, the plastic deformation is increased, the residual stress and the forming load of the material are reduced, the yield strength of the sheet metal is reduced, namely the force applied by forming is reduced, the expected deformation effect is more easily generated, the accuracy of controlling the size of the sheet metal is improved, and the defects and flaws in the forming process of the sheet metal are reduced
The double-sided flexible force control and auxiliary heating forming equipment and the method can overcome the defects of the traditional stamping process, namely, the mould with high production cost in large batch and high cost, can deal with complex shapes, and realize the processing of the characteristics of the undercut and the deep cone through the combined action of the control device, the force detection device, the force adjusting device, the electric heating device and the temperature sensor, thereby efficiently realizing the light weight and customized production, realizing the unique shape design of metal parts, and having the characteristics of excellent quality of processed products, high efficiency and easy realization of vivid characteristics.
The above description is only an exemplary embodiment of the present invention, and is not intended to limit the scope of the present invention. Any equivalent changes and modifications that can be made by one skilled in the art without departing from the spirit and principles of the invention should fall within the protection scope of the invention. It should be noted that the components of the present invention are not limited to the above-mentioned whole application, and various technical features described in the present specification can be selected to be used alone or in combination according to actual needs, so that the present invention naturally covers other combinations and specific applications related to the invention.
Claims (10)
1. A double-sided flexible force-controlled and assisted thermoforming apparatus, characterized in that it comprises:
fixing the frame;
the pressing forming device comprises a force detection device and two opposite mechanical arms arranged at intervals, wherein the first end of each mechanical arm can be rotatably connected with the fixed rack, the second end of each mechanical arm is connected with a cutter, and the force detection device can detect the force application magnitude of the cutter;
the electric heating device is provided with a positive electrode connecting end and a negative electrode connecting end, and the positive electrode connecting end and the negative electrode connecting end are respectively connected with the two cutters;
the fixed clamp is connected to the fixed rack and positioned between the two mechanical arms, and the fixed clamp can limit the sheet metal between the two mechanical arms in a vertical state;
and the control device is electrically connected with the pressure forming device and the electric heating device, can adjust the pressure applying force of the two mechanical arms according to the detection result of the force detection device, and can adjust the heating temperature of the electric heating device.
2. The double-sided flexible force-controlled and assisted heat-forming apparatus of claim 1,
the force detection device is connected to the second end of one of the two mechanical arms.
3. The double-sided flexible force-controlled and assisted heat-forming apparatus of claim 1,
the cutter passes through the dynamics adjusting device with the arm meets, the dynamics adjusting device with the controlling means electricity is connected, controlling means can control the action of dynamics adjusting device.
4. The double-sided flexible force-controlled and assisted heat-forming apparatus of claim 1,
and the pressure forming device is also connected with a temperature sensor for detecting the temperature of the sheet metal, and the temperature sensor is electrically connected with the control device.
5. The double-sided flexible force-controlled and assisted heat-forming apparatus of claim 1,
an operation panel is arranged on the control device.
6. A double-sided flexible force-controlled and assisted thermoforming method, using the double-sided flexible force-controlled and assisted thermoforming apparatus of claim 1, the double-sided flexible force-controlled and assisted thermoforming method comprising:
the controller obtains the running paths of the two cutters of the double-sided flexible force control and auxiliary heating forming equipment according to the 3D model of the target shape;
the controller adjusts the pressure applying force of the two mechanical arms of the double-sided flexible force control and auxiliary heating forming equipment according to the material thickness and the shape of the plate to be processed;
the controller adjusts the heating temperature of the electric heating device of the double-sided flexible force control and auxiliary heating forming equipment according to the material of the sheet metal to be processed;
and the controller drives the two mechanical arms of the double-sided processing forming equipment to synchronously move according to the acquired running path and the set running speed.
7. The double-sided flexible force-controlled and assisted heat-forming method of claim 6,
when the pressing and forming device of the double-sided flexible force control and auxiliary heating and forming equipment is connected with a temperature sensor, the double-sided flexible force control and auxiliary heating and forming method further comprises the following steps:
and the controller adjusts the heating temperature of the electric heating device according to the feedback signal of the temperature sensor.
8. The double-sided flexible force-controlled and assisted heat-forming method of claim 7,
the controller is provided with an alarm, and when a feedback signal of the temperature sensor is greater than a first preset value, the controller controls the alarm to give an alarm;
and when the feedback signal of the temperature sensor is greater than a second preset value, the controller controls the two mechanical arms to stop moving.
9. The double-sided flexible force-controlled and assisted heat-forming method of claim 6,
when the pressing forming device of the double-sided flexible force control and auxiliary heating forming equipment is connected with a force detection device, the double-sided flexible force control and auxiliary heating forming method further comprises the following steps:
and the controller judges the moving direction of the cutter according to the feedback signal of the force detection device.
10. The double-sided flexible force-controlled and assisted heat-forming method of claim 7,
when the cutter is connected with the mechanical arm through the force adjusting device, the double-sided flexible force control and auxiliary heating forming method further comprises the following steps:
the controller controls the force adjusting device to drive the cutter to move towards or away from the sheet metal according to the feedback signal of the force detecting device.
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