CN113000680A - Forming method of aluminum alloy top cover component with convex hole - Google Patents
Forming method of aluminum alloy top cover component with convex hole Download PDFInfo
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- CN113000680A CN113000680A CN202110170886.4A CN202110170886A CN113000680A CN 113000680 A CN113000680 A CN 113000680A CN 202110170886 A CN202110170886 A CN 202110170886A CN 113000680 A CN113000680 A CN 113000680A
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- positioning
- ring
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- forming
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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
- 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
- B21D37/10—Die sets; Pillar guides
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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
- B21D37/10—Die sets; Pillar guides
- B21D37/12—Particular guiding equipment, e.g. pliers; Special arrangements for interconnection or cooperation of dies
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
Abstract
The invention provides a forming method of an aluminum alloy top cover component with a convex hole, which comprises the steps of using a forming device, wherein the forming device comprises a die main body, an embedded ring and a lifting lug bolt, the die main body comprises a forming surface of the die main body, a top plate, a positioning part A, an annular groove and a supporting structure, the annular groove is arranged in a downward concave mode from the upper surface of the forming surface of the die main body, the positioning part A is arranged on an inner ring or an outer ring of the annular groove and used for positioning the embedded ring, and the embedded ring comprises an embedded ring forming surface, a concave hole, a positioning part B and a first threaded hole, wherein the positioning part B is matched and positioned with the positioning part; the forming method comprises the steps of replacing or determining the embedded ring, positioning and placing the plate, applying external load, creep aging, removing the external load and the like. The forming method provided by the invention overcomes the problems of low manufacturing precision, multiple processing procedures and the like of the traditional process of the top cover with the convex hole, and has the advantages of high forming precision, good process repeatability, low residual stress, good dimensional stability and the like.
Description
Technical Field
The invention belongs to the field of forming of aluminum alloy top cover components, and particularly relates to a forming method of an aluminum alloy top cover component with a convex hole.
Background
The creep age forming technology is a technology which is generated for solving the difficult problem of high-performance and high-precision manufacturing of large-scale complex integral components in aerospace. The technology utilizes the creep and time effect strengthening characteristics of the material under the action of a stress field and a temperature field, enables a workpiece to be attached to the molded surface of a die in a vacuum loading mode without a convex die or a mechanical loading mode with the convex die, and keeps the material in a constant temperature state for a certain time to enable the material to generate plastic flow so as to realize the forming and forming cooperative manufacturing of the component.
The creep age forming technology not only can realize the integrated forming of large components, but also can greatly improve the mechanical property of materials. Compared with the traditional integral wallboard component forming technology, the technology has the advantages of high forming precision, good dimensional stability, difficulty in generating processing cracks and the like.
With the rapid development of modern aviation industry, the performance requirements of aerospace components continuously tend to high reliability, high stability, long service life and light weight, and research on creep age forming of large-scale complex integral components and component production strength are increased by domestic and foreign scientific research institutions and processing enterprises.
The large-scale top cover with the convex hole and the small flanging hole at the periphery is a main structure component of an aerospace carrier rocket fuel storage tank, the traditional forming method of the component is stamping forming, the method has the problems of low forming precision, long processing period and the like, and the flanging forming of the convex hole further influences the overall shape precision of the top cover component because the flanging process of the convex hole is positioned after the stamping process of the component main body, and the final size precision of the component can be influenced because of large residual stress in the component after the component is formed.
The creep age forming process can be divided into three stages: the method comprises a loading stage, a creep aging stage and an unloading stage, wherein in the process that the component is gradually deformed and attached to the molded surface of the mold under the action of an external load in the loading stage, the position state of a convex hole of the component is also changed, the position precision of the convex hole is difficult to ensure after the component is formed, and the problem is always a difficult problem of realizing integrated forming of the component with the convex hole.
The die is a tool required by creep age forming, and in the existing creep age die equipment technology, one set of die can only form a component with a certain fixed shape and size, but cannot realize the production of components with various specifications. The number, the size and the position of the convex holes related to the components with the convex holes of different specifications are different, and the design of the creep aging forming device capable of forming the components with various specifications has important significance for reducing the production cost.
Therefore, in order to solve the above problems, there is a need in the art for a new apparatus and method for forming an aluminum alloy roof member with a convex hole.
Disclosure of Invention
The invention utilizes the creep and aging strengthening characteristics of the material, and uses a set of mosaic type device to form various large components with the convex holes with different sizes, so as to realize the characteristics of high shape and size precision, short processing period, low production cost and the like of the formed components with the convex holes.
The invention firstly provides a forming device of an aluminum alloy top cover component with a convex hole, which comprises a die main body, an embedded ring and a lifting lug bolt, wherein the die main body comprises a downward recessed die main body forming surface, a top plate arranged at the periphery of the die main body forming surface, a positioning part A, an annular groove and a supporting structure for supporting the die main body forming surface and the top plate, the annular groove is recessed from the upper surface of the die main body forming surface, the annular groove is used for embedding the embedded ring, the positioning part A is arranged in a structure which is radially protruded or recessed at least at a certain position on an inner ring or an outer ring of the annular groove and is used for positioning the embedded ring, and the embedded ring comprises an embedded ring forming surface, one or more concave holes matched with the convex hole of the aluminum alloy top cover component, and at least a certain position on the inner ring or the outer ring of the embedded ring and is radially recessed or protruded for being matched with the positioning part A The positioning part B is matched and positioned, and the first threaded hole is arranged on the forming surface of the embedded ring and is used for screwing a lifting lug bolt; at least comprises a forming surface of the die body and a forming surface of the insert ring which jointly form a die profile of the forming device.
In a specific embodiment, the positioning component a (15) is a positioning block, the positioning block is arranged at the lower part of the annular groove (16) and used for positioning the embedded ring (4), the positioning component B (43) is a positioning groove, and the positioning groove is arranged at the lower part of the embedded ring (4) and used for matching and positioning with the positioning block.
In a specific embodiment, the positioning block (15) is a V-shaped positioning block, and the positioning groove (43) is a V-shaped positioning groove.
In a specific embodiment, the first threaded holes (44) are more than three and uniformly distributed on the embedded ring (4) in the circumferential direction, and each threaded hole is preferably arranged at the same distance from the inner ring and the outer ring of the embedded ring.
In a specific embodiment, the annular groove (16) is a sunken groove structure arranged on the die body, and the concave hole (42) is a through hole structure arranged on the embedded ring (4); a gap exists between the die main body (1) and the embedding ring (4), the matching system is in clearance fit, and the preferred matching gap is smaller than 1 mm.
In a specific embodiment, the supporting structure comprises side plates (13) vertically arranged at the peripheral position of the mould main body and a clamping plate (18) used for connecting each side plate, and hollow holes (20) used for reducing the weight of the mould are arranged on the side plates and the clamping plate.
In a specific embodiment, the positioning component A (15) is more than two arranged at different positions of the circumferential direction of the annular groove (16), the positioning component B (43) is more than two arranged at different positions of the circumferential direction of the embedded ring (4), and preferably, the plurality of positioning components A (15) and the plurality of positioning components B (43) are all uniformly arranged in the circumferential direction.
In a specific embodiment, the forming device further comprises an insert (2) matched with one or more concave holes (42), and a positioning part C (45) is radially arranged on at least one position of the concave hole in a protruding or concave mode, the insert (2) comprises an insert forming surface (21), a positioning part D (22) which is radially arranged on one position of the insert in a protruding or concave mode and used for matching and positioning with the positioning part C (45), and a second threaded hole (23) which is arranged on the insert forming surface (21) and used for screwing in the lug bolt (6); the forming surface (11) of the die main body, the forming surface (41) of the insert ring and the insert forming surface (21) of the partial insert jointly form a die surface (3) of the forming device.
In a specific embodiment, the positioning component C (45) is a V-shaped block, the V-shaped block is arranged at the lower position of the concave hole, and the positioning component D (22) is a V-shaped groove, and the V-shaped groove is arranged at the lower position of the insert.
In a specific embodiment, the second threaded hole (23) is arranged at the center of the insert forming surface (21), the positioning parts C (45) are more than two arranged at different positions in the circumferential direction of the concave hole, the positioning parts D (22) are more than two arranged at different positions in the circumferential direction of the insert, and preferably, the plurality of positioning parts C (45) and the plurality of positioning parts D (22) are uniformly arranged in the circumferential direction; and a forming fillet (46) matched with the arc transition angle of the convex hole of the aluminum alloy top cover member is also arranged at the concave hole (42) of the embedding ring (4), and an embedding block fillet (24) matched with the forming fillet (46) is arranged between the side surface of the embedding block (2) and the embedding block forming surface (21).
The invention also provides a forming method of the aluminum alloy roof member with the convex hole, which comprises the step of using a forming device of the aluminum alloy roof member with the convex hole, wherein the forming device comprises a die main body (1), an embedded ring (4) and a lifting lug bolt (6), the die main body (1) comprises a die main body forming surface (11) recessed downwards, a top plate (12) arranged at the periphery of the die main body forming surface (11), a positioning part A (15), an annular groove (16) and a supporting structure for supporting the die main body forming surface (11) and the top plate (12), the annular groove (16) is recessed downwards from the upper surface of the die main body forming surface (11), the annular groove (16) is used for the embedded arrangement of the embedded ring (4), the positioning part A (15) is arranged in a structure which radially protrudes or is recessed at least at a certain position on the inner ring or the outer ring of the annular groove for positioning the embedded ring (4), the embedded ring (4) comprises an embedded ring forming surface (41), one or more concave holes (42) matched with the convex holes of the aluminum alloy top cover component, a positioning part B (43) which is arranged at least at a certain position on the inner ring or the outer ring of the embedded ring (4) and is radially recessed or protruded for matching and positioning with the positioning part A (15), and a first threaded hole (44) which is arranged on the embedded ring forming surface (41) and is used for screwing a lifting lug bolt (6); the forming device at least comprises a die main body forming surface (11) and an insert ring forming surface (41) which jointly form a die profile (3) of the forming device;
the forming method includes the steps of;
step A, replacing or determining an inlaid ring: correspondingly replacing or determining a correct embedding ring according to the model of the target component, namely according to the number, the size and the position of the convex holes on the target component;
b, positioning and placing the plates: placing an aluminum alloy plate provided with a central hole and peripheral holes on the molded surface of the mold, so that the central point of the central hole of the aluminum alloy plate and the central point of the mold main body are on the same vertical line, and the projection of the peripheral holes of the aluminum alloy plate on the molded surface of the mold falls on the connecting line of the central point of the mold main body and the central point of the concave hole of the mold;
step C, applying an external load: gradually attaching the aluminum alloy plate to the molded surface of the mold by using a vacuum loading or mechanical loading method, and enabling peripheral holes of the aluminum alloy plate, namely component convex holes, to fall into the concave holes of the mold;
step D, creep aging: placing the aluminum alloy top cover component raw material and the die into an autoclave together, and enabling the aluminum alloy material to generate plastic flow under certain temperature, pressure and time;
e, unloading the external load: and (4) removing the external load to enable the aluminum alloy top cover member to rebound, so as to obtain the aluminum alloy top cover member with the convex hole, which meets the target profile precision.
In a specific embodiment, the positioning component A (15) is a positioning block which is arranged at the lower part of the annular groove (16) and is used for positioning the embedded ring (4), the positioning component B (43) is a positioning groove which is arranged at the lower part of the embedded ring (4) and is used for matching and positioning with the positioning block; preferably, the positioning block (15) is a V-shaped positioning block, and the positioning groove (43) is a V-shaped positioning groove; the first threaded holes (44) are more than three and are circumferentially and uniformly distributed on the embedded ring (4), and preferably, each threaded hole is equal to the distance between the inner ring and the outer ring of the embedded ring.
In a specific embodiment, the annular groove (16) is a sunken groove structure arranged on the die body, and the concave hole (42) is a through hole structure arranged on the embedded ring (4); a gap is formed between the die main body (1) and the embedding ring (4), the matching system is in clearance fit, and the preferred matching gap is smaller than 1 mm; the supporting structure comprises side plates (13) vertically arranged at the periphery of the mould main body and a clamping plate (18) used for connecting the side plates, and hollow holes (20) used for reducing the weight of the mould are formed in the side plates and the clamping plate; preferably, the positioning component A (15) is arranged at more than two circumferential different positions of the annular groove (16), the positioning component B (43) is arranged at more than two circumferential different positions of the embedded ring (4), and preferably, the plurality of positioning components A (15) and the plurality of positioning components B (43) are uniformly arranged in the circumferential direction.
In a specific embodiment, the forming device further comprises an insert (2) matched with one or more concave holes (42), and a positioning part C (45) is radially arranged on at least one position of the concave hole in a protruding or concave mode, the insert (2) comprises an insert forming surface (21), a positioning part D (22) which is radially arranged on one position of the insert in a protruding or concave mode and used for matching and positioning with the positioning part C (45), and a second threaded hole (23) which is arranged on the insert forming surface (21) and used for screwing in the lug bolt (6); the forming surface (11) of the die main body, the forming surface (41) of the insert ring and the insert forming surface (21) of the partial insert jointly form a die surface (3) of the forming device.
In a specific embodiment, the positioning component C (45) is a V-shaped block, the V-shaped block is arranged at the lower position of the concave hole, and the positioning component D (22) is a V-shaped groove, and the V-shaped groove is arranged at the lower position of the insert.
In a specific embodiment, the second threaded hole (23) is arranged at the center of the insert forming surface (21), the positioning parts C (45) are more than two arranged at different positions in the circumferential direction of the concave hole, the positioning parts D (22) are more than two arranged at different positions in the circumferential direction of the insert, and preferably, the plurality of positioning parts C (45) and the plurality of positioning parts D (22) are uniformly arranged in the circumferential direction; and a forming fillet (46) matched with the arc transition angle of the convex hole of the aluminum alloy top cover member is also arranged at the concave hole (42) of the embedding ring (4), and an embedding block fillet (24) matched with the forming fillet (46) is arranged between the side surface of the embedding block (2) and the embedding block forming surface (21).
In a specific embodiment, step a is preceded by designing a mold matching the target aluminum alloy cap member by computer simulation.
In a specific implementation mode, the die design comprises the steps of firstly using a computer to carry out component forming finite element simulation and die profile springback compensation to obtain a final die profile, then carrying out plane expansion on a target aluminum alloy top cover component and the die profile to obtain a plane expansion diagram of the component and the die profile, wherein the position of a central point of a concave hole or an insert is the position of the central point of a convex hole after the component with the convex hole is expanded; and the width of the embedding ring is determined according to the diameter of the convex hole of the aluminum alloy top cover component.
In a specific embodiment, according to the type of the aluminum alloy top cover component, as many concave holes as possible are formed in one embedded ring, and partial concave holes are filled with the embedded blocks during forming, so that the same embedded ring can form as many different types of components with convex holes as possible.
In a specific embodiment, the step a further comprises replacing or determining the insert, namely replacing or determining the correct insert ring and insert according to the number, size and position of the convex holes of the target member, so that the number, size and position of the concave holes on the die which are not filled by the insert are consistent with the convex holes of the target aluminum alloy top cover member.
In a specific embodiment, in step D, the forming of the apertured top cover member of different thicknesses is achieved by controlling creep aging process parameters including temperature, pressure and time.
The invention also provides a forming die of the aluminum alloy top cover component, which is used for forming the aluminum alloy top cover component with the convex hole, characterized in that the forming die comprises a die main body (1) and one or more concave holes (42) matched with the convex holes of the aluminum alloy top cover component, the mould body (1) comprises a mould body forming surface (11) which is concave downwards, a top plate (12) which is arranged at the periphery of the mould body forming surface (11) and a supporting structure which is used for supporting the mould body forming surface (11) and the top plate (12), the supporting structure comprises side plates (13) vertically arranged at the peripheral position of the mould main body and clamping plates (18) used for connecting the side plates, the side plates and the clamping plates are provided with hollowed holes (20) for reducing the weight of the mold, and the concave holes (42) are hole site structures which are recessed downwards from the forming surface (11) of the mold main body.
In a specific embodiment, the forming die further comprises a positioning column (17) which is arranged on the top plate (12) and used for positioning the aluminum alloy sheet.
In a specific embodiment, the positioning column (17) is fixed on the top plate in a welding mode.
In a specific embodiment, the positioning column (17) comprises more than two circumferential different positions arranged on the radial outer side of the forming surface (11) of the die main body.
In a specific embodiment, the positioning column (17) comprises two oppositely arranged positioning columns.
In a specific embodiment, the forming die further comprises a bottom plate (19) fixedly connected to the lower position of the side plate (13), and the bottom plate (19) is also provided with a hollow hole (20) for reducing the weight of the die.
In a specific embodiment, the forming die further comprises a cushion block (14) which is arranged on the lower side of the bottom plate (19) and is used for increasing the contact area of the die bottom plate and air so as to improve the heat transfer and ventilation rate of the die and increase the uniformity of the heat distribution of the die.
In a specific embodiment, the upper portion of the concave hole (42) is provided with a formed fillet (46) for matching with the arc transition angle of the convex hole on the aluminum alloy roof member.
In a particular embodiment, the top plate (12) is a horizontally disposed plate.
In a specific embodiment, forming die is still including inlaying ring (4), insert (2) and lug bolt (6), the shrinkage pool all sets up on inlaying ring (4) and the number of shrinkage pool be four or more, mould main part (1) still includes locating part A (15) and ring channel (16), ring channel (16) set up from the upper surface undercut of mould main part shaping surface (11), just ring channel (16) are used for inlaying ring (4) and inlaying the setting wherein, locating part A (15) set up to be used for to inlaying ring (4) location for the radial protrusion of certain position or the structure of recess at least on the inner ring of ring channel or outer loop, inlay ring (4) including inlaying ring shaping surface (41), shrinkage pool (42), set up at least certain position and radial recess or protrusion on the inner ring of inlaying ring (4) or outer loop and be used for with locating part A (15) matches the location of location A component B (43) and a first threaded hole (44) which is arranged on the embedding ring forming surface (41) and is used for screwing a lifting lug bolt (6); the insert (2) is matched with the concave holes, a positioning part C (45) is radially arranged at a certain position of at least one concave hole in a protruding or concave mode, the insert (2) comprises an insert forming surface (21), a positioning part D (22) which is radially arranged at a certain position of the insert in a protruding or concave mode and used for being matched and positioned with the positioning part C (45), and a second threaded hole (23) which is arranged on the insert forming surface (21) and used for being screwed into a lug bolt (6); the forming surface (11) of the die main body, the forming surface (41) of the insert ring and the insert forming surface (21) of the partial insert jointly form a die surface (3) of the forming device.
Compared with the prior art, the invention has at least the following effects:
1) according to the creep age forming method for the large-scale top cover component with the convex holes, provided by the invention, the traditional stamping forming process is replaced by the creep age forming process, the problems of low manufacturing precision, multiple processing procedures and the like of the traditional process for the top cover with the convex holes are solved, and the creep age forming method has the advantages of high forming precision, good process repeatability, low residual stress, good dimensional stability and the like.
2) The creep age forming method of the large-scale top cover component with the convex holes realizes the high-efficiency shape integrated manufacture and the age strengthening effect of the large-scale top cover with the convex holes, and shortens the manufacturing period.
3) According to the creep age forming device for the large-scale top cover component with the convex holes, the modular creep age forming die is adopted, the die insert ring and the insert are correspondingly replaced and adjusted according to the size and position conditions of the convex holes in the component, and the forming of the top cover components of different models is realized by adjusting the technological parameters of creep age, so that the flexibility of the forming of the convex holes is improved, the problem of compatibility of the creep forming die for the characteristics of different convex holes is solved, namely, one set of creep forming die can realize the forming of components with different structural characteristics, and the production cost is greatly reduced.
Drawings
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention will become apparent from the following detailed description of the invention which refers to the accompanying drawings.
FIG. 1 is a schematic view of a creep age forming apparatus for large cap members with male apertures;
FIG. 2 is a schematic view of a creep age forming apparatus in another state;
FIG. 3 is an exploded view of a creep age forming apparatus;
FIG. 4 is a cross-sectional view of a creep age forming apparatus;
FIG. 5 is a schematic structural view of a mold body;
FIG. 6 is a schematic illustration of an insert;
FIG. 7 is a schematic view of a damascene ring;
FIG. 8 is a three-dimensional simulation of a creep age forming apparatus for a large cap member with a male opening;
FIG. 9 is a pictorial view of a creep age forming apparatus for a large apertured roof member;
fig. 10 is a diagram showing the actual effect of a large-scale top cover component with convex holes formed by using the device of the invention.
Wherein, 1-a mold body; 2-an insert; 3-molding surface of the mold; 4-embedding a ring; 6-a lug bolt; 11-the forming surface of the mould main body; 12-a top plate; 13-side plate; 14-a cushion block; 15-positioning part a; 16-an annular groove; 17-a positioning column; 18-a card board; 19-a base plate; 20-hollow holes; 21-insert forming face; 22-positioning means D; 23-a second threaded hole; 24-insert fillet; 41-insert ring forming surface; 42-concave holes; 43-positioning part B; 44-a first threaded hole; 45-positioning part C; 46-forming a fillet; 2.1-a first insert; 2.2-second insert; 2.3-third insert.
Detailed Description
The accompanying drawings, which are included to provide a further understanding of the invention, 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 and do not constitute a limitation of the invention.
Referring to fig. 1 to 4, the apparatus for creep age forming provided by the invention comprises a die body 1, an insert ring 4 embedded in an annular groove of the die body, an insert 2 embedded in the insert ring, and an eye bolt 6.
Referring to fig. 5 to 7, the mold main body comprises a mold main body forming surface 11, a top plate 12 arranged on the periphery of the mold main body forming surface, a side plate 13 arranged on the periphery of the mold main body, a clamping plate 18 connected with the side plate, a bottom plate 19 at the bottom of the mold main body, and a cushion block 14 arranged below the bottom plate for increasing the heat transfer area of the bottom plate and improving the ventilation rate, wherein an annular groove 16 and two positioning blocks 15 which are symmetrically distributed in the annular groove for positioning are arranged in the mold main body forming surface, and two positioning columns 17 which are symmetrical to each other are welded above the top plate; the embedded ring comprises an embedded ring forming surface 41, through holes arranged in the embedded ring, four threaded holes with the same diameter, uniform distribution and the same distance with the inner diameter and the outer diameter of the embedded ring, and a V-shaped block arranged in the through holes; the insert comprises an insert forming surface 21, two uniform and symmetrical V-shaped grooves at the bottom of the insert, a threaded hole 23 arranged at the center of the insert, and an insert round angle 24 with a transition effect between the side surface and the forming surface of the insert.
The die body 1, the embedding ring 4 and the insert 2 are separate parts, the embedding ring 4 is placed in an annular groove 16 in the die body, and the insert is embedded in a through hole in the embedding ring. The molding surface 11 of the die body, the molding surface 41 of the insert ring and the molding surface 21 of the insert constitute a die surface 3.
In the embodiment, the positions of the insert 2 and the insert ring 4 are determined according to the positions and the sizes of the convex holes of the components, and the distance from the center point of the insert to the center position of the die is obtained by performing plane expansion calculation on the top cover component and the die profile, wherein the distance from the center point of the insert to the center position of the die is 450mm, and the width of the insert ring is 260 mm. The die body 1 and the embedding ring 4 are in clearance fit, the outer circle of the embedding ring is matched with the die body in a base hole mode, the inner circle of the embedding ring is matched with the die body in a base shaft mode, and the clearance between the inner circle of the embedding ring and the die body is smaller than 1 mm.
Referring to fig. 4, in order to realize uniform heat transfer of the mold, reduce the weight of the mold and the manufacturing cost of the mold, a plurality of vent holes are formed in the side plate, the clamping plate and the bottom plate, the total area of the vent holes of the side plate is larger than 60% of the total area of the side plate, the total area of the vent holes of the clamping plate is larger than 30% of the total area of the clamping plate, and the total area of the vent holes of the bottom plate is larger than 65% of the total.
Referring to fig. 7, the bottom of the embedded ring 4 is provided with two positioning grooves matched with the positioning blocks 15, the top of the concave hole 42 is provided with four forming fillets 46 with the radius equal to that of the transition fillet of the convex hole of the component, and the bottom of the embedded ring is provided with a chamfer, so that the embedded ring can smoothly enter the annular groove when being placed, the placing speed of the embedded ring is improved, and the chamfer size is C5.
In this embodiment, a large capping member with a convex hole is formed by a vacuum loading method, which includes the following specific steps:
step one, replacing the module: and screwing the lug bolt into a threaded hole in the insert 2.1 shown in the figure 1, and using external lifting force to act on the lug bolt to take away the insert 2.1, reserving the insert 2.2 and the insert 2.3 shown in the figure 1 and also reserving the insert ring 4, and taking away all the lug bolts in the figure 1 to obtain the creep age forming die with two die concave holes shown in the figure 2.
Step two, placing the plate: placing a circular plate with a large hole in the middle and two small holes in the periphery on the molded surface of a mold, adjusting the relative positions of the plate and the mold to ensure that the center point of the large hole in the middle of the plate is superposed with the projection of the center point of the main body of the mold on the horizontal plane, and ensuring that the projections of the two small holes in the periphery on the molded surface of the mold fall on the connecting line of the center point of the main body of the mold and the center point of the.
Thirdly, applying an external load: and integrally wrapping the component by using an air felt, covering the surface of the mold by using a vacuum bag, exhausting air in the bag after sealing is finished, maintaining the pressure for 5-20 minutes, gradually attaching the component to the molded surface of the mold, and enabling the convex hole of the component to fall into the concave hole of the mold.
Step four, creep aging stage: and pushing the component and the tooling thereof into the autoclave, and arranging thermocouples on the component and the tooling to detect the temperature condition of each area in the forming process. The creep age forming process comprises the following steps: keeping the air pressure in the tank at 1.5-2MPa, the aging temperature at 150-.
Step five, an unloading stage: and after the creep aging stage is finished, taking out the test component and the tooling thereof, removing the vacuum bag, unloading the vacuum pressure, and rebounding the component to obtain the top cover component with the convex hole, which meets the target profile precision.
Fig. 10 is a real view of the large-sized lid member with protruding holes obtained in this embodiment.
In the invention, because the first threaded hole and the second threaded hole are small in size, the forming precision of the aluminum alloy top cover component is not influenced by the existence of the threaded holes during creep age forming, and M12 bolts are selected as the corresponding lifting lug bolts, namely the diameter of the bolts is 12 mm.
In the invention, the embedding ring and the embedding block can be replaced correspondingly according to the number, the size and the position of the convex holes on the target component.
Preferably, the die main body is in clearance fit with the embedding ring, and the clearance between the die main body and the embedding ring is less than 1mm, so that the embedding ring is convenient to replace, and the forming precision of the component is not influenced.
Preferably, the inner part of the mosaic ring is provided with four threaded holes with the same diameter and uniform distribution, and the distances between the threaded holes and the outer diameter of the mosaic ring are equal; the insert is characterized in that a threaded hole is formed in the center of the insert and used for connecting the lug bolt, when the insert ring or the insert is replaced, external lifting force acts on the lug bolt firstly, and then the lug bolt acts on the insert ring and the insert, so that the effect of convenient replacement is achieved.
Preferably, two symmetrical positioning blocks are arranged in the annular groove, the bottom of the embedding ring is provided with corresponding positioning grooves, and the positioning blocks are matched with the positioning grooves and used for positioning the embedding ring in the placing process and preventing the embedding ring from moving under the action of an external load in the using process so as to avoid the profile precision and the convex hole position precision error of the component.
Preferably, the top of the concave hole is provided with a forming fillet, when no insert is placed at the concave hole, the concave hole is a mold concave hole to accommodate the convex hole of the component, the transition position of the convex hole of the component and the molded surface of the component is in transition with a certain fillet, and the radius of the forming fillet is equal to the radius of the transition fillet of the convex hole of the component for realizing the forming precision of the convex hole of the component.
Preferably, two symmetrical V-shaped blocks are arranged in the concave hole, and a V-shaped groove matched with the V-shaped block is formed in the bottom of the insert, so that the insert is accurately positioned, and the insert is prevented from rotating in the creep age forming process.
Preferably, the bottom of the embedding ring is provided with a chamfer so that the embedding ring can smoothly enter the annular groove when the embedding ring is placed, and the placing speed of the embedding ring is improved.
Preferably, the side plates, the clamping plate and the bottom plate are all provided with vent holes so as to realize uniform heat transfer of the die, reduce the weight of the die and reduce the manufacturing cost of the die.
Preferably, an insert fillet is formed between the side surface of the insert and the insert forming surface, and the size of the fillet is consistent with that of a fillet formed in the insert ring and is also equal to the radius of a transition fillet of a convex hole of a component to be formed correspondingly.
Preferably, the bottom plate is provided with a cushion block at the lower side thereof so as to increase the contact area between the bottom plate of the mold and air, improve the heat transfer and ventilation rate of the mold, increase the heat distribution uniformity of the mold and improve the forming precision of the component.
According to the invention, the embedding rings (4) are embedded in the annular groove (16), so that different embedding rings (4) can correspondingly form different aluminum alloy top cover components. Furthermore, the invention also provides a plurality of concave holes (42) on the embedded ring (4) and an embedded block (2) matched with the concave holes (42), so that each embedded ring (4) in the forming device can correspondingly form a plurality of different aluminum alloy top cover components; the cost savings of the forming die are further increased. Because the carrier rocket is a carrier space vehicle composed of multiple stages of rockets, each stage of rocket is provided with propellant storage tanks with different types, each propellant storage tank comprises a front bottom top cover and a rear bottom top cover, and parameters such as the number, the position, the size, the thickness of components and the like of convex holes on the front bottom top cover and the rear bottom top cover with different types are different, the cost of the mold is overhigh when each set of aluminum alloy top cover component corresponds to one set of forming mold, and the forming cost of the aluminum alloy top cover component is overhigh. Therefore, the forming device provided by the invention can adapt to the forming of different aluminum alloy roof cover members with convex holes, thereby obviously saving the forming cost.
In addition, the invention solves the problem of the position precision of the convex hole of the component by the computer simulation design of the die.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several simple deductions and substitutions can be made without departing from the spirit of the invention, and all shall be considered as belonging to the protection scope of the invention.
Claims (10)
1. A forming method of an aluminum alloy roof member with a lug hole includes using a forming device of the aluminum alloy roof member with the lug hole, the forming device includes a die main body (1), an insert ring (4) and a lug bolt (6), the die main body (1) includes a die main body forming surface (11) recessed downward, a top plate (12) provided at the periphery of the die main body forming surface (11), a positioning part A (15), an annular groove (16) and a supporting structure for supporting the die main body forming surface (11) and the top plate (12), the annular groove (16) is recessed downward from the upper surface of the die main body forming surface (11), and the annular groove (16) is used for the insert ring (4) to be embedded therein, the positioning part A (15) is provided with a structure protruding or recessed radially at least at a certain position on the inner ring or the outer ring of the annular groove for positioning the insert ring (4), the embedded ring (4) comprises an embedded ring forming surface (41), one or more concave holes (42) matched with the convex holes of the aluminum alloy top cover component, a positioning part B (43) which is arranged at least at a certain position on the inner ring or the outer ring of the embedded ring (4) and is radially recessed or protruded for matching and positioning with the positioning part A (15), and a first threaded hole (44) which is arranged on the embedded ring forming surface (41) and is used for screwing a lifting lug bolt (6); the forming device at least comprises a die main body forming surface (11) and an insert ring forming surface (41) which jointly form a die profile (3) of the forming device;
the forming method includes the steps of;
step A, replacing or determining an inlaid ring: correspondingly replacing or determining a correct embedding ring according to the model of the target component, namely according to the number, the size and the position of the convex holes on the target component;
b, positioning and placing the plates: placing an aluminum alloy plate provided with a central hole and peripheral holes on the molded surface of the mold, so that the central point of the central hole of the aluminum alloy plate and the central point of the mold main body are on the same vertical line, and the projection of the peripheral holes of the aluminum alloy plate on the molded surface of the mold falls on the connecting line of the central point of the mold main body and the central point of the concave hole of the mold;
step C, applying an external load: gradually attaching the aluminum alloy plate to the molded surface of the mold by using a vacuum loading or mechanical loading method, and enabling peripheral holes of the aluminum alloy plate, namely component convex holes, to fall into the concave holes of the mold;
step D, creep aging: placing the aluminum alloy top cover component raw material and the die into an autoclave together, and enabling the aluminum alloy material to generate plastic flow under certain temperature, pressure and time;
e, unloading the external load: and (4) removing the external load to enable the aluminum alloy top cover member to rebound, so as to obtain the aluminum alloy top cover member with the convex hole, which meets the target profile precision.
2. The forming method according to claim 1, wherein the positioning member a (15) is a positioning block provided at a lower portion of the annular groove (16) for positioning the insert ring (4), the positioning member B (43) is a positioning groove provided at a lower portion of the insert ring (4) for mating positioning with the positioning block; preferably, the positioning block (15) is a V-shaped positioning block, and the positioning groove (43) is a V-shaped positioning groove; the first threaded holes (44) are more than three and are circumferentially and uniformly distributed on the embedded ring (4), and preferably, each threaded hole is equal to the distance between the inner ring and the outer ring of the embedded ring.
3. The forming method according to claim 1, wherein the annular groove (16) is a counter groove structure provided on a mold body, and the recessed hole (42) is a through hole structure provided on the insert ring (4); a gap is formed between the die main body (1) and the embedding ring (4), the matching system is in clearance fit, and the preferred matching gap is smaller than 1 mm; the supporting structure comprises side plates (13) vertically arranged at the periphery of the mould main body and a clamping plate (18) used for connecting the side plates, and hollow holes (20) used for reducing the weight of the mould are formed in the side plates and the clamping plate; preferably, the positioning component A (15) is arranged at more than two circumferential different positions of the annular groove (16), the positioning component B (43) is arranged at more than two circumferential different positions of the embedded ring (4), and preferably, the plurality of positioning components A (15) and the plurality of positioning components B (43) are uniformly arranged in the circumferential direction.
4. A forming method according to any one of claims 1 to 3, wherein the forming apparatus further comprises an insert (2) disposed in cooperation with one or more recesses (42) and provided with a positioning member C (45) radially projecting or recessed at least at a position of one recess, the insert (2) comprising an insert forming surface (21), a positioning member D (22) radially recessed or projecting at a position of the insert and adapted to be positioned in cooperation with the positioning member C (45), and a second threaded hole (23) provided in the insert forming surface (21) and adapted to be screwed into the lug bolt (6); the forming surface (11) of the die main body, the forming surface (41) of the insert ring and the insert forming surface (21) of the partial insert jointly form a die surface (3) of the forming device.
5. The forming method according to claim 4, wherein the positioning member C (45) is a V-shaped block provided at a lower position of the recessed hole, and the positioning member D (22) is a V-shaped groove provided at a lower position of the insert.
6. The forming method according to claim 4, wherein the second threaded hole (23) is provided in the midpoint of the insert forming surface (21), the positioning members C (45) are two or more provided at different positions in the circumferential direction of the recessed hole, the positioning members D (22) are two or more provided at different positions in the circumferential direction of the insert, and preferably the plurality of positioning members C (45) and the plurality of positioning members D (22) are all provided uniformly in the circumferential direction; and a forming fillet (46) matched with the arc transition angle of the convex hole of the aluminum alloy top cover member is also arranged at the concave hole (42) of the embedding ring (4), and an embedding block fillet (24) matched with the forming fillet (46) is arranged between the side surface of the embedding block (2) and the embedding block forming surface (21).
7. A forming method according to any one of claims 1 to 6, further comprising designing a die matching the target aluminum alloy roof member by computer simulation before step A.
8. The forming method according to claim 7, wherein the die design comprises firstly using a computer to perform finite element simulation of member forming and compensation of die profile springback to obtain a final die profile, then performing planar development on the target aluminum alloy top cover member and the die profile to obtain a planar development diagram of the member and the die profile, wherein the position of the central point of the concave hole or the insert is the position of the central point of the convex hole after the member with the convex hole is developed; and the width of the embedding ring is determined according to the diameter of the convex hole of the aluminum alloy top cover component.
9. A forming method as claimed in claim 8, wherein, according to the type of the aluminum alloy top cover member, as many recesses as possible are provided in one insert ring, and a part of the number of recesses is filled with the inserts during forming, so that as many different types of components with convex holes as possible can be formed by the same insert ring.
10. The forming method according to any one of claims 1 to 6, wherein the step A further comprises replacing or determining the insert, namely replacing or determining the correct insert ring and insert according to the number, size and position of the convex hole of the target member, so that the number, size and position of the concave hole on the die which is not filled with the insert are consistent with the convex hole of the target aluminum alloy top cover member; and D, forming the top cover component with the convex holes with different thicknesses by controlling creep aging process parameters including temperature, pressure and time.
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