CN113714359B - Multi-pass robot flexible flanging full-mold forming method - Google Patents

Multi-pass robot flexible flanging full-mold forming method Download PDF

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CN113714359B
CN113714359B CN202111024436.0A CN202111024436A CN113714359B CN 113714359 B CN113714359 B CN 113714359B CN 202111024436 A CN202111024436 A CN 202111024436A CN 113714359 B CN113714359 B CN 113714359B
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flanging
coordinate
pass
plate
roller
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CN113714359A (en
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赵亦希
程旋
于忠奇
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Shanghai Jiaotong University
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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
    • B21D19/00—Flanging or other edge treatment, e.g. of tubes
    • B21D19/02—Flanging or other edge treatment, e.g. of tubes by continuously-acting tools moving along the edge
    • B21D19/04—Flanging or other edge treatment, e.g. of tubes by continuously-acting tools moving along the edge shaped as rollers
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F17/00—Digital computing or data processing equipment or methods, specially adapted for specific functions
    • G06F17/10—Complex mathematical operations
    • G06F17/15—Correlation function computation including computation of convolution operations

Abstract

A flexible flanging full-mold forming method of a multi-pass robot is characterized in that in a process planning stage, a three-dimensional rectangular coordinate system is established by taking the lower plane of a plate to be formed as a reference surface and the center of a circle of the plate as an origin, a roller is arranged to move to a movement starting point along an X axis, and then multi-pass flanging forming is arranged around a Y axis according to a flanging open angle of a target flanging part; according to the inner diameter, the arc opening angle and the thickness of an original plate, the flanging opening angle and the transition fillet radius of a target flanging piece, the length of a pressing part of a plate to be formed, the length of a flanging part, the radius of a roller and the distance from the bottom surface of the roller to a theoretical tangent point when the roller and the plate are formed; calculating the Y-axis coordinate of the mold plane to obtain the initial coordinate of the roller in each pass; in the execution stage, the rollers are controlled by an industrial six-axis robot to reach the initial coordinates of the rollers of each pass and apply forming force to the part to be flanged of the sheet material so as to realize flexible flanging forming.

Description

Multi-pass robot flexible flanging full-mold forming method
Technical Field
The invention relates to a technology in the field of sheet metal part manufacturing, in particular to a flexible flanging full-mold forming method of a multi-pass robot.
Background
The sheet metal flanging component has wide application in the aerospace field. However, due to the fact that the sheet metal flanging parts are multiple in variety and few in batch, at present, the flanging of the sheet metal flanging parts is formed by adopting a manual hammering mode, noise is high, forming efficiency is low, and quality stability and consistency of the flanging parts are difficult to guarantee. Along with the increasing abundance of sheet metal flanging structural parts and the shortening of product development period, the existing manual hammering flanging forming process and manufacturing quality are difficult to meet the continuously changing product requirements and the continuously accelerated production takt. Therefore, a new sheet metal flanging process is urgently to be developed to solve the manufacturing problem of the sheet metal flanging structural member at present.
Disclosure of Invention
The invention provides a multi-pass robot flexible flanging full-mold forming method, aiming at the defects that the forming efficiency of the existing flanging forming technology is low, the quality stability and consistency of a flanging piece are difficult to guarantee, the flanging part is easy to dent, and the flanging piece can only be used for accurately forming the flanging piece with a small arc radius and a small arc open angle, so that the forming performance of a sheet metal flanging piece is effectively improved, the forming quality is improved, the method is simple and feasible, the production efficiency is high, and the method has important engineering application value and obvious economic benefit in the engineering fields of aviation, aerospace, automobile manufacturing and the like.
The invention is realized by the following technical scheme:
the invention relates to a flexible flanging full-mold forming method of a multi-pass robot, which comprises the steps of establishing a three-dimensional rectangular coordinate system by taking the lower plane of a plate to be formed as a reference surface and the center of a circle of the plate as an original point at a process planning stage, setting a roller to move to a movement initial point along an X axis, and then setting n-pass flanging forming according to a flanging open angle alpha of a target flanging piece in a range of (beta/2, -beta/2) around a Y axis; according to the inner diameter R of the original plate0Arc opening angle beta and thickness d, flanging opening angle alpha of target flanging piece, transition fillet radius r, and length L of compression part of plate to be formed1Length L of the turnup portion2Radius of the roller rwDistance h from bottom surface of roller to theoretical tangent point of roller and plate when formingw(ii) a And the Y-axis coordinate of the mold plane is Y0Calculating to obtain the initial coordinates of the rollers in each pass; in the execution stage, the rollers are controlled by an industrial six-axis robot to reach the initial coordinates of the rollers in each pass and apply forming force to the part, to be flanged, of the plate material so as to realize flexible flanging forming.
The compression module comprises: and the triangular cushion blocks and the straight tooth pressing plates are respectively contacted with the side surface and the top surface of the plate to be formed.
The full-mold flanging workbench is a workbench with an inclined surface, the inclined surface and the plane part of the workbench are in smooth transition through a transition fillet, the inclined angle of the inclined surface is the same as the flanging angle of the target flanging piece, and the length of the inclined surface is larger than the flanging height of the target flanging piece.
Technical effects
The invention integrally solves the problems that the forming efficiency of the existing flanging forming technology is low, the quality stability and consistency of a flanging piece are difficult to ensure, the flanging part is easy to dent, and the flanging piece can only be used for accurately forming the flanging piece with a small arc radius and a small arc open angle;
compared with the prior art, the multi-pass gradual flanging forming can be carried out on the plate only by controlling the robot to drive the tool head in the flanging forming process; meanwhile, the springback amount can be compensated and adjusted in real time by adjusting the rotation angle and the initial coordinate of each pass of the roller. The method is simple and feasible, and after the process planning is finished, only ten minutes are needed for forming a qualified part, so that the forming efficiency is greatly improved.
Drawings
FIG. 1 is a diagram of a multi-pass robot flexible flanging full-mold forming device according to an embodiment;
FIG. 2 is a graph of the original sheet dimensions of the example;
FIG. 3 is a dimension chart of an embodiment target turned-up side member;
FIG. 4 is a schematic diagram showing the relative positions of the roller and the mold in the flanging process according to the embodiment;
in the figure: the device comprises a full-mold flanging workbench 1, triangular cushion blocks 2, a screw rod 3, a nut 4, a washer 5, a straight tooth pressing plate 6, a plate 7, a target flanging piece pressing part 701, a target flanging piece flanging part 702 and an industrial six-axis robot position and posture control roller 8.
Detailed Description
As shown in fig. 1, the present embodiment relates to a multi-pass robot flexible flanging full-mold forming device, which includes: the full mould turn-ups workstation 1, set up the module that compresses tightly and be used for the gyro wheel 8 that takes shape on it, wherein: and a plate material 7 to be formed is arranged below the pressing module on the full-mold flanging workbench 1.
The compression module comprises: triangle cushion 2 and straight-tooth clamp plate 6 that contact with the side and the top surface of waiting to take shape sheet material 7 respectively, wherein: the straight tooth pressing plate 6 is fixedly arranged on the full-mold flanging workbench 1 through a screw rod 3 and a nut 4.
The full-mold flanging workbench 1 is a workbench with an inclined surface, the inclined surface and the plane part are in smooth transition through a transition fillet, and the radius of the transition fillet is set to be 3 mm; the inclination angle of the inclined plane is the same as the flanging angle of the target flanging piece and is set to be 108 degrees, and the length of the inclined plane is larger than the flanging height of the target flanging piece and is set to be 36 mm.
The plate 7 to be formed is made of 5A06 aluminum alloy.
The embodiment relates to a multi-pass robot flexible flanging full-mold forming method, which comprises the following steps:
firstly, dividing a plate 7 into a pressing part 701 and a flanging part 702 based on the part characteristics of a target flanging part;
secondly, measuring to obtain the inner diameter R of the original plate01200mm, an arc opening angle beta of 90 degrees and a thickness d of 2mm, the flanging opening angle alpha of the target flanging piece is 120 degrees, the radius r of the transition fillet is 10mm, and the length L of the compression part 701 is1Is 100mm and the length L of the turned-up portion 7022Is 32 mm; and then according to the length L of the turn-up portion 7022Determining the roller radius rwIs 24mm and the distance h from the bottom surface of the roller to the theoretical tangent point of the roller and the plate when the plate is formedwIs 30 mm;
thirdly, establishing a three-dimensional rectangular coordinate system by taking the lower plane of the plate 7 as a reference plane and the circle center of the plate 7 as an origin, wherein the Y-axis coordinate of the plane of the die is Y0The number of the rollers is 0, the roller 8 firstly moves to the movement starting point along the X axis, and then flanging forming is carried out in the range of (45 degrees and minus 45 degrees) around the Y axis;
fourthly, setting 6-pass flanging forming according to the flanging opening angle alpha of the target flanging piece as 120 degrees;
the fifth step of using R0、d、α、β、r、L1、L2、hw、y0Calculating to obtain the initial coordinates of the roller in each pass, and specifically comprising the following steps:
the first pass X coordinate is:
Figure BDA0003242624970000031
Figure BDA0003242624970000032
y coordinate is
Figure BDA0003242624970000033
Figure BDA0003242624970000034
Z coordinate is
Figure BDA0003242624970000035
Figure BDA0003242624970000036
The second pass X coordinate is:
Figure BDA0003242624970000037
Figure BDA0003242624970000038
y coordinate is
Figure BDA0003242624970000039
Figure BDA00032426249700000310
The Z coordinate is:
Figure BDA00032426249700000311
Figure BDA00032426249700000312
the X coordinate of the third pass is as follows:
Figure BDA00032426249700000313
Figure BDA00032426249700000314
y coordinate is
Figure BDA00032426249700000315
Figure BDA00032426249700000316
The Z coordinate is:
Figure BDA00032426249700000317
Figure BDA00032426249700000318
the fourth pass X coordinate is as follows:
Figure BDA00032426249700000319
Figure BDA00032426249700000320
the Y coordinate is:
Figure BDA00032426249700000321
Figure BDA00032426249700000322
the Z coordinate is:
Figure BDA00032426249700000323
Figure BDA00032426249700000324
the fifth pass X coordinate is as follows:
Figure BDA00032426249700000325
Figure BDA00032426249700000326
the Y coordinate is:
Figure BDA00032426249700000327
Figure BDA00032426249700000328
the Z coordinate is:
Figure BDA00032426249700000329
Figure BDA00032426249700000330
the sixth pass X coordinate is:
Figure BDA00032426249700000331
Figure BDA00032426249700000332
the Y coordinate is:
Figure BDA00032426249700000333
Figure BDA0003242624970000041
the Z coordinate is:
Figure BDA0003242624970000042
Figure BDA0003242624970000043
according to the process analysis method, the initial coordinates of the roller position obtained through calculation are the initial coordinates of the circle center of the bottom of the roller, the original coordinate data are imported into a robot control program, and the program is started, so that the rapid and accurate forming of the flanging piece can be realized.
Through specific experiments, the deviation between the actual profile and the theoretical profile of the flanging part obtained by the method is less than or equal to 0.5mm/m, the surface is flat, and obvious defects such as impression, wave and the like are avoided; the radius of the formable arc is larger than 1000mm, the opening angle of the arc is larger than 100 degrees, and the flanging piece is formed accurately, as shown in the following table:
Figure BDA0003242624970000044
compared with the existing method that the labor hour is 5 hours for forming a part by manually knocking and flanging, the method has the advantages that after the process planning is completed, the time for forming the part is only 0.5 hour, and the forming efficiency is greatly improved; compared with the prior art, the invention can improve the forming quality of the surface of the part, and the surface of the part is smooth and has no obvious defects of coining, waves and the like.
The foregoing embodiments may be modified in many different ways by those skilled in the art without departing from the spirit and scope of the invention, which is defined by the appended claims and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

Claims (3)

1. A flexible flanging full-mold forming method of a multi-pass robot is characterized in that in a process planning stage, a lower plane of a plate to be formed is taken as a baseThe method comprises the following steps of (1) aligning a plane, taking the center of a plate as an origin, establishing a three-dimensional rectangular coordinate system, setting a roller to move to a movement initial point along an X axis, and then setting n-pass flanging formation according to a flanging opening angle alpha of a target flanging piece in a (beta/2, -beta/2) range around a Y axis; according to the inner diameter R of the original plate0Arc opening angle beta and thickness d, flanging opening angle alpha of target flanging piece, transition fillet radius r, and length L of compression part of plate to be formed1Length L of the turnup portion2Radius of the roller rwDistance h from bottom surface of roller to theoretical tangent point of roller and plate when formingw(ii) a And the Y-axis coordinate of the mold plane is Y0Calculating to obtain the initial coordinates of the rollers in each pass; in the execution stage, the roller is controlled by an industrial six-axis robot to reach the initial coordinate of the roller in each pass and apply forming force to the part of the plate to be flanged so as to realize flexible flanging and forming, and the method specifically comprises the following steps:
i) measuring to obtain the inner diameter R of the original plate01200mm, an arc opening angle beta of 90 degrees and a thickness d of 2mm, a flanging opening angle alpha of 120 degrees, a transition fillet radius r of 10mm and a length L of a compression part of the target flanging piece1Is 100mm and the length L of the turned-up portion2Is 32 mm; then according to the length L of the turned-up portion2Determining the roller radius rwIs 24mm and the distance h from the bottom surface of the roller to the theoretical tangent point when the roller and the plate are formedwIs 30 mm;
ii) establishing a three-dimensional rectangular coordinate system by taking the lower plane of the plate as a reference surface and the circle center of the plate as an origin, wherein the Y-axis coordinate of the plane of the die is Y0The number of the rollers is 0, the rollers firstly move along the X axis to the movement starting point, and then flanging forming is carried out in the range of (45 degrees, -45 degrees) around the Y axis;
iii) setting 6-pass flanging forming according to the flanging opening angle alpha of the target flanging piece being 120 degrees;
iv) by means of R0、d、α、β、r、L1、L2、hw、y0Calculating to obtain the initial coordinates of the roller in each pass, and specifically comprising the following steps:
the first pass X coordinate is:
Figure FDA0003628755860000011
Figure FDA0003628755860000012
y coordinate is
Figure FDA0003628755860000013
Figure FDA0003628755860000014
Z coordinate is
Figure FDA0003628755860000015
Figure FDA0003628755860000016
The second pass X coordinate is:
Figure FDA0003628755860000017
Figure FDA0003628755860000018
y coordinate is
Figure FDA0003628755860000019
Figure FDA00036287558600000110
The Z coordinate is:
Figure FDA00036287558600000111
Figure FDA00036287558600000112
the X coordinate of the third pass is as follows:
Figure FDA00036287558600000113
Figure FDA00036287558600000114
y coordinate is
Figure FDA00036287558600000115
Figure FDA0003628755860000021
The Z coordinate is:
Figure FDA0003628755860000022
Figure FDA0003628755860000023
the fourth pass X coordinate is:
Figure FDA0003628755860000024
Figure FDA0003628755860000025
the Y coordinate is:
Figure FDA0003628755860000026
Figure FDA0003628755860000027
the Z coordinate is:
Figure FDA0003628755860000028
Figure FDA0003628755860000029
the X coordinate of the fifth pass is as follows:
Figure FDA00036287558600000210
Figure FDA00036287558600000211
the Y coordinate is:
Figure FDA00036287558600000212
Figure FDA00036287558600000213
the Z coordinate is:
Figure FDA00036287558600000214
Figure FDA00036287558600000215
the X coordinate of the sixth pass is as follows:
Figure FDA00036287558600000216
Figure FDA00036287558600000217
the Y coordinate is:
Figure FDA00036287558600000218
Figure FDA00036287558600000219
the Z coordinate is:
Figure FDA00036287558600000220
Figure FDA00036287558600000221
2. the multi-pass robot flexible flanging full-mold forming method of claim 1, wherein the forming is realized by a forming device, the forming device comprises a full-mold flanging workbench, a pressing module arranged on the full-mold flanging workbench and rollers for forming, wherein: the plate to be formed is arranged below the pressing module on the full-mold flanging workbench;
the compression module comprises: the triangular cushion block and the straight tooth pressing plate are respectively contacted with the side surface and the top surface of the plate to be formed.
3. The multi-pass robot flexible flanging whole-die forming method of claim 2, wherein the whole-die flanging workbench is a workbench with an inclined surface, the inclined surface and the plane part are in smooth transition through a transition fillet, the inclined angle of the inclined surface is the same as the flanging angle of the target flanging piece, and the length of the inclined surface is larger than the flanging height of the target flanging piece.
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