CN113909802B - Manufacturing method and structure of aluminum alloy headstock - Google Patents
Manufacturing method and structure of aluminum alloy headstock Download PDFInfo
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- CN113909802B CN113909802B CN202111046840.8A CN202111046840A CN113909802B CN 113909802 B CN113909802 B CN 113909802B CN 202111046840 A CN202111046840 A CN 202111046840A CN 113909802 B CN113909802 B CN 113909802B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
- B61D17/00—Construction details of vehicle bodies
- B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/40—Engine management systems
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Abstract
Five large plates of the aluminum alloy headstock manufactured by adopting a superplastic forming method: curb plate 1, roof 2, preceding window board 3 and window hypoplastron 4, every board all adopt three-layer aluminum plate composite construction, and first outer panel 7 replaces traditional locomotive skin, and intermediate lamella 8 replaces traditional locomotive skeleton, and second outer panel 9 replaces traditional cab to be built-in, and the assembly welding again after the integrated into one piece of whole structure adopts the sheet metal can satisfy intensity, rigidity etc. demand, satisfies the demand of lightweight to intensity and rigidity can also improve by a wide margin.
Description
Technical Field
The invention belongs to the technical field of rail vehicle manufacturing, and particularly relates to a manufacturing method and a structure of an aluminum alloy headstock.
Background
Along with the continuous development and the perfection of a rail transit system, the attractive appearance, the environmental protection, the high speed and the energy conservation become important marks of modern rail transit, the rapid development of vehicles in the market domain brings higher requirements to the structural design of the front-end cab of the vehicle, and the novel front-end cab structure taking weight reduction and energy conservation as the main tasks is an important guarantee for realizing the long-term healthy development of enterprises. At present, a cab at the front end of a railway vehicle adopts a design structure of externally-coated aluminum skins of plate beams, is mainly manufactured by adopting a welding process, has complex fixture, low production efficiency and large welding deformation, and has the important defect of restricting the development of aluminum alloy heads.
Disclosure of Invention
The invention aims to solve the problems that the traditional aluminum alloy headstock adopts a structure that an aluminum skin is welded on the outer side of a plate beam, and a tooling fixture is complex, large in welding deformation and heavy in weight, so that the manufacturing method and the structure of the aluminum alloy headstock are provided, the welding amount in the manufacturing process is greatly reduced, the welding deformation is small, and meanwhile, the tooling fixture is correspondingly reduced, and the whole headstock is simple in structure, light in weight and suitable for the light-weight requirement.
In order to achieve the above object, the present invention provides a method for manufacturing an aluminum alloy headstock, comprising the steps of:
step 1: the three-layer aluminum plate composite structure of the headstock side plate, the top plate, the front window plate and the window lower plate is molded, and the molding process is divided into the following steps:
and (3) blanking: cutting the aluminum plate according to the size of the part;
deoiling and pickling: removing greasy dirt and an oxide film on the surface of the aluminum plate by wiping and pickling;
sealing and welding the plate material: the method comprises the steps of stacking a first outer side plate and a middle plate together, carrying out laser welding according to a set position, wherein the width of a welding line is twice the wall thickness, stacking a second outer side plate, carrying out laser welding on the second outer side plate and the middle plate at the set position, ensuring that the width of the welding line is twice the wall thickness, enabling the initial position and the end position of all the welding lines to be at a certain distance from the edge of a three-layer plate, arranging gaps required by bulging air inlet among the welding lines, arranging an aluminum pipe between two adjacent layers of the air inlet side of the three-layer plate, welding the periphery of the three-layer plate to form a closed structure, and reserving gaps between the welding lines of the periphery of the three-layer plate and the welding lines of the middle part;
checking air tightness: introducing gas into the aluminum pipe, and checking the air tightness between two adjacent plates;
filling into a mold and charging into a furnace: loading the combined three-layer plate integral structure into a die, fixing the die in a furnace chamber of a special super-molding press, and sealing the furnace chamber;
vacuumizing: vacuumizing the inside of the three-layer aluminum plate structure through an aluminum pipe;
heating and heating: the furnace chamber heating equipment heats the whole three-layer plate structure to a set temperature;
superplastic forming: performing hot stamping on a special press machine for superplastic forming to finish preforming, wherein the radian of a preformed three-layer plate is close to that of a finished product, then closing a die, applying pressure to ensure sealing edges by sealing grooves, controlling gas pressure to be introduced into gaps between two side plates and a middle plate according to a simulation result, simultaneously performing bulging, and performing bulging at a constant strain rate to ensure that the three-layer plate is completely attached to a die to finish superplastic forming;
and (3) cooling: taking out the formed product from the die by using a special lifting appliance, and cooling to room temperature;
cutting off the margin of the circumference: cutting off the allowance of the peripheral ring to obtain a single part;
step 2: machining: machining the periphery of a side plate, a top plate, a front window plate and a window lower plate of the headstock according to a product drawing, and machining an upper window of the front window plate and an upper side window of the side plate;
step 3: and (3) assembly welding: the side plates, the top plate, the front window plate and the window lower plate of the headstock are assembled on a welding fixture, and are welded after spot welding;
step 4: shot peening strengthening: and (5) carrying out surface shot peening strengthening treatment on the headstock.
Further, in the step 1, simulation of the superplastic forming step is to use MSC.MARC software to establish a four-node quadrilateral thin-shell unit grid model, and simulate the four-node quadrilateral thin-shell unit grid model according to a strain rate of 0.0001/s.
Further, pre-bulging is performed for 20min when bulging is performed in the superplastic forming step in step 1, air is slowly introduced at low pressure under the air pressure of 0.1Mpa, after most of the air is attached to the die, the air is gradually increased, and air is introduced at the maximum air pressure of 0.5Mpa, so that the attachment of the reverse bulging groove is controlled; then the air pressure is gradually increased, the expansion is carried out for 30min under the pressure of not more than 2Mpa, and the temperature is maintained at 480 ℃ in the forming process.
The invention also provides an aluminum alloy headstock structure, which is manufactured by the manufacturing method of the integral bearing type aluminum alloy headstock.
Compared with the prior manufacturing method and structure of the locomotive, the manufacturing method and structure of the aluminum alloy locomotive have the following advantages:
(1) The welding quantity is small, and the welding deformation is small. The side plate, the top plate, the front window plate and the window lower plate are formed by the superplastic forming method and then assembled and welded into the headstock, so that the quantity of welding lines is small, the welding deformation is small, and the headstock is more attractive, round and smooth in appearance.
(2) The fixture is simple and the production efficiency is high. The aluminum alloy headstock structure adopts the three-layer aluminum plate composite structure plates to be assembled and welded together, so that a large number of tools such as positioning and clamping used by the traditional plate girder structure are reduced while welding lines are reduced, a large number of tool cost is saved, and the production efficiency is improved.
(3) The weight is light. The aluminum alloy headstock adopts a three-layer aluminum plate composite structure to replace three parts in the headstock skin, the headstock framework and the cab in the traditional sense, and adopts thin plates to meet the requirements of strength, rigidity and the like, so that the overall weight of the front-end cab structure is greatly reduced.
(4) The strength and the rigidity are good. The three-layer aluminum plate composite structure of the aluminum alloy headstock forms a whole, the strength and the rigidity are obviously improved, and the headstock stability is higher when bearing load.
Drawings
FIG. 1 is a flow chart of the aluminum alloy headstock manufacturing process of the present invention;
fig. 2 is a schematic diagram showing the connection of a three-layer aluminum plate composite structure
Fig. 3 is a schematic view of a vehicle head structure
Wherein: 1. a side plate; 2. a top plate; 3. a front window panel; 4. a window lower plate; 5. a front window; 6. a side window; 7. a first outer side plate; 8. an intermediate plate; 9. and a second outer side plate.
Detailed Description
In order to better understand the purpose, structure and function of the present invention, a method for manufacturing an aluminum alloy headstock and the structure thereof are described in further detail below with reference to the accompanying drawings.
Referring to fig. 1, the manufacturing method of the aluminum alloy headstock of the present invention divides the headstock into five large blocks, namely two side plates 1, a top plate 2, a front window plate 3 and a window lower plate 4, respectively, and the headstock side plates 1, the top plate 2, the front window plate 3 and the window lower plate 4 are firstly respectively molded, and the headstock five large blocks all adopt a three-layer aluminum plate composite structure, and the molded side plates 1, the top plate 1, the front window plate 3 and the window lower plate 4 are assembled and welded.
The three-layer aluminum plate composite structure forming process of the side plate 1, the top plate 2, the front window plate 3 and the window lower plate 4 comprises the following steps:
and (3) blanking: the aluminum plate is cut according to the size of the part, wherein two outer side plates are aluminum plates with the thickness of 2mm, and an intermediate plate 8 is an aluminum plate with the thickness of 1.5 mm;
deoiling and pickling: removing impurities such as greasy dirt and the like by wiping with alcohol or other organic solvents, and removing an oxide film on the surface of the aluminum plate material by pickling;
sealing and welding the plate material: stacking the first outer side plate 7 and the middle plate 8 together, and performing multi-channel laser welding according to a set position, wherein welding seams are arranged at equal intervals, and the width of the welding seams is twice the wall thickness; then stacking a second outer side plate, and performing laser welding on the second outer side plate 9 and the middle plate 8 at a set position, wherein the welding seams of the embodiment are arranged at the middle position of the welding seams of the middle plate 8, are arranged in parallel in a staggered manner, and ensure that the width of the welding seams is twice the wall thickness; the starting positions and the ending positions of all the welding seams are at a certain distance from the edges of the three-layer plates; and finally, arranging an aluminum pipe between two adjacent plates at one side of the welding line end of the three-plate, and welding the circumference of the three-plate to form a closed structure, wherein a gap is reserved between the welding line of the circumference of the three-plate and the existing welding line of the plate, so that air intake is facilitated in the follow-up air tightness inspection and bulging. The weld width is twice the wall thickness and is mainly used for ensuring the strength required by subsequent bulging. It should be noted that the arrangement of the weld seam may be changed according to the requirements of strength and structure, may be parallel to each other, may be at a certain angle, and the position where bulging is not required may be completely closed, and the gap required for bulging air intake needs to be left at the position where bulging is required.
Checking air tightness: introducing gas with the air pressure of 0.2MPa into the aluminum pipe, and checking the air tightness between two adjacent plates;
filling into a mold and charging into a furnace: loading the combined three-layer plate integral structure into a die, fixing the die in a furnace chamber of a special super-molding press, and sealing the furnace chamber;
vacuumizing: vacuumizing the inside of the three-layer aluminum plate composite structure through an aluminum pipe between two layers of plates;
heating and heating: the furnace chamber heating equipment heats the whole three-layer aluminum plate composite structure to 480 ℃;
superplastic forming: the method comprises the steps of firstly adopting hot stamping at the speed of 10mm/s to finish preforming on a special press machine for superplastic forming, enabling radian of three layers of plates to be close to that of a finished product piece after preforming, enabling the wall thickness of the whole part to be 5.44mm-5.53mm at the moment, then closing a die, applying pressure to ensure sealing edges by sealing grooves, controlling gas pressure to be introduced into gaps between two side plates and a middle plate according to simulation results, simultaneously bulging, performing simulation by adopting MSC (mobile switching center) MARC software for simulation, establishing a four-node quadrilateral thin-shell unit grid model, and performing simulation according to the strain rate of 0.0001/s. The method comprises the steps of pre-bulging for 20min during bulging, slowly feeding air at the low pressure under the air pressure of 0.1MPa, gradually increasing the air feeding pressure after 70-80% of the die is attached, feeding air at the maximum air pressure of 0.5MPa, controlling the attachment of the reverse bulging groove, and generally prolonging the air feeding pressure gradually along with the time to prevent the initial air pressure from being excessively large to break the plate. Finally, gradually increasing the air inlet pressure, controlling the maximum pressure to be 2Mpa, and performing high-pressure bulging for 30min, wherein the temperature is kept at 480 ℃ in the forming process, and the bulging is performed at a constant strain rate, so that the three-layer plate is completely attached to the die, and the superplastic forming is completed;
and (3) cooling: taking out the formed product from the die by using a special lifting appliance, and cooling the formed product to room temperature in air;
cutting off the margin of the circumference: cutting off the allowance of the peripheral ring to obtain a single part;
after the side plates, the top plate, the front window plate and the lower window plate are formed, machining the side plates, the top plate, the front window plate and the lower window plate of the headstock according to a product drawing; after machining, the side plates, the top plate, the front window plate and the window lower plate of the headstock are assembled on a welding fixture, and are welded after spot welding. Shot peening may also be performed after welding to improve material properties.
The aluminum alloy headstock manufactured by the method is divided into five blocks: curb plate 1, roof 2, preceding window board 3 and window hypoplastron 4, every board all adopt three-layer aluminum plate composite construction, and first outer panel 7 replaces traditional locomotive skin, and intermediate lamella 8 replaces traditional locomotive skeleton, and second outer panel 9 replaces traditional cab to be built-in, and the whole structure integrated into one piece can, adopt the sheet metal can satisfy intensity, rigidity etc. demand, satisfies the demand of lightweight to intensity and rigidity can also improve by a wide margin.
Claims (4)
1. The manufacturing method of the aluminum alloy headstock is characterized by comprising the following steps of:
step 1: the three-layer aluminum plate composite structure of the headstock side plate (1), the top plate (2), the front window plate (3) and the window lower plate (4) is molded, and the molding process is divided into the following steps:
and (3) blanking: cutting the aluminum plate according to the size of the part;
deoiling and pickling: removing greasy dirt and an oxide film on the surface of the aluminum plate by wiping and pickling;
sealing and welding the plate material: firstly, stacking a first outer side plate (7) and a middle plate (8) together, carrying out laser welding according to a set position, wherein the width of a welding line is twice the wall thickness, then stacking a second outer side plate (9), carrying out laser welding on the second outer side plate (9) and the middle plate (8) at the set position, ensuring that the width of the welding line is twice the wall thickness, enabling the starting position and the ending position of all the welding lines to be at a certain distance from the edges of three plates, arranging gaps required by bulging air inlet among the welding lines, finally arranging an aluminum pipe between two adjacent plates on the air inlet side of the three plates, welding the periphery of the three plates to form a closed structure, and reserving gaps between the periphery welding lines of the three plates and the middle welding line;
checking air tightness: introducing gas into the aluminum pipe, and checking the air tightness between two adjacent plates;
filling into a mold and charging into a furnace: loading the combined three-layer plate integral structure into a die, fixing the die in a furnace chamber of a special super-molding press, and sealing the furnace chamber;
vacuumizing: vacuumizing the inside of the three-layer aluminum plate structure through an aluminum pipe;
heating and heating: the furnace chamber heating equipment heats the whole three-layer plate structure to a set temperature;
superplastic forming: performing hot stamping on a special press machine for superplastic forming to finish preforming, wherein the radian of a preformed three-layer plate is close to that of a finished product, then closing a die, applying pressure to ensure sealing edges by sealing grooves, controlling gas pressure to be introduced into gaps between two side plates and a middle plate according to a simulation result, simultaneously performing bulging, and performing bulging at a constant strain rate to ensure that the three-layer plate is completely attached to a die to finish superplastic forming;
and (3) cooling: taking out the formed product from the die by using a special lifting appliance, and cooling to room temperature;
cutting off the margin of the circumference: cutting off the allowance of the peripheral ring to obtain a single part;
step 2: machining: machining the peripheries of a side plate, a top plate, a front window plate and a window lower plate of the headstock according to a product drawing, and machining a front window (5) of the front window plate and an upper side window (6) of the side plate;
step 3: and (3) assembly welding: the side plates, the top plate, the front window plate and the window lower plate of the headstock are assembled on a welding fixture, and are welded after spot welding;
step 4: shot peening strengthening: and (5) carrying out surface shot peening strengthening treatment on the headstock.
2. The method for manufacturing the integral bearing type aluminum alloy headstock according to claim 1, wherein the method comprises the following steps: in the step 1, simulation of the superplastic forming step is to establish a four-node quadrilateral thin-shell unit grid model by adopting MSC.MARC software, and simulate according to the strain rate of 0.0001/s.
3. The method for manufacturing the integral bearing type aluminum alloy headstock according to claim 1, wherein the method comprises the following steps: the step 1 is that pre-bulging is carried out for 20min when the super-plastic forming step is bulging, air is slowly introduced at low pressure under the air pressure of 0.1Mpa, after most of the air is attached to the die, the air is introduced at the maximum under the air pressure of 0.5Mpa, and the attachment of the reverse bulging groove is controlled; then the air pressure is gradually increased, the expansion is carried out for 30min under the pressure of not more than 2Mpa, and the temperature is maintained at 480 ℃ in the forming process.
4. An aluminium alloy headstock structure manufactured by a monolithic load bearing aluminium alloy headstock manufacturing method according to any one of claims 1 to 3.
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Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109434380A (en) * | 2018-11-05 | 2019-03-08 | 北京星航机电装备有限公司 | A kind of Varying-thickness lightweight missile wing covering manufacturing process |
| CN109604444A (en) * | 2018-11-13 | 2019-04-12 | 北京航星机器制造有限公司 | A kind of shaping dies and manufacturing process of large-sized aluminium alloy covering |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| TW261590B (en) * | 1992-07-17 | 1995-11-01 | Hitachi Seisakusyo Kk | |
| CN209208762U (en) * | 2018-09-26 | 2019-08-06 | 重庆中车长客轨道车辆有限公司 | A kind of railcar and its headstock |
| CN111891158A (en) * | 2020-07-29 | 2020-11-06 | 中车长春轨道客车股份有限公司 | High-strength locomotive aluminum structure of railway vehicle |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109434380A (en) * | 2018-11-05 | 2019-03-08 | 北京星航机电装备有限公司 | A kind of Varying-thickness lightweight missile wing covering manufacturing process |
| CN109604444A (en) * | 2018-11-13 | 2019-04-12 | 北京航星机器制造有限公司 | A kind of shaping dies and manufacturing process of large-sized aluminium alloy covering |
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