CN113953485A - Liquid die forging forming process method based on boost rate control - Google Patents
Liquid die forging forming process method based on boost rate control Download PDFInfo
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- CN113953485A CN113953485A CN202111096732.1A CN202111096732A CN113953485A CN 113953485 A CN113953485 A CN 113953485A CN 202111096732 A CN202111096732 A CN 202111096732A CN 113953485 A CN113953485 A CN 113953485A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
Abstract
The invention discloses a liquid die forging forming process method based on boost rate control, which belongs to the technical field of metal liquid die forging forming and comprises the following steps: firstly, a manipulator loads a liquid die forging aluminum alloy raw material into a lower die; in the mold filling stage, the proportional pump drives a movable cross beam of the hydraulic machine and drives an upper mold to move downwards, the descending speed is controlled to be 6-7 mm/s, the PLC is used as a controller, and the flow of the proportional pump is output by applying a closed-loop PI control algorithm after speed information is collected, so that the stable speed in the mold filling process is obtained; thirdly, a pressurizing stage, wherein the method of controlling the boosting rate is adopted in the pressurizing stage, and the expected pressure is continuously increased; in the stage, the expected pressure is obtained by controlling a proportional pump, and the opening of a proportional overflow valve in a hydraulic system is always given to be 100 percent of the maximum value; and fourthly, a pressure maintaining stage, namely reducing the temperature of the liquid die forging aluminum alloy raw material to a solid temperature, wherein the pressure of a system is controlled by a proportional overflow valve in the pressure maintaining stage, and the duration time of the pressure maintaining stage is 120-360 seconds.
Description
Technical Field
The invention belongs to the technical field of metal liquid die forging forming, and particularly relates to a liquid die forging forming process method based on boost rate control.
Background
In recent years, with the rapid development of the automobile industry, technicians develop key part key breakthrough projects, guide the automobile industry to strengthen the cooperation with related industries such as raw materials and the like, and cooperatively develop the industrialization and batch application research of high-strength aluminum alloy liquid die forging forming parts. Meanwhile, with the continuous and rapid development of economy in China, the automobile demand will keep growing in the future for a long period of time, and the application of the aluminum alloy liquid die forging forming part in the automobile industry is wide, so that the development of a liquid die forging forming process method is important to meet the performance requirements of aluminum alloy products and the market requirements.
Disclosure of Invention
The invention provides a liquid die forging forming process method based on boost rate control, which aims to solve the technical problems in the prior art, adopts a method that a PLC of a hydraulic machine controls the flow output and the pressure output of a proportional pump to realize the control of the boost rate in the aluminum alloy liquid die forging forming process, and thus, the expected key indexes of the aluminum alloy product, such as tensile strength, elongation and the like, are achieved.
The invention aims to provide a liquid die forging forming process method based on pressure rise rate control, which comprises the following steps:
step one, feeding: the manipulator loads the liquid die forging aluminum alloy raw material into a lower die;
step two, in the mold filling stage, when the temperature of the liquid die forging aluminum alloy raw material is 650-; the proportional pump drives a movable cross beam of the hydraulic machine and drives an upper die to descend, the descending speed is controlled to be 6-7 mm/s, the PLC acquires the descending real-time speed information of the sliding block, and the flow of the output proportional pump is obtained based on a closed-loop PI control algorithm, so that the stable speed in the mold filling process is obtained;
step three, in the pressurizing stage, along with the gradual reduction of the temperature of the liquid die forging aluminum alloy raw material, the state of the liquid die forging aluminum alloy raw material is changed from a liquid state to a solid state; the method for controlling the boosting rate is adopted at the stage, and the expected pressure is continuously increased; in the stage, the expected pressure is obtained by controlling a proportional pump, and the opening of a proportional overflow valve in a hydraulic system is always given to be 100 percent of the maximum value; two forming processes are adopted at the stage, wherein one process is constant boosting rate control, the adjusting range of the boosting rate is 6-20 bar/s, and the linear rising of the pressure intensity is expected; the other process is two-stage boosting rate control, the low boosting rate in the first stage is adjusted within the range of 6-20 bar/s, the boosting rate in the second stage is 20-35 bar/s, the pressure is expected to rise in a piecewise linear mode, and the variable point of the two-stage boosting is 65-75 bar;
the pressure control algorithm formula of the system is as follows:
wherein T is the cyclic scan time, upiFor the proportional pump output at the present moment, upi-1For proportional pump output at the previous moment, KpAs a proportional parameter, TIAs an integral time parameter, TDAs an integration time parameter, epiFor the pressure deviation at the present moment, epi-1For the pressure deviation at the last instant, epi-2Is the pressure deviation at the next previous moment;
the pressure which is increased continuously is required to be dynamically controlled at the stage, the expected pressure of the PLC controller is calculated once in 100ms, and the implemented control command is output to the proportional pump; because the pressure control range is 6-315 bar, the control range is large, a PID parameter is given by adopting a segmented PID method, and the PID parameter can be continuously changed in the operation process because the expected pressure is changed in real time;
and step four, a pressure maintaining stage, wherein when the temperature of the liquid die forging aluminum alloy raw material is reduced to the solid temperature, the PLC controls the pressure of the pressure maintaining stage according to the relationship between the set pressure and the opening size of the proportional overflow valve, and the duration time of the pressure maintaining stage is 120-360 seconds.
Further, in the second step, the descending speed is controlled to be 6mm/s or 7 mm/s.
Further, in the third step, when the constant pressure rising rate is controlled, the adjusting parameter of the pressure rising rate is 6bar/s or 20 bar/s.
Further, in the third step, when the two-stage pressure increasing rate is controlled, the low pressure increasing rate of the first stage is adjusted to be 6bar/s or 20bar/s, and the pressure increasing rate of the second stage is 20bar/s or 35 bar/s.
Further, in step four, the duration of the pressure holding period is 120s or 360 s.
The invention has the advantages and positive effects that:
in the traditional design method, a method for controlling the flow output of the proportional pump is adopted in the first stage, a pressure-boosting rate curve is fitted, and the control precision is low; in the method of the two-stage pressurizing stage, the first stage adopts a method of controlling the flow output of the proportional pump to fit the boosting rate, and the second stage adopts a method of rapidly pressurizing the energy accumulator, so that the boosting rate is not adjustable, and the flexible control capability of the method is poor. According to the method, the pressure increasing rate can be directly controlled in two stages of pressurization for the first time, the regulating range of the pressure increasing rate can be controlled within 6-35 bar/s, and the flexible control capability is strong.
The invention realizes the control of the pressure increasing rate in the liquid die forging forming process of the aluminum alloy, thereby achieving the key indexes of the expected aluminum alloy product, such as tensile strength, elongation and the like.
Drawings
FIG. 1 is a graph illustrating a desired boost rate for a segment of pressurization in a preferred embodiment of the present invention;
FIG. 2 is a graph illustrating a desired pressure for a section of pressurization in a preferred embodiment of the present invention;
FIG. 3 is a graph of the desired boost rate for two stages of pressurization in a preferred embodiment of the present invention;
fig. 4 is a graph of the desired pressure for two stages of pressurization in a preferred embodiment of the invention.
Detailed Description
In order to further understand the contents, features and effects of the present invention, the following embodiments are illustrated and described in detail with reference to the accompanying drawings:
the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art without creative efforts based on the technical solutions of the present invention belong to the protection scope of the present invention.
In the description of the present invention, it is to be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention.
Please refer to fig. 1 to fig. 4.
A liquid die forging forming process method based on pressure rise rate control comprises the following steps:
step one, a manipulator loads liquid die forging aluminum alloy raw materials into a lower die.
Step two, in the mold filling stage, when the temperature of the liquid die forging aluminum alloy raw material is 650-; the proportional pump drives a movable cross beam of the hydraulic machine and drives an upper die to descend, the descending speed is controlled to be 6-7 mm/s, the PLC acquires the descending real-time speed information of the sliding block, and the flow of the output proportional pump is obtained based on a closed-loop PI control algorithm, so that the stable speed in the mold filling process is obtained;
and step three, in the pressurizing stage, the temperature of the liquid die forging aluminum alloy raw material is gradually reduced, and the state and the performance of the liquid die forging aluminum alloy raw material are gradually changed from a liquid state to a solid state. This phase uses a method of controlling the rate of boost pressure, and the desired pressure is increasing. The desired pressure is obtained by controlling the proportional pump in such a way that the proportional relief valve opening in the hydraulic system is always given a maximum of 100% (without controlling the pressure from the proportional relief valve). In the stage, two forming processes are adopted, wherein one process is constant-boost rate control, the regulation range of the boost rate is 6-20 bar/s, and the linear rise of the pressure is expected, as shown in figures 1 and 2; the other process is two-stage boosting rate control, the low boosting rate in the first stage is adjusted within the range of 6-20 bar/s, the boosting rate in the second stage is 20-35 bar/s, the pressure is expected to rise in a piecewise linear mode, and the variable point of the two-stage boosting is generally 65-75 bar, as shown in fig. 3 and 4.
The pressure control algorithm formula of the system is as follows:
wherein T is the cyclic scan time, upiFor the proportional pump output at the present moment, upi-1For proportional pump output at the previous moment, KpAs a proportional parameter, TIAs an integral time parameter, TDAs an integration time parameter, epiFor the pressure deviation at the present moment, epi-1For the pressure deviation at the last instant, epi-2Is the pressure deviation at the next previous moment;
different from a constant pressure control method, the requirement of the stage for dynamically controlling the increasing pressure has high requirement on the quick response capability of a controller and an execution element, the expected pressure of the PLC controller is calculated once in 100ms, and the implemented control command is output to the proportional pump. Because the pressure control range is 6-315 bar, the control range is large, the PID parameters are given by adopting a segmented PID method, and because the expected pressure is changed in real time, the PID parameters can be changed continuously in the operation process.
And step four, in the pressure maintaining stage, the temperature of the liquid die forging aluminum alloy raw material is reduced to the solid temperature, and the state and the performance of the liquid die forging aluminum alloy raw material are gradually changed from the liquid state to the solid state. The PLC controls the pressure in the pressure maintaining stage according to the relationship between the set pressure and the opening size of the proportional overflow valve, the duration time of the pressure maintaining stage is generally 120-360 s, and deformation resilience of the solid metal is mainly prevented.
The above description is only for the preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and all simple modifications, equivalent changes and modifications made to the above embodiment according to the technical spirit of the present invention are within the scope of the technical solution of the present invention.
Claims (5)
1. A liquid die forging forming process method based on pressure rise rate control is characterized by comprising the following steps:
step one, feeding: the manipulator loads the liquid die forging aluminum alloy raw material into a lower die;
step two, in the mold filling stage, when the temperature of the liquid die forging aluminum alloy raw material is 650-700 ℃, the state is a liquid state; the proportional pump drives a movable cross beam of the hydraulic machine and drives an upper die to descend, the descending speed is controlled to be 6-7 mm/s, the PLC acquires the descending real-time speed information of the sliding block, and the flow of the output proportional pump is obtained based on a closed-loop PI control algorithm, so that the stable speed in the mold filling process is obtained;
step three, in the pressurizing stage, along with the gradual reduction of the temperature of the liquid die forging aluminum alloy raw material, the state of the liquid die forging aluminum alloy raw material is changed into a solid state from a liquid state; the expected pressure is continuously increased by adopting a method for controlling the boosting rate; the expected pressure is obtained by controlling a proportional pump, and the opening of a proportional overflow valve in a hydraulic system is always given to be 100 percent of the maximum value; the pressing stage includes two forming processes:
one process is constant pressure rise rate control, the regulation range of the pressure rise rate is 6-20 bar/s, and the pressure rise is expected to be linear;
the other process is two-stage boosting rate control, the low boosting rate in the first stage is adjusted within the range of 6-20 bar/s, the boosting rate in the second stage is 20-35 bar/s, the pressure is expected to rise in a piecewise linear mode, and the variable point of the two-stage boosting is 65-75 bar;
the pressure control algorithm formula of the system is as follows:
wherein T is the cyclic scan time, upiFor the proportional pump output at the present moment, upi-1For proportional pump output at the previous moment, KpAs a proportional parameter, TIAs an integral time parameter, TDAs an integration time parameter, epiFor the pressure deviation at the present moment in time,epi-1for the pressure deviation at the last instant, epi-2Is the pressure deviation at the next previous moment;
the expected pressure of the dynamic control is continuously increased, the expected pressure of the PLC controller for one time is calculated within 100ms, and an implemented control command is output to the proportional pump; because the pressure control range is 6-315 bar, the control range is large, a PID parameter is given by adopting a segmented PID method, and the PID parameter can be continuously changed in the operation process because the expected pressure is changed in real time;
and step four, a pressure maintaining stage, wherein when the temperature of the liquid die forging aluminum alloy raw material is reduced to the solid temperature, the PLC controls the pressure of the pressure maintaining stage according to the relationship between the set pressure and the opening size of the proportional overflow valve, and the duration time of the pressure maintaining stage is 120-360 seconds.
2. The liquid die forging forming process method based on the boost rate control according to claim 1, wherein in the second step, the descending speed is controlled to be 6mm/s or 7 mm/s.
3. The liquid die forging forming process method based on pressure increasing rate control according to claim 1, wherein in the step three, when the pressure increasing rate is controlled, the adjusting parameter of the pressure increasing rate is 6bar/s or 20 bar/s.
4. The liquid die forging forming process method based on pressure increasing rate control of claim 1, wherein in the third step, when the pressure increasing rates of the two stages are controlled, the low pressure increasing rate of the first stage is adjusted to be 6bar/s or 20bar/s, and the pressure increasing rate of the second stage is adjusted to be 20bar/s or 35 bar/s.
5. The liquid die forging forming process based on pressure increasing rate control of claim 1, wherein in step four, the duration of the pressure maintaining period is 120s or 360 s.
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