CN114669961B - Method for forming large aluminum alloy thick-wall special-shaped shell - Google Patents
Method for forming large aluminum alloy thick-wall special-shaped shell Download PDFInfo
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- CN114669961B CN114669961B CN202210195080.5A CN202210195080A CN114669961B CN 114669961 B CN114669961 B CN 114669961B CN 202210195080 A CN202210195080 A CN 202210195080A CN 114669961 B CN114669961 B CN 114669961B
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Abstract
A method for forming a large aluminum alloy thick-wall special-shaped shell comprises the following steps: firstly, segmenting a target object according to the outline shape of the target object and forming a plurality of target units with consistent appearance characteristics; enveloping each target unit and preparing an enveloping body uniquely corresponding to the target unit; step three, lofting each enveloping body and obtaining cutting and forming parameters; cutting the plate according to the forming parameters, and then bending the cut plate; and fifthly, finishing and welding the bent plate according to the size of the target object. The present invention can be produced using existing equipment capabilities. The invention is put into practical production, and can prepare the special-shaped shell based on the existing production capacity, thereby improving the production capacity and bearing more complex tasks. In addition, the invention reduces the investment of the die and greatly reduces the production cost of the special-shaped shell.
Description
Technical Field
The invention belongs to the technical field of metal workpiece forming, and particularly relates to a forming method of a large aluminum alloy thick-wall special-shaped shell.
Background
For large-sized special-shaped parts, the surface structure is complex, and parts meeting the requirements are difficult to manufacture by the conventional forming method.
For example, in the prior art, a large-sized shell part with a complex curved surface is generally formed by pressing through a forming die. For those skilled in the art, the use cost of the large complex curved surface shell part forming mold is very high, and cannot be borne by common manufacturers. Further, since parts similar to such large-sized complicated curved surface housings are very rare in the field of molding, there is a problem that the investment in manufacturing cost is extremely high and the use rate of the mold is low.
Disclosure of Invention
Problem (A)
In summary, how to solve the problems of high investment cost and low utilization rate of the manufacturing mold of large-sized and special-shaped shell structure parts in the prior art becomes a problem to be solved urgently by the technical personnel in the field.
(II) technical scheme
The invention provides a method for forming a large aluminum alloy thick-wall special-shaped shell, which comprises the following steps:
firstly, segmenting a target object according to the outline shape of the target object and forming a plurality of target units with consistent appearance characteristics;
enveloping each target unit and preparing an enveloping body uniquely corresponding to the target unit;
step three, lofting each enveloping body and obtaining cutting and forming parameters;
cutting the plate according to the forming parameters, and then bending the cut plate;
and step five, finishing and welding the bent plate according to the size of the target object.
Preferably, in the method for forming the large thick-walled special-shaped aluminum alloy shell, in the first step, the target object is segmented along the axial direction of the target object, and then each segment is segmented along the circumferential direction to form a plurality of target units with curved surface structures.
Preferably, in the method for forming the aluminum alloy large-sized thick-walled special-shaped shell, in the second step, an aluminum plate is used as an enveloping body raw material, and the thickness of the enveloping body raw material is greater than that of the target unit.
Preferably, in the method for forming a large-sized thick-walled special-shaped aluminum alloy shell, in the second step, the enveloping body raw material is selected and then rolled into an elliptic cone shape.
Preferably, in the method for forming the large thick-wall special-shaped aluminum alloy shell, in the third step, the enveloping body which is rolled into the elliptic cone shape is lofted by adopting a triangular lofting technology.
Preferably, in the method for forming the large-sized thick-wall special-shaped aluminum alloy shell, in the third step, the surface of the enveloping body which is rolled into the elliptic cone shape is divided into triangles, the side length of all the triangles is obtained, the lofting size group of the enveloping body is obtained, then the lofting size groups of the enveloping body corresponding to the target units of the same section are sequentially spliced, lofting operation is carried out along the axial direction, and the lofted structure is unfolded to obtain the cutting forming parameters.
Preferably, in the method for forming the large aluminum alloy thick-wall special-shaped shell, in the fourth step, the plate is cut by adopting a water cutting mode.
Preferably, in the method for forming the large thick-wall special-shaped aluminum alloy shell, an oil press is adopted to bend the cut plate along the lofting bus.
Preferably, in the method for forming the large aluminum alloy thick-wall special-shaped shell, the bent plate is calibrated, and the calibration tool used for calibration comprises at least two calibration curved surfaces which are relatively fixed and eccentric.
Preferably, in the method for forming the large aluminum alloy thick-wall special-shaped shell, in the fifth step, the bent elliptical cone sheet is firstly placed on a machine tool for alignment, and a reference surface is milled at one end; then, the inner and outer shapes are milled by a ball cutter by using a datum plane mounting clamp for alignment, and the wall thickness is ensured; and finally, milling peripheral and longitudinal grooves and finally welding.
(III) advantageous effects
The invention provides a method for forming a large aluminum alloy thick-wall special-shaped shell, which comprises the following steps: firstly, segmenting a target object according to the outline shape of the target object and forming a plurality of target units with consistent appearance characteristics; enveloping each target unit and preparing an enveloping body uniquely corresponding to the target unit; step three, lofting each enveloping body and obtaining cutting and forming parameters; cutting the plate according to the forming parameters, and then bending the cut plate; and fifthly, finishing and welding the bent plate according to the size of the target object.
The method for forming the large aluminum alloy thick-wall special-shaped shell realizes the forming of the special-shaped shell, has novel design concept and simple and convenient operation, is easy to operate and form plates, and can be used for producing the plates by using the existing equipment capacity. The invention is put into practical production, and can prepare the special-shaped shell based on the existing production capacity, thereby improving the production capacity and bearing more complex tasks. In addition, the invention reduces the investment of the die and greatly reduces the production cost of the special-shaped shell.
Drawings
FIG. 1 is an axial view of a target object in an embodiment of the invention;
FIG. 2 is a side view of a target object in an embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating segmentation of a target object according to an embodiment of the present invention;
FIG. 4 is a diagram illustrating segmentation of segment A of a target object according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a target unit after segmentation is performed on segment A of a target object according to an embodiment of the present invention;
FIG. 6 is a diagram illustrating an envelope after enveloping a target unit according to an embodiment of the present invention;
FIG. 7 is a schematic diagram of lofting of an envelope after lofting according to an embodiment of the present invention;
fig. 8 is a schematic structural diagram of a calibration fixture in an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
In addition, in the description of the present invention, the terms "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of describing the present invention but do not require that the present invention must be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. The terms "connected" and "connected" used herein should be interpreted broadly, and may include, for example, a fixed connection or a detachable connection; they may be directly connected or indirectly connected through intermediate members, and specific meanings of the above terms will be understood by those skilled in the art as appropriate.
Referring to fig. 1 to 8, fig. 1 is an axial view of a target object according to an embodiment of the present invention; FIG. 2 is a side view of a target object in an embodiment of the present invention; FIG. 3 is a schematic diagram illustrating segmentation of a target object according to an embodiment of the present invention; FIG. 4 is a diagram illustrating segmentation of segment A of a target object according to an embodiment of the present invention; FIG. 5 is a schematic diagram of a target unit after segmentation is performed on segment A of a target object according to an embodiment of the present invention; FIG. 6 is a diagram illustrating an envelope after enveloping a target unit according to an embodiment of the present invention; FIG. 7 is a schematic diagram of lofting of an envelope after lofting according to an embodiment of the present invention; fig. 8 is a schematic structural diagram of a calibration fixture in an embodiment of the present invention.
The invention provides a method for forming a large aluminum alloy thick-wall special-shaped shell, which is suitable for barrel-shaped components, namely hollow components (the middle space of the components has no structure), has a certain wall thickness and has a set external contour shape (the shape of the external surface is set).
In the invention, the method for molding the large aluminum alloy thick-wall special-shaped shell comprises the following steps:
firstly, segmenting the target object according to the contour shape of the target object (the segmentation mode is to cut the target object along the axial direction of the target object) and forming a plurality of appearance features (the appearance features refer to the shape features of a target unit formed after segmentation, for example, the appearance features of the target unit are gradually enlarged or gradually reduced in a certain direction if the target unit is in a truncated cone shape), wherein the appearance features are consistent target units (if the appearance changes obviously, the appearance features are inconsistent, for example, the caliber is gradually enlarged and then gradually reduced in a certain direction, the appearance features are inconsistent, or if the caliber gradually enlarged and changed in a certain direction is smaller, and then the change rate is larger, the appearance features are inconsistent).
Further, in the first step, the target object is segmented along the axial direction of the target object, and then each segment is segmented along the circumferential direction to form a plurality of target units of the curved surface structure.
In the industrial field, even a special-shaped structural member has a certain design rule, and the shape of the external contour is not disordered, so that the structural member (defined as a target object in the invention) can be divided, and each divided part has certain external features, such as a smooth curved surface, a flat surface or other regular shapes (such as a wave shape). The object in the practical operation of the invention is an eccentric ellipsoid structure, so that the target object can be segmented according to the eccentric inflection point (the eccentric connecting line is not a straight line and is turned), the axis of the segmented ellipsoid is approximate to a straight line, and the external contour characteristics of each segment (the external contour characteristics refer to the contour shape of each segment) after segmentation are basically consistent.
And step two, enveloping each target unit and preparing an enveloping body uniquely corresponding to the target unit.
Specifically, in the second step, the aluminum plate is used as the raw material of the enveloping body, the thickness of the raw material of the enveloping body is larger than that of the target unit, and after the raw material of the enveloping body is selected, the raw material of the enveloping body is rolled into an elliptic cone shape.
The present invention segments the target object into a plurality of "sheet" structures in step one, and then the present invention employs an aluminum plate (having a thickness greater than the thickness of each sheet structure) as the envelope raw material in step two. The aluminum plate may be pre-shaped according to the shape of each sheet structure (target unit), for example, bent into a bent sheet structure similar to the sheet structure, and then a groove structure may be provided on the aluminum plate, which can completely enclose the target unit. Then, the enveloping body is coiled into an elliptic cone shape (so as to facilitate subsequent lofting operation).
And step three, lofting each enveloping body and obtaining cutting and forming parameters.
Specifically, in the third step, the enveloping body which is rolled into the elliptic cone shape is lofted by adopting a triangular lofting technology. Furthermore, in the third step, the surface (elliptic annular surface) of the enveloping body which is rolled into an elliptic cone shape is divided by adopting a triangle, the side length of all triangles is obtained, an enveloping body lofting size group is obtained, then the enveloping body lofting size groups corresponding to a plurality of target units in the same section are spliced in sequence and lofted along the axial direction, and the lofted structure is unfolded to obtain cutting forming parameters.
And step four, cutting the plate according to the forming parameters, and then bending the cut plate.
Specifically, in the fourth step, the plate is cut by adopting a water cutting mode.
Specifically, an oil press is adopted to bend the cut plate along the lofting bus. In addition, the bent plate is calibrated, and the calibration tool used for calibration comprises at least two calibration curved surfaces which are relatively fixed and eccentric.
In view of the above, the present invention performs axial segmentation on the target object according to the segmentation based on the eccentric inflection point, that is, two adjacent segments must be eccentric. Therefore, the calibration tool provided by the invention comprises at least two eccentric calibration curved surfaces, and can calibrate the curved surfaces of two adjacent segments.
And step five, finishing and welding the bent plate according to the size of the target object. In the fifth step, firstly, the bent elliptic conical sheet is placed on a machine tool for alignment, and a reference surface is milled at one end of the elliptic conical sheet; then, the inner and outer shapes are milled by a ball cutter by using a datum plane mounting clamp for alignment, and the wall thickness is ensured; and finally milling peripheral and longitudinal grooves and finally welding.
In one embodiment of the invention, a certain type of product is taken as an example, the maximum diameter of the product is 2.4 meters, the overall shape of the product is like a small airplane, and the external shape is mostly streamline. Since the product is a special-shaped component (and a shell-type part), the forming difficulty of the large complex shell is very high. By analyzing the shape of the product of the model, the product can be determined to be of a variable cross section (the shapes of the axial cross sections are different), an ellipse (the axial cross sections are all elliptical) and an eccentric (the centroids of the elliptical structures of the axial cross sections are not coaxially arranged). Through measurement, the size of a front ellipse of the product is 2087.5 multiplied by 2084.3, the shape value of a rear section is a gradual change ellipse structure, the ellipses of the sections are eccentric in a certain sequence, the size of the last ellipse is 1773.3 multiplied by 1462.8, the maximum eccentricity is 58.4, the total length of the shell is 1440mm, and the integral wall thickness is 25mm.
According to the structure and the product requirement of a target product (the target product refers to a product of a certain type), and according to the method provided by the invention, the following processing scheme is established:
1. the product is divided into 12 pieces by integrating the product structure, bending, machining and welding processes. The product is divided into three sections along the axial direction of the product, and each section is circumferentially cut into four parts, wherein three parts is four parts and = twelve parts.
As shown in FIG. 3, the product is divided into three sections (three sections A \ B \ C in FIG. 1) along the axial direction of the product in FIG. 3.
As shown in FIG. 4, the segment A is divided into four segments in the circumferential direction in FIG. 4, which are respectively A1\ A2\ A3\ A4.
2. Enveloping the curved surface (each slice), specifically enveloping each cut slice structure. Through three-dimensional analysis and research on each sheet, the aluminum sheet with the thickness of 40mm is adopted (the thickness of the adopted aluminum sheet must be larger than the maximum thickness of a target product, in addition, other metal materials can also be adopted as an enveloping body), and the aluminum sheet is rolled into an elliptic cone (the conical body is the enveloping body) to envelop each curved surface respectively, so that the curved surfaces can be enveloped.
3. And (5) lofting the enveloping body. Since the target product in the present invention is irregular in shape, the developed size and shape of the target product cannot be calculated by a conventional method. For this purpose, the invention uses a triangular lofting technique to loft the envelope (elliptical cone shape).
The specific lofting operation is as follows: the lofting operation was performed using CAD software, dividing each envelope (elliptical cone) into a number (64) of small triangles, and recording by measuring the length of three sides of each small triangle. Then, 64 small triangles are connected in sequence according to the positions of the enveloping bodies (elliptic cones), a lofting drawing of each section of the enveloping bodies (elliptic cones) is drawn, and the unfolding size and the shape of each section are approximately obtained (the following drawing). And cutting corresponding sizes at the positions of the sheets in the lofting drawing, adding machining allowance to obtain the water cutting and blanking size of the product, and blanking according to the shape of the drawing.
4. And bending the plate.
According to the shape and curvature change of a product, a set of bending tool is designed, and the bending tool is fixed on a 350-ton open type oil press. And (4) performing water cutting blanking according to the lofting size of the blank (the lofting size of the enveloping body), and then scribing a pressure type datum line on the surface of the aluminum plate. In the present invention, the bus bar of the proof chart is used as a reference for the profiling. And placing an aluminum plate in the middle of the upper die and the lower die, wherein the datum line on the aluminum plate is aligned with the central line of the die. The stroke of the oil press is adjusted to drive the upper die to move up and down, and the pressure of the oil press is utilized to deform the aluminum plate. And adjusting the central line of the next datum line die of the aluminum plate to align, adjusting the upper die to perform profiling, and repeatedly bending. The profiling process is a very tedious process, and the position of the die and the plate needs to be adjusted repeatedly to ensure the forming.
5. Alignment with template: in order to verify that the shape of the bend meets the design requirements, a template as shown in fig. 8 was designed. The template connects two different enveloping ellipses at the front and the back of each section by a middle screw rod, an eccentric elliptic cone is formed in space, and a three-dimensional template is formed according to the inner size of the enveloping elliptic cone. And comparing the shapes of the bent shapes by using the template, and if the bent shapes completely accord with the template, determining that the bent shapes form an enveloping elliptic cone.
6. The internal and external shapes of each chip are added. Firstly, placing a bent elliptic conical sheet on a machine tool for alignment, and milling a reference surface at one end; then, the inner and outer shapes are milled by a ball cutter for alignment by mounting and clamping the reference surface, and the wall thickness is ensured; and finally milling peripheral and longitudinal grooves.
7. Welding to form the enclosure. And punching the reinforcing ribs, connecting the reinforcing ribs according to the correct positions of drawings to form an inner mold, butting four machined reinforcing ribs into a surrounding shell, welding a fixing block, fixing the position by using the fixing block, and welding a longitudinal welding line to form the shell. And then butt-welding each section into a surrounding shell.
Therefore, the invention provides a method for forming the aluminum alloy large-scale thick-wall special-shaped shell, which comprises the following steps: firstly, segmenting a target object according to the outline shape of the target object and forming a plurality of target units with consistent appearance characteristics; enveloping each target unit and preparing an enveloping body uniquely corresponding to the target unit; step three, lofting each enveloping body and obtaining cutting and forming parameters; cutting the plate according to the forming parameters, and then bending the cut plate; and fifthly, finishing and welding the bent plate according to the size of the target object.
The method for forming the large aluminum alloy thick-wall special-shaped shell realizes the forming of the special-shaped shell, has novel design concept and simple and convenient operation, is easy to operate and form plates, and can be used for producing the plates by using the existing equipment capacity. The invention is put into practical production, and can prepare the special-shaped shell based on the existing production capacity, thereby improving the production capacity and bearing more complex tasks. In addition, the invention reduces the investment of the die and greatly reduces the production cost of the special-shaped shell.
It will be appreciated by those skilled in the art that the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed above are therefore to be considered in all respects as illustrative and not restrictive. All changes which come within the scope of or are equivalent to the scope of the invention are intended to be embraced therein.
Claims (10)
1. A method for forming a large aluminum alloy thick-wall special-shaped shell is characterized by comprising the following steps:
firstly, segmenting a target object according to the outline shape of the target object and forming a plurality of target units with consistent appearance characteristics;
enveloping each target unit and preparing an enveloping body uniquely corresponding to the target unit;
thirdly, lofting each enveloping body and obtaining cutting and forming parameters;
cutting the plate according to the cutting forming parameters, and then bending the cut plate;
and fifthly, finishing and welding the bent plate according to the size of the target object.
2. The forming method of large thick-walled special-shaped aluminum alloy shell according to claim 1,
in the first step, the target object is segmented along the axial direction of the target object, and then each segment is segmented along the circumferential direction to form a plurality of target units with curved surface structures.
3. The forming method of large thick-walled special-shaped aluminum alloy shell according to claim 2,
in the second step, an aluminum plate is used as an enveloping body raw material, and the thickness of the enveloping body raw material is larger than that of the target unit.
4. A large-scale thick-walled special-shaped aluminum alloy shell molding method according to claim 3,
in the second step, after the enveloping body raw material is selected, the enveloping body raw material is rolled into an elliptic cone shape.
5. The method of claim 4, wherein the aluminum alloy is formed into a large thick-walled special-shaped shell,
in the third step, the enveloping body which is rolled into the elliptic cone shape is lofted by adopting a triangular lofting technology.
6. A large-scale thick-walled special-shaped aluminum alloy shell molding method according to claim 5,
in the third step, the surface of the enveloping body which is rolled into the elliptic cone shape is divided by adopting a triangle, the side length of all the triangles is obtained, the lofting size group of the enveloping body is obtained, then the lofting size groups of the enveloping body corresponding to the target units at the same section are sequentially spliced, lofting operation is carried out along the axial direction, and the lofted structure is unfolded to obtain the cutting forming parameters.
7. The method of claim 6,
and in the fourth step, the plate is cut in a water cutting mode.
8. The forming method of large thick-walled special-shaped aluminum alloy shell according to claim 6,
and bending the cut plate along the lofting bus by using an oil press.
9. The method of claim 8, wherein the aluminum alloy is formed into a large thick-walled special-shaped shell,
the bent plate is calibrated, and a calibration tool used for calibration comprises at least two calibration curved surfaces which are fixed relatively and eccentric.
10. The forming method of large thick-walled special-shaped aluminum alloy shell according to claim 1,
in the fifth step, firstly, the bent elliptic conical sheet is placed on a machine tool for alignment, and a reference surface is milled at one end of the elliptic conical sheet; then, the inner and outer shapes are milled by a ball cutter by using a datum plane mounting clamp for alignment, and the wall thickness is ensured; and finally, milling peripheral and longitudinal grooves and finally welding.
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| FR2689187B1 (en) * | 1992-03-24 | 1995-05-24 | Fresnes Forges | Method of assembling two ends of facing elements and removable links produced by this method. |
| US5501011A (en) * | 1992-05-18 | 1996-03-26 | Societe Europeenne De Propulsion | Method of manufacture of an enclosure containing hot gases cooled by transportation, in particular the thrust chamber of a rocket engine |
| CN104007697B (en) * | 2014-05-05 | 2016-12-07 | 上海交通大学 | Five axle multirow Flank machining tool path scheduling methods |
| US9714583B2 (en) * | 2014-08-21 | 2017-07-25 | Honeywell International Inc. | Fan containment cases for fan casings in gas turbine engines, fan blade containment systems, and methods for producing the same |
| CN105817841B (en) * | 2016-04-21 | 2018-06-29 | 重庆通用工业(集团)有限责任公司 | Shape tube forming method |
| CN109676326B (en) * | 2019-01-14 | 2020-02-18 | 蓝箭航天空间科技股份有限公司 | Forming method of jet pipe part of aerospace engine |
| CN110153643B (en) * | 2019-04-15 | 2020-05-12 | 浙江大学 | Method for eliminating accumulated errors in material increase and decrease manufacturing process |
| CN113878300B (en) * | 2021-09-27 | 2023-05-26 | 重庆大学 | Porous structure connection method for additive manufacturing |
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