CN115283530A

CN115283530A - Hydraulic forming device and method suitable for manufacturing frame tubular beams of two-wheel vehicles

Info

Publication number: CN115283530A
Application number: CN202210650091.8A
Authority: CN
Inventors: 樊天荣; 董杰; 廖家正; 黄竹愉
Original assignee: Zhangyi Iron And Steel Works Co ltd
Current assignee: Zhangyi Iron And Steel Works Co ltd
Priority date: 2022-06-10
Filing date: 2022-06-10
Publication date: 2022-11-04

Abstract

A hydroforming fixture for use in manufacturing tubular beams for the frame of a two-wheeled vehicle, comprising: the die comprises an upper die and a lower die, wherein the lower die can accommodate a pipe blank; a front hydraulic cylinder can be connected with the front end of the pipe blank; the rear hydraulic cylinder can be connected with the rear end of the pipe blank; a front pressure control module is connected with the front hydraulic cylinder; the rear pressure control module is connected with the rear hydraulic cylinder; and a controller.

Description

Hydraulic forming device and method suitable for manufacturing frame tubular beams of two-wheel vehicles

The technical field is as follows:

the present invention relates to a hydroforming apparatus, and more particularly to a hydroforming apparatus without an extra-high pressure source

Background art:

in the traditional hydroforming process, a pre-forming procedure is adopted before bulging, and a pipe fitting is bent or flattened by a die so as to be placed in a die cavity of a hydroforming die. The pipe fitting through preforming because of receiving external force extrusion, local area can have little fillet or fold, must adopt the utmost point high pressure to carry out the expansion square and eliminate. When the pressure in the pipe is too high, the expansion process can cause the pipe to crack. When the energy of the machine table is limited and the sealing pressure in the pipe cannot be increased, the material cannot be attached to the mould surface, so that the surface profile forming performance is poor.

Chinese patent CN104438540B discloses a low-pressure internal high-pressure forming device for a torsion beam, which maintains a certain working pressure inside a pipe during the pressing process of a mold, so that a part is pushed into a mold cavity without providing an ultrahigh working pressure from the outside, and the manufacturing cost of the device can be saved. The working principle is suitable for volume forming of the torsion beam, and excessive extrusion deformation of the pipe fitting is avoided by keeping the pressure in the pipe in the pressing process. Wherein the liquid discharge absorption and pressure regulation are performed only by means of a servo pressure control device in the apparatus.

The invention content is as follows:

an embodiment of the present invention provides a hydroforming apparatus for manufacturing a tubular beam of a frame of a motorcycle, which is suitable for manufacturing a tubular beam of a motorcycle or a bicycle, and which performs liquid discharge absorption and pressure adjustment not only by a servo pressure control device in the apparatus, including: the die comprises an upper die and a lower die, wherein the lower die can accommodate a pipe blank; a front hydraulic cylinder can be connected with the front end of the pipe blank; the rear hydraulic cylinder can be connected with the rear end of the pipe blank; a front pressure control module is connected with the front hydraulic cylinder; the rear pressure control module is connected with the rear hydraulic cylinder; and a controller; the front pressure control module comprises a pipeline, the pipeline comprises an inlet and an outlet, the inlet is connected with the front hydraulic cylinder, the outlet is provided with a pressure release valve, a throttle valve is arranged between the inlet and the pressure release valve, a front pressure gauge is arranged between the inlet and the throttle valve to measure upstream pressure, a rear pressure gauge is arranged between the pressure release valve and the throttle valve to measure downstream pressure, a liquid storage barrel connected with the pipeline is arranged between the throttle valve and the pressure release valve, and the liquid storage barrel comprises a pressure regulator used for regulating pressure fluctuation of the pipeline; wherein the controller controls an opening and closing degree of the throttle valve according to a pressure difference between the front pressure gauge and the rear pressure gauge.

One embodiment of the present invention provides a hydraulic molding method for manufacturing a tubular beam for a motorcycle frame, which is suitable for manufacturing a tubular beam for a motorcycle or a bicycle, and which performs liquid discharge absorption and pressure regulation not only by a servo pressure control device in the equipment, including: providing a hydraulic forming device, which comprises a die, an upper die and a lower die, wherein a pipe blank is clamped between the upper die and the lower die, a front hydraulic cylinder is connected with the front end of the pipe blank, a rear hydraulic cylinder is connected with the rear end of the pipe blank, a front pressure control module comprises a pipeline, a rear pressure control module is connected with the rear hydraulic cylinder, the pipeline comprises an inlet end and an outlet end, and the inlet end is connected with the front hydraulic cylinder; filling the tube blank with a liquid; the upper die and the lower die pressurize the pipe blank; the front hydraulic cylinder and the rear hydraulic cylinder pressurize the pipe blank; adjusting a parison hydraulic pressure of the parison using the front pressure control module and the rear pressure control module, wherein the front pressure control module adjusts a pressure surge of the pipeline based on an upstream pressure at the inlet end and a downstream pressure at the outlet end; drilling at least one hole into the tube stock and discharging the liquid.

Description of the drawings:

FIG. 1 is a schematic view of a hydroforming apparatus according to an embodiment of the present invention.

FIG. 2 is a schematic view of a hydraulic cylinder and a plug according to an embodiment of the present invention.

FIG. 3 is a diagram of a front pressure control module according to an embodiment of the invention.

Fig. 4 is a schematic view of a needle punching device according to an embodiment of the present invention.

FIG. 5 is a diagram of a rear pressure control module according to an embodiment of the invention.

FIG. 6 is a control graph of a hydroforming process, in accordance with an embodiment of the present invention.

Fig. 7 is an external view of a tubular beam after hydroforming according to an embodiment of the present invention.

Fig. 8 is an external view of a tubular beam after hydroforming according to an embodiment of the present invention.

Fig. 9 is an external view of a tubular beam which is processed after hydroforming according to an embodiment of the present invention.

Reference numerals:

1. hydraulic forming device

2. Pipe beam after hydraulic forming

3. Reprocessed tubular beam

10. Upper die holder

20. Upper die

21. Punch needle seat head

22. Front punching needle

23. Back punch needle

30. Lower die holder

40. Lower die

41. Front end of tube blank

42. Rear end of the pipe blank

50. Front hydraulic cylinder

51. Front plug

60. Rear hydraulic cylinder

61. Rear plug

70. Front pressure control module

71. Liquid filling port

72. One-way valve

73. Air valve

74. Throttle valve

75. Pressure relief valve

76. Front pressure gauge

77. Rear pressure gauge

78. Liquid storage barrel

781. Voltage regulator

791. Inlet end

792. An outlet end

793. Pipeline

80. Rear pressure control module

81. Pressure chamber

82. Piston rod

83. Electric machine

84. Electrical machine

C1 Amount of mold pressing

C2 Plug auxiliary pushing amount

C3 Volume of liquid in the tube blank

C4 Displacement of punch needle

The specific implementation mode is as follows:

in one embodiment, referring to fig. 1 and 2, a hydraulic molding apparatus 1 for manufacturing a tube beam of a motorcycle or a bicycle includes an upper mold base 10, an upper mold 20, a lower mold base 30, a lower mold 40, a front hydraulic cylinder 50, a rear hydraulic cylinder 60, a front pressure control module 70, and a rear pressure control module 80. The front hydraulic cylinder 50 is connected to the front end 41 of the pipe blank received in the lower mold 40 through a front plug 51, and is connected to the inlet end 791 of the front pressure control module 70. The rear hydraulic cylinder 60 is connected to the rear end 42 of the pipe blank received in the lower mold 40 through a rear plug 61 at one side and to the rear pressure control module 80 at the other side. The upper die 20 is provided with a punch needle holder head 21, a front punch needle 22 and a rear punch needle 23. Wherein, the pipe blank (not shown in the figures) is a bent but not preformed pipe fitting, and is disposed in the lower mold 40, and the upper mold 20 and the lower mold 40 can clamp and press the pipe blank.

In one embodiment, referring to FIG. 3, the front pressure control module 70 includes a conduit 793, the filling port 71 is connected to the conduit 793 through a one-way valve 72, and the conduit 793 is sequentially provided with a gas valve 73, a throttle valve 74 and a pressure relief valve 75 from an inlet end 791 to an outlet end 793. A front pressure gauge 76 is provided between the throttle valve 74 and the inlet port 791, and a rear pressure gauge 77 is provided between the throttle valve 74 and the relief valve 75. Stock solution bucket 78 and pipeline 793 are connected, have pressure regulator 781 in the stock solution bucket 78, can utilize the backpressure compensation to adjust the pressure fluctuation of pipeline 793.

In one embodiment, referring to fig. 4, the punching device 24 is disposed on the upper die 20, and the extension and retraction of the front punch pin 22 and the rear punch pin 23 can be controlled by the punch pin seat head 21 and the hydraulic pipeline design.

In one embodiment, referring to FIG. 5, the rear pressure control module 80 includes a pressure chamber 81, a piston rod 82, a motor 83, and a motor 84. The pressure chamber 81 is connected to the rear hydraulic cylinder 60, and the motor 83 and the motor 84 regulate the pressure of the pressure chamber 81 through the piston rod 82.

In one embodiment, referring to fig. 6, a control curve applicable to a hydraulic forming method is suitable for manufacturing a tube beam of a locomotive or a bicycle, where C1 is a pressing amount of a mold, C2 is an auxiliary pushing amount of a plug, C3 is a liquid volume in a tube blank, and C4 is a displacement amount of a punch pin. The hydroforming apparatus 1 includes a controller (not shown) for regulating the blank hydraulic pressure using the front pressure control module 70 and the rear pressure control module 80.

0-T0 stage: the upper die holder 10 is closed towards the lower die holder 30, the upper die 20 and the lower die 40 clamp the tube blank arranged on the lower die 40, and the front plug 51 and the rear plug 52 tightly push the tube blank to realize sealing.

Sections T0 to T1: (1) The liquid injection port 71 of the front pressure module 70 injects liquid, such as water, through the check valve 72, into the pipe 793 of the front pressure module 70, and flows into the pipe blank through the front hydraulic cylinder 50, the front plug 51, the rear plug 61, the rear hydraulic cylinder 60, and the rear pressure module 80, such as a servo pressure control device, from the interior of the pipe blank to enter the pressure chamber 81; (2) The tube blank is filled with liquid, during which process gas from the tube blank entering the front pressure module 70 can be vented through the gas valve 73, and gas from the tube blank entering the pressure chamber 81 of the rear pressure module 80 can be vented through the vent (not shown).

Sections T1 to T2: (1) extruding the pipe blank by an upper die 20 and a lower die 40; (2) The front hydraulic cylinder 50 and the rear hydraulic cylinder 60 respectively extrude the pipe blank through the front plug 51 and the rear plug 61 to perform auxiliary pushing; the pressing of the upper and lower molds 20 and 40, and the pressing of the front and rear plugs 51 and 61, may be performed simultaneously or separately; (3) When the hydraulic pressure of the pipe blank is too high, the liquid in the pipe blank can flow into the pipeline 793 of the front pressure module 70, the pressure release valve 75 releases the pressure by discharging the liquid, and the fluid is immediately closed when the pressure of the fluid is lower than a set value; (4) The liquid storage barrel 78 can absorb the pressure surge generated by the over-high pressurizing speed by using the pressure regulator 781 and compensate the pressure drop caused by excessive discharge; (5) The throttle valve 74 is provided with a front pressure gauge 76 and a rear pressure gauge 77 respectively upstream (near the inlet end 791) and downstream (near the outlet end 792) of the conduit 793, and the degree of opening and closing of the throttle valve 74 is adjusted by measuring the upstream pressure P1 and the downstream pressure P2 of the conduit 793. When both P1 and P2 are greater than the set pressure, the throttle valve 46 reaches the maximum opening and closing degree; when P1 is less than the set pressure, the throttle valve 74 reaches a minimum opening and closing degree; when P1 is greater than the set pressure and P2 is less than the set pressure, the opening and closing degree of the throttle valve 74 changes in negative correlation with the difference between P1 and P2; (6) In excess of the load energy of the pressure relief valve 75 and the reservoir 78, the piston rod 82 in the pressure cylinder 81 in the rear pressure module 80 moves backwards to assist in flowing excess fluid in the tube into the pressure chamber 81 in the rear pressure module 80 through the rear plug 61; if the pressure of the liquid in the tube blank is too low due to excessive discharge, the piston rod 82 in the pressure cylinder 81 in the rear pressure module 80 moves forward to assist the liquid in the pressure chamber 81 in the rear pressure module 80 to flow into the tube blank through the rear plug 61; (7) Pressure pulsation is generated, and closed-loop control is performed by reducing the degree of opening and closing of the throttle valve 45 and by controlling the displacement of the piston rod 82 in the rear pressure module 80.

Sections T2 to T3: when the expansion of the tube blank is completed, the punching device 24 utilizes the front punching needle 22 and the rear punching needle 23 to punch the two ends of the tube blank out of the positioning holes, and the pressure of the liquid in the tube is removed.

Sections T3 to T4: after the pressure relief is finished, (1) the punching device 24 retracts the front punching needle 21 and the rear punching needle 22; (2) withdrawing the front plug 51 and the rear plug 61, and releasing the sealing; (3) A pressure regulator 781 of the liquid storage barrel 78 discharges the redundant liquid to restore the initial state due to the action of back pressure; and (4) moving the upper die base 10 and the upper die 20 upwards to realize die opening.

Referring to fig. 7 and 8, the tubular beam 2 is formed by hydroforming according to the above embodiment, and the appearance is schematically shown at different angles. Fig. 9 is a schematic external view of the tubular beam 3, which is reprocessed after hydroforming, on opposite sides.

In one embodiment, the tube beam is hydroformed by passive pressure build-up to volume method for manufacturing tube beam of motorcycle or bicycle. In the mold pressurizing stage, the hydraulic pressure in the pipe blank is generated due to volume compression, so that the pipe fitting is freely expanded and attached to the mold surface, and ultrahigh pressure is not required to be provided through a pressurizing system.

In one embodiment, the hydroforming apparatus has a dynamic seal design, so that during the volume forming stage of the mold pressurization, the

plugs

51 and 61 at the two ends of the tube blank can still maintain the seal of the tube blank, but when the hydraulic pressure of the tube blank is too high, the

pressure control modules

70 and 80 can be used for adjusting the hydraulic pressure of the tube blank through the

plugs

51 and 61 at the two ends of the tube blank.

Claims

1. A hydroforming fixture for use in manufacturing tubular beams for the frame of a two-wheeled vehicle, comprising:

the die comprises an upper die and a lower die, wherein the lower die can accommodate a pipe blank;

a front hydraulic cylinder can be connected with the front end of the pipe blank;

a rear hydraulic cylinder can be connected with the rear end of the pipe blank;

a front pressure control module is connected with the front hydraulic cylinder;

the rear pressure control module is connected with the rear hydraulic cylinder; and

a controller;

the device is characterized in that the front pressure control module comprises a pipeline, the pipeline comprises an inlet and an outlet, the inlet is connected with the front hydraulic cylinder, the outlet is provided with a pressure release valve, a throttle valve is arranged between the inlet and the pressure release valve, a front pressure gauge is arranged between the inlet and the throttle valve to measure upstream pressure, a rear pressure gauge is arranged between the pressure release valve and the throttle valve to measure downstream pressure, a liquid storage barrel connected with the pipeline is arranged between the throttle valve and the pressure release valve, and the liquid storage barrel comprises a pressure regulator used for regulating pressure fluctuation of the pipeline;

wherein the controller controls the opening and closing degree of the throttle valve according to a pressure difference between the front pressure gauge and the rear pressure gauge.

2. The hydroforming apparatus according to claim 1, wherein the controller comprises a set pressure, and wherein the degree of opening and closing is inversely related to the pressure differential when the upstream pressure is greater than the set pressure and the downstream pressure is less than the set pressure.

3. The hydroforming apparatus according to claim 1, wherein the rear pressure control module comprises at least one motor, a piston rod, and a pressure chamber, wherein the controller controls the motor to move the piston rod back and forth in the pressure chamber to adjust a blank hydraulic pressure of the blank or generate a pressure pulse to the blank.

4. A hydraulic forming method suitable for manufacturing a tube beam of a frame of a two-wheel vehicle is characterized by comprising the following steps:

providing a hydraulic forming device, which comprises a die, an upper die and a lower die, wherein a pipe blank is clamped between the upper die and the lower die, a front hydraulic cylinder is connected with the front end of the pipe blank, a rear hydraulic cylinder is connected with the rear end of the pipe blank, a front pressure control module comprises a pipeline, and a rear pressure control module is connected with the rear hydraulic cylinder, wherein the pipeline comprises an inlet end and an outlet end, and the inlet end is connected with the front hydraulic cylinder;

filling the tube blank with a liquid;

the upper die and the lower die pressurize the pipe blank;

the front hydraulic cylinder and the rear hydraulic cylinder pressurize the pipe blank;

adjusting a parison hydraulic pressure of the tube parison using the front pressure control module and the rear pressure control module, wherein the front pressure control module adjusts a pressure fluctuation of the pipeline based on an upstream pressure of the inlet end and a downstream pressure of the outlet end when the front pressure control module adjusts the parison hydraulic pressure;

drilling at least one hole into the tube stock and discharging the liquid.

5. The hydroforming method according to claim 4, wherein the front pressure control module includes a throttle valve, and a pressure difference between the upstream pressure and the downstream pressure is inversely related to a degree of opening and closing of the throttle valve when the upstream pressure is greater than a set pressure value and the downstream pressure is less than the set pressure value.

6. The hydroforming method according to claim 4, wherein the rear pressure control module comprises at least one motor, a piston rod, and a pressure chamber, wherein the motor controls the piston rod to move back and forth in the pressure chamber to adjust the hydraulic pressure of the tube blank or generate a pressure pulsation to the tube blank.