CN115635249A - Forming, correcting and manufacturing method for stainless steel camber beam of urban railway vehicle - Google Patents
Forming, correcting and manufacturing method for stainless steel camber beam of urban railway vehicle Download PDFInfo
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- CN115635249A CN115635249A CN202211251651.9A CN202211251651A CN115635249A CN 115635249 A CN115635249 A CN 115635249A CN 202211251651 A CN202211251651 A CN 202211251651A CN 115635249 A CN115635249 A CN 115635249A
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Abstract
The invention discloses a forming, correcting and manufacturing method of a stainless steel camber beam of an urban railway vehicle, which comprises the steps of S1, processing a blank; s2, male die pressing; s3, performing wrinkle treatment after the flanging of the bent beam is primarily formed; s4, bending the primary formed curved beam; s5, plasma edge cutting; s6, manufacturing a bent beam cutting explorator; and S7, manufacturing a bent beam shape-correcting tool. The correction manufacturing method of the invention utilizes the complementary application of the double-layer film and the flanging oil in the flanging forming process of the die, the double-layer film plays a good lubricating role, ensures that the material is fully and uniformly extended, avoids the phenomenon of tension cracking caused by excessive local material deformation, and simultaneously allows the forming process to apply enough blank holding force to the part, thereby reducing the generation of edge wrinkles of the material part.
Description
Technical Field
The invention relates to the technical field of railway passenger cars, in particular to a method for forming, correcting and manufacturing a stainless steel curved beam of an urban railway vehicle.
Background
The method is characterized in that bending beams with various structures exist in the manufacturing production of urban railway vehicle bodies, and the forming of the bending beams adopts the working procedures of stamping die flanging primary forming, vibration hammer trimming, numerical control equipment bending forming, plasma edge cutting, manual correction trimming and the like. The prior art is limited by a die structure, the initial forming of the camber beam is close to the limit of the flanging height, the heavy-load spring is used for pressing, the edge of a formed material part is slightly wrinkled, and the flatness of the middle part of the material part is insufficient due to insufficient pressing force. Subsequent bending and plasma cutting have large size fluctuation due to the error defects of parts in the previous process, the rejection rate is high, the time for shape correction by a vibration hammer and manual correction is long, and the production requirement cannot be met.
Therefore, in view of the above technical problems, there is a need for developing a method for forming and straightening a stainless steel camber beam of an urban railway vehicle.
Disclosure of Invention
The invention aims to provide a forming, correcting and manufacturing method of a stainless steel camber beam of an urban railway vehicle, which can improve the once forming quality of the camber beam, reduce the rejection rate, reduce the flanging and wrinkling of the camber beam, improve the plasma cutting quality and the vibration hammer shape correction and manual correction efficiency.
In order to achieve the above purpose, the invention provides the following technical scheme:
the invention relates to a forming, correcting and manufacturing method of a stainless steel camber beam of an urban railway vehicle, which mainly comprises the following steps of:
s1, processing a blank, covering films on the upper surface and the lower surface of the blank, and smearing flanging oil;
s2, male die pressing, namely pressing the processed blank through a male die to form a primary formed bent beam;
s3, performing wrinkle treatment after the flanging and primary forming of the bent beam, and leveling the planeness of the ground of the primary forming of the bent beam, wherein the planeness is less than or equal to 0.5mm;
s4, bending the primary formed curved beam by using numerical control bending equipment;
s5, plasma edge cutting is carried out, and the allowance of the curved beam in positioning and bending at two ends is cut;
s6, manufacturing a bent beam cutting explorator, and attaching the bent beam by using the bent beam cutting explorator so as to reserve the processing amount of the expanding material when the arc is cut off and pressed by using plasma;
and S7, manufacturing a camber beam shape-modifying tool, and performing manual correction forming on the camber beam shape-modifying tool.
Further, in the step S1, the upper surface and the lower surface of the blank are covered with two layers of films;
and flanging oil is coated on one side of the film close to the blank and one side of the film far away from the blank.
Further, in the step S2, the male die includes a forming male die and an upper male die matched with the forming male die, the blank is located between the forming male die and the upper male die, and a stripper plate is arranged at the forming male die;
and the primary forming curved beam pressed by the forming male die and the upper male die is withdrawn through the stripper plate.
Further, the primary formed camber beam is configured into a semi-open disc structure, and the bottom surface of the primary formed camber beam is a plane;
in the step S3, the wrinkles of the edge of the primary formed curved beam are flattened by a KS compression die, and the operating pressure of the KS compression die is 55.2N.
Further, in step S4, the numerical control bending apparatus includes:
an upper clamping fixture and a lower clamping fixture;
a bending space of the primary forming curved beam is arranged between the upper mould and the lower mould, and the primary forming curved beam is placed in the bending space;
and one side of the numerical control bending equipment is provided with two rear blocking rulers, and the initially formed curved beam is positioned through the rear blocking rulers.
Further, the step S4 further includes the following steps after the bending process:
s401, cushioning the closing positions at the two ends of the camber beam at the corners of the manual correction and adjustment platform, and processing the sunken part by using a hand hammer, wherein the size of the closing positions at the two ends of the camber beam is 50mm +/-1 mm after processing;
s402, adjusting and repairing folds on the arc, arranging four arc corners of the bent beam and a flanging fold pad on the platform, and hammering the bent beam and the flanging fold pad by hands to enable the pivot and the arc to be in smooth transition;
s403, adjusting and repairing parallelism of two arc sides of the bent beam, arranging the arc pad of the bent beam on an arc tool, striking the edge of the bent beam along the arc direction by using a hammer, and measuring by using a ruler, wherein a flash seam of a measuring result is less than or equal to 0.5mm;
s404, adjusting and repairing the middle size of the bent beam, compacting the two ends of the bent beam by using sizing blocks, hammering and striking the convex positions of the two sides by using hands, adjusting and repairing the two sides into straight lines and measuring the two sides by using a measuring tape, wherein the adjusted and repaired size of the two ends of the bent beam is 110mm.
Further, in the step S6, the master form is configured to be attached to the bent beam;
the explorator comprises an explorator body and explorator edges positioned at two ends of the explorator body;
the profiling body is embedded into the bending part of the bent beam, and the edge of the profiling is attached to the surface of the side wing of the bent beam;
the edge of the profiling is configured as a cutting line of the plasma cutting equipment, and the material expansion allowance processing amount is reserved when the cutting bolt head of the plasma cutting equipment cuts the arc pressing shape along the cutting line.
Further, in the step S7, one side of the curved beam shaping tool, which is matched with the curved beam, is configured to be an arc-shaped surface;
the side wing of the camber beam is attached to the arc-shaped surface of the camber beam profiling tool.
In the technical scheme, the forming, correcting and manufacturing method for the stainless steel camber beam of the urban railway vehicle has the following beneficial effects:
the correction manufacturing method of the invention utilizes the complementary application of the double-layer film and the flanging oil in the flanging forming process of the die, the double-layer film plays a good lubricating role, ensures that the material is fully and uniformly extended, avoids the phenomenon of tension cracking caused by excessive local material deformation, and simultaneously allows the forming process to apply enough blank holding force to the part, thereby reducing the generation of edge wrinkles of the material part.
The curved beam shape correction tool of the correction manufacturing method disclosed by the invention is manufactured to improve the arc correction efficiency, ensure the arc parallelism of the curved beam and improve the curved beam repair efficiency;
the correction manufacturing method of the invention has determined sequence, and the production efficiency can be improved only by judging the sequence of the correction parts, so that the arc shape, the arc parallelism and the arc straightness of the bent beam can be ensured, and the processing quality of the bent beam is improved.
Drawings
In order to more clearly illustrate the embodiments of the present application or technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments described in the present invention, and other drawings can be obtained by those skilled in the art according to the drawings.
FIG. 1 is a schematic structural diagram of a blank of a method for forming, correcting and manufacturing a stainless steel camber beam of an urban railway vehicle, which is disclosed by the embodiment of the invention;
FIG. 2 is a schematic drawing I of male stamping of a forming correction manufacturing method for stainless steel camber beams of urban railway vehicles according to the embodiment of the invention;
FIG. 3 is a schematic diagram II of male die pressing for the forming, correcting and manufacturing method of a stainless steel camber beam of an urban railway vehicle, which is disclosed by the embodiment of the invention;
FIG. 4 is a schematic structural diagram of a primary formed camber beam with folded edges according to an embodiment of the manufacturing method for forming and correcting a stainless steel camber beam for an urban railway vehicle;
FIG. 5 is a schematic structural diagram of a primarily formed camber beam with wrinkles removed according to an embodiment of the manufacturing method for shaping and correcting a stainless steel camber beam for an urban railway vehicle;
FIG. 6 is a schematic structural diagram of a numerical control bending device for processing a primarily formed curved beam in the forming correction manufacturing method for the stainless steel curved beam of the urban railway vehicle, which is disclosed by the embodiment of the invention;
FIG. 7 is a schematic structural diagram of a camber beam of the shaping, correcting and manufacturing method for the stainless steel camber beam of the urban railway vehicle, which is disclosed by the embodiment of the invention;
FIG. 8 is a schematic diagram of plasma cutting by a master form according to a method for shaping, correcting and manufacturing stainless steel camber beams of urban railway vehicles in accordance with an embodiment of the present invention;
fig. 9 is a schematic structural view of adjusting and repairing a side wing by using a camber beam shaping tool in the method for shaping, correcting and manufacturing a stainless steel camber beam of an urban railway vehicle according to the embodiment of the invention.
Description of reference numerals:
1. a blank;
101. a film; 102. flanging oil;
201. forming a male die; 202. an upper male die; 203. a material returning plate;
10. primarily forming a curved beam;
11. bending the beam;
1101. a bending part; 1102. a side wing;
301. mounting a mould; 302. a lower mould; 303. a tailgate;
4. profiling; 401. a master form body; 402. profiling edges;
501. cutting the bolt head; 502. cutting a line;
6. a curved beam shaping tool; 601. an arc-shaped surface.
Detailed Description
In order to make the technical solutions of the present invention better understood, those skilled in the art will now describe the present invention in further detail with reference to the accompanying drawings.
See fig. 1-9;
the method for forming, correcting and manufacturing the stainless steel camber beam of the urban railway vehicle mainly comprises the following steps of:
s1, processing a blank 1, covering films 101 on the upper surface and the lower surface of the blank 1, and smearing flanging oil 102;
s2, male die pressing, namely pressing the processed blank 1 through a male die to form a primary formed curved beam 10;
s3, performing wrinkle treatment after the flanging of the bent beam is primarily formed, and leveling the planeness of the primarily formed ground of the bent beam, wherein the planeness is less than or equal to 0.5mm;
s4, bending the primary formed curved beam 10, and bending the primary formed curved beam 10 by using numerical control bending equipment;
s5, plasma edge cutting is carried out, and the allowance of the curved beam in positioning and bending at two ends is cut;
s6, manufacturing a bent beam cutting explorator 4, and attaching the bent beam 11 to the bent beam cutting explorator 4 so as to reserve the processing amount of the expanding material when the arc is cut off and pressed by using plasma;
and S7, manufacturing the camber beam shaping tool 6, and performing manual correction shaping on the camber beam shaping tool 6.
Preferably, in step S1 of this embodiment, the upper surface and the lower surface of the blank 1 are covered with two layers of films 101;
the side of the film 101 close to the blank 1 and the side of the film 101 far from the blank 1 are coated with the flanging oil 102.
The embodiment renovates a flanging lubricating medium, the flanging is protected by the double-layer film 101 and is protected by the flanging oil 102, the double-layer film 101 is placed on the upper surface and the lower surface of the blank 1 in the flanging forming process of the die, the flanging oil 102 is coated on the surface of the film 101, the lubricating effect in the flanging process is met, the die surface and the camber beam surface are protected, and the forming of the camber beam is facilitated.
The double-layer film 101 can ensure that the material is fully and uniformly extended, avoid the phenomenon of tension fracture caused by overlarge local material deformation, and allow the forming process to apply enough blank pressing force to the bent beam, thereby reducing the generation of material part edge wrinkles.
Preferably, in step S2 of this embodiment, the punches include a forming punch 201 and an upper punch 202 matched with the forming punch 201, the blank 1 is located between the forming punch 201 and the upper punch 202, and the forming punch 201 has a stripper plate 203;
the primary formed curved beam 10 after being pressed by the forming punch 201 and the upper punch 202 is withdrawn through the stripper plate 203.
The primary formed curved beam 10 of the present embodiment is configured as a semi-open disc structure, and the bottom surface of the primary formed curved beam 10 is a plane;
in step S3, the wrinkles of the edges of the preliminarily formed bent beam 10 are flattened by the KS compression die, and the operating pressure of the KS compression die is 55.2N.
Preferably, in step S4 of this embodiment, the numerical control bending apparatus includes:
an upper mold 301 and a lower mold 302;
a bending space of the primary formed curved beam 10 is formed between the upper mould 301 and the lower mould 302, and the primary formed curved beam 10 is placed in the bending space;
one side of the numerical control bending equipment is provided with two rear blocking rulers 303, and the pre-formed curved beam 10 is positioned through the rear blocking rulers 303.
In the embodiment, the upper mold 301 is an R5 mold, the lower mold 302 is a V12 mold, and the bending is positioned by side positioning and a rear stop ruler 303 to ensure the forming size.
Preferably, the step S4 of this embodiment further includes the following steps after the bending treatment:
s401, padding the closing positions at the two ends of the curved beam 11 at the corners of the manual correction and adjustment platform, and processing the concave part by using a hand hammer, wherein the size of the closing positions at the two ends of the curved beam 11 after processing is 50mm +/-1 mm;
s402, adjusting and repairing folds on the arc, arranging four arc corners of the bent beam and a flanging fold pad on the platform, and hammering the bent beam and the flanging fold pad by hands to enable the pivot and the arc to be in smooth transition;
s403, adjusting and repairing parallelism of two arc sides of the bent beam, arranging the arc pad of the bent beam on an arc tool, striking the edge of the bent beam along the arc direction by using a hammer, and measuring by using a ruler, wherein a flash seam of a measuring result is less than or equal to 0.5mm;
s404, adjusting and repairing the middle size of the bent beam, compacting the two ends of the bent beam by using sizing blocks, hammering and striking the convex positions of the two sides by using hands, adjusting and repairing the two sides into straight lines and measuring the two sides by using a measuring tape, wherein the adjusted and repaired size of the two ends of the bent beam is 110mm.
Preferably, in step S6 of the present embodiment, the master form 4 is configured to be attached to the bent beam 11;
the explorator 4 comprises an explorator body 401 and explorator edges 402 positioned at two ends of the explorator body 401;
the profiling body 401 is embedded into a bending part 1101 of the bent beam 11, and the profiling edge 402 is abutted against the surface of a side wing 1102 of the bent beam 11;
the template edge 402 is configured as a cutting line 502 of the plasma cutting device, and a cutting bolt head 501 of the plasma cutting device cuts off the material expansion allowance processing amount when the arc-shaped press is formed along the cutting line 502.
The plasma cutting explorator 4 is manufactured by combining the molded surface and the final size of the curved beam 11, and the problems of low efficiency and poor quality of manual marking and cutting are solved. After the profiling 4 of this embodiment is laminated with the 11 arcs of curved beams, utilize the unilateral facade of curved beams as the locating surface, effectively guarantee the requirement of cutting efficiency and part final dimension precision.
Preferably, in step S7 of this embodiment, the side of the curved beam shaping tool 6, which is matched with the curved beam 11, is configured as an arc-shaped surface 601;
the side wing 1102 of the camber beam 11 is attached to the arc-shaped surface 601 of the camber beam shaping tool 6.
The camber beam shaping tool 6 of the embodiment utilizes the blank support to ensure the precision of the detection tool by using the numerical control milling machine for processing. When the manual correction is formed, the tool replaces a sample plate for detection, and the production efficiency is greatly improved.
In the technical scheme, the forming, correcting and manufacturing method for the stainless steel camber beam of the urban railway vehicle has the following beneficial effects:
according to the correction manufacturing method, the double-layer film 101 and the flanging oil 102 are complementarily applied in the flanging forming process of the die, the double-layer film 101 plays a good lubricating role, the material is ensured to be fully and uniformly extended, the phenomenon of tension cracking caused by excessive local material deformation is avoided, and meanwhile, enough blank holding force is allowed to be applied to the part in the forming process, so that the generation of edge wrinkles of the part is reduced.
The curved beam shaping tool 6 of the correction manufacturing method of the invention is manufactured to improve the arc correction efficiency, ensure the arc parallelism of the curved beam 11 and improve the curved beam repairing efficiency;
the correction manufacturing method of the invention has the advantages that the order is determined, the production efficiency can be improved only by judging the order of the correction parts, the arc shape, the arc parallelism and the arc straightness of the curved beam can be ensured, and the processing quality of the curved beam is improved.
While certain exemplary embodiments of the present invention have been described above by way of illustration only, it will be apparent to those of ordinary skill in the art that the described embodiments may be modified in various different ways without departing from the spirit and scope of the invention. Accordingly, the drawings and description are illustrative in nature and are not to be construed as limiting the scope of the invention.
Claims (8)
1. A forming, correcting and manufacturing method for a stainless steel camber beam of an urban railway vehicle is characterized by mainly comprising the following steps of:
s1, processing a blank (1), covering films (101) on the upper surface and the lower surface of the blank, and coating flanging oil (102);
s2, male die pressing, namely pressing the processed blank (1) through a male die to form a primary formed curved beam (10);
s3, performing wrinkle treatment after the flanging of the bent beam is primarily formed, and leveling the planeness of the primarily formed ground of the bent beam, wherein the planeness is less than or equal to 0.5mm;
s4, bending the primary formed curved beam (10), and bending the primary formed curved beam (10) by using numerical control bending equipment;
s5, plasma edge cutting is carried out, and the reserved quantity of the bent beam in positioning bending at two ends is cut;
s6, manufacturing a bent beam cutting explorator (4), and attaching the bent beam (11) by using the bent beam cutting explorator (4) so as to reserve the processing amount of expanding materials when arc pressing is cut off by using plasma;
s7, manufacturing a curved beam shape-modifying tool (6), and performing manual correction forming on the curved beam shape-modifying tool (6).
2. The forming correction manufacturing method for the stainless steel camber beam of the urban railway vehicle according to the claim 1, wherein in the step S1, the upper surface and the lower surface of the blank (1) are covered with two layers of films (101);
and flanging oil (102) is coated on one side of the film (101) close to the blank (1) and one side of the film (101) far away from the blank (1).
3. The forming correction manufacturing method for the stainless steel camber beam of the urban railway vehicle is characterized in that in the step S2, the male dies comprise a forming male die (201) and an upper male die (202) matched with the forming male die, the blank (1) is positioned between the forming male die (201) and the upper male die (202), and the forming male die (201) is provided with an ejector plate (203);
and the primary forming curved beam (10) which is pressed by the forming male die (201) and the upper male die (202) is withdrawn through the stripper plate (203).
4. The forming correction manufacturing method for the stainless steel camber beam of the urban railway vehicle is characterized in that the primary formed camber beam (10) is configured into a semi-open disc structure, and the bottom surface of the primary formed camber beam (10) is a plane;
in the step S3, the wrinkles of the edges of the primary formed bent beam (10) are flattened by a KS compression die, and the operating pressure of the KS compression die is 55.2N.
5. The forming, correcting and manufacturing method of the stainless steel camber beam of the urban railway vehicle according to claim 1, wherein in the step S4, the numerical control bending equipment comprises:
an upper mold (301) and a lower mold (302);
a bending space of the primary forming curved beam (10) is formed between the upper mould (301) and the lower mould (302), and the primary forming curved beam (10) is placed in the bending space;
one side of the numerical control bending equipment is provided with two rear blocking rulers (303), and the primary forming curved beam (10) is positioned through the rear blocking rulers (303).
6. The forming, correcting and manufacturing method of the urban railway vehicle stainless steel camber beam according to claim 1, characterized in that the following process steps are further included after the bending treatment in the step S4:
s401, cushioning the closing positions of the two ends of the camber beam (11) at the corners of a manual correction adjusting and repairing platform, and processing the sunken part by using a hand hammer, wherein the size of the closing positions of the two ends of the camber beam (11) after processing is 50mm +/-1 mm;
s402, adjusting and repairing the wrinkles on the arc, and arranging the four arc corners of the bent beam (11) and a turned-over wrinkle pad on the platform and hammering the four arc corners and the turned-over wrinkle pad by hands so as to enable the fulcrum to be in smooth transition with the arc;
s403, adjusting and repairing parallelism of two arc sides of the bent beam, arranging the arc pad of the bent beam on an arc tool, striking the edge of the bent beam along the arc direction by using a hammer, and measuring by using a ruler, wherein a flash seam of a measuring result is less than or equal to 0.5mm;
s404, adjusting and repairing the middle size of the bent beam, compacting the two ends of the bent beam by using sizing blocks, hammering and striking the convex positions of the two sides by using hands, adjusting and repairing the two sides into straight lines and measuring the two sides by using a measuring tape, wherein the adjusted and repaired size of the two ends of the bent beam is 110mm.
7. The method for forming, correcting and manufacturing the urban railway vehicle stainless steel camber beam according to claim 1, wherein in the step S6, the profiling (4) is configured to be attached to the bent camber beam (11);
the explorator (4) comprises an explorator body (401) and explorator edges (402) positioned at two ends of the explorator body (401);
the profile body (401) is embedded into a bending part (1101) of the bent beam (11), and the profile edge (402) is abutted against the surface of a side wing (1102) of the bent beam (11);
the profiling edge (402) is configured as a cutting line (502) of the plasma cutting device, and a cutting bolt head (501) of the plasma cutting device cuts off the bulging allowance processing amount when the arc is pressed along the cutting line (502).
8. The forming and correcting manufacturing method for the stainless steel camber beam of the urban railway vehicle as claimed in claim 7, wherein in the step S7, the side of the camber beam shaping tool (6) matched with the camber beam (11) is configured to be an arc surface (601);
and the side wing (1102) of the bent beam (11) is attached to the arc-shaped surface (601) of the bent beam shape-modifying tool (6).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211251651.9A CN115635249A (en) | 2022-10-13 | 2022-10-13 | Forming, correcting and manufacturing method for stainless steel camber beam of urban railway vehicle |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211251651.9A CN115635249A (en) | 2022-10-13 | 2022-10-13 | Forming, correcting and manufacturing method for stainless steel camber beam of urban railway vehicle |
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| CN115635249A true CN115635249A (en) | 2023-01-24 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202211251651.9A Pending CN115635249A (en) | 2022-10-13 | 2022-10-13 | Forming, correcting and manufacturing method for stainless steel camber beam of urban railway vehicle |
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| Country | Link |
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| CN (1) | CN115635249A (en) |
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- 2022-10-13 CN CN202211251651.9A patent/CN115635249A/en active Pending
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