CN115740062A - Production method of large-caliber thin-wall special-shaped cavity aluminum alloy profile - Google Patents
Production method of large-caliber thin-wall special-shaped cavity aluminum alloy profile Download PDFInfo
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Abstract
Description
技术领域technical field
本发明涉及铝合金型材加工技术领域，具体涉及一种大口径薄壁异形空腔铝合金型材生产方法。The invention relates to the technical field of processing aluminum alloy profiles, in particular to a method for producing aluminum alloy profiles with large-diameter thin-wall special-shaped cavities.
背景技术Background technique
大口径薄壁异形空腔铝合金型材具有一次成型性好、产品内腔容量大、表面光滑、无焊接焊缝、尺寸均匀等优点，可实现航空航天等领域用大型轻质合金构件的薄壁化、截面复杂化、整体化，也可满足航空航天、轨道交通、石油化工等行业对零部件结构轻量化、复杂化要求的一种重要产品。Large-caliber thin-wall special-shaped cavity aluminum alloy profiles have the advantages of good one-time formability, large inner cavity capacity, smooth surface, no welding seam, uniform size, etc., and can realize thin-walled large-scale light alloy components used in aerospace and other fields. It is an important product that can meet the requirements of aerospace, rail transit, petrochemical and other industries for lightweight and complex parts structure.
上述铝合金型材传统生产方式有钣焊、铸造等方式。钣焊生产存在焊缝缺陷多、壁厚且不均匀、焊接性能低、质量稳定性差等问题，如某型号结构折分为24个零件进行拼焊，焊缝多达54条，焊接变形大，产品精度及质量往往达不到设计指标要求；采用铸造生产方式，壁厚3.3±0.7mm的尺寸公差已不能满足产品减重的要求，同时存在超重及内部质量差等问题。The traditional production methods of the above-mentioned aluminum alloy profiles include sheet welding and casting. Sheet welding production has problems such as many weld defects, uneven wall thickness, low welding performance, and poor quality stability. For example, a certain model structure is divided into 24 parts for tailor welding, with as many as 54 welds and large welding deformation. The precision and quality of the product often fail to meet the design requirements; the casting production method, the dimensional tolerance of the wall thickness of 3.3±0.7mm can no longer meet the requirements of product weight reduction, and there are problems such as overweight and poor internal quality.
近年来，航空航天、轨道交通、石油化工等行业对零部件结构轻量化、复杂化、一体化制造的要求越来越高，为满足上述需求，大型轻质合金挤压型材被广泛应用。随着技术的发展，大型轻质合金挤压型材的薄壁化、截面复杂化、形状尺寸高精度化成为行业内的重要研究课题。但在型材挤压过程中，坯料在挤压杆的挤压作用下进入挤压模具型腔发生分流焊合，最终在下模的工作带部位成形为等截面型材并从出口处流出，坯料与挤压筒及挤压模具之间产生强烈的摩擦作用，大口径薄壁异形空腔筒断采用传统分流模直接挤压模具中心承担巨大的挤压力，会对模具的模芯等结构产生冲击，导致模具开裂报废，造成局部波浪、塌陷、壁厚不均及轮廓度超差等成形精度问题，难以实现该类产品的挤压成型。In recent years, aerospace, rail transit, petrochemical and other industries have higher and higher requirements for lightweight, complex and integrated manufacturing of parts and components. In order to meet the above requirements, large-scale lightweight alloy extrusion profiles are widely used. With the development of technology, thin-walled, complex cross-section and high-precision shape and dimension of large light-weight alloy extruded profiles have become important research topics in the industry. However, during the extrusion process of the profile, the billet enters the cavity of the extrusion die under the extrusion of the extrusion rod to be shunted and welded. Finally, it is formed into a profile with equal cross-section at the working zone of the lower die and flows out from the exit. The billet and extrusion There is a strong friction between the pressure cylinder and the extrusion die. The large-diameter thin-walled special-shaped cavity cylinder is directly extruded by the traditional splitter die to bear the huge extrusion force, which will have an impact on the mold core and other structures. This leads to mold cracking and scrapping, resulting in forming accuracy problems such as local waves, collapse, uneven wall thickness, and out-of-tolerance contours, making it difficult to achieve extrusion molding of such products.
发明内容Contents of the invention
针对挤压成型性能差的技术问题，本发明提供一种大口径薄壁异形空腔铝合金型材生产方法，可以有效降低中心挤压力，改善模具形变，实现大口径薄壁异形空腔筒断挤压精确控制成形，制品最小壁厚2～5mm，厚度均匀且表面光滑无焊接焊缝，改善挤压成型性能。Aiming at the technical problem of poor extrusion molding performance, the present invention provides a production method of aluminum alloy profiles with large-diameter thin-walled special-shaped cavity, which can effectively reduce the central extrusion force, improve mold deformation, and realize large-diameter thin-walled special-shaped cavity cylinder breaking. The extrusion is precisely controlled and formed, the minimum wall thickness of the product is 2-5mm, the thickness is uniform and the surface is smooth without welding seam, which improves the extrusion forming performance.
本发明提供一种大口径薄壁异形空腔铝合金型材生产方法，包括如下步骤：The invention provides a method for producing a large-diameter thin-walled special-shaped cavity aluminum alloy profile, which includes the following steps:
S1、根据型材产品结构进行产品设计，设计方法为在型材空腔内设有加强筋，加强筋将型材空腔内分隔为至少两个空腔，加强筋端部通过撕裂口与型材产品内壁连接；S1. Carry out product design according to the product structure of the profile. The design method is to provide a reinforcing rib in the cavity of the profile. The reinforcing rib divides the cavity of the profile into at least two cavities. The end of the reinforcing rib passes through the tear opening and the inner wall of the profile product. connect;
S2、根据设计的型材产品，制备型材产品对应的模具；S2. According to the designed profile product, prepare a mold corresponding to the profile product;
S3、将空心铝棒在模具中挤压成型后获得管坯，管坯张力矫直获得型坯；S3, extruding the hollow aluminum rod in a mold to obtain a tube blank, and straightening the tube blank under tension to obtain a parison;
S4、将型坯内加强筋做剃筋处理；S4, shaving the reinforcing ribs in the parison;
S5、型坯人工时效，获得成品。S5. The parison is artificially aged to obtain a finished product.
进一步的，步骤S1中，加强筋为一体式结构，且加强筋分为横纵分布的子加强筋，横纵方向子加强筋排列组合，将大口径薄壁异形空腔筒分割为多个空腔。Further, in step S1, the reinforcing rib is an integrated structure, and the reinforcing rib is divided into sub-reinforcing ribs distributed horizontally and vertically. cavity.
进一步的，步骤S3中，空心铝棒制备方法为，铝棒经过车皮、镗孔制得。Further, in step S3, the method for preparing the hollow aluminum rod is that the aluminum rod is made by wagoning and boring.
进一步的，步骤S3中，挤压成型的工艺方法为，挤压压力≤147MN，将空心铝棒加热到470～510℃，挤压速度为1.0～1.4mm/s，出口温度≥520℃，快速风冷至室温，冷却速度为35～60℃/s。Further, in step S3, the extrusion molding process is as follows: the extrusion pressure is ≤147MN, the hollow aluminum rod is heated to 470-510°C, the extrusion speed is 1.0-1.4mm/s, the outlet temperature is ≥520°C, and the Cool to room temperature by air at a cooling rate of 35-60°C/s.
进一步的，步骤S3中，张力矫直后管坯的变形量为1.2％～1.5％。Further, in step S3, the deformation of the tube blank after tension straightening is 1.2%-1.5%.
进一步的，步骤S4中，剃筋处理的方法为，采用钢丝绳将每一个撕裂口拉断，将空腔内的加强筋整体移出。Further, in step S4, the tendon shaving method is to break each tear opening with a steel wire rope, and remove the reinforcing ribs in the cavity as a whole.
进一步的，撕裂口壁厚为0.5～1.85mm，撕裂口长度为10～15mm，加强筋壁厚为2.5～3mm。Further, the wall thickness of the tear opening is 0.5-1.85 mm, the length of the tear opening is 10-15 mm, and the wall thickness of the reinforcing rib is 2.5-3 mm.
进一步的，型材产品的最小壁厚为2～5mm。Further, the minimum wall thickness of profile products is 2-5mm.
本发明的有益效果在于，本发明通过在铝合金型材空腔内设计带有撕裂口的加强筋，在产品生产后期，将内腔加强筋再次剔除，得到满足要求的一种大口径薄壁异形空腔型材。通过上述方法，本发明制得大口径薄壁异形空腔型材具有一次成型性好、产品内腔容量大、表面光滑、无焊接焊缝、尺寸均匀等优点，使航空航天等领域用大型轻质合金构件的薄壁化、截面复杂化、整体化挤压成形得以实现，有利于工业化批量生产。The beneficial effect of the present invention lies in that the present invention designs a reinforcing rib with a tear opening in the cavity of the aluminum alloy profile, and removes the inner cavity reinforcing rib again in the later stage of product production to obtain a large-diameter thin-walled rib that meets the requirements. Shaped cavity profiles. Through the above method, the present invention has the advantages of good one-time formability, large inner cavity capacity, smooth surface, no welding seam, and uniform size, etc. The thin-walled, complex cross-section and integral extrusion of alloy components can be realized, which is conducive to industrial mass production.
附图说明Description of drawings
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，对于本领域普通技术人员而言，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, for those of ordinary skill in the art, In other words, other drawings can also be obtained from these drawings on the premise of not paying creative work.
图1是本发明具体实施方式实施例1铝合金型材产品结构示意图。Fig. 1 is a schematic diagram of the structure of an aluminum alloy profile product in Example 1 of the specific embodiment of the present invention.
图2是本发明具体实施方式实施例1铝合金型材产品设计结构示意图。Fig. 2 is a schematic diagram of the design structure of an aluminum alloy profile product in Example 1 of the specific embodiment of the present invention.
图3是图2中P处局部放大图。Fig. 3 is a partial enlarged view of P in Fig. 2 .
图中，1-铝合金型材，2-子加强筋，3-加强筋，4-撕裂口。In the figure, 1-aluminum alloy profile, 2-sub-reinforcing rib, 3-reinforcing rib, 4-tear opening.
具体实施方式Detailed ways
为了使本技术领域的人员更好地理解本发明中的技术方案，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都应当属于本发明保护的范围。In order to enable those skilled in the art to better understand the technical solutions in the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described The embodiments are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts shall fall within the protection scope of the present invention.
实施例1Example 1
一种大口径薄壁异形空腔铝合金型材生产方法，包括如下步骤：A method for producing a large-diameter thin-walled special-shaped cavity aluminum alloy profile, comprising the following steps:
S1、根据型材产品结构进行产品设计，结合图1，设计方法为，图1中，铝合金型材1外接圆直径为690mm，周长为1152cm，最小壁厚为2(-0.2，+0.5)mm，最大壁厚为5mm，实体面积为35cm2，米重为11.2Kg。图2中，铝合金型材1空腔内设有加强筋3，加强筋3为一体式结构，加强筋3分为横纵分布的子加强筋2，子加强筋2排列组合将型材空腔内分隔为多个空腔，如图2，加强筋3端部通过撕裂口4与铝合金型材1产品内壁连接，增加带撕裂口4的加强筋3后，产品外接圆直径、周长及壁厚等不变，实体面积变为151.64cm2，米重为41Kg。加强筋4共计三横五竖，壁厚为3mm，撕裂口位置壁厚为0.5mm，长度为15mm；S1. Carry out product design according to the profile product structure. Combined with Figure 1, the design method is as follows. In Figure 1, the diameter of the circumscribed circle of the
S2、根据设计的型材产品，制备型材产品对应的模具，模具采用现有技术常规方法制备，制备方法包括机加、电火花、线切割等，得到超大规格产品模具结构；S2. According to the designed profile product, prepare the mold corresponding to the profile product. The mold is prepared by the conventional method of the prior art. The preparation method includes machining, electric spark, wire cutting, etc., to obtain the mold structure of the super-large product;
S3、将铝棒经过车皮、镗孔制得空心铝棒，空心铝棒经均匀化处理后在模具中挤压成型后获得管坯，挤压成型的工艺方法为，挤压压力＜145MN(14500t)，将空心铝棒加热到500℃，挤压速度为1.2mm/s，出口温度为530℃，快速风冷至室温，冷却速度为50℃/s；管坯张力矫直获得型坯，张力矫直后管坯的变形量为1.25％；S3. The aluminum rod is passed through the car body and bored to obtain a hollow aluminum rod. After the hollow aluminum rod is homogenized, it is extruded in a mold to obtain a tube blank. The extrusion molding process is that the extrusion pressure is less than 145MN (14500t ), the hollow aluminum rod is heated to 500°C, the extrusion speed is 1.2mm/s, the outlet temperature is 530°C, and it is quickly air-cooled to room temperature, and the cooling speed is 50°C/s; The deformation of the tube blank after straightening is 1.25%;
S4、将型坯内加强筋做剃筋处理，筋处理的方法为，将型坯筒段放在拉绳式作业工装上，工装包括设备支架、电机、卷扬机、钢丝绳及夹钳，然后利用该工装钢丝绳将每一个撕裂口4拉断，在产品内部做好防护，将内腔加强筋3整体移出；S4. Shaving the reinforcing ribs inside the parison. The method of rib treatment is to put the parison tube section on the rope-drawn work tooling. The tooling includes equipment brackets, motors, hoists, wire ropes and clamps, and then use the The tooling wire rope pulls off each
S5、型坯人工时效，获得成品，产品壁厚、米重、产品形状、间隙等等均满足产品设计要求。S5. The parison is artificially aged, and the finished product is obtained. The product wall thickness, meter weight, product shape, clearance, etc. all meet the product design requirements.
实施例2Example 2
一种大口径薄壁异形空腔铝合金型材生产方法，包括如下步骤：A method for producing a large-diameter thin-walled special-shaped cavity aluminum alloy profile, comprising the following steps:
S1、根据型材产品结构进行产品设计，设计方法为，铝合金型材外接圆直径380mm，周长为115cm，最小壁厚为3(±0.3)mm，最大壁厚为9mm，实体面积为50cm2，米重为13.5Kg。铝合金型材空腔内设有加强筋，加强筋为一体式结构，加强筋分为横纵分布的子加强筋，子加强筋排列组合将型材空腔内分隔为多个空腔，加强筋端部通过撕裂口与铝合金型材产品内壁连接，增加带撕裂口的加强筋后，产品外接圆直径、周长及壁厚等不变，实体面积变为95.4cm2，米重为25.76Kg。加强筋两竖井字形，壁厚为2.5mm，撕裂口位置壁厚为1.5mm，长度为10mm；S1. Carry out product design according to the profile product structure. The design method is that the diameter of the circumscribed circle of the aluminum alloy profile is 380 mm, the circumference is 115 cm, the minimum wall thickness is 3 (±0.3) mm, the maximum wall thickness is 9 mm, and the solid area is 50 cm 2 . Rice weighs 13.5Kg. The aluminum alloy profile cavity is provided with reinforcing ribs, the reinforcing ribs are an integrated structure, and the reinforcing ribs are divided into sub-reinforcing ribs distributed horizontally and vertically. The sub-reinforcing ribs are arranged and combined to divide the profile cavity into multiple cavities. The part is connected with the inner wall of the aluminum alloy profile product through the tear opening. After adding the reinforcing rib with the tear opening, the circumscribed circle diameter, circumference and wall thickness of the product remain unchanged, the solid area becomes 95.4cm 2 , and the meter weight is 25.76Kg . The reinforcing ribs are in the shape of two vertical wells, with a wall thickness of 2.5mm, a wall thickness of 1.5mm at the location of the tear, and a length of 10mm;
S2、根据设计的型材产品，制备型材产品对应的模具，模具采用现有技术常规方法制备，制备方法包括机加、电火花、线切割等，得到超大规格产品模具结构；S2. According to the designed profile product, prepare the mold corresponding to the profile product. The mold is prepared by the conventional method of the prior art. The preparation method includes machining, electric spark, wire cutting, etc., to obtain the mold structure of the super-large product;
S3、将铝棒经过车皮、镗孔制得空心铝棒，空心铝棒经均匀化处理后在模具中挤压成型后获得管坯，挤压成型的工艺方法为，挤压压力＜147MN(14700t)，将空心铝棒加热到470℃，挤压速度为1.0mm/s，出口温度为520℃，快速风冷至室温，冷却速度为35℃/s；管坯张力矫直获得型坯，张力矫直后管坯的变形量为1.2％；S3. The aluminum rod is passed through the wagon and bored to obtain a hollow aluminum rod. The hollow aluminum rod is homogenized and extruded in a mold to obtain a tube blank. The extrusion molding process is that the extrusion pressure is less than 147MN (14700t ), the hollow aluminum rod is heated to 470°C, the extrusion speed is 1.0mm/s, the outlet temperature is 520°C, and it is quickly air-cooled to room temperature, and the cooling speed is 35°C/s; The deformation of the tube blank after straightening is 1.2%;
S4、将型坯内加强筋做剃筋处理，筋处理的方法为，将型坯筒段放在拉绳式作业工装上，工装包括设备支架、电机、卷扬机、钢丝绳及夹钳，然后利用该工装钢丝绳将每一个撕裂口拉断，在产品内部做好防护，将内腔加强筋整体移出；S4. Shaving the reinforcing ribs inside the parison. The method of rib treatment is to put the parison tube section on the rope-drawn work tooling. The tooling includes equipment brackets, motors, hoists, wire ropes and clamps, and then use the The tooling wire rope pulls off each tear opening, protects the inside of the product, and removes the inner cavity reinforcement as a whole;
S5、型坯人工时效，获得成品，产品壁厚、米重、产品形状、间隙等等均满足产品设计要求。S5. The parison is artificially aged, and the finished product is obtained. The product wall thickness, meter weight, product shape, clearance, etc. all meet the product design requirements.
实施例3Example 3
一种大口径薄壁异形空腔铝合金型材生产方法，包括如下步骤：A method for producing a large-diameter thin-walled special-shaped cavity aluminum alloy profile, comprising the following steps:
S1、根据型材产品结构进行产品设计，设计方法为，铝合金型材外接圆直径为695mm，周长为910.76cm，最小壁厚为4(±0.3)mm，最大壁厚为16mm，实体面积为185.6cm2，米重为58.3Kg。铝合金型材空腔内设有加强筋，加强筋为一体式结构，加强筋分为横纵分布的子加强筋，子加强筋排列组合将型材空腔内分隔为多个空腔，加强筋端部通过撕裂口与铝合金型材产品内壁连接，增加带撕裂口的加强筋后，产品外接圆直径、周长及壁厚等不变，实体面积变为264.39cm2，米重为71.38Kg。加强筋两竖井字形，壁厚为3mm，撕裂口位置壁厚1.85为mm，长度为10mm；S1. Carry out product design according to the profile product structure. The design method is that the diameter of the circumscribed circle of the aluminum alloy profile is 695mm, the circumference is 910.76cm, the minimum wall thickness is 4 (±0.3)mm, the maximum wall thickness is 16mm, and the solid area is 185.6 cm 2 , the weight of a meter is 58.3Kg. The aluminum alloy profile cavity is provided with reinforcing ribs, the reinforcing ribs are an integrated structure, and the reinforcing ribs are divided into sub-reinforcing ribs distributed horizontally and vertically. The sub-reinforcing ribs are arranged and combined to divide the profile cavity into multiple cavities. The part is connected with the inner wall of the aluminum alloy profile product through the tear opening. After adding the reinforcing rib with the tear opening, the circumscribed circle diameter, circumference and wall thickness of the product remain unchanged, the solid area becomes 264.39cm 2 , and the meter weight is 71.38Kg . The reinforcing rib has two vertical wells, the wall thickness is 3mm, the wall thickness at the tear opening is 1.85mm, and the length is 10mm;
S2、根据设计的型材产品，制备型材产品对应的模具，模具采用现有技术常规方法制备，制备方法包括机加、电火花、线切割等，得到超大规格产品模具结构；S2. According to the designed profile product, prepare the mold corresponding to the profile product. The mold is prepared by the conventional method of the prior art. The preparation method includes machining, electric spark, wire cutting, etc., to obtain the mold structure of the super-large product;
S3、将铝棒经过车皮、镗孔制得空心铝棒，空心铝棒经均匀化处理后在模具中挤压成型后获得管坯，挤压成型的工艺方法为，挤压压力＜135MN(13500t)，将空心铝棒加热到510℃，挤压速度为1.4mm/s，出口温度为520℃，快速风冷至室温，冷却速度为50℃/s；管坯张力矫直获得型坯，张力矫直后管坯的变形量为1.5％；S3. The aluminum rod is passed through the wagon and bored to obtain a hollow aluminum rod. The hollow aluminum rod is homogenized and extruded in a mold to obtain a tube blank. The extrusion molding process is that the extrusion pressure is less than 135MN (13500t ), the hollow aluminum rod is heated to 510°C, the extrusion speed is 1.4mm/s, the outlet temperature is 520°C, and it is quickly air-cooled to room temperature, and the cooling speed is 50°C/s; The deformation of the tube blank after straightening is 1.5%;
S4、将型坯内加强筋做剃筋处理，筋处理的方法为，将型坯筒段放在拉绳式作业工装上，工装包括设备支架、电机、卷扬机、钢丝绳及夹钳，然后利用该工装钢丝绳将每一个撕裂口拉断，在产品内部做好防护，将内腔加强筋整体移出；S4. Shaving the reinforcing ribs inside the parison. The method of rib treatment is to put the parison tube section on the rope-drawn work tooling. The tooling includes equipment brackets, motors, hoists, wire ropes and clamps, and then use the The tooling wire rope pulls off each tear opening, protects the inside of the product, and removes the inner cavity reinforcement as a whole;
S5、型坯人工时效，获得成品，产品壁厚、米重、产品形状、间隙等等均满足产品设计要求。S5. The parison is artificially aged, and the finished product is obtained. The product wall thickness, meter weight, product shape, clearance, etc. all meet the product design requirements.
本发明通过在铝合金型材空腔内设计带有撕裂口的加强筋，在产品生产后期，将内腔加强筋再次剔除，得到满足要求的一种大口径薄壁异形空腔型材。通过上述方法，本发明制得大口径薄壁异形空腔型材具有一次成型性好、产品内腔容量大、表面光滑、无焊接焊缝、尺寸均匀等优点，使航空航天等领域用大型轻质合金构件的薄壁化、截面复杂化、整体化挤压成形得以实现，有利于工业化批量生产。In the present invention, a reinforcement rib with a tear opening is designed in the cavity of the aluminum alloy profile, and the reinforcement rib in the inner cavity is removed again in the later stage of product production to obtain a large-diameter thin-wall special-shaped cavity profile that meets the requirements. Through the above method, the present invention has the advantages of good one-time formability, large inner cavity capacity, smooth surface, no welding seam, and uniform size, etc. The thin-walled, complex cross-section and integral extrusion of alloy components can be realized, which is conducive to industrial mass production.
尽管通过参考附图并结合优选实施例的方式对本发明进行了详细描述，但本发明并不限于此。在不脱离本发明的精神和实质的前提下，本领域普通技术人员可以对本发明的实施例进行各种等效的修改或替换，而这些修改或替换都应在本发明的涵盖范围内/任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到变化或替换，都应涵盖在本发明的保护范围之内。Although the present invention has been described in detail in conjunction with preferred embodiments with reference to the accompanying drawings, the present invention is not limited thereto. Without departing from the spirit and essence of the present invention, those skilled in the art can make various equivalent modifications or replacements to the embodiments of the present invention, and these modifications or replacements should be within the scope of the present invention/any Those skilled in the art can easily think of changes or substitutions within the technical scope disclosed in the present invention, and all should be covered within the protection scope of the present invention.
Claims (8)
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