CN117798254A - Integral forming structure, system and method for ultrahigh-strength tubular beam and aluminum alloy die casting - Google Patents
Integral forming structure, system and method for ultrahigh-strength tubular beam and aluminum alloy die casting Download PDFInfo
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- CN117798254A CN117798254A CN202410032568.5A CN202410032568A CN117798254A CN 117798254 A CN117798254 A CN 117798254A CN 202410032568 A CN202410032568 A CN 202410032568A CN 117798254 A CN117798254 A CN 117798254A
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 168
- 238000004512 die casting Methods 0.000 title claims abstract description 151
- 238000000034 method Methods 0.000 title claims abstract description 43
- 230000008569 process Effects 0.000 claims abstract description 23
- 238000005266 casting Methods 0.000 claims description 39
- 238000007789 sealing Methods 0.000 claims description 32
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 22
- 238000001816 cooling Methods 0.000 claims description 22
- 239000002826 coolant Substances 0.000 claims description 16
- 229910052757 nitrogen Inorganic materials 0.000 claims description 10
- 239000007789 gas Substances 0.000 claims description 8
- 238000005452 bending Methods 0.000 claims description 7
- 238000000465 moulding Methods 0.000 claims description 6
- 230000007246 mechanism Effects 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 4
- 229910000734 martensite Inorganic materials 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 3
- 238000007711 solidification Methods 0.000 claims description 3
- 230000008023 solidification Effects 0.000 claims description 3
- 238000004891 communication Methods 0.000 claims description 2
- 239000007921 spray Substances 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 20
- 230000004927 fusion Effects 0.000 abstract description 3
- 238000012545 processing Methods 0.000 abstract description 3
- 230000001788 irregular Effects 0.000 description 6
- 230000008901 benefit Effects 0.000 description 5
- 239000007788 liquid Substances 0.000 description 5
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 239000000110 cooling liquid Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910001873 dinitrogen Inorganic materials 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/033—Deforming tubular bodies
- B21D26/047—Mould construction
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/033—Deforming tubular bodies
- B21D26/045—Closing or sealing means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/033—Deforming tubular bodies
- B21D26/049—Deforming bodies having a closed end
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/16—Heating or cooling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
- B22D17/2272—Sprue channels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/32—Controlling equipment
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
The invention discloses an integral forming structure, system and method of an ultra-high strength pipe beam and an aluminum alloy die casting, which realize the integral forming of the thermal expansion of the ultra-high strength pipe beam and the aluminum alloy die casting, realize the fusion of two processes by one set of die and one process, simplify the process route, reduce the production time and improve the production efficiency, and the formed ultra-high strength pipe beam is wrapped by the aluminum alloy die casting, so that the structural strength of the ultra-high strength pipe beam is further increased; in addition, the contact surface of the aluminum alloy die casting and the ultrahigh-strength pipe beam is concave-convex embedded, so that the bonding strength and the integrity of the aluminum alloy die casting and the ultrahigh-strength pipe beam can be enhanced, and the integral structural strength of the integrated structure of the ultrahigh-strength pipe beam and the aluminum alloy die casting is further enhanced. The invention solves the problems of the prior art that the ultra-high strength tubular beam and the aluminum alloy die casting are respectively produced, the processing period is long, the process route is complex, the production efficiency is low, the production cost is high and the riveting structure strength is not high.
Description
Technical Field
The invention relates to the technical field of metal forming, in particular to an integral forming structure, an integral forming system and an integral forming method for an ultrahigh-strength tubular beam and an aluminum alloy die casting.
Background
With the increasing requirements of light weight and collision safety of automobile bodies, the application of ultra-high strength tubular beams and aluminum alloy die castings is becoming wider. The strength of the ultra-high strength tubular beam generally requires 1500-2000 MP, and the closed cross-sectional shape can obtain better structural strength. The pipe beam combining the ultra-high strength and the closed cross-section shape has wide application in improving the collision safety of the car body with relatively small wall thickness, light weight and high strength. The aluminum alloy die castings are widely applied to automobile bodies due to the excellent characteristics of light weight, high strength, strong corrosion resistance and the like. The connection between the high-strength tubular beam and the aluminum alloy die castings on the automobile body is usually riveted, taking the left and right longitudinal beams in the front engine cabin as an example, the longitudinal beams are the ultrahigh-strength tubular beams, the mounting seat plates adjacent to the longitudinal beams are the aluminum alloy die castings, and the longitudinal beams and the mounting seat plates are connected together in a riveting mode.
The above-mentioned known existing process route is: the ultrahigh-strength pipe beam and the aluminum alloy die casting are produced and supplied by two supply lines respectively, and then are riveted and assembled through a special assembly station, so that the connection of the two parts is completed. The existing process route has the following problems: the ultrahigh-strength tubular beam and the aluminum alloy die casting are respectively produced, the processing period is long, the process route is complex, the production efficiency is low, the production cost is high, the riveting strength is limited by the riveting form and the rivet strength, and the structural strength is not high. Therefore, the invention provides a scheme for integrally forming the ultrahigh-strength tubular beam and the aluminum alloy die casting, so as to solve the problems of the prior art.
Disclosure of Invention
The invention aims to provide an integral forming structure, system and method for an ultrahigh-strength tubular beam and an aluminum alloy die casting, which adopt a set of die system and a set of working procedures to realize the integral forming of the ultrahigh-strength tubular beam and the aluminum alloy die casting, and the integral forming structure has the advantages of simple process route, short production period, high production efficiency, and the formed integral piece in which the ultrahigh-strength tubular beam is wrapped by the aluminum alloy die casting, thereby improving the structural strength of the tubular beam strength and the junction of the tubular beam and the aluminum alloy die casting, and solving the problems of long processing period, complicated process route, low production efficiency, high production cost and low riveting structural strength of the ultrahigh-strength tubular beam and the aluminum alloy die casting in the prior art.
In order to achieve the above object, the present invention provides the following solutions:
the invention provides an integral forming structure of an ultra-high strength pipe beam and an aluminum alloy die casting, which comprises the ultra-high strength pipe beam and the aluminum alloy die casting, wherein the aluminum alloy die casting is die-cast at a corresponding position of the ultra-high strength pipe beam so as to form an integral structure with the ultra-high strength pipe beam, the aluminum alloy die casting is wrapped on the periphery of the ultra-high strength pipe beam, and the contact surface of the aluminum alloy die casting and the ultra-high strength pipe beam is concave-convex embedded.
Optionally, the ultrahigh-strength tubular beam is a left longitudinal beam or a right longitudinal beam in a front cabin of the automobile engine; the aluminum alloy die castings are mounting seat plates adjacent to the left longitudinal beam or the right longitudinal beam.
Optionally, the shape of the cross section of the part of the ultra-high strength tubular beam, which is wrapped by the aluminum alloy die casting, is not completely the same.
The invention provides an integral forming system of an ultra-high strength pipe beam and an aluminum alloy die casting, which is used for preparing the integral forming structure of the ultra-high strength pipe beam and the aluminum alloy die casting, and comprises the following steps:
the integrated forming die comprises a tube beam cavity matched with the ultra-high strength tube beam and a casting cavity matched with the aluminum alloy die casting, wherein the casting cavity is partially wrapped on the periphery of the tube beam cavity, a concave ring cavity communicated with the tube beam cavity is formed on the periphery of the tube beam cavity, and the concave ring cavity is used for forming a concave-convex mosaic contact surface of the aluminum alloy die casting and the ultra-high strength tube beam; the integral forming die is provided with a pouring port communicated with the casting cavity;
the hot air expansion forming assembly comprises a sealing push head and a nozzle, wherein the sealing push head is used for being externally connected with feeding equipment, and the feeding equipment is used for pushing the sealing push head against the two ends of the tubular beam preform so as to press the two ends of the tubular beam preform into a shape required by sealing, so that the sealing push head can seal the inner cavity of the tubular beam preform; the spray head is arranged in the sealing push head, and is used for filling high-pressure nitrogen or high-pressure air into the tubular beam preform, so that the tubular beam preform is subjected to hot gas expansion forming in the tubular beam cavity, and part of the tubular beam preform bulges into the concave ring cavity to form the ultra-high strength tubular beam with the contact convex surface outside; pouring aluminum alloy into the casting cavity through the pouring opening to perform die casting forming of the aluminum alloy die casting, wherein the aluminum alloy die casting is inlaid with the contact convex surface in a concave-convex manner through a die casting forming part in the concave ring cavity;
the temperature control assembly comprises a controller, a die temperature sensor and a part temperature sensor, wherein the die temperature sensor and the part temperature sensor are embedded and installed in the integrated forming die, the die temperature sensor is used for detecting the temperature of the integrated forming die, and the part temperature sensor is used for detecting the temperature of the part in the tubular beam cavity and/or the casting cavity; the die temperature sensor and the part temperature sensor are both in communication connection with the controller;
the cooling assembly comprises a cooling channel embedded in the integrated forming die, and a cooling medium is used for passing through the cooling channel so as to cool down the tubular beam cavity and/or the part in the casting cavity.
Optionally, the integrated forming die comprises a first module and a second module matched with the first module; and the first module is also provided with a piece withdrawing mechanism.
Optionally, at least one of an aluminum alloy casting system, a high-pressure nitrogen gas supply device, a high-pressure air supply device and a cooling medium supply device is also included.
Optionally, a plurality of concave annular cavities are arranged on the periphery of the tubular beam cavity at intervals along the axial direction of the tubular beam cavity; and the cross section shapes of the tube beam cavities are not completely the same in all areas where the concave ring cavities are distributed.
The invention also provides an integral forming method of the ultrahigh-strength pipe beam and the aluminum alloy die casting, which is implemented by adopting the integral forming system of the ultrahigh-strength pipe beam and the aluminum alloy die casting and comprises the following steps:
s1, preparing the ultrahigh-strength tubular beam by adopting a hot gas expansion forming process;
s2, after the ultrahigh-strength pipe beam is cooled to a proper temperature, pressing molten aluminum alloy into the casting cavity so as to form the aluminum alloy die casting at a corresponding position of the periphery of the ultrahigh-strength pipe beam in a die casting mode, and thus the ultrahigh-strength pipe beam and aluminum alloy die casting integrated forming structure is obtained.
Optionally, the method for integrally forming the ultrahigh-strength tubular beam and the aluminum alloy die casting further comprises a step S3 of demolding and taking out the ultrahigh-strength tubular beam and aluminum alloy die casting integrated forming structure.
Optionally, step S1 includes the steps of:
s11, preparing a prefabricated pipe blank;
s12, bending the prefabricated pipe blank;
s13, stamping and forming the prefabricated pipe blank after the pipe bending treatment;
s14, heating and preserving heat of the preformed tube blank after stamping forming, austenitizing the preformed tube blank and forming a tubular beam preformed piece;
s15, placing the tubular beam preform in the tubular beam cavity, sealing the tubular beam preform at two ends by using the sealing push heads, and then filling high-pressure nitrogen or high-pressure air into the tubular beam preform through the nozzle so as to enable the tubular beam preform to be formed by thermal inflation in the tubular beam cavity, and enabling part of the tubular beam preform to bulge out into the concave ring cavity to form the ultra-high strength tubular beam with the outer part in contact with the convex surface;
s16, introducing the cooling medium into the cooling channel to cool the ultra-high strength tubular beam at a speed of not less than 30 ℃/S until the ultra-high strength tubular beam is martensitic.
Optionally, in step S2, when the part temperature sensor detects that the temperature of the ultra-high strength tubular beam is reduced to 150-200 ℃, the molten aluminum alloy is pressed into the casting cavity through the pouring opening and a certain pressure is kept in the casting cavity, and meanwhile, the pressure or the circulation speed of the cooling medium in the cooling channel is adjusted to promote the mold filling and solidification of the aluminum alloy in the casting cavity.
Optionally, in step S2, when the aluminum alloy is poured into the casting cavity, a certain pressure is maintained in the ultra-high strength tubular beam, so as to prevent the ultra-high strength tubular beam from deforming.
Compared with the prior art, the invention has the following technical effects:
according to the integral structure of the ultrahigh-strength tubular beam and the aluminum alloy die casting, the aluminum alloy die casting is directly die-cast at the corresponding position of the ultrahigh-strength tubular beam, and the integral structure is formed with the ultrahigh-strength tubular beam. The advantage of this integral structure is as follows: (1) The aluminum alloy die casting is wrapped on the periphery of the ultrahigh-strength tubular beam, so that the structural strength of the ultrahigh-strength tubular beam is further improved; (2) The contact surface of the aluminum alloy die casting and the ultrahigh-strength pipe beam is embedded in a concave-convex manner, so that the bonding strength and the integrity of the aluminum alloy die casting and the ultrahigh-strength pipe beam can be enhanced, and the integral structural strength of the integrated structure of the ultrahigh-strength pipe beam and the aluminum alloy die casting is further enhanced; (3) The process route is simple, the production period is short, the production efficiency is high, the ultrahigh-strength tube beam in the formed integrated piece is wrapped by the aluminum alloy die casting, the strength of the tube beam and the structural strength of the junction of the tube beam and the aluminum alloy die casting are improved, and the problem that the riveting structural strength between the existing ultrahigh-strength tube beam and the aluminum alloy die casting is not high is solved.
The system and the method for integrally forming the ultrahigh-strength pipe beam and the aluminum alloy die casting realize the integral formation of the ultrahigh-strength pipe beam by thermal expansion and aluminum alloy die casting, realize the fusion of two processes by one set of die and one process, simplify the process route, reduce the production time and improve the production efficiency, and the formed ultrahigh-strength pipe beam is wrapped by the aluminum alloy die casting, thereby objectively further improving the strength of the pipe beam.
According to the technical schemes disclosed by the invention, the casting cavity is partially wrapped on the periphery of the tubular beam cavity, the concave ring cavity communicated with the tubular beam cavity is formed on the periphery of the tubular beam cavity, the embracing ring structure can be formed on the aluminum alloy die casting and wrapped outside the ultrahigh-strength tubular beam, and the embracing ring structure is inlaid with the contact surface of the ultrahigh-strength tubular beam in a concave-convex manner, so that the embracing ring structures of the two materials are inlaid with each other, and the structural strength of the ultrahigh-strength tubular beam and the bonding strength of the ultrahigh-strength tubular beam and the aluminum alloy die casting are further improved by matching with the wrapping of the embracing ring structure in the aluminum alloy die casting. In addition, the cross sections of the tube beam cavities are not identical in shape, so that the ultra-high strength tube beam with a variable cross section and an irregular shape can be formed, the bonding strength of the ultra-high strength tube beam and the aluminum alloy die casting is further improved, and the integrity of the ultra-high strength tube beam and the aluminum alloy die casting are improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic view of an integrally formed structure of an ultra-high strength tubular beam and an aluminum alloy die casting according to an embodiment of the present invention;
FIG. 2 is a schematic flow chart of a method for integrally forming an ultra-high strength tubular beam and an aluminum alloy die casting according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of the operation of the system for integrally forming an ultra-high strength tubular beam and an aluminum alloy die casting according to an embodiment of the present invention;
FIG. 4 is a cross-sectional view A-A of FIG. 3;
FIG. 5 is a section B-B of FIG. 3;
fig. 6 shows an integrated mold according to an embodiment of the present invention.
Wherein, the reference numerals are as follows:
1. an integral forming structure of the ultrahigh-strength tubular beam and the aluminum alloy die casting; 11. an ultra-high strength tubular beam; 111. a contact convex surface; 112. a cross section; 12. aluminum alloy die casting; 121. a contact concave surface; 122. a clasping ring structure;
2. the ultrahigh-strength pipe beam and aluminum alloy die casting integrated forming system; 21. an integral forming die; 211. a first module; 212. a second module; 22. a piece withdrawing mechanism; 23. sealing the push head; 24. a feeding device; 25. a mold temperature sensor; 26. a part temperature sensor; 27. and a cooling channel.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention aims to provide an integral forming structure of an ultrahigh-strength tubular beam and an aluminum alloy die casting, which has the advantages of simple process route, short production period and high production efficiency, and the ultrahigh-strength tubular beam in the formed integral piece is wrapped by the aluminum alloy die casting, so that the structural strength of the tubular beam and the junction of the tubular beam and the aluminum alloy die casting is improved, and the problem of low riveting structural strength between the conventional ultrahigh-strength tubular beam and the aluminum alloy die casting is solved.
The invention also aims to provide an integrated forming system for the ultrahigh-strength pipe beam and the aluminum alloy die casting, which can prepare the integrated forming structure for the ultrahigh-strength pipe beam and the aluminum alloy die casting, and adopts a set of die system and a set of working procedures to realize the integrated forming of the ultrahigh-strength pipe beam and the aluminum alloy die casting.
The invention also aims to provide an integral forming method of the ultra-high-strength pipe beam and the aluminum alloy die casting, which is implemented based on the integral forming system of the ultra-high-strength pipe beam and the aluminum alloy die casting.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.
Example 1
As shown in fig. 1, the embodiment provides an integrally formed structure 1 of an ultra-high strength pipe beam and an aluminum alloy die casting, which comprises an ultra-high strength pipe beam 11 and an aluminum alloy die casting 12, wherein the aluminum alloy die casting 12 is die-cast at a corresponding position of the ultra-high strength pipe beam 11 and forms an integral structure with the ultra-high strength pipe beam 11, the aluminum alloy die casting 12 is wrapped on the periphery of the ultra-high strength pipe beam 11, and the contact surface of the aluminum alloy die casting 12 and the ultra-high strength pipe beam 11 is embedded in a concave-convex manner.
In this embodiment, the ultra-high strength tubular beam 11 may be a left longitudinal beam or a right longitudinal beam in a front cabin of an automobile engine; the aluminum alloy die cast 12 may specifically be a mounting saddle adjacent to either the left or right stringer.
In this embodiment, the shape of the cross section 112 is not exactly the same at the portion of the ultra-high strength tubular beam 11 wrapped by the aluminum alloy die casting 12, that is, the shape of the cross section 112 is continuously changed along the axial direction of the ultra-high strength tubular beam 11, and the size of the cross section 112 is also continuously changed, so that at least the portion of the ultra-high strength tubular beam 11 contacting with the aluminum alloy die casting 12 is in a variable cross section irregular shape, and as for other portions of the ultra-high strength tubular beam 11, the variable cross section irregular shape can be set as required. As shown in fig. 4 and 5, that is, the shapes of two cross sections 112 of different parts of the ultra-high strength tubular beam 11 are respectively illustrated, and the shapes and the sizes of the two cross sections 112 are respectively different as shown in fig. 4 and 5. The part of the ultra-high strength tubular beam 11, which is at least in contact with the aluminum alloy die casting 12, is arranged to be in an irregular shape with a variable cross section, so that the bonding strength and the integrity of the ultra-high strength tubular beam and the aluminum alloy die casting 12 are improved, and the overall structural strength of the ultra-high strength tubular beam and aluminum alloy die casting integrated structure 1 is further improved.
In this embodiment, the part of the aluminum alloy die casting 12 wrapped outside the ultra-high strength tubular beam 11 is preferably a clasping structure 122, the clasping structure 122 is preferably generally a closed-loop structure, and the inner contour is adapted to the outer contour of the ultra-high strength tubular beam 11 at the corresponding position (i.e. the contour shape of the cross section 112 at the position), i.e. the clasping structure 122 wraps the entire periphery of the corresponding position of the ultra-high strength tubular beam 11. In order to enhance the bonding strength, it is preferable that the inner annular surface of any one of the hoop structures 122 be concavely and convexly fitted to the outer surface of the ultra-high strength tubular beam 11 at the corresponding position.
In this embodiment, it is generally preferable that the aluminum alloy die cast 12 is wrapped around the outer periphery of the ultra-high strength tubular beam 11 by a plurality of clasping structures 122 arranged at intervals.
Therefore, the ultra-high strength tubular beam and aluminum alloy die casting integrated structure 1 provided by the technical scheme is characterized in that the aluminum alloy die casting 12 is directly die-cast at the corresponding position of the ultra-high strength tubular beam 11 to form an integrated structure with the ultra-high strength tubular beam 11. The advantage of this integral structure is as follows:
(1) The aluminum alloy die casting 12 wraps the periphery of the ultra-high strength tubular beam 11, so that the structural strength of the ultra-high strength tubular beam 11 is further improved;
(2) The contact surface of the aluminum alloy die casting 12 and the ultrahigh-strength pipe beam 11 are embedded in a concave-convex manner, so that the bonding strength and the integrity of the aluminum alloy die casting 12 and the ultrahigh-strength pipe beam 11 can be enhanced, and the overall structural strength of the ultrahigh-strength pipe beam and aluminum alloy die casting integrated structure 1 is further enhanced;
(3) The process route is simple, the production period is short, the production efficiency is high, the ultrahigh-strength tube beam in the formed integrated piece is wrapped by the aluminum alloy die casting, the strength of the tube beam and the structural strength of the junction of the tube beam and the aluminum alloy die casting are improved, and the problem that the riveting structural strength between the existing ultrahigh-strength tube beam and the aluminum alloy die casting is not high is solved.
Example two
As shown in fig. 3 to 6, the present embodiment provides an integral forming system 2 for an ultra-high strength pipe beam and an aluminum alloy die casting, which is used for preparing an integral forming structure 1 for an ultra-high strength pipe beam and an aluminum alloy die casting disclosed in the first embodiment. The system 2 for integrally forming the ultrahigh-strength pipe beam and the aluminum alloy die casting comprises an integral forming die 21, a hot gas expansion forming assembly, a temperature control assembly and a cooling assembly, wherein the integral forming die 21 comprises a pipe beam cavity matched with the ultrahigh-strength pipe beam 11 and a casting cavity matched with the aluminum alloy die casting 12, the casting cavity is partially wrapped on the periphery of the pipe beam cavity, a concave annular cavity communicated with the pipe beam cavity is formed on the periphery of the pipe beam cavity, and the concave annular cavity is used for forming a concave-convex mosaic contact surface of the aluminum alloy die casting 12 and the ultrahigh-strength pipe beam 11 and simultaneously generating the embracing ring structure 122; the integral molding die 21 is provided with a pouring gate communicating with the casting cavity, and the pouring gate is generally provided with a sealing plug, so that the pouring gate can be sealed, and the sealing plug can be opened to pour aluminum liquid or aluminum alloy liquid into the casting cavity through the pouring gate, thereby performing die casting molding of the aluminum alloy die casting 12. The air-expansion forming assembly comprises a sealing push head 23 and a nozzle, wherein the sealing push head 23 is used for being externally connected with a feeding device 24, the feeding device 24 is used for pushing the sealing push head 23 against two ends of a tubular beam preform so as to press out the shape required by sealing on the two ends of the tubular beam preform, the sealing of the sealing push head 23 on the inner cavity of the tubular beam preform is realized, and the tubular beam preform can be directly placed in the tubular beam cavity for hot air expansion forming; the nozzle is disposed in the sealing push head 23, and is used for filling high-pressure nitrogen or high-pressure air into the tubular beam preform, so that the tubular beam preform is subjected to hot gas expansion forming in the tubular beam cavity, and the part of the tubular beam preform bulges into the concave annular cavity but does not fill the concave annular cavity, thereby forming the ultra-high strength tubular beam 11 with the contact convex surface 111 (the contact convex surface 111 is the outer surface of the part of the tubular beam preform bulged into the concave annular cavity). After the ultra-high strength tubular beam 11 with the contact convex surface 111 is formed, the position of the ultra-high strength tubular beam 11 in the tubular beam cavity is kept unchanged, aluminum alloy is poured into the casting cavity through a pouring opening to carry out die casting forming of the aluminum alloy die casting 12, the poured aluminum alloy (aluminum liquid) is filled between the contact convex surface 111 and the concave ring cavity, a holding ring structure 122 is formed by die casting in the concave ring cavity, the holding ring structure 122 is held tightly on the periphery of the contact convex surface 111, a contact concave surface 121 matched with the contact convex surface 111 is formed on the inner annular surface of the holding ring structure 122, and the holding ring structure 122 is inlaid with the corresponding contact convex surface 111 in a concave-convex manner through the contact concave surface 121. The temperature control assembly comprises a controller, a die temperature sensor 25 and a part temperature sensor 26, wherein the die temperature sensor 25 and the part temperature sensor 26 are embedded and installed in the integrated forming die 21, the die temperature sensor 25 is used for detecting the temperature of the integrated forming die 21, the part temperature sensor 26 is used for detecting the temperature of a part in a tubular beam cavity and/or a casting cavity, and the part temperature sensor 26 is generally preferably arranged on the peripheries of the tubular beam cavity and the casting cavity; the mold temperature sensor 25 and the part temperature sensor 26 are both communicatively connected to the controller. The cooling assembly comprises a cooling channel 27 embedded in the integrated forming die 21, wherein the cooling channel 27 is mainly distributed on the peripheries of the tube beam cavity and the casting cavity, and the cooling channel 27 is used for communicating cooling medium so as to cool the tube Liang Xingqiang and the parts in the casting cavity.
In this embodiment, the feeding device 24 is preferably a hydraulic cylinder.
In this embodiment, the integral molding die 21 includes a first module 211 and a second module 212 mated with the first module 211; the first module 211 is further provided with a withdrawal mechanism 22. The first module 211 and the second module 212 are preferably left-right split type, and the ejection mechanism 22 is a conventional ejection demolding structure in a mold, and the specific structure and working principle are not described herein.
In the present embodiment, the ultra-high strength pipe beam and aluminum alloy die casting integrated forming system 2 may further be configured with at least one of an aluminum alloy pouring system, a high-pressure nitrogen gas supply device, a high-pressure air supply device, and a cooling medium supply device. The aluminum alloy pouring system, the high-pressure nitrogen supply device, the high-pressure air supply device and the cooling medium supply device are arranged at the same time, and the aluminum alloy pouring system can be a heat-insulating tank filled with aluminum liquid and used for pouring aluminum alloy (aluminum liquid) into a casting cavity; the high-pressure nitrogen supply device and the high-pressure air supply device can be respectively a high-pressure nitrogen storage tank and a high-pressure air storage tank, and are commonly used alternatively; the cooling medium supply device is typically a cooling liquid reservoir for supplying cooling liquid into the cooling passage 27. The outlet of the coolant reservoir is preferably provided with an electrically operated valve and a flow meter to facilitate the regulation of the flow rate of the coolant from the coolant reservoir into the cooling channel 27.
In this embodiment, a plurality of concave ring cavities are arranged on the periphery of the tubular beam cavity along the axial direction thereof at intervals, that is, in the formed integral forming structure 1 of the ultra-high strength tubular beam and the aluminum alloy die casting, the aluminum alloy die casting 12 is integrated with the ultra-high strength tubular beam 11 through a plurality of holding ring structures 122. In all areas of the tubular beam cavity, in which the concave annular cavity is arranged, the cross section 112 of the tubular beam cavity is not completely identical in shape, so that the ultra-high strength tubular beam 11 with a variable cross section and an irregular shape is formed.
The method for integrally forming the ultrahigh-strength pipe beam and the aluminum alloy die casting by adopting the system 2 for integrally forming the ultrahigh-strength pipe beam and the aluminum alloy die casting comprises the following steps:
s1, preparing an ultra-high strength tubular beam 11 by adopting a hot gas expansion forming process;
and S2, after the ultrahigh-strength tubular beam 11 is cooled to a proper temperature, pressing molten aluminum alloy (namely die-casting aluminum alloy) into a casting cavity to die-cast the aluminum alloy die-casting 12 at the corresponding position of the periphery of the ultrahigh-strength tubular beam 11, so as to obtain the ultrahigh-strength tubular beam and aluminum alloy die-casting integrated structure 1.
In this embodiment, the method for integrally forming the ultra-high strength tubular beam and the aluminum alloy die casting further includes the step S3 of demolding: namely, the ultra-high strength tubular beam and the aluminum alloy die casting integrated structure 1 is taken out after demoulding.
In this embodiment, the step S1 is specifically performed according to the following steps:
s11, pipe making: preparing a prefabricated pipe blank;
s12, bending: bending the prefabricated pipe blank;
s13, preforming: stamping and forming the prefabricated pipe blank after the pipe bending treatment;
s14, heating, heat preservation and austenitizing: heating and preserving heat to the preformed tube blank after stamping forming, austenitizing the preformed tube blank and forming a tubular beam preformed piece;
s15, placing the mold and performing hot air expansion forming: after the release agent is sprayed into the integral forming die 21, a mechanical arm can be utilized to rapidly place a tubular beam preform into a tubular beam cavity, sealing push heads 23 are sealed at two ends of the tubular beam preform, under the action of a high-pressure oil cylinder, the sealing push heads 23 press the two ends of the tubular beam preform into a shape required by sealing, high-pressure nitrogen or high-pressure air is filled into the tubular beam preform through a nozzle in the tubular beam preform, so that the tubular beam preform is formed by hot inflation in the tubular beam cavity, and part of the tubular beam preform bulges into a concave ring cavity, so that the ultra-high-strength tubular beam 11 with the contact convex surface 111 outside is formed;
s16, pressure maintaining quenching to generate martensite: in this cooling stage, the pressure in the ultra-high strength tubular beam 11 is generally reduced, and the cooling medium is directly introduced into the cooling passage 27 to cool the ultra-high strength tubular beam 11 at a rate of not less than 30 ℃/sec until the ultra-high strength tubular beam 11 is martensitic.
In this embodiment, in step S2, when the temperature of the ultra-high strength tubular beam 11 is detected to be reduced to 150-200 ℃ by the part temperature sensor 26, a signal is sent to the aluminum alloy pouring system, the molten aluminum alloy is initially pressed into the casting cavity through the pouring gate, and a certain pressure is maintained in the casting cavity (the pressure is adapted to the die-casting pressure of the molten aluminum alloy to ensure the smooth progress of the aluminum alloy die-casting process, which is a conventional design and is not described in detail), and meanwhile, the pressure or the circulation speed of the cooling liquid (typically cooling water) in the cooling channel 27 is adjusted to promote the die filling and solidification of the aluminum alloy in the casting cavity.
In this embodiment, in step S2, when the aluminum alloy is poured into the casting cavity, a certain pressure is required to be maintained in the ultra-high strength tubular beam 11, and the ultra-high strength tubular beam 11 is generally kept filled with high pressure gas (the pressure is adjusted and set according to the actual situation) to prevent the ultra-high strength tubular beam 11 from deforming.
In this embodiment, in the cooling process, if necessary, the sealing push heads 23 at the two ends of the pipe beam can be controlled by the high-pressure oil cylinder to retract, so that the two ends of the pipe beam are opened and are in a non-sealing state, and then the nozzle in the sealing push heads 23 can be utilized to blow air (high-pressure air) into the pipe beam, so as to cool the inner wall of the pipe beam.
Therefore, the system and the method for integrally forming the ultrahigh-strength pipe beam and the aluminum alloy die casting provided by the technical scheme realize the integral formation of the ultrahigh-strength pipe beam by hot air expansion and aluminum alloy die casting, realize the fusion of two processes by one set of die and one process, simplify the process route, reduce the production time, improve the production efficiency, and the formed ultrahigh-strength pipe beam is wrapped by the aluminum alloy die casting, thereby objectively further improving the strength of the pipe beam.
In addition, through partly wrapping up foundry goods die cavity in the periphery of tubular beam die cavity to form the concave ring chamber with tubular beam die cavity intercommunication in the periphery of tubular beam die cavity, can form on aluminum alloy die casting and hold the ring structure parcel outside the ultra-high strength tubular beam, and hold the ring structure and the unsmooth mosaic of contact surface of ultra-high strength tubular beam, thereby realize that the ring structure of two materials is each other for the mosaic structure, hold the ring structure in the cooperation aluminum alloy die casting to the parcel of ultra-high strength tubular beam has further promoted the structural strength of ultra-high strength tubular beam and the bonding strength of ultra-high strength tubular beam and aluminum alloy die casting. In addition, the cross sections of the tube beam cavities are not identical in shape, so that the ultra-high strength tube beam with a variable cross section and an irregular shape can be formed, the bonding strength of the ultra-high strength tube beam and the aluminum alloy die casting is further improved, and the integrity of the ultra-high strength tube beam and the aluminum alloy die casting are improved.
The foregoing description of the preferred embodiments of the present application is not intended to be limiting, but is intended to cover any and all modifications, equivalents, or alternatives falling within the spirit and principles of the present application.
Claims (10)
1. The utility model provides an ultra-high strength tubular beam and aluminum alloy die casting integrated into one piece structure, its characterized in that includes ultra-high strength tubular beam and aluminum alloy die casting, aluminum alloy die casting in the corresponding position of ultra-high strength tubular beam, and with ultra-high strength tubular beam forms an integrated structure, wherein, aluminum alloy die casting parcel in ultra-high strength tubular beam periphery, just aluminum alloy die casting with the unsmooth mosaic of contact surface of ultra-high strength tubular beam.
2. An integral molding system for an ultra-high strength tubular beam and an aluminum alloy die casting for preparing the integral molding structure for an ultra-high strength tubular beam and an aluminum alloy die casting according to claim 1, comprising:
the integrated forming die comprises a tube beam cavity matched with the ultra-high strength tube beam and a casting cavity matched with the aluminum alloy die casting, wherein the casting cavity is partially wrapped on the periphery of the tube beam cavity, a concave ring cavity communicated with the tube beam cavity is formed on the periphery of the tube beam cavity, and the concave ring cavity is used for forming a concave-convex mosaic contact surface of the aluminum alloy die casting and the ultra-high strength tube beam; the integral forming die is provided with a pouring port communicated with the casting cavity;
the hot air expansion forming assembly comprises a sealing push head and a nozzle, wherein the sealing push head is used for being externally connected with feeding equipment, and the feeding equipment is used for pushing the sealing push head against the two ends of the tubular beam preform so as to press the two ends of the tubular beam preform into a shape required by sealing, so that the sealing push head can seal the inner cavity of the tubular beam preform; the spray head is arranged in the sealing push head, and is used for filling high-pressure nitrogen or high-pressure air into the tubular beam preform, so that the tubular beam preform is subjected to hot gas expansion forming in the tubular beam cavity, and part of the tubular beam preform bulges into the concave ring cavity to form the ultra-high strength tubular beam with the contact convex surface outside; pouring aluminum alloy into the casting cavity through the pouring opening to perform die casting forming of the aluminum alloy die casting, wherein the aluminum alloy die casting is inlaid with the contact convex surface in a concave-convex manner through a die casting forming part in the concave ring cavity;
the temperature control assembly comprises a controller, a die temperature sensor and a part temperature sensor, wherein the die temperature sensor and the part temperature sensor are embedded and installed in the integrated forming die, the die temperature sensor is used for detecting the temperature of the integrated forming die, and the part temperature sensor is used for detecting the temperature of the part in the tubular beam cavity and/or the casting cavity; the die temperature sensor and the part temperature sensor are both in communication connection with the controller;
the cooling assembly comprises a cooling channel embedded in the integrated forming die, and a cooling medium is used for passing through the cooling channel so as to cool down the tubular beam cavity and/or the part in the casting cavity.
3. The ultra-high strength tubular beam and aluminum alloy die casting integrated forming system of claim 2, wherein the integrated forming die comprises a first module and a second module mated with the first module; and the first module is also provided with a piece withdrawing mechanism.
4. The ultra-high strength tubular beam and aluminum alloy die casting integrated forming system of claim 2, further comprising at least one of an aluminum alloy gating system, a high pressure nitrogen supply, a high pressure air supply, and a cooling medium supply.
5. The integrated molding system of an ultra-high strength tubular beam and an aluminum alloy die casting according to any one of claims 2 to 4, wherein a plurality of concave annular cavities are arranged at intervals along the axial direction of the periphery of the tubular beam cavity; and the cross section shapes of the tube beam cavities are not completely the same in all areas where the concave ring cavities are distributed.
6. An integral forming method for an ultrahigh-strength tubular beam and an aluminum alloy die casting, which is characterized by being implemented by adopting the integral forming system for the ultrahigh-strength tubular beam and the aluminum alloy die casting according to any one of claims 2 to 5, and comprising the following steps:
s1, preparing the ultrahigh-strength tubular beam by adopting a hot gas expansion forming process;
s2, after the ultrahigh-strength pipe beam is cooled to a proper temperature, pressing molten aluminum alloy into the casting cavity so as to form the aluminum alloy die casting at a corresponding position of the periphery of the ultrahigh-strength pipe beam in a die casting mode, and thus the ultrahigh-strength pipe beam and aluminum alloy die casting integrated forming structure is obtained.
7. The method for integrally forming an ultrahigh-strength tubular beam and an aluminum alloy die casting according to claim 6, further comprising a step S3 of removing the ultrahigh-strength tubular beam and the aluminum alloy die casting integrally formed structure from the mold.
8. The method for integrally forming an ultra-high strength tubular beam and an aluminum alloy die casting according to claim 6 or 7, wherein step S1 comprises the steps of:
s11, preparing a prefabricated pipe blank;
s12, bending the prefabricated pipe blank;
s13, stamping and forming the prefabricated pipe blank after the pipe bending treatment;
s14, heating and preserving heat of the preformed tube blank after stamping forming, austenitizing the preformed tube blank and forming a tubular beam preformed piece;
s15, placing the tubular beam preform in the tubular beam cavity, sealing the tubular beam preform at two ends by using the sealing push heads, and then filling high-pressure nitrogen or high-pressure air into the tubular beam preform through the nozzle so as to enable the tubular beam preform to be formed by thermal inflation in the tubular beam cavity, and enabling part of the tubular beam preform to bulge out into the concave ring cavity to form the ultra-high strength tubular beam with the outer part in contact with the convex surface;
s16, introducing the cooling medium into the cooling channel to cool the ultra-high strength tubular beam at a speed of not less than 30 ℃/S until the ultra-high strength tubular beam is martensitic.
9. The method according to claim 8, wherein in step S2, when the temperature of the ultra-high strength pipe beam is detected by the part temperature sensor to be reduced to 150 to 200 ℃, molten aluminum alloy is pressed into the casting cavity through the pouring port and a certain pressure is maintained in the casting cavity, and at the same time, the pressure or circulation speed of the cooling medium in the cooling passage is adjusted to promote mold filling and solidification of the aluminum alloy in the casting cavity.
10. The method of integrally forming an ultra-high strength tubular beam and an aluminum alloy die casting according to claim 8, wherein in step S2, a certain pressure is maintained in the ultra-high strength tubular beam to prevent the ultra-high strength tubular beam from being deformed when the aluminum alloy is poured into the casting cavity.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410032568.5A CN117798254A (en) | 2024-01-09 | 2024-01-09 | Integral forming structure, system and method for ultrahigh-strength tubular beam and aluminum alloy die casting |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410032568.5A CN117798254A (en) | 2024-01-09 | 2024-01-09 | Integral forming structure, system and method for ultrahigh-strength tubular beam and aluminum alloy die casting |
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| CN117798254A true CN117798254A (en) | 2024-04-02 |
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Effective date of registration: 20240522 Address after: 1101-03, 11th Floor, Building 57, No. 2 Jingyuan North Street, Beijing Economic and Technological Development Zone, Daxing District, Beijing, 100176 (Yizhuang Cluster, High end Industrial Zone, Beijing Pilot Free Trade Zone) Applicant after: Future Tiangong (Beijing) Technology Co.,Ltd. Country or region after: China Address before: 1101-03, 11th Floor, Building 57, No. 2 Jingyuan North Street, Beijing Economic and Technological Development Zone, Daxing District, Beijing, 100176 Applicant before: Tong Zhenyu Country or region before: China |