CN1970185A - 中空铝合金挤压型材的弯曲成形方法 - Google Patents
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Abstract
本发明公开了一种中空铝合金挤压型材的弯曲成形方法,该方法是将一件需要弯曲成形的中空薄壁封闭挤压型材,先对零件的一开口端进行严密的焊接封口;焊端面朝下竖立起,并从上开口端向内灌沙,灌至离开口端,留出一小段不灌沙余量长度;并保持零件竖直,再从开口端向零件内缓慢灌水至略高于沙面;然后在沙和水不至流出零件条件下,放入冷冻室冷冻,待沙和水冻结后,用事先制好的楔子打入开口端将其开口严密封闭;将上述零件装夹于拉弯机或滚弯机进行拉弯或滚弯成形。本发明采用沙水填充,冷冻成形薄壁中空封闭铝合金挤压型材弯成形的零件,避免了中空截面在弯曲成形时的凹陷和凸出。解决了弯曲成形中截面变形的问题,保持了零件原始不变形的横截面积。
Description
技术领域:
本发明涉及为现有中空薄壁铝合金挤压型材挤的弯曲成形方法。在本发明描述的中空薄壁铝合金挤压型材包括但不限于是中空铝合金封闭铝合金挤压型材,还可以为中空的其它低温无脆性金属材料的薄壁型材。
背景技术
为了达到提高有轨车辆轻量化及高强度化的需求,薄壁轻量化构件以管材为结构材,在重量相同而刚性及强度较高的情况下,细长比较大的截面形状多样复杂的中空薄壁封闭铝合金挤压型材或管材,所采取的成形方法为液静压挤压成形、弯曲及鼓胀加工之复合成形方法。目前主要用于交通车辆结构的骨架铝合金封闭箱型铝合金挤压型材,特别是有轨列车采用的各种复杂的铝合金封闭铝合金挤压型材,主要采用拉弯成形或滚弯成形方法弯曲成形。由于中空的薄壁铝合金挤压型材零件截面封闭,按照常规的拉弯或滚弯成形,在弯曲成形过程中,由于中空薄壁铝合金封闭铝合金挤压型材截面封闭,内部中空,在弯曲成形过程的巨大载荷下,受拉压应力的作用,变形不均匀,截面会产生凹陷和凸出的严重变形,导致弯曲成形后的型材沿纵向表面发生下凹或上凸,而无法保持原材料的截面形状,满足和构成合格产品。因此目前国内还没有对这类零件更好的成形工艺方法。铝合金封闭铝合金挤压型材在国外虽然有一定程度的运用,但目前还没有如何解决中空封闭铝合金挤压型材弯曲成形问题的相关报道。
发明内容:
本发明的目的是提供一种能够保持中空薄壁铝合金挤压型材零件原始横截面积不变形,能够避免其在弯曲成形中截面凹陷和凸出的弯曲成形方法。
本发明实现上述目的的技术解决方案是:本发明提供的一种中空铝合金挤压型材的弯曲成形方法,包括如下步骤:
1.取一件需要弯曲成形的中空薄壁封闭挤压型或类似的板材,对中空封闭铝合金挤压型材零件的一开口端进行严密的焊接封口;将已焊接封闭的端面朝下竖立起,从上开口端向内灌沙,并不断采用震动的方法惯性压紧沙层,灌至离开口端,留出一小段不灌沙余量长度;
2.保持零件竖直,从开口端向零件内缓慢灌水,灌至水面略高于沙面,水面不往下降为止;
3.在沙和水不至流出零件条件下,放入冷冻室冷冻,待沙和水冻结后,用事先制好的楔子打入开口端将其开口严密封闭或将开口端进行焊接封口;
4.将上述零件装夹于拉弯机或滚弯机进行拉弯或滚弯成形;
5.校正零件,切割零件两端头余量,完成零件成形制造。
本发明具有如下有益效果。
本发明采用沙水填充,冷冻成形薄壁中空封闭铝合金挤压型材拉弯或滚弯成形的零件,不仅制造成本低、效率高,而且避免了中空截面在拉弯或滚弯成形时的凹陷和凸出。通过砂粒在外部弯曲载荷压力下,均布扩散内部内应力,解决了弯曲成性过程中引起的截面变形问题,保持了零件原始不变形的横截面积,零件直线度低于0.2mm。
附图说明
为可清楚地理解本发明,先将通过本发明实施例以举例的方式,同时参照附图,来描述本发明。
图1是按照本发明的一种待弯曲成形的铝合金封闭铝合金挤压型材的示意图。
具体实施方式:
用本发明的方法,在单件操作中可以弯曲成形的铝合金中空薄壁封闭铝合金挤压型材、外形类似于的封闭截面板材或封闭铝合金挤压型材,,一般长度至少在1米以上。弯曲前,应制备一个截面同于铝合金封闭铝合金挤压型材内截面,长度约80-100mm左右的楔子,楔子的硬度通常应低于铝合金挤压型材的硬度,最好采用木楔子。把该铝合金封闭铝合金挤压型材零件的一开口端进行无缝隙焊接封口,将开口封闭。焊接端朝下竖立起铝合金封闭铝合金挤压型材零件,然后,从未封口零件开口端向内灌细沙,或类似沙粒的物质材料。灌沙过程中零件基本保持竖直抬起,并迅速往地上震动式放压,利用震动惯性不断使下层沙粒压紧,同时可以采用木榔头轻敲零件使灌沙下落压紧沙粒,灌至沙粒离开口端有约100mm余量不要灌沙。保持铝合金封闭铝合金挤压型材零件基本竖直,再从零件开口端向内灌水,让水会缓慢浸入零件底部,灌至水面略高于沙面,水位不再往下降为止。然后将零件的开口端倾斜保持高于焊接端,在沙水不被倒出的条件下,将其放入冷冻室进行冷冻。沙水冻结后,拿出冷冻室,迅速把事前制备的木楔子打入零件开口端进行严密封口。再将两端已封口的零件迅速装夹在拉弯机或滚弯机上进行拉弯或滚弯成形。零件成形后进行快校正,最后切割掉零件两端头的多余余量。沙水填充混合冻结是本发明的一个重要而关键的特征。沙水填充混合的顺序步骤可以互换。如果没有冷冻室冷冻,可以在灌沙水后,对另一端可以进行焊接封闭,然后再弯曲成形,效果也应比较理想。
Claims (2)
1.一种中空铝合金挤压型材的弯曲成形方法,包括如下步骤:
1).取一件需要弯曲成形的中空薄壁封闭挤压型或类似的板材,对中空封闭铝合金挤压型材零件的一开口端进行严密的焊接封口;将已焊接封闭的端面朝下竖立起,从上开口端向内灌沙,并不断采用震动的方法惯性压紧沙层,灌至离开口端,留出一小段不灌沙余量长度;
2).保持零件竖直,从开口端向零件内缓慢灌水,灌至水面略高于沙面,水面不往下降为止;
3).在沙和水不至流出零件条件下,放入冷冻室冷冻,待沙和水冻结后,用事先制好的楔子打入开口端将其开口严密封闭或将开口端进行焊接封口;
4).将上述零件装夹于拉弯机或滚弯机进行拉弯或滚弯成形;
5).校正零件,切割零件两端头余量,完成零件成形制造。
2.按权利要求书1所述的弯曲成形方法,其特征在于,沙水填充混合的顺序步骤可以互换,可以在灌沙水后,对另一端进行焊接封闭,然后弯曲成形。
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