RU2299107C2 - Method for shaping elongated blanks and multi-functional bending-straightening machine tool for performing the same - Google Patents

Abstract

FIELD: plastic working of metals, namely manufacture of parts from shapes.

SUBSTANCE: method comprises steps of applying bending loads at predetermined force or camber of blank for one or several transitions along surface area of blank by means of rotation-local deforming along curvature lines by means of pressing moving roller on extensible bearing units mounted in such a way that to provide different spacing between said bearing units depending upon curvature radius of part. Shaping is realized at minimization of contact spot of upper pressing roller and blank due to lowered diameter of roller and its curvature radius in cross direction. Method is realized by means of machine tool whose upper deforming member is in the form of mounted in rod power drive of roller. Lower deforming member of machine tool is in the form of two extensible sections mounted with possibility of engaging with upper deforming roller. Machine tool is provided with manipulators for supporting worked blank.

EFFECT: modified design of machine tool, reduced power consumption.

10 cl, 4 dwg, 1 tbl, 1 ex

Description

The invention relates to the processing of metals by pressure, in particular the manufacture of hull parts for skin and corrugated bulkheads of ships, as well as bent piles and parts of widespread use from profiles.

Known and widely used are methods of forming long bent sheet parts on sheet bending roll machines (rollers), as well as on hydraulic presses. However, these processes and equipment are capital-, material- and energy-intensive due to the high values of bending efforts (up to 5000 tf).

In recent years, the scientific foundations and the bending-correct equipment of a new generation for mini-force rotational-local deformation (RLD) have been created (see Alexandrov V.L., Gorbach V.D., Kuklin OS, Shabarshin V.P. High breakthrough bending and straightening technologies. “Bulletin of shipbuilding technology” No. 4, 1996).

Closest to the claimed is a method of forming bent sheet parts according to the patent of the Russian Federation No. 2199408, which is taken as a prototype. This method of forming bent sheet parts on spaced supports, which consists in applying bending loads with a given force or deflection of the sheet stock for one or more transitions over the workpiece area, while bending loads are applied locally-sequentially (deformation method - PLD) or rotational-locally ( RLD method) along the lines of curvature, and the deflection or force is changed proportionally to the curvature of the bending of the sheet stock under load, taking into account their shape.

In the proposed method of forming long workpieces, bending and dressing are carried out by rotational-local deformation on spaced apart sliding supports installed at different distances between them depending on the shape of the part and the radii of curvature of the part along the bending lines. In this case, bending loads are applied with a given force or a given deflection of the sheet stock in one or more transitions over its area. The blanking is carried out with minimization of the contact spot of the upper pressure roller with the workpiece in the direction of its movement by reducing the diameter of the roller and the radius of curvature in the transverse direction. The aforementioned conditions exclude the crushing of the pressure roller, and the crushing and thinning of the workpiece does not exceed the permissible values, and the working surface of the roller is surface hardened, for example, using high-frequency currents (HDTV), which does not require the use of particularly strong steels, moreover, the roller remains pliable the core, which favors the deformation of various blanks.

In the particular case of the proposed method, the width of the upper pressure roller is chosen to be the greatest of the conditions for achieving plastic deformation of the bend or thinning of the workpiece and with a radius close to the bending radius of the workpiece in its transverse direction, which is achieved by changing the roller.

In another particular case, when editing a long sheet blank, it is initially bent on the support beams until the generators along the length of the workpiece are straightened on the bent workpiece, and then after folding, it is bent on the same supports to a flat state.

In the third particular case, the rotational-local rolling of the blanks is carried out on a flat insert prism mounted along the axis of application of bending loads between the supports or on the supports. In this case, there is a change in the scheme of application of effort: “free bending” on the sliding supports is replaced by “constrained bending” (rolling), because between the supports or on the supports, an insertion prism is installed on which this operation is performed. As a rule, bending of the workpiece by the rotational-local method on the supports is carried out by free bending.

In the fourth particular case of the proposed method, for workpieces of parts having double longitudinal-transverse curvature, preliminary, in the areas of double curvature, the rotational-local rolling of the part is carried out by the pressure roller along a flat prism, and then the pressure-roller is bent on supports using rotational-local bending. For parts having double curvature, first in areas of double curvature, rolling is performed on a flat prism, and then bending by free bending, i.e. change the scheme of application of effort: “constrained bending” (rolling) is replaced by “free bending” on supports.

In the fifth particular case, when dressing and bending strip blanks to an edge, rolling is performed along the plane of the strip by a pressure roller on a flat prism with a gradual turn of the blank along the normal to the radius of curvature.

The rolling of strip parts, for which l / b <5, is performed not along the center line or the entire width, but along one edge, as a result of which, after the first pass, the part acquires a certain radius, for subsequent passes after the first for a straight path of movement of the bending roller, the part is necessary unfold under the roller normal to the radius of curvature.

To expand the arsenal of long technical workpieces used for shaping, we propose a multifunctional bending machine with a chassis for reciprocating movement relative to the base, a bed made in the form of two frames and traverses placed between the frames, carrying respectively the upper and lower deforming elements, the top of which is made in the form of a roller mounted on the rod of the power drive of the chassis with the possibility of reciprocating displacements in the vertical plane towards the lower cross member and along it, and the bottom - in the form of two support beams mounted to cooperate with the upper deforming roller. In this case, the machine is equipped with manipulators to support the workpiece, and the support beams of the lower deforming element are made in the form of split sections with the possibility of their separation.

In the particular case of the proposed device, the total length of the cutting sections is at least 12 m.

In another particular case of the proposed device, its support beams are made with openings with a width of up to 5 thicknesses of the workpiece for access by manipulators.

In another particular case of the proposed device, the grippers of the manipulators, which are equipped with the proposed device for supporting the workpiece for one or both ends during its movement, are configured to support the workpiece both above and below the supporting surface of the support beams.

Compared with the prototype and other analogues, the proposed method, due to the above differences, minimizes bending efforts and minimizes transitions from one bending line to another, choosing the radii of transverse and longitudinal curvature is the least possible, and the width, on the contrary, is the most possible of these conditions and design considerations, as well as optimization application of processes of rotational-local bending on sliding supports and rotational-local rolling on a flat prism.

The claimed multifunctional bending machine for implementing the method can perform rotational-local bending along the length of the workpiece, and not along its width, as in the considered analogue, which greatly expands its capabilities. To bend sheets on both sides of the workpiece, the manipulators are equipped with grippers that support and move the workpiece both in the plane of the support beams (see prototype) and above or below the support surface of the support beams.

The essence of the invention is illustrated by the accompanying schemes:

Figure 1 - General view of a multifunctional bending machine,

Figure 2 is a side view of a multifunctional bending machine with rotational-local bending of a sheet blank with manipulators;

Figure 3 - the same with the rotational-local rolling section of the sheet blanks of double curvature (the manipulator is not shown);

Figure 4 - bending and editing on the edge of a long workpiece from the profile (top view of a flat prism).

Multifunctional bending machine (Figure 1-3) consists of a bed made in the form of two frames 1, placed between the frames of the upper 2 and lower 3 traverses, respectively: upper deforming element in the form of a roller 4, which is mounted on the rod 5 of the power drive and moves in the vertical direction 6 and along the yoke in directions 7, and the lower one in the form of support beams 8, consisting of sections 9 and sliding apart by a distance L depending on the radius of curvature R of the workpiece 10 (Fig.1-2).

Shaping is carried out by minimizing the contact patch width 2a of the upper pressing roller 4 with the workpiece 10 in the direction 7 of its displacement, which is achieved by decreasing to the permissible value may roller 4 and the diameter d _p of radius of curvature R In rotationally local bending (2) _at at transverse direction; in order to increase the productivity of the process, the width b _{p of the} pressure roller 4 is chosen to be the greatest from the condition of achieving plastic deformation or thinning Δs of the workpiece 10 with an initial thickness s, and the radius R _{in the} roller is chosen closest to the bending radius R of the workpiece 10 in its transverse direction.

Moving 12 (figure 2) of the sheet stock 10, positioning it with rotation to align the longitudinal axis with the bending line, moving the workpiece to the next bending line with step t, removing the bending from the working area is carried out by manipulators 13 (figure 2) with grips below 14 and above 13 the plane of the support beams 8 or by other means when the pressure roller 4 moves away from the workpiece 10.

Rotational-local rolling (figure 3) for the section of the workpiece 10 with a double curvature l _{p is} carried out by the upper roller 4 along a flat prism 11 installed along the axis of application of bending loads P on the support beams 8 (figure 3) or between them.

Editing of the sheet blanks 10 is performed initially by rotational-local bending on the support beams 8 (Fig. 2) until the generators are straightened along the length of the workpiece, and then after tilting it is unbent on the same supports to a flat state, thereby eliminating the waviness and warping of the workpiece.

Straightening and bending of strip blanks and profile 15 on the edge (4) is performed on the shaded 16 is rolled profile ribs 4 on the roller plane of a flat prism 11 mounted on the sections 9 of support beams 8 with the workpiece 15 to steer the radius of curvature R of bending _straight profile.

The above technical solutions for the method and multifunctional bending machine are obtained according to the results of research and development performed by FSUE TsNIITS according to the federal target programs in the development and experimental development of new technologies and bending equipment of the new generation based on the principles of rotational-local deformation during sheet and profile parts.

An example of the use of the proposed method is the pilot work carried out on a multi-function bending and straightening machine MGPS-25 with a force of 25 tf when testing its new modification MGPS-25M, as well as during the development of a machine with MGPSM-50K manipulators for bending and straightening sheets with overall dimensions up to 3.2 × 12 m.

A comparison of new bending technologies with new methods on new equipment is presented in the attached table, from which it follows that MGPSM-50K type machines provide significant resource savings compared to traditional methods and equipment:

- the proposed machines replace the technological capabilities of hydraulic presses and rollers with an force of 16-40 times large;

- the mass of equipment is reduced by 10-15 times, the mass of equipment is more than 100 times;

- the energy intensity of the process is reduced by 4-6 times.

Table Comparison of bending equipment Options New equipment Replaceable bending and leveling equipment (OJSC "Severnaya Verf") MGPSM-50K, Russia Press PB192, Ukraine Press PB 3239, Ukraine LMP 16 × 2500, Germany LGM "Fuji Car", Japan LGM "Demag", Germany LGM small / 3 units / Force kN 500 4000 8000 - 20000 5000 - Overall dimensions of sheets, mm 30 × 3200 × 1200 0 24 × 2000 × 6000 30 × 2500 × 8000 16 × 2500 × 8000 30 × 2500 × 10000 16 × 2500 × 8000 12 × 2500 × 4000 Overall dimensions of the equipment (l × b × h), m 15.4 × 7.2 × 4.9 9.2 × 5.0 × 9.6 11.0x6.4 × 10.5 8.3 × 4.3 × 6.3 18.1 × 4.8 × 1 3.7 12.0 × 4.0 × 8.5 5.0 × 1.6 × 2.5 Occupied area, m ² 40,0 56.0 70.0 37.0 89.0 48.0 80.3 ∑380 Installed power, kW 36.0 74.3 126.8 320,0 88.0 50,0 30,0 ∑689 Mass of equipment, t 56.0 72.0 160,0 92.6 344.0 120.0 80.3 869 Attendants, people 2 3 3 2 3 3 2 Bending and straightening accuracy, mm 2-5 3-12 3-12 3-10 2-5 2-5 3-5 Types of manufactured parts Any, including corrugations of chemical carriers Cylinder, sail, saddle, sphere Cylinder, sail, saddle, sphere Flat sheet (except edges) Cylinder, cone (without bending) Cylinder (without bending) Cylinder (without bending)

Table continuation Options New equipment Replaceable bending and leveling equipment (Severnaya Verf shipyard) MGPSM-50K, Russia Press PB 192, Ukraine Press PB 3239, Ukraine LMP 16 × 2500, Germany LGM "Fuji Car", Japan LGM "Demag", Germany LGM small / 3 units / With allowances The performance of sheets of complex shape per shift, pcs 6-8 1.4 1,5 2.7 2,5 2,5 Machine time,% including strain% 90 eighteen fifteen 60 fifty fifty fifty 95 3 3 35 35 35 35 Download% up to 85 38 eighteen 10 10 5 5 Cost, thousand US dollars 400 400 700 250 1200 600 300 ∑3450

Claims (10)

1. A method of forming long workpieces on spaced supports, including applying bending loads with a given effort or deflection of the workpiece for one or more transitions over the workpiece area by rotational-local deformation along the curvature lines by a moving push roller on the sliding supports installed at different distances between them in depending on the radii of curvature of the part, characterized in that the shaping is carried out with minimizing the contact spot of the upper pressure roller with cooking by reducing the diameter of the roller and the radius of its curvature in the transverse direction. 2. The method according to claim 1, characterized in that the width of the upper pressure roller is chosen to be the greatest of the conditions for achieving plastic deformation of the bend or thinning of the workpiece and with a radius close to the bending radius of the workpiece in its transverse direction. 3. The method according to claim 1, characterized in that when shaping the sheet blank, it is straightened, in which the blank is initially bent on the support beams until the generators are straightened along the length of the blank, and then, after tilting, it is bent on the same supports to a flat state. 4. The method according to claim 1, characterized in that the rotational-local rolling of the blanks is carried out on a plug-in prism mounted along the axis of application of bending loads between the supports or on the supports. 5. The method according to claim 4, characterized in that for the shaping of workpieces of parts having double longitudinal-transverse curvature, preliminary, in areas of double curvature, the rotational-local rolling is performed by a pressure roller on a flat prism, and then rotational-local bending is performed by a pressure roller on the supports. 6. The method according to claim 3, characterized in that when dressing and bending strip blanks to an edge, rolling is performed along the plane of the strip by a pressure roller on a flat prism with a gradual turn of the blank along the normal to the radius of curvature. 7. A multifunctional bending machine, comprising a chassis for reciprocating movement relative to the base, a bed made in the form of two frames, placed between the frames of the beam, bearing, respectively, the upper and lower deforming elements, the upper of which is made in the form of a roller, mounted on the rod of the power drive of the chassis with the possibility of reciprocating movement in a vertical plane in the direction of the lower beam and along it, and the lower one in the form of two support beams, tanovlenii to cooperate with the upper deforming roller, characterized in that it is provided with manipulators to maintain the workpiece and the support beams lower deforming member are in the form of split sections, with their spreads. 8. The multifunctional bending machine according to claim 7, characterized in that the total length of the cutting sections is at least 12 m. 9. The multifunctional bending machine according to claim 7, characterized in that the support beams are made with openings up to 5 widths of the workpiece to be accessed by manipulators. 10. The multifunctional bending machine according to claim 7, characterized in that the grips of the manipulators supporting the workpiece for one or both ends during its movement are made with the possibility of supporting the workpiece both above and below the supporting surface of the support beams.

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