WO2020051814A1 - 带有连接边的异形管件成形方法 - Google Patents

带有连接边的异形管件成形方法 Download PDF

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Publication number
WO2020051814A1
WO2020051814A1 PCT/CN2018/105368 CN2018105368W WO2020051814A1 WO 2020051814 A1 WO2020051814 A1 WO 2020051814A1 CN 2018105368 W CN2018105368 W CN 2018105368W WO 2020051814 A1 WO2020051814 A1 WO 2020051814A1
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Prior art keywords
special
pipe
shaped pipe
blank
original
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PCT/CN2018/105368
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English (en)
French (fr)
Inventor
何祝斌
林艳丽
凡晓波
苑世剑
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Dalian University of Technology
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Dalian University of Technology
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Priority to AU2018441227A priority Critical patent/AU2018441227A1/en
Priority to PCT/CN2018/105368 priority patent/WO2020051814A1/zh
Publication of WO2020051814A1 publication Critical patent/WO2020051814A1/zh
Anticipated expiration legal-status Critical
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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
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/86—Making other particular articles other parts for bicycles or motorcycles

Definitions

  • the invention belongs to the field of processing and forming special-shaped pipe fittings, and particularly relates to a method for forming special-shaped pipe fittings with connecting edges.
  • the weight reduction of components is mainly achieved by two ways: first, by optimizing the structure, adopting a more reasonable structural form of the bearing capacity and optimizing the wall thickness distribution in the structure, etc., under the premise of ensuring the comprehensive performance of the structure Reduce structural weight as much as possible. Second, use lighter materials with higher specific strength, such as aluminum alloys, magnesium alloys, and titanium alloys. Using such materials can greatly reduce structural weight.
  • the internal high-pressure forming technology that has appeared in recent years has been widely used to achieve the integral forming of longer-length curved axis structures.
  • This technology generally uses a tube blank with a circular cross section as the original blank, and uses bending, preforming, and final forming processes to form an overall complex curved axis tube structure.
  • the U-shaped sub-frame on the chassis of a car is manufactured from a tube blank with a circular cross-section, a numerically controlled bending, flattening pre-forming, and internal high-pressure shaping scheme to replace the previously segmented tailor-welded U-shaped sub-frame.
  • the U-shaped subframe that is integral in the axial direction is not used alone. It also needs to be connected to adjacent chassis structures and engines. Therefore, multiple connection platforms, Connect the holes, and then connect multiple connection plates to the overall subframe, and these connection plates are then connected to other structures.
  • the number of connecting plates is often as many as 20, and the weight is about 10 kg, which weakens the weight reduction effect of the overall sub-frame to a certain extent.
  • a plurality of local structures need to be formed in advance on the overall sub-frame.
  • connection units such as multiple connection plates
  • the present invention is to solve the problems that the existing special-shaped pipe fittings need to additionally add a plurality of complex-shaped connecting plates to achieve fixation and connection with other structures, which results in complex processes, low structural reliability, high manufacturing costs, and the like, and proposes special-shaped pipe fittings with connecting edges. Forming method.
  • the method for forming a special-shaped pipe with a connecting edge is as follows:
  • Step 1 According to the connection requirements of the special-shaped pipe and the adjacent structure, design / select or process the original pipe blank with integrated flange outside;
  • Step 2 Fix the original tube blank with an integrated flange edge on the outside on the pre-forming mold, and use the flange edge to position and restrain the original tube blank;
  • Step 3 The preform mold is closed, and the original tube blank is subjected to a bending or flattening pre-deformation treatment, so that the original tube blank and its flange are deformed to approximate the cross-sectional shape and bending axis of the final part to obtain the preformed tube blank;
  • Step 4 Place the preformed tube blank in the final forming mold, and use the flange edge to position and restrain the preformed tube blank;
  • Step 5 The final forming mold is closed, and the preformed tube is deformed under the external load of the internal pressure and axial thrust, so that the preformed tube is abutted against the mold to form the required bending axis and cross-sectional shape to obtain the final abnormal shape.
  • Pipe fittings
  • Step 6 Take out the final shaped pipe, machine the external integrated flange and the corresponding position of the pipe wall to obtain the required connection holes, and complete the processing of the shaped pipe with integrated connecting edges.
  • the original pipe blank is an extruded profile or a rolled plate profile.
  • the material is aluminum alloy or magnesium alloy.
  • the edge of the slab on the side of the special-shaped pipe and the connecting edge form a closed shaped cross-section by butt or overlap; the overlap method is external overlap and internal overlap.
  • the positioning method is: insert the flange edge on the original tube blank into the groove on the mold, or use a divided mold to clamp the flange edge The way.
  • a support is placed inside the special-shaped tube; when the support is solid, the yield strength of the solid support is 30 to 200 MPa lower than that of the special-shaped tube; When the support is a fluid, the pressure of the fluid support is 10 to 100 MPa.
  • the solid support is a rubber or polyurethane rod.
  • the working temperature of the final forming mold is normal temperature
  • water, oil or an oil-water mixture is filled into the preformed tube blank
  • the working temperature of the final forming mold is 300 to 650 ° C
  • the preformed tube is filled with high-pressure air, nitrogen or argon, and the gas pressure is 5 ⁇ 70MPa.
  • the original blank used has an integrated flange edge, and the deformed section tube and the flange edge are deformed at the same time and always remain as a whole, and are connected to other structures through the connecting edge. It is connected to avoid forming complicated connecting bosses or fixing holes on the shaped pipe body, thereby greatly simplifying the shape complexity of the shaped pipe body and reducing the manufacturing cost;
  • the original blank used has an integrated flange edge, and the special-shaped cross-section pipe and the flange edge are deformed at the same time and are always maintained as a whole.
  • the connecting edge and the special-shaped pipe body The structure is compact and the integrity is good.
  • the external structure is directly connected to the flange. There is no need to set a connecting plate or a local reinforcement structure at the connection of the special-shaped pipe, so the weight of the component is significantly reduced;
  • the original blank used has an integrated flange edge, and the special-shaped section tube and the flange edge are deformed at the same time and always remain as one, eliminating the use of a split structure
  • the weld between the connecting plate and the special-shaped pipe fittings has significantly improved the overall mechanical properties, fatigue resistance and corrosion resistance of the component
  • the method for forming a special-shaped pipe fitting with a connecting edge uses an integrated flange edge on the original blank, and the deformed section tube and the flange edge are simultaneously deformed and maintained as one, avoiding the use of a split structure
  • complex thermal deformation occurs, which affects the precision of special-shaped pipe fittings and the accuracy of assembly with other structures;
  • the method for forming a special-shaped pipe fitting with a connecting edge adopts an original flange with an integrated flange edge, and the deformed section tube and the flange edge are deformed at the same time and are always maintained as one because the shape of the integrated connection edge Relatively simple and generally unobstructed structure around, so different types of connection structures can be easily and flexibly processed on the connection side, which provides the possibility for implementing various forms of local connections;
  • the original blank used has an integrated flange edge, and the deformed section tube and the flange edge are deformed at the same time and are always maintained as a whole.
  • the blank can be produced by either extrusion or rolling.
  • the original blank has low manufacturing cost and does not need to add complicated mold tooling in the subsequent forming of shaped pipes. Therefore, the manufacture of shaped pipes with integrated connecting edges Cost is lower than traditional structure;
  • the original blank used has an integrated flange edge, and the special-shaped tube and the flange edge are deformed at the same time and always remain as one, the special-shaped tube and the flange
  • the edge can be welded to form a closed-section shaped cross-section lumen first, and then subjected to subsequent forming, or it can be not welded to form a closed shaped-section lumen first, and then fixed by spot welding and other methods after forming.
  • FIG. 1 is a schematic diagram of an integrally-shaped shaped cross-section pipe according to the present invention.
  • FIG. 2 is a schematic diagram of connecting the integrally shaped cross-section pipe fitting of the present invention with an adjacent structure using a connecting plate.
  • FIG. 3 is a schematic diagram of a special-shaped pipe with a connecting edge according to the present invention (final part).
  • FIG. 4 is a schematic view of a profiled section pipe and a flange edge manufactured by an extrusion method according to the present invention; wherein (a-1) and (a-2) are a profiled pipe with a circular section and a sectional view thereof, (b-1) And (b-2) are square-shaped shaped tubes and their sectional views, and (c-1) and (c-2) are triangular-shaped shaped tubes and their sectional views.
  • FIG. 5 is a schematic diagram of forming a special-shaped pipe with a connecting edge according to the present invention.
  • the original tube blank is manufactured by an extrusion method, including: bending, pre-forming, and internal pressure bulging; three main processes; (a) is a bending pre- Deformation, (b) is flattening pre-deformation, and (c) is internal pressure bulging.
  • FIG. 6 is a schematic diagram of a special-shaped cross-section pipe and a flange edge manufactured by a sheet bending method according to the present invention (an initial cross-section of a special-shaped cross-section pipe that is closed and welded at an edge).
  • (a) is a circular cross section
  • (b) is a square cross section, the connecting side is on one side
  • (c) is a square cross section, and the connecting side is in the middle.
  • FIG. 7 is a schematic diagram of a special-shaped section pipe and a flange edge manufactured by a sheet bending method according to the present invention (initial welding of a special-shaped section pipe blank, an internal overlap method).
  • (a) is a circular cross section
  • (b) is a square cross section, the connecting side is on one side
  • (c) is a square cross section, and the connecting side is in the middle.
  • FIG. 8 is a schematic diagram of a special-shaped cross-section pipe and a flange edge manufactured by a sheet bending method according to the present invention (initial welding of a special-shaped cross-section pipe blank, external lapping method).
  • (a) is a circular cross section
  • (b) is a square cross section, the connecting side is on one side
  • (c) is a square cross section, and the connecting side is in the middle.
  • FIG. 9 is a schematic diagram of a mold compression seal when a shaped pipe with a connecting edge according to the present invention is formed.
  • (A) is a solid medium without a seal ring
  • (b) is a fluid medium with a seal ring.
  • FIG. 10 is a schematic diagram of a split mold used for forming a shaped pipe with a connecting edge according to the present invention (in the case of preforming and final forming, a split mold is used for a shaped tube and a connecting edge).
  • Embodiment 1 The method for forming a special-shaped pipe with a connecting edge according to the present invention is implemented according to the following steps:
  • Step 1 According to the connection requirements of the special-shaped pipe and the adjacent structure, design / select / process the original pipe blank with the integrated flange outside;
  • Step 2 Fix the original tube blank with the integrated flange edge on the outside of the preforming mold, and use the flange edge to position and restrain the original tube blank;
  • Step 3 Perform pre-deformation such as bending or flattening the original tube blank, so that the original tube blank and its flange are deformed to approximate the cross-sectional shape and bending axis of the final part;
  • Step 4 Place the pre-deformed tube blank with the flange edge in the final forming mold, and use the flange edge to position and constrain the pre-formed tube blank;
  • Step 5 Close the final forming mold to deform the preformed tube blank under the external load such as internal pressure and axial thrust, and form the tube blank against the mold to form the required bending axis and cross-sectional shape;
  • Step 6 Take out the final shaped pipe, machine the external integrated connecting edge and the corresponding position of the pipe wall to obtain the required connection holes, etc., and obtain the finally required shaped pipe with integrated connecting edge.
  • Embodiment 2 The method for forming a special-shaped pipe with a connecting edge according to the present invention is characterized in that, in step 1, the original pipe blank used is an extruded profile, and the material is an aluminum alloy or a magnesium alloy. There are no welds between the profiled pipe on the original extruded profile and the flange. Others are the same as the first embodiment.
  • the beneficial effect of this embodiment is that the special-shaped pipe and the flange on the original pipe blank are obtained by one-time forming during the extrusion process, and the special-shaped pipe and the flange will also always remain as one during the subsequent deformation process, and there is no need to form Before the part or after forming the part, the special-shaped pipe and the connecting edge are connected by welding and other methods.
  • Embodiment 3 The method for forming a special-shaped pipe with a connecting edge according to the present invention is characterized in that, in step two, a flange edge on the original pipe blank is inserted into a groove on a mold, or a block mold is used.
  • the clamping mode realizes the fixation and positioning of the original tube blank on the forming mold.
  • Others are the same as the first embodiment.
  • the beneficial effect of this embodiment is that since the special-shaped pipe and the flange side on the original pipe blank are integrated, when the flange side is clamped and fixed, the section of the special-shaped pipe can be restricted from being deformed during subsequent bending or flattening deformation. Unreasonable rotation of the axis can ensure that the cross-sectional shape and axis shape of the deformed tube after bending or squashing pre-deformation can be effectively controlled, to prevent uncontrolled deformation of the deformed tube during pre-deformation and affect subsequent internal pressure expansion .
  • Embodiment 4 The method for forming a special-shaped pipe with a connecting edge according to the present invention is characterized in that in step 3, before performing pre-deformation such as bending or squeezing, a solid support such as rubber, polyurethane rod, etc. is placed inside the special-shaped pipe. , Or filled with gas, liquid and other fluid support.
  • the yield strength of the solid support is 30 to 200 MPa lower than that of the shaped tube, and the pressure of the fluid support is 10 to 100 MPa.
  • Others are the same as the first and second embodiments.
  • the beneficial effect of this embodiment is that since the special-shaped pipe is a closed structure, it is easy to establish a certain support pressure inside the special-shaped pipe. Under the support of internal pressure, the shaped tube can undergo more complex bending or flattening deformation without local folding and cracking or abnormal indentation in the cross section. This is not a pre-deformation that is not conducive to subsequent bulging, which is the subsequent bulging by internal pressure Obtaining the final profiled fittings guarantees.
  • Embodiment 5 The method for forming a special-shaped pipe with a connecting edge according to the present invention is characterized in that, in step 5, the final forming mold used is at a normal temperature state, and water or oil is charged into the preformed tube blank. Or oil-water mixture; or, the final forming mold used is in a heated state of 300 to 650 ° C, and high-pressure air or nitrogen or argon is charged into the preformed tube blank, and the gas pressure is 5 to 70 MPa. Others are the same as the first and second embodiments.
  • the beneficial effect of this embodiment is that according to the difference between the preformed tube blank and the final mold cavity, a reasonable mold temperature is selected for subsequent deformation.
  • the deformation can be performed at normal temperature; when the difference is large or the fillet radius is less than 1.5 times on the mold cavity
  • the mold can be heated to a suitable temperature (for 6061 aluminum alloy, it is heated to 350 ⁇ 550 ° C, and for AZ31 magnesium alloy, it is heated to 280 ⁇ 500 ° C) and then formed. Avoiding the problems of early cracking or insufficient filling of small fillets when forming under unreasonable temperature conditions.
  • Embodiment 6 The method for forming a special-shaped pipe with a connecting edge according to the present invention is characterized in that, in step 1, the original blank used is a special-shaped cross-section with a flange edge obtained by bending a plate. The edge of the slab on the side of the special-shaped pipe and the special-shaped pipe or the connecting edge are butted to form a closed special-shaped cross-section. Others are the same as the first embodiment.
  • the beneficial effect of this embodiment is that since the edge of the side of the profiled pipe on the slab directly abuts the slab to form a closed section, there is no excess transition material between the profiled pipe and the flange side, so this form of original blank
  • the lightest weight, its preparation process is similar to the traditional round section tube blank, and the cost is lower.
  • Embodiment 7 The method for forming a special-shaped pipe with a connecting edge according to the present invention is characterized in that, in step 1, the original blank used is a special-shaped cross-section with a flange edge obtained by bending a plate. The edge of the slab on the side of the shaped pipe and the shaped pipe or flange are overlapped to form a closed shaped section. Others are the same as the first embodiment.
  • the beneficial effect of this embodiment is that the edge of the slab on the side of the special-shaped pipe forms a closed section with the slab through overlap, and the position of the overlap can be either on the special-shaped pipe or on the edge of the flange;
  • the joints are welded in advance with the profiled tube / flange and then subsequently shaped. It can also be welded after bending or flattening and final internal pressure bulging; it can also be achieved by mold compression during bulging.
  • the overlap method can be used to achieve reasonable connection / restraint of the special-shaped pipe and the flange edge, which provides more possibilities for the reasonable control of material deformation during the pre-forming and final internal pressure bulging process.
  • Embodiment 8 The method for forming a special-shaped pipe with a connecting edge according to the present invention is characterized in that: in step two, before fixing the original pipe blank in a mold, the flange edge on the original pipe blank is processed to Get the required connection hole or connection structure. Others are the same as the first embodiment.
  • connection hole or the connection structure is directly processed on the flange edge of the original tube blank. Since the flange edge is a flat form, it is easy to clamp when machining and the machining equipment used is simple. When the final profiled pipe with integrated connection edges is relatively simple, no severe cross-sectional changes and axis distortions will occur during the pre-forming and final internal pressure bulging process. Using this solution can greatly improve efficiency and reduce costs.
  • Embodiment 9 The method for forming a special-shaped pipe fitting with a connecting edge according to the present invention is characterized in that: in step 2 and step 4, the pre-forming mold and the final forming mold adopt a split structure, and the independent tube is used for the original tube blank. Or, the flange edge on the preform is used for positioning and restraint, and an independent module is used as a forming die for the shaped pipe. Others are the same as the first embodiment.
  • the beneficial effect of this embodiment is that, since the flange side is positioned and restrained by using an independent module, the positioning / constraint / deformation of the flange side will be independent of and subsequent to the mold clamping, loading, and deformation processes of the special-shaped pipe. .
  • the two independent modules of this embodiment can more accurately realize the deformation of the flange edge and the special-shaped pipe. At the same time, mold design and processing and equipment control requirements are greatly reduced.

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  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

一种带有连接边的异形管件成形方法，属于异形管件加工成形领域。首先将适配于相邻结构连接要求的带有一体化法兰边（4-2）的原始管坯（4）固定于模具（5，6）上，对原始管坯进行弯曲或压扁的预变形处理，使原始管坯及其法兰边变形为接近最终零件的截面形状和弯曲轴线，得到预成形管坯（5-3，6-3）；然后将预成形管坯置于终成形模具中，预成形管坯在内部压力、轴向推力的外部载荷作用下发生变形，使预成形管坯贴靠模具成形为需要的弯曲轴线和截面形状，得到最终的异形管件；最后对外侧的一体化法兰和管壁的相应位置进行机械加工，获得需要的连接孔，完成加工。本方法工序简单、结构可靠性高，制造成本低，是一种新型的异形管件加工成形方法。

Description

带有连接边的异形管件成形方法 技术领域
本发明属于异形管件加工成形领域，具体涉及带有连接边的异形管件成形方法。
 背景技术
在航空航天、高铁、汽车及自行车等领域，为了减轻结构重量，需要采用多种形式的轻量化构件。一般而言，构件的轻量化主要通过两个途径实现：一是通过优化结构，采用承载能力更为合理的结构形式并对结构中的壁厚分布等进行优化，在保证结构综合性能的前提下尽量减轻结构重量；二是采用比强度更高的轻质材料如铝合金、镁合金、钛合金等，采用此类材料可以大幅减轻结构重量。
在结构优化方面，采用整体结构代替分块拼接结构，是非常重要的实施途径。近年来出现的内高压成形技术已被广泛用来实现尺寸较长的弯曲轴线结构的整体成形。该技术一般以截面为圆形的管坯为原始坯料，采用弯曲、预成形、终成形等工序，成形出整体的复杂弯曲轴线管类结构。例如，汽车底盘上的U形副车架，就是通过圆截面管坯，通过数控弯曲、压扁预成形、内高压整形的方案制造，用以代替以前的分段拼焊的U形副车架，实现了明显的减重效果。
但是，在轴线方向上为整体的U形副车架并不是单独使用，其还需要与相邻的底盘结构件以及发动机等实现连接，因此在整体副车架上还需要设置多个连接平台、连接孔，然后将多个连接板与整体副车架相连，这些连接板再与其他结构连接。在一个U形副车架上，连接板的数量往往多达20个、重量约10公斤，这就在一定程度上削弱了采用整体副车架的减重效果。而且，为了实现与连接板的可靠连接，需要在整体副车架上预先成形出多个局部结构，这些局部结构的直径、曲率半径等往往与相邻区域相差很大，这必然加大了整体副车架的成形难度，特别是容易导致整体副车架的尺寸精度和一致性变差，这进一步导致整体副车架与连接板的装配难度大、焊接精度和可靠性差。
为了解决现有异形管件在与其他结构连接固定时需要额外增加连接单元（如多个连接板）导致结构重量增加、结构整体性和可靠性变差，而且狭窄空间中焊接和铆接困难、尺寸精度和可靠性难以保证的问题，需要开发一种新的异形管件及其成形方法。
 技术问题
本发明是为解决现有的异形管件需要额外增加多个复杂形状连接板实现与其他结构的固定与连接，导致工序复杂、结构可靠性低、制造成本高等问题，提出带有连接边的异形管件成形方法。
 技术解决方案
本发明的技术方案：
带有连接边的异形管件成形方法，步骤如下：
步骤一、根据异形管件与相邻结构的连接要求，设计/选择或加工外侧带有一体化法兰边的原始管坯；
步骤二、将外侧带有一体化法兰边的原始管坯固定于预成形模具上，利用法兰边对原始管坯进行定位和约束；
步骤三、闭合预成形模具，对原始管坯进行弯曲或压扁的预变形处理，使原始管坯及其法兰边变形为接近最终零件的截面形状和弯曲轴线，得到预成形管坯；
步骤四、将预成形管坯置于终成形模具中，利用法兰边对预成形管坯进行定位和约束；
步骤五、闭合终成形模具，预成形管坯在内部压力、轴向推力的外部载荷作用下发生变形，使预成形管坯贴靠模具成形为需要的弯曲轴线和截面形状，得到最终的异形管件；
步骤六、将最终的异形管件取出，对外侧的一体化法兰和管壁的相应位置进行机械加工，获得需要的连接孔，完成带有一体化连接边异形管件的加工。
所述的原始管坯为挤压型材或板材弯卷型材，原始管坯为挤压型材时，原始挤压型材上的异形管和法兰边之间无焊缝，材料为铝合金或镁合金；原始管坯为板材弯卷型材时，板坯上位于异形管一侧的边缘与连接边通过对接或搭接形成封闭异形截面；搭接的方式为外部搭接和内部搭接。
所述步骤二中，原始管坯固定于预成形模具上时，定位方式为：将原始管坯上带有的法兰边插入模具上的凹槽中，或采用分块模具夹紧法兰边的方式。
所述步骤三中，对原始管坯进行弯曲或压扁等预变形之前，在异形管内部放置支撑物；当支撑物为固体时，固体支撑物的屈服强度比异形管低30~200MPa；当支撑物为流体时，流体支撑物的压力为10~100MPa。所述的固体支撑物为橡胶或聚氨酯棒。
所述步骤五中，当终成形模具的工作温度为常温时，预成形管坯内充入的是水、油或油水混合物；当终成形模具的工作温度为300~650℃时，向预成形管坯内充入的是高压空气、氮气或氩气，气体压力为5~70MPa。
 有益效果
本发明的有益效果：
（1）本发明的带有连接边的异形管件成形方法，采用的原始坯料上带有一体化法兰边，异形截面管和法兰边同时变形并始终保持为一体，通过连接边与其他结构相连，避免在异形管件本体上成形复杂的连接凸台或固定孔等，从而可大幅简化异形管件本体的形状复杂程度，降低制造成本；
（2）本发明的带有连接边的异形管件成形方法，采用的原始坯料上带有一体化法兰边，异形截面管和法兰边同时变形并始终保持为一体，这就避免了在成形后的异形管件（弯曲轴线、异形截面）上再焊接或铆接独立的连接板时容易出现连接板与异形管件空间定位困难、焊接质量差、一致性差、局部狭窄位置无法实现连接的难题；
（3）本发明的带有连接边的异形管件成形方法，采用的原始坯料上带有一体化法兰边，异形截面管和法兰边同时变形并始终保持为一体，连接边与异形管件本体之间结构紧凑、整体性好，外部结构直接与法兰边相连，无需在异形截面管件的连接处再设置连接板或局部增强结构，因此构件的重量明显减轻；
（4）本发明的带有连接边的异形管件成形方法，采用的原始坯料上带有一体化法兰边，异形截面管和法兰边同时变形并始终保持为一体，消除了采用分体式结构时连接板与异形管件之间的焊缝，构件的整体力学性能、抗疲劳性能及抗腐蚀性能明显提高；
（5）本发明的带有连接边的异形管件成形方法，采用的原始坯料上带有一体化法兰边，异形截面管和法兰边同时变形并始终保持为一体，避免了采用分体式结构时在连接板和异形管件焊接过程中产生复杂的热变形、从而影响异形管件精度以及与其他结构装配精度的问题；
（6）本发明的带有连接边的异形管件成形方法，采用的原始坯料上带有一体化法兰边，异形截面管和法兰边同时变形并始终保持为一体，因为一体化连接边形状相对简单且周围一般无阻碍结构，所以可以在连接边上方便、灵活地加工出不同形式的连接结构，为实现各种形式的局部连接提供了可能；
（7）本发明的带有连接边的异形管件成形方法，采用的原始坯料上带有一体化法兰边，异形截面管和法兰边同时变形并始终保持为一体，带法兰边的原始坯料既可以通过挤压方法生产，也可以通过辊压方法生产，原始坯料的制造成本低，在后续成形异形管件时也无需增加复杂的模具工装，因此带有一体化连接边的异形管件的制造成本要低于传统结构；
（8）本发明的带有连接边的异形管件成形方法，采用的原始坯料上带有一体化法兰边，异形截面管和法兰边同时变形并始终保持为一体，异形截面管和法兰边既可以先焊接形成封闭截面的异形截面管腔，然后再进行后续成形，也可以先不焊接成封闭的异形截面管腔，待成形以后再通过点焊等方法加强固定。
 附图说明
图1为本发明的整体式异形截面管件示意图。
图2为本发明的整体式异形截面管件与相邻结构采用连接板连接的示意图。
图3为本发明的带有连接边的异形管件示意图（最终零件）。
图4为本发明的采用挤压方法制造的异形截面管与法兰边示意图；其中，（a-1）和（a-2）为圆形截面异型管及其截面图，（b-1）和（b-2）为方形截面异型管及其截面图，（c-1）和（c-2）为三角形截面异型管及其截面图。
图5为本发明的带有连接边的异形管件成形示意图，原始管坯为挤压方法制造，包括：弯曲、预成形、内压胀形，三个主要工序；其中，（a）为弯曲预变形，（b）为压扁预变形，（c）为内压胀形。
图6为本发明的采用板材弯卷方法制造的异形截面管与法兰边示意图（初始焊接封闭的异形截面管，边缘对接方式）。其中，（a）为圆形截面，（b）为方形截面，连接边在一侧，（c）为方形截面，连接边在中部。
图7为本发明的采用板材弯卷方法制造的异形截面管与法兰边示意图（初始焊接的异形截面管坯，内部搭接方式）。其中，（a）为圆形截面，（b）为方形截面，连接边在一侧，（c）为方形截面，连接边在中部。
图8为本发明的采用板材弯卷方法制造的异形截面管与法兰边示意图（初始焊接的异形截面管坯，外部搭接方式）。其中，（a）为圆形截面，（b）为方形截面，连接边在一侧，（c）为方形截面，连接边在中部。
图9为本发明的带有连接边的异形管件成形时采用模具压紧密封的示意图。（a）为固体介质，无密封圈，（b）为流体介质，用密封圈。
图10为本发明的带有连接边的异形管件成形时采用分体模具示意图（预成形和终成形时，异形管和连接边采用分体模具）。
图中：1整体式异形截面管件；2连接板；3带有连接边的异形截面管件；3-1异形截面管；3-2连接边；3-3连接孔；4带有法兰边的异形截面原始管坯； 4-2法兰边；5弯曲模具；5-1弯曲预成形上模；5-2弯曲预成形下模；5-3弯曲预成形后管坯；6预成形模具；6-1 压扁预成形上模；6-2压扁预成形下模；6-3 压扁预成形后管坯；7内压胀形模具；7-1内压胀形上模；7-2内压胀形下模；7-3内压胀形后管坯；8焊缝（初始管坯已焊好）；8-1对接焊缝；8-2内部搭接焊缝；8-3外部搭接焊缝；9压紧密封模具；10固体介质；11液体介质；12密封圈/条（初始不焊，预成形或内压胀形时密封用）。
 本发明的实施方式
下面将结合具体实施例和附图对本发明的技术方案进行进一步的说明。
实施例1：本发明的带有连接边的异形管件成形方法是按照以下步骤实现的：
步骤一、根据异形管件与相邻结构的连接要求，设计/选择/加工带有外侧一体化法兰边的原始管坯；
步骤二、将带有外侧一体化法兰边的原始管坯固定于预成形模具上，利用法兰边对原始管坯进行定位和约束；
步骤三、对原始管坯进行弯曲或压扁等预变形，使原始管坯及其法兰边变形为接近最终零件的截面形状和弯曲轴线；
步骤四、将预变形后的带有法兰边的管坯置于终成形模具中，利用法兰边对预成形管坯进行定位和约束；
步骤五、闭合终成形模具，使预成形管坯在内部压力、轴向推力等外部载荷的作用下发生变形，使管坯贴靠模具成形为需要的弯曲轴线和截面形状；
步骤六、将最终的异形管件取出，对外侧一体化连接边和管壁的相应位置进行机械加工获得需要的连接孔等，得到最终需要的带有一体化连接边的异形管件。
【以下为采用挤压型材的方式】
实施例2：本发明的带有连接边的异形管件成形方法，其特征在于：在步骤一中，所采用的原始管坯为挤压型材，材料为铝合金或镁合金。原始挤压型材上的异形管和法兰边之间无焊缝。其他与具体实施方式一相同。
本实施方式的有益效果是：原始管坯上的异形管和法兰边是在挤压过程中一次成形获得，在后续变形过程中异形管和法兰边也将始终保持为一体，无需在成形零件前或成形零件后再通过焊接等方法实现异形管和连接边的连接。
实施例3：本发明的带有连接边的异形管件成形方法，其特征在于：在步骤二中，将原始管坯上带有的法兰边插入模具上的凹槽中，或采用分块模具夹紧的方式，实现原始管坯在成形模具上的固定和定位。其他与具体实施方式一相同。
本实施方式的有益效果是：由于原始管坯上的异形管和法兰边为一体，当对法兰边进行夹紧固定时，可以限制异形管部分在后续弯曲或压扁变形过程中沿中轴线发生不合理的旋转，从而可以保证经过弯曲或压扁预变形后的异形管的截面形状和轴线形状得到有效控制，避免预变形过程中异形管发生不可控变形而影响后续的内压胀形。
实施例4：本发明的带有连接边的异形管件成形方法，其特征在于：在步骤三中，在进行弯曲或压扁等预变形之前，在异形管内部放置橡胶、聚氨酯棒等固体支撑物，或充入气体、液体等流体支撑物。固体支撑物的屈服强度比异形管低30~200MPa，流体支撑物的压力为10~100MPa。其他与具体实施方式一、二相同。
本实施方式的有益效果是：由于异形管为封闭结构，所以容易在异形管内部建立起一定的支撑压力。在内部压力的支撑作用下，异形管可以经历比较复杂的弯曲或压扁变形而不会出现局部折叠开裂或截面异常内凹等不利于后续胀形的预变形，这为后续通过内压胀形获得最终的异形管件提供保证。
实施例5：本发明的带有连接边的异形管件成形方法，其特征在于：在步骤五中，所采用的终成形模具处于常温状态，向预成形管坯内充入的是水或油或油水混合物；或者，所采用的终成形模具处于300~650℃的加热状态，向预成形管坯内充入的是高压空气或氮气或氩气，气体压力为5~70MPa。其他与具体实施方式一、二相同。
本实施方式的有益效果是：根据预成形管坯与最终模具型腔的差异程度，选择合理的模具温度进行后续的变形。当差异程度较小且模具型腔上不存在圆角半径小于1.5倍管材壁厚的局部结构时，可以在常温下进行变形；当差异程度较大或者模具型腔上存在圆角半径小于1.5倍管材壁厚的局部结构时，可以将模具加热到合适温度（对于6061铝合金，加热到350~550℃，对于AZ31镁合金，加热到280~500℃）再成形。避免了在不合理的温度条件下成形时容易出现早期开裂或局部小圆角充填不足的问题。
【以下为板材弯卷型材】
实施例6：本发明的带有连接边的异形管件成形方法，其特征在于：在步骤一中，所采用的原始坯料为通过板材弯卷获得的带有法兰边的异形截面型材。板坯上位于异形管一侧的边缘与异形管或连接边通过对接形成封闭异形截面。其他与具体实施方式一相同。
本实施方式的有益效果是：由于板坯上异形管一侧的边缘直接与板坯对接形成封闭截面，异形截面管与法兰边之间无任何多余的过渡材料，所以这种形式的原始坯料重量最轻，其制备工艺类似传统的圆截面管坯，成本较低。
实施例7：本发明的带有连接边的异形管件成形方法，其特征在于：在步骤一中，所采用的原始坯料为通过板材弯卷获得的带有法兰边的异形截面型材。板坯上位于异形管一侧的边缘与异形管或法兰边通过搭接形成封闭异形截面。其他与具体实施方式一相同。
本实施方式的有益效果是：板坯上位于异形管一侧的边缘通过搭接与板坯形成封闭截面，搭接的位置既可以位于异形管上也可以位于法兰边上；既可以将搭接边与异形管/法兰边预先焊接然后进行后续成形，也可以在弯曲或压扁等预成形后再进行焊接并进行最终内压胀形；还可以在胀形时采用模具压紧方式实现搭接边与异形管/法兰边的密封，在最终成形后再根据需要决定是点焊还是满焊。采用搭接的方式，可根据需要实现异形管和法兰边的合理连接/约束，为在预成形和最终内压胀形过程中合理控制材料的变形提供了更多可能。
实施例8：本发明的带有连接边的异形管件成形方法，其特征在于：在步骤二中，在将原始管坯固定于模具中之前，先对原始管坯上的法兰边进行加工以获得需要的连接孔或连接结构。其他与具体实施方式一相同。
本实施方式的有益效果是：直接在原始管坯的法兰边上加工连接孔或连接结构，因法兰边为平面形式，所以机械加工时容易装夹、所用机械加工设备简单。当最终的带一体化连接边的异形管件比较简单，在预成形及最后的内压胀形过程中不会发生剧烈的截面变化和轴线扭曲时，利用该方案可以大大提高效率、降低成本。
实施例9：本发明的带有连接边的异形管件成形方法，其特征在于：在步骤二和步骤四中，预成形模具和终成形模具采用分体结构，利用独立的模块对原始管坯或预成形后管坯上的法兰边进行定位和约束，利用独立的模块作为异形管的成形用模具。其他与具体实施方式一相同。
本实施方式的有益效果是：由于采用独立模块对法兰边进行定位和约束，所以法兰边的定位/约束/变形将与后续异形管的合模、加载、变形过程相互独立、互不影响。当最终零件上的连接边和异形管的变形程度、变形方式差异较大时，采用本实施方式的两个独立模块可以更为精确地实现法兰边和异形管的变形。同时，模具设计和加工以及对设备的控制要求也大大降低。

Claims (8)

  1. 一种带有连接边的异形管件成形方法，其特征在于，步骤如下：
    步骤一、根据异形管件与相邻结构的连接要求，设计/选择或加工外侧带有一体化法兰边的原始管坯；
    步骤二、将外侧带有一体化法兰边的原始管坯固定于预成形模具上，利用法兰边对原始管坯进行定位和约束；
    步骤三、闭合预成形模具，对原始管坯进行弯曲或压扁的预变形处理，使原始管坯及其法兰边变形为接近最终零件的截面形状和弯曲轴线，得到预成形管坯；
    步骤四、将预成形管坯置于终成形模具中，利用法兰边对预成形管坯进行定位和约束；
    步骤五、闭合终成形模具，预成形管坯在内部压力、轴向推力的外部载荷作用下发生变形，使预成形管坯贴靠模具成形为需要的弯曲轴线和截面形状，得到最终的异形管件；
    步骤六、将最终的异形管件取出，对外侧的一体化法兰和管壁的相应位置进行机械加工，获得需要的连接孔，完成带有一体化连接边异形管件的加工。
  2. 根据权利要求1所述的带有连接边的异形管件成形方法，其特征在于，所述的原始管坯为挤压型材或板材弯卷型材，原始管坯为挤压型材时，原始挤压型材上的异形管和法兰边之间无焊缝，材料为铝合金或镁合金；原始管坯为板材弯卷型材时，板坯上位于异形管一侧的边缘与连接边通过对接或搭接形成封闭异形截面；搭接的方式为外部搭接或内部搭接。
  3. 根据权利要求1或2所述的带有连接边的异形管件成形方法，其特征在于，步骤二中，原始管坯固定于预成形模具上时，定位方式为：将原始管坯上带有的法兰边插入模具上的凹槽中，或采用分块模具夹紧法兰边。
  4. 根据权利要求1或2所述的带有连接边的异形管件成形方法，其特征在于，步骤三中，对原始管坯进行弯曲或压扁等预变形之前，在异形管内部放置支撑物；当支撑物为固体时，固体支撑物的屈服强度比异形管件低30~200MPa；当支撑物为流体时，流体支撑物的压力为10~100MPa；所述的固体支撑物为橡胶或聚氨酯棒。
  5. 根据权利要求3所述的带有连接边的异形管件成形方法，其特征在于，步骤三中，对原始管坯进行弯曲或压扁等预变形之前，在异形管内部放置支撑物；当支撑物为固体时，固体支撑物的屈服强度比异形管件低30~200MPa；当支撑物为流体时，流体支撑物的压力为10~100MPa；所述的固体支撑物为橡胶或聚氨酯棒。
  6. 根据权利要求1、2或5所述的带有连接边的异形管件成形方法，其特征在于，步骤五中，当终成形模具的工作温度为常温时，预成形管坯内充入的是水和/或油；当终成形模具的工作温度为300~650℃时，向预成形管坯内充入的是高压空气、氮气或氩气，气体压力为5~70MPa。
  7. 根据权利要求3所述的带有连接边的异形管件成形方法，其特征在于，步骤五中，当终成形模具的工作温度为常温时，预成形管坯内充入的是水和/或油；当终成形模具的工作温度为300~650℃时，向预成形管坯内充入的是高压空气、氮气或氩气，气体压力为5~70MPa。
  8. 根据权利要求4所述的带有连接边的异形管件成形方法，其特征在于，步骤五中，当终成形模具的工作温度为常温时，预成形管坯内充入的是水和/或油；当终成形模具的工作温度为300~650℃时，向预成形管坯内充入的是高压空气、氮气或氩气，气体压力为5~70MPa。
PCT/CN2018/105368 2018-09-13 2018-09-13 带有连接边的异形管件成形方法 Ceased WO2020051814A1 (zh)

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