WO2020155881A1 - 高速动车大曲面板材棱线快超塑成形模具及成形方法 - Google Patents

高速动车大曲面板材棱线快超塑成形模具及成形方法 Download PDF

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WO2020155881A1
WO2020155881A1 PCT/CN2019/125139 CN2019125139W WO2020155881A1 WO 2020155881 A1 WO2020155881 A1 WO 2020155881A1 CN 2019125139 W CN2019125139 W CN 2019125139W WO 2020155881 A1 WO2020155881 A1 WO 2020155881A1
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forming
sheet
superplastic
fast
mold
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PCT/CN2019/125139
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English (en)
French (fr)
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邓海
梁继业
王超
王树宾
董雪妍
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中车长春轨道客车股份有限公司
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Publication of WO2020155881A1 publication Critical patent/WO2020155881A1/zh

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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
    • B21D26/021—Deforming sheet bodies
    • 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
    • B21D26/021—Deforming sheet bodies
    • B21D26/031—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
    • 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
    • B21D26/053—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 characterised by the material of the blanks
    • B21D26/055—Blanks having super-plastic properties
    • 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
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards

Definitions

  • the invention relates to the technical field of superplastic forming, and more specifically, to a fast superplastic forming die and a forming method for the ridgeline of a large-curved plate of a high-speed train.
  • Aluminum alloy plays an important role in rail transit and automobile lightweight. Using aluminum alloy to replace traditional steel materials to make the car body can reduce body weight by 50% and fuel consumption by 28%; when the bearing capacity is the same, aluminum alloy is 60% lighter than steel; withstand the same impact, aluminum alloy absorbs 50% more impact than steel Yes, more security.
  • aluminum alloy sheets Compared with steel plates under cold stamping conditions, aluminum alloy sheets have the disadvantages of low plasticity and greater resilience.
  • the high-temperature forming properties of aluminum alloys in the superplastic state can avoid parts cracking, high temperature and low flow stress and other defects, which can eliminate backlash Elastic deformation, so superplastic forming technology is used to form complex-shaped aluminum alloy car body covers and structural parts.
  • Ordinary sheet metal superplastic forming is to blow a high-temperature flat blank into a cavity through gas pressure, and the strain rate and forming speed of the sheet deformation are controlled by the inflation pressure-time curve, as shown in Figure 1-3.
  • Figure 1 shows the layout of the die and the plate during the sheet superplastic forming process;
  • Figure 2 shows the schematic diagram of the sheet deformation process during the sheet superplastic forming process;
  • Figure 3 shows the sheet forming during the sheet superplastic forming process Schematic diagram after the structure.
  • Superplastic forming is a forming cycle process.
  • the upper mold 1 ⁇ and the lower mold 2 ⁇ clamp the plate 3 ⁇ between them, the upper mold 1 ⁇ is provided with a vent 4 ⁇ , and the lower mold 2 ⁇ is provided with a forming groove 5 ⁇ , the plate 3 ⁇ is subjected to the air pressure of the vent 4 ⁇ and deformed into the forming groove 5 ⁇ .
  • the forming process includes blank preparation, heating, lubrication, charging, forming and unloading.
  • the time of a forming cycle is equal to each The sum of the time spent in the link is not efficient.
  • the purpose of the present invention is to provide a fast superplastic forming mold for the ridgeline of the large-curved sheet of high-speed trains to improve the forming efficiency of superplastic forming; the present invention also provides a fast superplasticizing mold for the ridgeline of the large-curved sheet of high-speed trains Plastic forming method.
  • a fast superplastic forming mold for large-curved sheet ridgelines of high-speed motor cars comprising an upper mold and a lower mold for superplasticizing a sheet, and the lower mold is provided with the sheet forming A forming groove on the forming surface, the upper mold is projected with a convex mold opposite to the forming groove, and the sheet material is extruded into the forming groove; the upper mold is also provided with a convex mold connected to it The end faces the air inlet passage through which the sheet material is inflated with air pressure.
  • the extrusion end of the convex mold is provided with an air inlet hole communicating with the air inlet channel.
  • the air intake holes include a plurality of evenly distributed around the circumference of the extrusion end of the convex die.
  • the extrusion end surface of the punch is provided with a forming edge angle corresponding to the position of the forming ridgeline of the sheet material.
  • a sealing groove is also provided on the pressing end surface of the upper mold and the sheet material.
  • a fast superplastic forming method for the ridge line of a large curved sheet of a high-speed motor car comprising the steps:
  • Step 1) From the convex mold projecting from the inner end surface of the upper mold, punch the sheet into the forming groove of the lower mold to complete the preformed sheet;
  • Step 2 Using superplastic inflating method to infuse air pressure from the air inlet channel of the upper mold, so that the preformed sheet is bulged and attached to the inner wall of the forming groove to obtain a molded sheet.
  • the fast superplastic forming method for the ridgeline of the large-curved sheet material of the high-speed motor car before the step 1), it further includes heating the sheet material and the upper mold to a predetermined forming temperature.
  • the forming edges of the punch press the sheet material against the inner end surface of the forming groove.
  • the present invention provides a fast superplastic forming mold for large-curved sheet ridgelines of a high-speed motor car, which includes an upper mold and a lower mold for superplasticizing the sheet.
  • the lower mold is provided with a forming groove for forming the sheet forming surface, and the upper mold extends upward There is a convex die opposite to the forming groove and squeezes the sheet into the forming groove; the upper mold is also provided with an air inlet channel connected to the inner end of the sheet to pass the inflatable forming air pressure.
  • the upper mold and the lower mold compress the sheet material, the lower mold is provided with a forming groove, and the upper mold protrudes from the punch arranged opposite to the forming groove.
  • the punch and the plate The sheet material is pressed into the forming groove when the material conflicts, and then the sheet material pressed into the forming groove is inflated and formed through the ventilation channel.
  • punch and inflatable forming the sheet is extruded by the punch to realize sheet forming and filling during the sheet forming process, reducing the surface wrinkles of the sheet, and then through inflating forming, the sheet can be realized
  • the coexistence of macro-domain large size and local small size improves the forming efficiency of superplastic forming.
  • the invention also provides a fast superplastic forming method for the ridgeline of a large-curved sheet of a high-speed motor train. After the sheet is pressed into the forming groove by a punch, the final sheet is obtained by inflating and forming, so that the wall thickness after the sheet is formed The thinning rate is small, the wall thickness is uniform, and the forming quality is improved.
  • Figure 1 is the layout diagram of the mold and the plate during the superplastic forming of the plate
  • Figure 2 is a schematic diagram of the sheet deformation process during the sheet metal superplastic forming process
  • Figure 3 is a schematic diagram of the structure of the sheet after the sheet is formed in the superplastic forming process of the sheet;
  • FIG. 4 is a diagram of the initial forming position in the first direction of the fast superplastic forming die for the large-curved sheet ridgeline of the high-speed motor car provided by the present invention
  • Figure 5 is a schematic diagram of the forming position of the punch of Figure 4.
  • Figure 6 is a schematic diagram of the inflatable forming position of Figure 4.
  • Fig. 7 is a view of the initial forming position in the second direction of the ridgeline fast superplastic forming mold for large curved sheets of high-speed trains provided by the present invention
  • FIG. 8 is a schematic diagram of the forming position of the punch of FIG. 7;
  • Fig. 9 is a schematic diagram of the inflation forming position of Fig. 7.
  • the present invention provides a fast superplastic forming mold for large-curved sheet ridgelines of high-speed trains, which includes an upper mold 1 and a lower mold 2 for superplasticizing the sheet, and the lower mold 2 is provided with
  • the forming groove 5 forming the forming surface of the sheet material
  • the upper mold 1 has a convex mold 11 which is opposite to the forming groove 5 and extrudes the sheet material 3 into the forming groove 5; the upper mold 1 is also provided with a punch 11 connected to it.
  • the end face of the sheet material 3 passes into the air inlet passage 4 through which the inflatable forming air pressure P is introduced.
  • the upper mold 1 and the lower mold 2 are pressed against the sheet material 3, the lower mold 2 is provided with a forming groove 5, and the upper mold 1 extends out of the convex mold 11 arranged opposite to the forming groove 5, and the upper mold 1 and the lower mold 2 counter the plate During the pressing process of the material 3, the punch 11 and the plate material 3 press the plate material 3 into the forming groove 5, and then the plate material 3 pressed into the forming groove 5 is inflated and formed through the ventilation channel 4.
  • the punch 11 extrudes the sheet 3 during the forming process of the sheet metal 3 to realize the sheet metal forming supplement, reducing the surface wrinkles of the sheet, and then through the inflatable forming method, It can realize the coexistence of the large size of the sheet material and the local small size, and improve the forming efficiency of superplastic forming.
  • the extrusion end of the punch 11 is provided with an air inlet hole communicating with the air inlet channel.
  • the extrusion end of the punch 11 first abuts the sheet material 3, and the sheet material 3 is squeezed into the forming groove 5 of the lower mold 2 and then passed into The inflatable air pressure bulges the sheet 3 from air pressure to the surface of the forming groove 5.
  • the convex mold 11 is provided with an air inlet hole communicating with the air inlet channel 4 of the upper mold 1, and the inflation air pressure introduced from the air inlet hole directly acts on the surface of the sheet material 3 to improve the forming efficiency and ensure the forming quality.
  • the air intake holes include a plurality of evenly distributed around the circumference of the extrusion end of the punch 11.
  • Inflatable air pressure is introduced into the forming groove 5. Since the punch 11 extends into the forming groove, in order to ensure the consistency of the bulging air pressure at each position of the sheet 3, the air inlet is set around the circumference of the extrusion end of the punch 11 In the inflatable forming process, uniform air pressure can be obtained at various positions on the plate surface of the sheet material 3 to further ensure the forming effect of the sheet material.
  • the extrusion end surface of the punch 11 is provided with a forming edge angle corresponding to the forming edge line position of the sheet material 3.
  • the sheet material 3 is formed by inflating to obtain the ridgeline structure on the large curved sheet of the high-speed motor car.
  • the extrusion end surface of the punch 11 is set with forming corners.
  • the punch The forming edges and corners on 11 are opposed to the sheet metal 3 and are squeezed into the forming groove 5.
  • the edge grooves on the forming end face of the forming groove 5 are opposite to each other, and the punches are squeezed into the forming groove.
  • the sheet material is compressed.
  • a certain degree of sheet metal can be pressed into the forming groove during the deformation process, which has the effect of replenishing the sheet material.
  • Setting the formed corners to correspond to the position of the ridge line on the formed sheet material can significantly reduce the amount of sheet metal deformation during the inflatable forming process , Reduce forming time to ensure forming quality.
  • a sealing groove is also provided on the pressing end surface of the upper mold 1 and the plate material 3.
  • the sheet is bulged by the bulging air pressure. Therefore, it is necessary to ensure the sealing between the upper mold and the sheet.
  • a sealing groove is set on the pressing end surface between the upper mold and the sheet to make the contact between the two Both can obtain stable sealing and ensure the forming quality. After the sheet material is formed, the bulging air pressure must be discharged, and an air vent should be provided in the upper or lower mold to avoid the air pressure interference and the sheet material cannot be completely filled into the forming groove.
  • the fast superplastic forming mold for the ridgeline of the large curved sheet of the high-speed motor car provided in this embodiment can organically integrate the two forming methods of high-speed hot stamping and superplastic inflatable forming, which integrates rigid punches and flexible gas forming media
  • the advantages of, establish the optimal ratio of rigid and flexible punches, can form parts with large scale and local small features coexisting in the macro domain, and realize the forming of local small fillets (r ⁇ t).
  • This embodiment also provides a fast superplastic forming method for the ridgeline of a large-curved sheet of a high-speed motor car, which includes the steps:
  • Step 1) From the convex mold projecting from the inner end surface of the upper mold, punch the sheet into the forming groove of the lower mold to complete the preformed sheet.
  • the upper die squeezes the sheet into the lower mold to ensure the accurate positioning of the extrusion end face of the punch and the forming corners on the forming end face.
  • its macroscopic appearance structure is basically formed in the forming groove.
  • Step 2 Air pressure is introduced from the air inlet channel of the upper mold by the superplastic inflation method, so that the preformed sheet is bulged and attached to the inner wall of the forming groove to obtain a molded sheet.
  • the superplastic inflating method can bulge the sheet into the forming surface of the forming groove. After the upper and lower molds are closed, the bulging air pressure is introduced into the surface of the sheet through the air inlet channel, and the sheet is bulged and attached On the inner wall of the forming groove, the local small features of the sheet material are attached to the forming groove to obtain a forming structure.
  • the invention also provides a fast superplastic forming method for the ridgeline of a large-curved sheet of a high-speed motor train. After the sheet is pressed into the forming groove by a punch, the final sheet is obtained by inflating and forming, so that the wall thickness after the sheet is formed The thinning rate is small, the wall thickness is uniform, and the forming quality is improved.
  • step 1) before step 1), it also includes heating the sheet material and the upper mold to a predetermined molding temperature.
  • the hot stamping pre-forming process is used for the sheet material, so that more sheet material can enter the cavity under the action of the rigid punch to realize the filling, and the flange area of the sheet metal forming does not appear wrinkles, and the sheet material is in The thinning in the thickness direction is small.
  • the surface After the sheet metal is formed, the surface has a small rounded corner structure, and the small rounded corners need to be forged. Through the hot stamping process, only a small amount of deformation is required for the sharp corners. Therefore, the thinning of the small rounded corners is greater than that of ordinary superplastic inflating Decrease.
  • the forming edges and corners of the punch press the sheet material against the inner end surface of the forming groove.
  • the forming edges and corners of the punch are opposite to the forming edge lines on the sheet metal, which ensures uniform deformation for inflatable forming and further ensures the uniform wall thickness distribution of sheet metal forming.

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  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

一种高速动车大曲面板材棱线快超塑成形模具，包括对板料进行超塑成形的上模（1）和下模（2），下模内设置有形成板料成型面的成形槽（5），上模上伸出有与成形槽相对，将板料（3）挤压入成形槽内的凸模（11）；上模上还设置有连通至其内端面对板料通入气胀成形气压的进气通道（4），凸模与板料相抵将板料压入到成型槽内，后通过通气通道对压入成形槽内的板料进行气胀成形。以及一种高速动车大曲面板材棱线快超塑成形方法。通过采用凸模和气胀成形组合的方式，使得板料成形过程中，由凸模挤压板料实现板料成形补料，减少板料表面褶皱，后通过气胀成形的方式，能够实现板料宏域大尺寸和局部小尺寸共存，提高超塑成形的成形效率。

Description

高速动车大曲面板材棱线快超塑成形模具及成形方法
本申请要求于2019年01月29日提交中国专利局、申请号为201910086170.9、发明名称为“高速动车大曲面板材棱线快超塑成形模具及成形方法”上述中国专利申请的优先权，其全部内容通过引用结合在上述申请中。
技术领域
本发明涉及超塑成形技术领域，更具体地说，涉及一种高速动车大曲面板材棱线快超塑成形模具及成形方法。
背景技术
轨道车辆轻量化对提升高速列车性能具有重要意义。铝合金在轨道交通、汽车轻量化中扮演重要的角色。铝合金替代传统钢铁材料制造车身可使车身减重50％，油耗降低达28％；在承力相同时，铝合金比钢轻60％；承受同样的冲击，铝合金比钢板多吸收50％冲击能，更具安全性。
在冷冲压条件下与钢板相比铝合金板材存在着塑性低和回弹大的缺点，但是在超塑状态下铝合金高温成形性能可避免零件开裂，高温和低流动应力等缺陷，可消除回弹变形，所以用超塑性成形技术成形出复杂形状的铝合金汽车车身覆盖件和结构件。
铝合金汽车覆盖件超塑成形工艺研究在国外已经有很多成功应用，但是我国轨道列车上还没有应用该技术，主要原因是该技术目前生产效率低、成本高。由于超塑气胀成形需要将模具和零件加热到较高温度，能耗较大，而且成形一个复杂形状零件，充气胀形就需要几十分钟甚至几个小时，这种生产效率难以满足轨道车辆零件大批量生产的需求。
普通的板料超塑成形是通过气体压力将高温平板坯料吹入凹模,由气胀压力—时间曲线控制着板料变形的应变速率和成形的速度，如图1-图3所示的板料超塑成形过程，图1为板料超塑成形过程中模具与板材的布置图；图2为板料超塑成形过程中板材变形过程示意图；图3为板料超塑成形过程中板材成形后的结构示意图。
超塑性变形的低应变速率特征决定了慢速是普通超塑胀形的固有缺点。超塑成形作为一个成形循环过程，上模1`和下模2`将板材3`夹紧于二者之间，上模1`上设置通气孔4`，下模2`上设置成形槽5`，板材3`受到通气孔4`气 压压力，形变至成形槽5`内，该成形过程包括坯料制备、加热、润滑、装料、成形和卸料多个环节，一个成形循环的时间等于各环节所用时间的总和，效率不高。
这里，应当指出的是，本部分中所提供的技术内容旨在有助于本领域技术人员对本发明的理解，而不一定构成现有技术。
发明内容
有鉴于此,本发明的目的是提供一种高速动车大曲面板材棱线快超塑成形模具，以提高超塑成形的成形效率；本发明还提供了一种高速动车大曲面板材棱线快超塑成形方法。
根据本发明的一个方面，提供一种高速动车大曲面板材棱线快超塑成形模具，包括对板料进行超塑成形的上模和下模，所述下模内设置有形成所述板料成型面的成形槽，所述上模上伸出有与所述成形槽相对，将所述板料挤压入所述成形槽内的凸模；所述上模上还设置有连通至其内端面对所述板料通入气胀成形气压的进气通道。
优选地，在上述高速动车大曲面板材棱线快超塑成形模具中，所述凸模的挤压端开设有连通所述进气通道的进气孔。
优选地，在上述高速动车大曲面板材棱线快超塑成形模具中，所述进气孔包括环绕所述凸模挤压端的周向均匀分布的多个。
优选地，在上述高速动车大曲面板材棱线快超塑成形模具中，所述凸模的挤压端面设置有所述板料的成形棱线位置对应的成形棱角。
优选地，在上述高速动车大曲面板材棱线快超塑成形模具中，所述上模与所述板料的压紧端面上还开设有密封槽。
一种高速动车大曲面板材棱线快超塑成形方法，包括步骤：
步骤1)由上模内端面上伸出的凸模，将板料冲压至下模的成形槽内，完成预成型的板料；
步骤2)采用超塑气胀法由所述上模的进气通道通入气压，使得预成型的所述板料胀形贴附于所述成形槽的内壁，获得成型后的板料。
优选地，在上述高速动车大曲面板材棱线快超塑成形方法中，所述步骤1)前还包括，将所述板料和所述上模加热预定成型温度。
优选地，在上述高速动车大曲面板材棱线快超塑成形方法中，所述凸模的成形棱角将所述板料压紧于所述成形槽的内端面上。
本发明提供的高速动车大曲面板材棱线快超塑成形模具，包括对板料进行超塑成形的上模和下模，下模内设置有形成板料成型面的成形槽，上模上伸出有与成形槽相对，将板料挤压入成形槽内的凸模；上模上还设置有连通至其内端面对板料通入气胀成形气压的进气通道。上模和下模对板料压紧，下模内设置成形槽，上模上伸出与成形槽相对布置的凸模，由上模和下模对板料压紧过程中，凸模与板料相抵将板料压入到成型槽内，后通过通气通道对压入成形槽内的板料进行气胀成形。通过采用凸模和气胀成形组合的方式，使得板料成形过程中，由凸模挤压板料实现板料成形补料，减少板料表面褶皱，后通过气胀成形的方式，能够实现板料宏域大尺寸和局部小尺寸共存，提高超塑成形的成形效率。
本发明还提供了一种高速动车大曲面板材棱线快超塑成形方法，由凸模将板料压入成形槽内后，再通过气胀成形，获得最终的板材，使得板材成形后壁厚减薄率小，壁厚均匀，提高成形质量。
附图说明
通过以下参照附图对本发明实施例的描述，本发明的上述以及其它目的、特征和优点将更为清楚，在附图中：
图1为板料超塑成形过程中模具与板材的布置图；
图2为板料超塑成形过程中板材变形过程示意图；
图3为板料超塑成形过程中板材成形后的结构示意图；
图4为本发明提供的高速动车大曲面板材棱线快超塑成形模具第一方向的初始成形位置图；
图5为图4的凸模成形位置示意图；
图6为图4的气胀成形位置示意图；
图7为本发明提供的高速动车大曲面板材棱线快超塑成形模具第二方向的初始成形位置图；
图8为图7的凸模成形位置示意图；
图9为图7的气胀成形位置示意图。
具体实施方式
以下基于实施例对本发明进行描述，但是本发明并不仅仅限于这些实施例。
如图4-9所示，本发明提供了一种高速动车大曲面板材棱线快超塑成形模具，包括对板料进行超塑成形的上模1和下模2，下模2内设置有形成板料成型面的成形槽5，上模1上伸出有与成形槽5相对，将板料3挤压入成形槽5内的凸模11；上模1上还设置有连通至其内端面对板料3通入气胀成形气压P的进气通道4。上模1和下模2对板料3压紧，下模2内设置成形槽5，上模1上伸出与成形槽5相对布置的凸模11，由上模1和下模2对板料3压紧过程中，凸模11与板料3相抵将板料3压入到成型槽5内，后通过通气通道4对压入成形槽5内的板料3进行气胀成形。通过采用凸模11和气胀成形组合的方式，使得板料3成形过程中，由凸模11挤压板料3实现板料成形补料，减少板料表面褶皱，后通过气胀成形的方式，能够实现板料宏域大尺寸和局部小尺寸共存，提高超塑成形的成形效率。
在本案一具体实施例中，凸模11的挤压端开设有连通进气通道的进气孔。上模1和下模2在对板料3成形过程中时，凸模11的挤压端首先与板料3相抵，并将板料3挤压至下模2成形槽5内，后通入气胀气压，将板料3由气压胀形至成形槽5的表面。将凸模11上设置连通上模1进气通道4的进气孔，由进气孔通入的气胀气压直接作用于板料3表面，提高成形效率，保证成形质量。
在本案一具体实施例中，进气孔包括环绕凸模11挤压端的周向均匀分布的多个。气胀气压通入到成形槽5内，由于凸模11伸入到成形槽内，为保证板料3各个位置胀形气压的一致性，将进气孔设置环绕凸模11挤压端周向的多个，则在气胀成形过程中，板料3的板面上各个位置可获得均匀的气压压力，进一步保证板料的成形效果。
在本案一具体实施例中，凸模11的挤压端面设置有板料3的成形棱线位置对应的成形棱角。板料3通过气胀成形，获得满足高速动车的大曲面板材上的棱线结构，将凸模11的挤压端面上设置成形棱角，上模1和下模2合模过 程中，由凸模11上的成形棱角与板料3相抵，并挤压至成形槽5内，由成形槽5成形端面上棱槽位置相对，由凸模挤入成形槽内，板料为被压紧，板料变形过程中可将一定程度的板料压入成形槽，起到对板料补料效果，设置成形棱角对应成形板料上的棱线位置，可使气胀成形过程中板料变形量明显降低，减少成形时间保证成形质量。
在本案一具体实施例中，上模1与板料3的压紧端面上还开设有密封槽。上模内通过胀形气压对板料胀形，因此需保证上模与板料之间的密封性，在上模和板料之间的压紧端面上设置密封槽，使得二者的接触部位均能获得稳定密封，保证成形质量。板料成形后需要将通入的胀形气压排出，在上模或下模内还应设置排气孔，避免气压干扰导致板料不能完全填充到成形槽内。
本实施例提供的高速动车大曲面板材棱线快超塑成形模具，可将高速热冲压成形和超塑气胀成形两种成形方式有机地整合到一起，综合了刚性凸模和柔性气体成形介质的优点，建立了最优刚柔性凸模比例关系，能够成形宏域大尺度和局部小特征共存的零件，实现局部小圆角(r≤t)的成形。
本实施例还提供了一种高速动车大曲面板材棱线快超塑成形方法，包括步骤：
步骤1)由上模内端面上伸出的凸模，将板料冲压至下模的成形槽内，完成预成型的板料。
上模将板料挤压至下模内，保证凸模的挤压端面与成形端面上的成形棱角位置定位准确，板料经初步成形，其宏观的外观结构在成形槽内基本成形。
步骤2)采用超塑气胀法由所述上模的进气通道通入气压，使得预成型的板料胀形贴附于成形槽的内壁，获得成型后的板料。所所述述
超塑气胀法可将板料通过胀形成形于成形槽的成形面，在上模和下模合模后，通过进气通道将胀形气压通入板料表面，板料胀形贴附于成形槽的内壁，板料的局部小特征通过与成形槽的贴附获得成形结构。
本发明还提供了一种高速动车大曲面板材棱线快超塑成形方法，由凸模将板料压入成形槽内后，再通过气胀成形，获得最终的板材，使得板材成形后壁厚减薄率小，壁厚均匀，提高成形质量。
在本案一具体实施例中，步骤1)前还包括，将板料和上模加热预定成型温度。对板料采用热冲压预成型的工艺，可以使得更多的板料可以在刚性凸模 的作用下进入型腔，实现补料，且板料成形的法兰区不会出现褶皱，板料在厚度方向减薄很小。板料成形后表面具有小圆角结构，小圆角处需要锻造成形，通过热冲压工艺，对于尖角部位仅需少量的变形，因此小圆角部分板材减薄相对于普通超塑性气胀大幅减小。
在本案一具体实施例中，凸模的成形棱角将板料压紧于成形槽的内端面上。凸模的成形棱角与板料上成形棱线位置相对，为气胀成形保证均匀变形量，进一步保证板料成形的壁厚分布均匀。
以上所述仅为本发明的优选实施例，并不用于限制本发明，对于本领域技术人员而言，本发明可以有各种改动和变化。凡在本发明的精神和原理之内所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (8)

  1. 一种高速动车大曲面板材棱线快超塑成形模具，其特征在于，包括对板料进行超塑成形的上模和下模，所述下模内设置有形成所述板料成型面的成形槽，所述上模上伸出有与所述成形槽相对，将所述板料挤压入所述成形槽内的凸模；所述上模上还设置有连通至其内端面对所述板料通入气胀成形气压的进气通道。
  2. 根据权利要求1所述的高速动车大曲面板材棱线快超塑成形模具，其特征在于，所述凸模的挤压端开设有连通所述进气通道的进气孔。
  3. 根据权利要求2所述的高速动车大曲面板材棱线快超塑成形模具，其特征在于，所述进气孔包括环绕所述凸模挤压端的周向均匀分布的多个。
  4. 根据权利要求1所述的高速动车大曲面板材棱线快超塑成形模具，其特征在于，所述凸模的挤压端面设置有所述板料的成形棱线位置对应的成形棱角。
  5. 根据权利要求1所述的高速动车大曲面板材棱线快超塑成形模具，其特征在于，所述上模与所述板料的压紧端面上还开设有密封槽。
  6. 一种高速动车大曲面板材棱线快超塑成形方法，其特征在于，包括步骤：
    步骤1)由上模内端面上伸出的凸模，将板料冲压至下模的成形槽内，完成预成型的板料；
    步骤2)采用超塑气胀法由所述上模的进气通道通入气压，使得预成型的所述板料胀形贴附于所述成形槽的内壁，获得成型后的板料。
  7. 根据权利要求6所述的高速动车大曲面板材棱线快超塑成形方法，其特征在于，所述步骤1)前还包括，将所述板料和所述上模加热预定成型温度。
  8. 根据权利要求7所述的高速动车大曲面板材棱线快超塑成形方法，其特征在于，所述凸模的成形棱角将所述板料压紧于所述成形槽的内端面上。
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