WO2021189824A1 - 一种深杯形薄壁零件电流辅助复合旋压成形装置及方法 - Google Patents

一种深杯形薄壁零件电流辅助复合旋压成形装置及方法 Download PDF

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WO2021189824A1
WO2021189824A1 PCT/CN2020/121361 CN2020121361W WO2021189824A1 WO 2021189824 A1 WO2021189824 A1 WO 2021189824A1 CN 2020121361 W CN2020121361 W CN 2020121361W WO 2021189824 A1 WO2021189824 A1 WO 2021189824A1
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Prior art keywords
spinning
blank
deep
current
shaping
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English (en)
French (fr)
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夏琴香
陈灿
程秀全
肖刚锋
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South China University of Technology SCUT
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South China University of Technology SCUT
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Priority to JP2022557763A priority Critical patent/JP7465582B2/ja
Priority to US17/913,832 priority patent/US20240216975A1/en
Publication of WO2021189824A1 publication Critical patent/WO2021189824A1/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
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/14—Spinning
    • B21D22/16—Spinning over shaping mandrels or formers
    • 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
    • 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
    • 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
    • B21D51/00—Making hollow objects
    • B21D51/02—Making hollow objects characterised by the structure of the objects
    • 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
    • B21D51/00—Making hollow objects
    • B21D51/02—Making hollow objects characterised by the structure of the objects
    • B21D51/10—Making hollow objects characterised by the structure of the objects conically or cylindrically shaped objects

Definitions

  • the invention relates to the field of plastic processing and forming in mechanical engineering, in particular to a current-assisted composite spinning forming device and method for deep cup-shaped thin-walled parts.
  • the deep cup-shaped thin-walled part is a thin-walled complex component with a bottom and a relatively large long diameter. Due to the large aspect ratio, the spinning process can be used for forming. Generally, it is necessary to first use multi-pass deep-drawing spinning forming to obtain a shallow cup-shaped part, and then perform multi-pass flow spinning forming to reduce the wall thickness to obtain a deep cup-shaped thin Wall parts.
  • the invention provides a current-assisted composite spinning forming device and method for deep cup-shaped thin-walled parts. It solves the problem that in the prior art, due to the discontinuity of the deep-spinning, flow-spinning (or plastic-spinning) operation process in the workpiece production process, the workpiece is hardened and the material is broken, the tooling needs to be re-adjusted when the process is replaced, and the production cycle is long And other issues.
  • a current-assisted composite spinning forming device for deep cup-shaped thin-walled parts comprising a spinning core mold 4, a tail top 6, and a plurality of spinning wheels 3 evenly distributed on the circumference of the spinning core mold 4; Spinning mandrels 4 are arranged at staggered intervals in the axial and radial directions; the spinning surface of each wheel 3 includes a drawing spinning surface 1, a flow spinning section, and a shaping spinning surface 2; the staggered arrangement is It means that the deep drawing and spinning surface 1, the flow spinning section and the shaping spinning surface 2 of each spinning wheel 3 are distributed at staggered intervals in the axial and radial directions of the spinning core die 4.
  • the number of the rotating wheels 3 is at least three, and the error distance distribution is embodied as follows:
  • the section line of the drawing and spinning surface 1 of each roller 3 is an arc line, and the arc radius of each drawing and spinning surface 1 gradually decreases in sequence;
  • the cross-sectional shape of the shaping and spinning surface 2 of each roller 3 is a straight line; according to the rotation sequence, the inclination angles of the shaping and spinning surfaces 2 of the first two adjacent rollers 3 with respect to the axis of the spinning core die 4 are the same or sequentially Decrease, and the inclination angle of the shaping and spinning surface 2 of the third rotating wheel 3 relative to the axis of the spinning core die 4 is smaller than the inclination angle of the first two rotating wheels 3;
  • Each flow spinning section has a tapered structure, which refers to the tip fillet part where the arc line of the deep drawing spinning surface 1 and the shaping spinning surface 2 linearly join, and the tip fillets of each flow spinning section are gradually staggered in sequence .
  • the same inclination angle of the first two adjacent wheels 3 means that they are the same in the range of 2° to 3°, and the successive decrease means that the inclination angles of the first two adjacent wheels 3 are successively decreased in the range of 2° to 3°;
  • the inclination angle of the wheel 3 is 0.5°-1°.
  • the current-assisted composite spinning forming device for deep cup-shaped thin-walled parts further includes a thrust reverser plate 5 that is in contact with the edge of the blank 7; electrodes are respectively provided on the thrust reverser plate 5 and the tail top 6, wherein the tail top 6 is It is a positive electrode, and the reverse thrust plate 5 is a negative electrode; in the spinning process, the pulse current flows from the center area of the blank 7 to the edge through the tail top 6 and the reverse thrust plate 5, as a current-assisted spinning.
  • the number of the rotating wheels 3 is three, they are uniformly distributed on the circumference of the spinning core mold 4 at 120°.
  • a current-assisted composite spinning forming method for deep cup-shaped thin-walled parts which includes the following steps:
  • tail top 6 Use the tail top 6 to center the circular plate-shaped blank 7 on the spinning core mold 4;
  • the drawing and spinning surface 1 of the spinning wheel 3 is in the working position; when there are three spinning wheels 3, the arc radius of each drawing and spinning surface 1 and the inclination angle of the shaping spinning surface 2 gradually decrease in sequence; Correspondingly, the gap between the tip fillet of the conical structure of the flow spinning section and the spinning core mold 4 is gradually reduced;
  • Spinning mandrel 4 rotates; according to the arrangement sequence of the arc radius of the rotating wheel from large to small, the drawing and spinning surface 1 gradually draws and spins the blank 7 in turn, when the blank passes through the tip fillet of the flow spinning section Complete the flow spinning of the blank 7 to complete the drawing and thinning of the blank 7; then enter the shaping and spinning surface 2, and then gradually smooth and shape the surface of the thinned blank 7; until the drawing and spinning of the blank 7 is completed Pressing, flow spinning and shaping spinning process, and then realize the spinning core die 4 rotation and the rotary wheel 3 one axial feed to complete the three processes of drawing, flow and shaping spinning, until the entire deep cup-shaped part is obtained The required wall thickness.
  • the rotating wheel 3 with the smallest gap between the tip fillet of the flow spinning section and the axial surface of the spinning core mold 4 determines the final wall thickness of the deep cup-shaped part after forming.
  • the current-assisted composite spinning forming method for deep cup-shaped thin-walled parts further includes a step for cutting off the margin of the mouth of the deep cup-shaped part.
  • the present invention has the following advantages and effects:
  • the present invention combines the functions of drawing spinning and flow spinning (or shaping spinning) in a staggered arrangement, cleverly integrated and compounded on a spinning wheel, eliminating the need for drawing spinning and flow spinning (Or shaping and spinning) the time for tool replacement, process switching and adjustment between multiple spinning processes. And it effectively overcomes the tedious process of re-adjusting the tooling every time the tooling is changed.
  • the present invention adopts the staggered distribution of each spinning wheel, that is, the difference or difference in the arc surface radius of the deep drawing and spinning surface 1 of the spinning wheel, the difference or difference in the inclination angle of the shaping spinning surface 2, and the flow spinning section is The difference or difference in the position of the tip fillet of the tapered structure.
  • each roller focuses on applying pressure to different parts of the blank, which is beneficial to increase
  • the amount of pass reduction and the reduction of spinning passes can not only improve production efficiency, but also help reduce defects such as discontinuity in the material processing process, which will eventually lead to the hardening of the workpiece and the material cracking and unusability.
  • the present invention adopts staggered spinning, and enables each spinning to complete partial drawing spinning, flow spinning and shaping spinning processes, not only the operation process is continuous, and the material hardening is effectively prevented, but also the maximum Limit increase in production efficiency.
  • the setting of the reverse thrust plate can also improve the stability of deep-drawing spinning forming to avoid material instability and wrinkles.
  • Figure 1 is a schematic diagram of the overall structure of the present invention; among them, the principle of staggered arrangement is compared, so three rotating wheels are stacked.
  • Figure 2 is a schematic diagram of the actual layout structure of the three rotating wheels of the present invention.
  • Fig. 3 is a schematic diagram of a partial cross-sectional structure of the rotary wheel of the present invention.
  • Fig. 4 is a schematic diagram of the contour structure comparison of the three rotating wheels of the present invention when they are stacked together.
  • the invention discloses a current-assisted composite spinning forming device for deep cup-shaped thin-walled parts, comprising a spinning core mold 4, a tail top 6, and a plurality of spinning wheels 3 equally distributed on the circumference of the spinning core mold 4; each The spinning wheels 3 are arranged at staggered intervals in the axial and radial directions of the spinning core mold 4; the spinning surface of each spinning wheel 3 includes a deep drawing spinning surface 1, a flow spinning section, and a shaping spinning surface 2;
  • the staggered arrangement means that the drawing and spinning surface 1, the flow spinning section and the shaping spinning surface 2 of each spinning wheel 3 are evenly staggered in the axial and radial directions of the spinning core die 4.
  • Figure 1 is the present invention, in order to facilitate the comparison of the relative positions of the three rotating wheels (the A wheel, the B wheel, and the C wheel) in the radial and axial directions, the three rotating wheels are placed at the same position in the circumferential direction.
  • the actual circumferential positions of the three spinning wheels are evenly arranged around the spinning core mold 4 as shown in FIG. 2.
  • the profile shape of each wheel is shown in Figure 3.
  • section I is mainly used for deep drawing and spinning
  • section II is mainly used for flow spinning and/or shaping spinning.
  • the A and B wheels are mainly used for deep drawing spinning and flow spinning
  • the C rotating wheel is mainly used for deep drawing spinning and shaping spinning.
  • the number of the rotating wheels 3 is at least three, and the error distance distribution is embodied as follows:
  • the section line of the drawing and spinning surface 1 of each roller 3 is an arc line, and the arc radius of each drawing and spinning surface 1 gradually decreases in sequence;
  • the cross-sectional shape of the shaping and spinning surface 2 of each roller 3 is a straight line; according to the rotation sequence, the inclination angles of the shaping and spinning surfaces 2 of the first two adjacent rollers 3 with respect to the axis of the spinning core die 4 are the same or sequentially Decrease, and the inclination angle of the shaping and spinning surface 2 of the third rotating wheel 3 relative to the axis of the spinning core die 4 is smaller than the inclination angle of the first two rotating wheels 3;
  • Each flow spinning section has a tapered structure, which refers to the tip fillet where the arc line of the deep drawing spinning surface 1 and the shaping spinning surface 2 linearly join, and the tip fillets of each flow spinning section are gradually staggered in sequence.
  • the stagger distribution of the present invention is the difference or difference in the arc surface radius of the deep drawing and spinning surface 1 of the rotating wheel, the difference or difference in the inclination angle of the shaping and spinning surface 2, and the flow spinning
  • the segment is the difference or difference in the position of the tip fillet of the tapered structure.
  • each roller focuses on applying pressure to different parts of the blank during each rotation of the spinning core mold.
  • the same inclination angle of the first two adjacent rotating wheels 3 means that the inclination angles are the same in the range of 2° to 3°, Sequential decrease means to decrease sequentially within the range of 2° ⁇ 3°; the inclination angle of the third rotating wheel 3 (the arc radius of the drawing and spinning surface 1 is the smallest, that is, the C rotating wheel) is 0.5° ⁇ 1°.
  • other angles can also be used.
  • the arc radius R should be gradually reduced from front to back (that is, from the A-wheel to the C-wheel). 1 >R 2 >R 3 , and make the arc profile of the deep spinning section of the next spinning wheel forward beyond the arc profile of the deep spinning section of the previous spinning wheel, and after drawing and spinning the previous spinning wheel The partial surface of the workpiece is pressed again, which has the effect of increasing the reduction of the pass.
  • the current-assisted composite spinning forming device for deep cup-shaped thin-walled parts of the present invention further includes a thrust reverser plate 5 that is in contact with the edge of the blank 7; electrodes are respectively provided on the thrust reverser plate 5 and the tail top 6, wherein the tail top 6 is It is a positive electrode, and the reverse thrust plate 5 is a negative electrode; in the spinning process, the pulse current flows from the center area of the blank 7 to the edge through the tail top 6 and the reverse thrust plate 5, as a current-assisted spinning. It can avoid the dynamic contact between the useful surface of the blank and the electrode to produce electric spark ablation, so as to protect the smoothness and accuracy requirements of the surface of the part. The final trimming process will remove the ablated edge to obtain high-quality spin. Pressure parts.
  • the pulse current is 1100A to 1400A during the current assisted spinning. The current required for other materials depends on the actual application.
  • the use of current-assisted forming can also improve material plasticity, especially for deep cup-shaped thin-walled parts spinning forming requires better material plasticity.
  • the conventional electrode wiring method is to connect one of the two electrodes to the surface of the component, but this dynamic contact generates electric sparks and ablates the surface of the component. It is currently difficult to overcome. For this reason, the present invention proposes the above-mentioned pulse current flow from the center area of the blank 7 to the edge through the tail top 6 and the reverse thrust plate 5 as a current-assisted spinning method.
  • the present invention proposes a method of applying current to the reverse thrust plate 5 and the tail top 6.
  • the principle structure is as shown in FIG. 1.
  • the setting of the reverse thrust plate can also improve the stability of deep-drawing spinning forming to avoid material instability and wrinkles.
  • the number of rotating wheels 3 selected in the embodiment of the present invention is three, which can be uniformly distributed on the circumference of the spinning core mold 4 at 120°. According to actual needs, the number can be more than two.
  • the current-assisted composite spinning forming method for deep cup-shaped thin-walled parts of the present invention can be realized through the following steps:
  • Step 1 Use the tail top 6 to center the circular plate-shaped blank 7 on the spinning core mold 4;
  • Step 2 Apply a thrust in the axial direction of the spinning core die 4 to the thrust reverser plate 5, that is, toward the blank 7 so that the thrust reverser plate 5 is pressed against the edge of the blank 7; at the top of the tail 6 and the reverse thrust plate A pulse current is applied to 5, and the pulse current flows from the center area of the blank 7 to the edge as a current-assisted spinning;
  • Step 3 The drawing and spinning surface 1 of the spinning wheel 3 is in the working position; when the number of spinning wheels 3 is three, the arc radius of each drawing and spinning surface 1 and the inclination angle of the shaping spinning surface 2 gradually gradually gradually Correspondingly, the gap between the tip fillet of the conical structure of the flow spinning section and the spinning core mold 4 is also gradually reduced;
  • Step 4 Spinning mandrel 4 rotates; according to the order of the arc radius of the rotating wheel from large to small, the drawing and spinning surface 1 gradually draws and spins the blank 7 in turn, when the drawing is spinning to flow spinning At the tip of the section, the flow spinning of the blank 7 is completed to complete the drawing and thinning of the blank 7; then it enters the shaping and spinning surface 2, and then the surface of the thinned blank 7 is gradually smoothed and shaped; until the blank 7 is completed The process of deep drawing spinning, flow spinning and shaping spinning is realized, and then the spinning core die 4 is rotated and the rotary wheel 3 is axially fed at one time to complete the three processes of drawing, flow and shaping spinning, until the entire The required wall thickness of the deep cup-shaped part, and finally the excess edge of the mouth of the deep cup-shaped part is cut off.
  • the rotary wheel 3 with the smallest gap between the tip fillet of the flow spinning section and the axial surface of the spinning core mold 4 determines the final wall thickness of the deep cup-shaped part after forming.
  • the present invention can be implemented well.
  • Three rotating wheels are used in the above process.
  • the structure and shape can be deduced by analogy, and the number can be one, two, three, four or more.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

一种深杯形薄壁零件电流辅助复合旋压成形装置，包括旋压芯模（4）和尾顶（6），以及均等分布在旋压芯模圆周的多个旋轮（3）；每个旋轮在旋压芯模的轴向和径向上均错距布置；每个旋轮的旋压面包括拉深旋压面（1）、流动旋压段、整形旋压面（2）；错距布置是每个旋轮的拉深旋压面、流动旋压段和整形旋压面在旋压芯模的轴向和径向上均错距分布。以及一种采用该旋压成形装置的旋压成形方法。由于各个旋轮用于拉深旋压的弧形型面形状结构的不同，在旋压芯模每旋转一圈的周期内，各旋轮侧重对坯料的不同部位施加压力，有利于增加道次压下量，减少旋压道次，不仅能提高生产效率，还有利于减小由于材料加工过程不连续，最终导致工件硬化导致材料破裂和无法使用等缺陷。

Description

一种深杯形薄壁零件电流辅助复合旋压成形装置及方法 技术领域
本发明涉及机械工程的塑性加工成形领域，尤其涉及一种深杯形薄壁零件电流辅助复合旋压成形装置及方法。
背景技术
深杯形薄壁零件是一种带底且长径比较大的薄壁复杂构件。由于长径比大，可以采用旋压工艺成形，一般需要先采用多道次拉深旋压成形得到浅杯形件，再进行多道次流动旋压成形使壁厚减薄得到深杯形薄壁零件。
主要存在如下几方面问题：
1、拉深旋压和流动旋压两个旋压工序彼此独立完全分开作业，使工件加工流程及作业时间过长；而且在拉深旋压作业后，还需要重新更换和调校工装，才能进行流动旋压作业，不仅耽误加工时间，而且零件精度也会受到一定影响。
2、拉深旋压成形时，采用单旋轮多道次，也或者采用相同几何参数的双(或者多个)旋轮，进行反复多道次成形，因为每个旋轮的几何参数相同，所以道次压下量受到限制，此时不得不增加道次数；这也会导致作业时间的增加；更重要的甚至因工件加工时间以及更换工装及调校时间的延长，使的工件生产工艺不连续，导致工件硬化导致材料破裂。
3、有些情况下采用了电流辅助旋压成形，但均将其中一个电极施加在工件即坯料的表面，因旋转时动态接触产生的电火花，使坯料表面烧蚀，导致成型后的零件表面受损严重，影响产品质量。
发明内容
本发明提供一种深杯形薄壁零件电流辅助复合旋压成形装置及方法。解决了现有技术中由于工件生产工艺中拉深旋压、流动旋压(或整形旋压)作业过程不连续，而使工件硬化导致材料破裂、更换工序时需要重新调校工装以及生产周期长等问题。
本发明通过下述技术方案实现：
一种深杯形薄壁零件电流辅助复合旋压成形装置，包括旋压芯模4和尾顶6，以及均等分布在旋压芯模4圆周的多个旋轮3；每个旋轮3在旋压芯模4的轴向和径向上均错距布置；每个旋轮3的旋压面包括拉深旋压面1、流动旋压段、整形旋压面2；所述错距布置是指每个旋轮3的拉深旋压面1、流动旋压段和整形旋压面2在旋压芯模4的轴向和径向上均错距分布。
所述旋轮3的数量为至少三个，所述错距分布体现如下：
各旋轮3的拉深旋压面1的剖面线为圆弧线，且各拉深旋压面1的圆弧半径依次逐渐减小；
各旋轮3的整形旋压面2的剖面形状为直线；根据旋转顺序，其中前两个相邻的旋轮3的整形旋压面2相对于旋压芯模4轴线的倾斜角度相同或者依次减小，而第三个旋轮3的整形旋压面2相对于旋压芯模4轴线的倾斜角度均小余前两个旋轮3的倾斜角度；
各流动旋压段为锥形结构，是指拉深旋压面1的圆弧线与整形旋压面2直线衔接处的尖端圆角部分，且各流动旋压段的尖端圆角依次逐渐错开。
所述前两个相邻的旋轮3的倾斜角度相同是指在2°～3°范围内相同，依次减小是指在2°～3°范围内依次减小；所述第三个旋轮3的倾斜角度为0.5°～1°。
所述深杯形薄壁零件电流辅助复合旋压成形装置，还包括一抵触在坯料7边缘的反推板5；在反推板5和尾顶6上分别设有电极，其中尾顶6上为正电极，反推板5为负电极；在旋压过程中，通过尾顶6和反推板5将脉冲电流 由坯料7的中心区域流向边缘，作为电流辅助旋压。
所述旋轮3的数量为三个时，呈120°均布在旋压芯模4的圆周。
一种深杯形薄壁零件电流辅助复合旋压成形方法，其包括如下步骤：
用尾顶6将圆板形的坯料7对中顶紧在旋压芯模4上；
给反推板5施加一个沿旋压芯模4轴向方向的推力，即向毛坯7方向，以使反推板5顶紧在坯料7的边缘；在尾顶6和反推板5上施加一个脉冲电流，脉冲电流由坯料7的中心区域流向边缘，作为电流辅助旋压；
旋轮3的拉深旋压面1处于工作工位；当旋轮3为三个时，每个拉深旋压面1的圆弧半径以及整形旋压面2的倾斜角度依次逐渐减小；相应地，流动旋压段锥形结构的尖端圆角与旋压芯模4之间的间隙也逐渐减小；
旋压芯模4旋转；根据旋轮圆弧半径由大至小的排列顺序，拉深旋压面1依次逐渐对坯料7进行拉深旋压，当坯料经过流动旋压段的尖端圆角时完成对坯料7流动旋压，以完成坯料7的拉深、减薄；接着进入整形旋压面2，再对减薄的坯料7的表面逐渐进行光整整形；直至完成坯料7的拉深旋压、流动旋压和整形旋压过程，进而实现旋压芯模4旋转和旋轮3一次轴向进给即可完成拉深、流动和整形旋压三个工序，直至得到整个深杯形零件的所需壁厚。
流动旋压段的尖端圆角与旋压芯模4轴面之间的间隙最小的那个旋轮3，决定了深杯形零件成形后的最终壁厚。
所述深杯形薄壁零件电流辅助复合旋压成形方法，还包括用于切除深杯形零件的口部余量的步骤。
本发明相对于现有技术，具有如下的优点及效果：
(1)本发明将拉深旋压和流动旋压(或整形旋压)功能，以错距布置的方式，巧妙的集成复合到一个旋轮上，省去了拉深旋压、流动旋压(或整形旋压)多个旋压工艺之间的工装更换、工序切换以及调校的时间。并有效克服了每次更换工装时都要重新调校工装的繁琐过程。
(2)现有技术拉深旋压成形时，采用单旋轮多道次，也或者采用相同几何参数的双(或者多个)旋轮，进行反复多道次成形，因为每个旋轮的几何参数相同，所以道次压下量受到限制，此时不得不增加道次数；这也会导致作业时间的增加；更重要的甚至因工件加工时间以及更换工装及调校时间的延长，使的工件生产工艺不连续，从而使工件硬化导致材料破裂。
本发明将各个旋轮采用错距分布，即旋轮的拉深旋压面1的弧面半径上的差异或者不同，整形旋压面2的倾斜角度的差异或者不同，以及流动旋压段为锥形结构的尖端圆角位置的差异或者不同。因此，由于各个旋轮用于拉深旋压的弧形型面形状结构的不同，在旋压芯模每旋转一圈的周期内，各旋轮侧重对坯料的不同部位施加压力，有利于增加道次压下量，减少旋压道次，不仅能提高生产效率，还有利于减小由于材料加工过程不连续，最终导致工件硬化导致材料破裂，无法使用等缺陷。
(3)本发明采用错距旋压，并使每道次旋压均能够完成部分拉深旋压、流动旋压及整形旋压工序，不仅作业过程连续，有效防止了材料硬化，而且能最大限度提高生产效率。
(4)通过利用尾顶和反推盘在坯料的中心区域和边缘部位施加脉冲电流，可以避免坯料有用表面与电极之间的动态接触产生电火花烧蚀，从而可以保护零件表面的光整度及精度要求。最终的修边工序将被烧蚀的无用边缘切除，即得到高质量的旋压零件。
采用电流辅助成形也进一步提高了材料的塑性。
设置反推板除了上述目的之外，还可以提高拉深旋压成形的稳定性以避免材料失稳起皱。
附图说明
图1为本发明整体结构示意图；其中为对比错距布置原理，故将三个旋轮叠置。
图2为本发明三个旋轮实际布局结构示意图。
图3为本发明旋轮的局部剖面结构示意图。
图4为本发明三个旋轮叠置在一起时的轮廓结构对比示意图。
具体实施方式
下面结合具体实施例对本发明作进一步具体详细描述。
实施例
如图1-4所述。本发明公开了一种深杯形薄壁零件电流辅助复合旋压成形装置，包括旋压芯模4和尾顶6，以及均等分布在旋压芯模4圆周的多个旋轮3；每个旋轮3在旋压芯模4的轴向和径向上均错距布置；每个旋轮3的旋压面包括拉深旋压面1、流动旋压段、整形旋压面2；所述错距布置是指每个旋轮3的拉深旋压面1、流动旋压段和整形旋压面2在旋压芯模4的轴向和径向上均错距分布。
图1是本发明为了便于比较三个旋轮(依次为A旋轮、B旋轮、C旋轮)在径向和轴向的相对位置，将三个旋轮放置在圆周方向的同一位置。实际三个旋轮的圆周位置如图2所示的均匀布置在旋压芯模4的周围。每个旋轮的型面形状如图3所示，其图中I段主要用于拉深旋压，II段主要用于流动旋压和/或整形旋压，图1中从左到右A、B、C三个旋轮中，A、B旋轮主要用于拉深旋压和流动旋压，C旋轮主要用于拉深旋压和整形旋压。
所述旋轮3的数量为至少三个，所述错距分布体现如下：
各旋轮3的拉深旋压面1的剖面线为圆弧线，且各拉深旋压面1的圆弧半径依次逐渐减小；
各旋轮3的整形旋压面2的剖面形状为直线；根据旋转顺序，其中前两个相邻的旋轮3的整形旋压面2相对于旋压芯模4轴线的倾斜角度相同或者依次减小，而第三个旋轮3的整形旋压面2相对于旋压芯模4轴线的倾斜角度均小余前两个旋轮3的倾斜角度；
在图3中，每个旋轮的整形旋压面2，按其功能不同设计其不同的倾斜角α，A和B旋轮用于流动旋压，可以按常规参数设计α A＝α B＝3°。因为每道次旋压时都存在拉深旋压、流动旋压，为避免产生明显的旋轮螺旋痕迹，将三个旋轮3均设计成具有拉深旋压和整形旋压功能，并设计α C＝0.5°以提高对零件表面的整形效果。当然，根据具体应用要求，角度可是灵活变动。
各流动旋压段为锥形结构，是指拉深旋压面1的圆弧线与整形旋压面2直线衔接处的尖端圆角，且各流动旋压段的尖端圆角依次逐渐错开。
从上述技术特征可以看出，本发明错距分布是旋轮的拉深旋压面1的弧面半径上的差异或者不同，整形旋压面2的倾斜角度的差异或者不同，以及流动旋压段为锥形结构的尖端圆角位置的差异或者不同。这种不同及差异，巧妙的将将拉深旋压和流动旋压(或整形旋压)功能，以错距布置的方式复合集成到一个旋轮上，省去了拉深旋压、流动旋压(或整形旋压)多个旋压工艺之间的工装更换、工序切换以及调校的时间。
现有技术拉深旋压成形时，采用单旋轮多道次，也或者采用相同几何参数的双(或者多个)旋轮，进行反复多道次成形，因为每个旋轮的几何参数相同，所以道次压下量受到限制，此时不得不增加道次数；这也会导致作业时间的增加；更重要的甚至因工件加工时间以及更换工装及调校时间的延长，使的工件生产工艺不连续，从而使工件硬化导致材料破裂。
如上所述，本发明由于各个旋轮用于拉深旋压的弧形型面形状结构的不同，在旋压芯模每旋转一圈的周期内，各旋轮侧重对坯料的不同部位施加压力，有利于增加道次压下量，减少旋压道次，不仅能提高生产效率，还有利于减小由于材料加工过程不连续，最终导致工件硬化导致材料破裂，无法使用等缺陷。
本发明前两个相邻的旋轮3(拉深旋压面1的圆弧半径最大的作为第一个，即A旋轮)的倾斜角度相同是指在2°～3°范围内相同，依次减小是指在2°～3°范围内依次减小；所述第三个旋轮3(拉深旋压面1的圆弧半径最小， 即C旋轮)的倾斜角度为0.5°～1°。然而，根据工件实际情况，也可以是其他角度。
如上所述，为了能在每道次拉深旋压过程中增加道次压下量，采用三个旋轮同时进行拉深旋压，并将三个旋轮的弧形型面设计成不同圆弧半径R，参见图4。
图4中，为了能让每一个旋轮均对拉深旋压的压下量有所贡献，应从前到后(即从A旋轮到C旋轮)逐渐减小圆弧半径R，即R 1>R 2>R 3，并让后一旋轮拉深旋压段的圆弧轮廓向前超出前一旋轮拉深旋压段的圆弧轮廓，对前一旋轮拉深旋压后的局部工件表面再次施压，从而起到增加道次压下量的效果。
本发明深杯形薄壁零件电流辅助复合旋压成形装置，还包括一抵触在坯料7边缘的反推板5；在反推板5和尾顶6上分别设有电极，其中尾顶6上为正电极，反推板5为负电极；在旋压过程中，通过尾顶6和反推板5将脉冲电流由坯料7的中心区域流向边缘，作为电流辅助旋压。可以避免坯料有用表面与电极之间的动态接触产生电火花烧蚀，从而可以保护零件表面的光整度及精度要求，最终的修边工序将会切除被烧蚀的边缘，得到高质量的旋压零件。当坯料7采用合金结构钢材料，电流辅助旋压时脉冲电流为1100A～1400A。其他材料所需电流根据实际应用而定。
采用电流辅助成形还可以提高材料塑性，特别是深杯形薄壁零件旋压成形时更需要较好的材料塑性。电流辅助旋压成形时，常规电极接线方式均是将两个电极中的一个接在构件表面，但这种动态接触产生电火花并烧蚀构件表面的现象目前尚难以克服。为此本发明提出了上述通过尾顶6和反推板5将脉冲电流由坯料7的中心区域流向边缘，作为电流辅助旋压方法。
为此，本发明提出在反推盘5和尾顶6上施加电流的方法，原理结构如 图1。设置反推板除了上述目的之外，还可以提高拉深旋压成形的稳定性以避免材料失稳起皱。
本发明实施例选用旋轮3的数量为三个，可呈120°均布在旋压芯模4的圆周。根据实际需要，数量可以是2个以上。
本发明深杯形薄壁零件电流辅助复合旋压成形方法，可通过如下步骤实现：
步骤一：用尾顶6将圆板形的坯料7对中顶紧在旋压芯模4上；
步骤二：给反推板5施加一个沿旋压芯模4轴向方向的推力，即向毛坯7方向，以使反推板5顶紧在坯料7的边缘；在尾顶6和反推板5上施加一个脉冲电流，脉冲电流由坯料7的中心区域流向边缘，作为电流辅助旋压；
步骤三：旋轮3的拉深旋压面1处于工作工位；当旋轮3为三个时，每个拉深旋压面1的圆弧半径以及整形旋压面2的倾斜角度依次逐渐减小；相应地，流动旋压段锥形结构的尖端圆角与旋压芯模4之间的间隙也逐渐减小；
步骤四：旋压芯模4旋转；根据旋轮圆弧半径由大至小的排列顺序，拉深旋压面1依次逐渐对坯料7进行拉深旋压，当拉深旋压至流动旋压段的尖端时完成对坯料7流动旋压，以完成坯料7的拉深、减薄；接着进入整形旋压面2，再对减薄的坯料7的表面逐渐进行光整整形；直至完成坯料7的拉深旋压、流动旋压和整形旋压过程，进而实现旋压芯模4旋转和旋轮3一次轴向进给即可完成拉深、流动和整形旋压三个工序，直至得到整个深杯形零件的所需壁厚，最后将深杯形零件的口部多余边缘切除。
流动旋压段的尖端圆角与旋压芯模4轴面之间的间隙最小的那个旋轮3，决定了深杯形零件成形后的最终的壁厚。
如上所述，便可较好地实现本发明。上述工艺中采用三个旋轮，实际应用中根据具体情况及应用要求，结构形状可以依次类推，数量可以是一个，两个，三个，四个或者更多。
本发明的实施方式并不受上述实施例的限制，其他任何未背离本发明的 精神实质与原理下所作的改变、修饰、替代、组合、简化，均应为等效的置换方式，都包含在本发明的保护范围之内。

Claims (9)

  1. 一种深杯形薄壁零件电流辅助复合旋压成形装置，包括旋压芯模(4)和尾顶(6)，以及均等分布在旋压芯模(4)圆周的多个旋轮(3)；其特征在于：每个旋轮(3)在旋压芯模(4)的轴向和径向上均错距布置；每个旋轮(3)的旋压面包括拉深旋压面(1)、流动旋压段、整形旋压面(2)；所述错距布置是指每个旋轮(3)的拉深旋压面(1)、流动旋压段和整形旋压面(2)在旋压芯模(4)的轴向和径向上均错距分布。
  2. 根据权利要求1所述深杯形薄壁零件电流辅助复合旋压成形装置，其特征在于，所述旋轮(3)的数量为至少三个，所述错距分布体现如下：
    各旋轮(3)的拉深旋压面(1)的剖面线为圆弧线，且各拉深旋压面(1)的圆弧半径依次逐渐减小；
    各旋轮(3)的整形旋压面(2)的剖面形状为直线；根据旋转顺序，其中前两个相邻的旋轮(3)的整形旋压面(2)相对于旋压芯模(4)轴线的倾斜角度相同或者依次减小，而第三个旋轮(3)的整形旋压面(2)相对于旋压芯模(4)轴线的倾斜角度均小余前两个旋轮(3)的倾斜角度；
    各流动旋压段为锥形结构，是指拉深旋压面(1)的圆弧线与整形旋压面(2)直线衔接处的尖端圆角，且各流动旋压段的尖端圆角依次逐渐错开。
  3. 根据权利要求2所述深杯形薄壁零件电流辅助复合旋压成形装置，其特征在于：所述前两个相邻的旋轮(3)的倾斜角度相同是指在2°～3°范围内相同，依次减小是指在2°～3°范围内依次减小；所述第三个旋轮(3)的倾斜角度为0.5°～1°。
  4. 根据权利要求3所述深杯形薄壁零件电流辅助复合旋压成形装置，其特征在于：所述深杯形薄壁零件电流辅助复合旋压成形装置，还包括一抵触 在坯料(7)边缘的反推板(5)；在反推板(5)和尾顶(6)上分别设有电极，其中尾顶(6)上为正电极，反推板(5)为负电极；在旋压过程中，通过尾顶(6)和反推板(5)将脉冲电流由坯料(7)的中心区域流向边缘，作为电流辅助旋压。
  5. 根据权利要求4所述深杯形薄壁零件电流辅助复合旋压成形装置，其特征在于：所述坯料(7)采用合金结构钢，电流辅助旋压时脉冲电流为1100A～1400A。
  6. 根据权利要求5所述深杯形薄壁零件电流辅助复合旋压成形装置，其特征在于：当旋轮(3)的数量为三个时，呈120°均布在旋压芯模(4)的圆周。
  7. 一种深杯形薄壁零件电流辅助复合旋压成形方法，其特征在于采用权利要求1-6中任一项所述装置实现，其包括如下步骤：
    用尾顶(6)将圆板形的坯料(7)对中顶紧在旋压芯模(4)上；
    给反推板(5)施加一个沿旋压芯模(4)轴向方向的推力，即向毛坯7方向，以使反推板(5)顶紧在坯料(7)的边缘；在尾顶(6)和反推板(5)上施加一个脉冲电流，脉冲电流由坯料(7)的中心区域流向边缘，作为电流辅助旋压；
    旋轮(3)的拉深旋压面(1)处于工作工位；当旋轮(3)为三个时，每个拉深旋压面(1)的圆弧半径以及整形旋压面(2)的倾斜角度依次逐渐减小；相应地，流动旋压段锥形结构的尖端圆角与旋压芯模(4)之间的间隙也逐渐减小；
    旋压芯模(4)旋转；根据旋轮圆弧半径由大至小的排列顺序，拉深旋压面(1)依次逐渐对坯料(7)进行拉深旋压，当拉深旋压至流动旋压段的尖端 圆角时完成对坯料(7)流动旋压，以完成坯料(7)的拉深、减薄；接着进入整形旋压面(2)，再对减薄的坯料(7)的表面逐渐进行光整整形；直至完成坯料(7)的拉深旋压、流动旋压和整形旋压过程，进而实现旋轮一次进给即可完成拉深、流动和整形旋压三个工序，直至得到整个深杯形零件的所需壁厚。
  8. 根据权利要求7所述深杯形薄壁零件电流辅助复合旋压成形方法，其特征在于：流动旋压段的尖端圆角与旋压芯模(4)轴面之间的间隙最小的那个旋轮(3)，决定了深杯形零件成形后的最终的壁厚。
  9. 根据权利要求8所述深杯形薄壁零件电流辅助复合旋压成形方法，其特征在于：深杯形零件达到需壁厚后，再切除深杯形零件的口部的余边。
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