WO2022134493A1 - 一种带安装槽异形杆的冷弯成型方法 - Google Patents
一种带安装槽异形杆的冷弯成型方法 Download PDFInfo
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- WO2022134493A1 WO2022134493A1 PCT/CN2021/099592 CN2021099592W WO2022134493A1 WO 2022134493 A1 WO2022134493 A1 WO 2022134493A1 CN 2021099592 W CN2021099592 W CN 2021099592W WO 2022134493 A1 WO2022134493 A1 WO 2022134493A1
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- Prior art keywords
- bending
- special
- substrate
- groove
- cold
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- 238000000034 method Methods 0.000 title claims abstract description 71
- 238000005452 bending Methods 0.000 claims abstract description 84
- 239000000758 substrate Substances 0.000 claims abstract description 64
- 238000003466 welding Methods 0.000 claims abstract description 11
- 238000003825 pressing Methods 0.000 claims description 60
- 238000009434 installation Methods 0.000 claims description 57
- 230000008569 process Effects 0.000 claims description 37
- 238000012545 processing Methods 0.000 claims description 36
- 238000001125 extrusion Methods 0.000 claims description 15
- 238000007493 shaping process Methods 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 description 15
- 239000010959 steel Substances 0.000 description 15
- 238000004519 manufacturing process Methods 0.000 description 6
- 230000000712 assembly Effects 0.000 description 5
- 238000000429 assembly Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 239000002994 raw material Substances 0.000 description 4
- 230000008859 change Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 229910000851 Alloy steel Inorganic materials 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000011031 large-scale manufacturing process Methods 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000009966 trimming Methods 0.000 description 2
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 1
- 230000001154 acute effect Effects 0.000 description 1
- 238000013475 authorization Methods 0.000 description 1
- 238000010622 cold drawing Methods 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000005098 hot rolling Methods 0.000 description 1
- 238000009439 industrial construction Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000005554 pickling Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000005480 shot peening Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
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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
- B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
- B21D11/10—Bending specially adapted to produce specific articles, e.g. leaf springs
Definitions
- the invention relates to the field of cold-bending forming of steel pipes, in particular to a cold-bending forming method of an installation groove and a cold-bending forming method comprising a special-shaped rod of the installation groove.
- Cold bending is a process technology that continuously bends metal sheets and strips laterally through sequentially arranged multi-pass forming rolls to form profiles with specific cross-sections.
- Cold forming is a material-saving, energy-saving, efficient, advanced and applicable metal forming process, and it is an important field for deep processing of sheet and strip. Small impact, easy to realize production automation, suitable for large-scale production operations, suitable for making cold-formed steel with a wide variety of materials and rich sources of raw materials.
- Cold-formed forming equipment can produce complex cross-sections and various types of cold-formed profiles that are difficult to produce by general hot rolling, so as to obtain maximum rigidity and strength with minimum metal consumption; in large-scale production, the cost of forming rolls is higher than There are fewer dies, and the service life is much longer than that of dies.
- the roll forming process is the main processing method of cold-formed steel. It gradually deforms the flat original plate through a set of longitudinally arranged rolls to make it meet the shape suitable for use; and the surface of the cold-formed product is smooth and clean.
- the appearance is good, the size is accurate, and the length can be adjusted flexibly according to the needs, all of which are supplied according to fixed length or double length, which improves the utilization rate of materials; it can also be matched with punching and other processes in production to meet different needs.
- the side length dimension of the square and rectangular tube along the width direction of the high-strength steel plate strip, divide the high-strength steel plate strip into the upper left section, the left section, the lower section, the right section and the upper right section, and perform the following steps in turn: bend the upper left section and the upper right section to a specified angle; Bend the left and right segments to a specified angle; bend the upper left, left, lower, right and upper right segments to a specified angle at the same time; weld the upper left and upper right segments and bend at the same time
- the upper left segment and the upper right segment ensure that the upper left segment and the upper right segment are aligned; the semi-formed high-strength steel square rectangular tube is reshaped.
- the mounting slot has good guiding and locking functions.
- the rod with the mounting slot is The supporting ability and bending resistance of the parts can be effectively strengthened, and are widely used in various products.
- a connection structure of a mounting slot column disclosed in the Chinese utility model patent document with the authorization announcement number CN201963652U includes a mounting slot column and a connecting plate, the side of the mounting slot column is provided with a mounting slot, and one end of the connecting plate is provided with a mounting slot. A tenon, the tenon is matched with the mounting groove. Since the utility model adopts the above technical scheme, a plurality of connecting plates can be connected through the cooperation of the tenon on the connecting plate and the mounting groove of the mounting groove column, and the installation is convenient.
- the purpose of the present invention is to provide a method for quickly and efficiently forming a dovetail-shaped mounting groove on a substrate through a cold-bending process, and also to provide a cold-bending method for a special-shaped rod with the mounting groove.
- the invention provides an installation groove and a cold-bending forming method with the special-shaped rod of the installation groove, which can effectively prevent the steel plate from breaking during the cold-bending process, precisely locate each installation groove, and improve the processing and forming efficiency and precision.
- a cold-bending forming method for a special-shaped rod with an installation groove characterized in that: the cold-bending forming method for a special-shaped rod with an installation groove comprises the following steps:
- a base groove that protrudes toward one side of the base plate is formed on the substrate by the first pressing roller assembly, and the base groove includes a connecting wall parallel to the base plate and connecting two ends of the connecting wall to the base groove respectively.
- the mounting walls of the base plates on both sides a first corner portion is formed between the connecting wall and the mounting wall, and a second corner portion is formed between the mounting wall and the base plate;
- the first and second folded corners connected to the same installation wall on the base groove are subjected to extrusion and bending processing through a second pressing roller assembly
- the second pressing roller assembly includes a relative The inner roller and the outer roller whose installation walls are staggered to each other, during the bending process, the inner roller is arranged at the first folded corner to press from the inside to the outside to form an inner turning portion, and the outer roller is arranged at the second folded corner from the inside to the outside.
- the external pressure is applied to form the external turning portion, thereby making the base groove into a mounting groove.
- the cold-bending forming method of the special-shaped rod with an installation groove further comprises the following steps: S3, forming a turning and bending part: the main body of the base plate connected with the two ends of the connecting plate on the installation groove is made of a third pressing roller The assembly is extruded and bent to form a turning cross angle, and a turning bending part is formed between the turning crossing angle and the outer turning angle; the turning bending parts located on both sides of a mounting groove, the cross turning angle, are connected to the cross turning angle. Part of the base plate and the mounting groove together form the mounting groove unit on the special-shaped rod.
- the cold-bending method for special-shaped rods with mounting grooves further includes the following steps: S4, repeating the steps S1-S3 on the substrate until all the mounting groove units on the substrate are formed, and the The two ends are close to each other to abut against each other or form a gap.
- the two ends of the base plate are connected together by welding at the places where the two ends of the base plate abut against each other or form a gap to form a special-shaped rod with a mounting slot.
- the number of mounting grooves contained in the final shaped special-shaped rod is taken as an integer N, and the width of the substrate is D, then the width of the processed substrate contained in each mounting groove unit is D/ N; step S1a is added before step S1, and the step S1a is as follows:
- S1a Divide the processing section: divide the substrate mark into N processing sections with a width of D/N, select a processing section on the substrate, and locate the forming base at the center of the processing section through the processing of the first pressing roller assembly Slots; the size of the cross swivel angle is 180°/N.
- the second pressure roller assembly in the step S2 includes two pairs of inner and outer pressure rollers that are symmetrical to each other, and the pair of inner and outer rollers located on one side of the second pressure roller assembly is located in the base groove first.
- the first folded corner portion and the second folded corner portion of one side are subjected to extrusion and bending processing, and an inner turning portion and an outer turning portion are formed on one side of the base groove;
- the inner roller and the outer roller are subjected to extrusion and bending processing on the first folded corner portion and the second folded corner portion located on the other side of the base groove, and an inner turn portion and an outer turn portion are formed on the other side of the base groove.
- the first pressing roller assembly includes a plurality of pressing rollers, and the distance between each pressing roller is variable. A number of installation grooves symmetrical to the center line of the base plate.
- the third pressing roller assembly includes a pair of left and right symmetrical pressing rollers, and the distance between the two parts of the pressing rollers is variable.
- the third pressing roller assembly presses and bends the substrate from the outside to the center of the substrate.
- the folding process forms each cross turning angle connected with the installation groove, and at the same time forms the installation groove unit.
- the first pressing roller assembly, the second pressing roller assembly and the third pressing roller assembly are all arranged in multiple passes, and the installation groove unit is formed by gradually performing extrusion and bending processing.
- a step of shaping and deforming the special-shaped rod is added at the end of the cold-bending forming method.
- the present invention can achieve the following beneficial effects:
- the method of manufacturing the mounting groove by pressing and bending the substrate with a pressure roller compared with the cold-drawing forming process, the required raw material does not need to be a preliminarily formed tube body, which greatly reduces the need for It reduces the space occupied by raw materials in the process of transportation and storage, improves the efficiency of transportation and storage, and reduces the expenditure cost in the process; compared with the ordinary bending process, the steel plate does not need to be heated and can effectively prevent the steel plate from being bent at the bending angle. The location is broken and damaged.
- the base groove is formed on the substrate by using the pressing roller, which is the basis for the manufacturing of the mounting groove, so as to facilitate the preliminary positioning and measurement of the position and shape and size of the base groove after the base groove is formed. Cumulative errors generated during the molding process.
- the base groove is directly bent and processed by a convex roller with an arc-shaped cross-sectional shape as the second pressing roller assembly, and at the same time the pressing roller in the second pressing roller assembly is bent.
- the two bending angles of the rollers relative to one side of the base groove are staggered, so that the bending angle of the base groove is arc-shaped in one forming process, which reduces the processing steps and saves the cost.
- the resulting stress makes the shape of the special-shaped rod formed by bending more precise.
- the base groove and the installation groove unit on the substrate are formed by cold bending one by one, which can accurately ensure the shape and size of each formed installation groove unit.
- the left and right sides relative to the central axis of the base plate are processed and formed from the center part of the base plate to both sides.
- Symmetrical base grooves make the position between the formed base grooves more accurate, and at the same time ensure the balance of the force on the substrate during processing, and avoid the substrate itself being tilted or offset, resulting in unqualified shapes and sizes. groove.
- the two ends of the base plate are extruded and bent toward the center, and the turning and bending parts are symmetrically formed on the base plate, so as to ensure the balance of the force on the base plate during processing.
- the method of forming the steering bending part makes the substrate part that is the basis of the processing all located on the same plane each time, which greatly reduces the Difficulty in processing.
- the special-shaped rod after the cold bending process is processed by the trimming equipment, and the special-shaped rod is further positioned and trimmed by passing the special-shaped rod through the shaping hole in the mold with the precise cross-sectional shape to reduce the belt during extrusion and bending. Enter the shape error, improve the standardization of the product.
- Figure 1 is a schematic cross-sectional view of a special-shaped rod with a mounting groove
- Fig. 2 is the structural schematic diagram of each part in the base groove
- Figure 3 is a schematic view of the force under the action of the second pressing roller assembly in the base groove
- Figure 4 is a schematic diagram of the structure of each part in the installation groove
- Figure 5 is a schematic diagram of the structure of the installation slot unit and part
- Figure 6 is a schematic diagram of the cross-sectional structure of the shaping die hole
- Figure 7 is a schematic diagram of the forming sequence of each main part
- FIG. 8 is a schematic flowchart of a cold-bending process method for a special-shaped rod with a mounting groove corresponding to Embodiment 3.
- FIG. 8 is a schematic flowchart of a cold-bending process method for a special-shaped rod with a mounting groove corresponding to Embodiment 3.
- 2 base groove
- 2a installation wall
- 2b connecting wall
- 2c first folded corner
- 2d second folded corner
- 3 installation groove
- 3a inner swivel part
- 3b outer swivel part
- 4 Installation slot unit
- 4a Specific bending part
- 4b Crossing angle
- Embodiment 1 a cold-bending forming process method with 3 special-shaped rods with installation grooves, comprising the following steps:
- S1a Select a steel raw material substrate 1 with a length of L and a width of D, for processing and forming a special-shaped rod with a mounting groove 3 with a height of L.
- N the number of mounting grooves 3 included in the final shaped rod to be shaped
- D/N the width of the processed substrate 1 contained in each mounting groove unit 4
- the substrate 1 is marked as divided into It is a processing section with a width of N and a width of D/N.
- a processing section is selected on the substrate 1, and the base groove 2 is positioned and formed at the center of the processing section by the processing of the first pressing roller assembly.
- the middle part of the selected processing section on the substrate 1 is gradually extruded and bent by the first pressing roller assembly arranged in multiple passes to form a base groove 2 that protrudes toward one side of the base plate 1.
- the base groove 2 includes a The connecting wall 2b parallel to the base plate 1 and the mounting walls 2a connecting the two ends of the connecting wall 2b and the base plates 1 on both sides respectively.
- a second angled portion 2d is formed between the mounting wall 2a and the base plate 1; specifically, both the first angled portion 2c and the second angled portion 2d are bent at 90°.
- the second pressing roller assembly includes an inner roller and an outer roller that are staggered relative to the mounting wall 2a.
- the rotation axes of the inner roller and the outer roller are parallel to each other and are no longer on the same straight line.
- the inner roller is arranged on the first corner portion 2c to press from the inside to the outside to form the inner turning portion 3a
- the outer roller is arranged on the second corner portion 2d to press from the inside to the outside to form the outer turning portion 3b.
- the acting force exerted by the corner portion 2c and the acting force exerted by the outer roller on the second corner portion 2d are opposite to each other and parallel to each other and are no longer on the same straight line.
- Both sides of the base groove 2 are processed by the second pressing roller assembly to make the base groove 2 into a mounting groove 3, wherein the angle between the two side walls of the inner turning part 3a and the outer turning part 3b is an acute angle, so that the The installation groove 3 is in a shape whose width gradually decreases from the inside to the outside.
- the surfaces of the inner roller and the outer roller in the second pressing roller assembly are arc-shaped, so that the bending angles in the formed inner turning portion 3a and the outer turning portion 3b are all rounded corners, which effectively reduces the size of the substrate 1 .
- the size of the internal stress prevents the breakage of the substrate 1 from being bent during the molding process.
- the main body of the base plate 1 connected with the two ends of the connecting plate on the installation groove 3 is subjected to extrusion and bending processing by using the third pressing roller assembly set in multiple passes to gradually form a turning intersection angle.
- the size of the crossing turning angle 4b is 180°/N, and a turning bending part 4a is formed between the turning crossing angle and the outer turning angle; Part of the base plate 1 on the crossed turning angle 4b and the mounting groove 3 together form the mounting groove unit 4 on the special-shaped rod.
- Steps S1-S3 are repeated to form all the mounting slot units 4 on the substrate 1.
- the ends on both sides of the substrate 1 are close to each other until they abut against each other or form an extremely small Clearance.
- the shape of the shaped special-shaped rod is further trimmed and processed to obtain a special-shaped rod with a more regular shape and higher strength.
- Embodiment 2 a cold-bending forming process method with 3 special-shaped rods with mounting grooves, characterized in that: the cold-bending forming process method comprises the following steps:
- a base groove 2 protruding to one side is formed on the base plate 1 by the first pressing roller assembly.
- the base groove 2 includes a connecting wall 2b parallel to the base plate 1 and protruding to one side relative to the base plate 1
- Extrusion and bending is performed on the first folded corner portion 2c and the second folded corner portion 2d on one side of the base groove 2 through a set of second pressing roller assemblies including inner rollers and outer rollers staggered to each other, so that the inner
- the first folded corner portion 2c of the roller bonding process forms an inner turning portion 3a
- the second folded corner portion 2d of the outer roller bonding process forms an outer turning portion 3b
- the inner turning portion 3a and the outer turning portion 3b are sandwiched between the two sides.
- the angles are all less than 90°;
- the distance between the two parts of the pressure rollers in the third pressure roller assembly By adjusting the distance between the two parts of the pressure rollers in the third pressure roller assembly, the distance between the two parts of the pressure rollers becomes smaller, and from the outside to the inside, adjust the distance between the two parts of the pressure rollers in step S5 on the other side of the installation groove 3 on both sides.
- the substrate 1 is subjected to extrusion and bending processing to bend the two parts of the substrate 1 from here to the side of the mounting groove 3 to form a turning and bending portion 4a located on both sides of the substrate 1 symmetrically;
- Steps S5-S6 are repeated to form several sets of symmetrical cross rotation angles 4b on both sides of the substrate 1 symmetrically until all the installation slot units 4 are formed, and at the same time, both sides of the main body of the substrate 1 are bent in the same direction Surrounding the preliminary forming rod forming the inner hollow, the two ends located at the outermost side of the base plate 1 abut against each other or form a gap;
- Embodiment 3 a cold-bending forming process method with 3 special-shaped rods with mounting grooves, characterized in that: the cold-bending forming process method comprises the following steps:
- a plurality of base grooves 2 are formed on the base plate 1 by the first pressing roller assembly and are protruded to one side and distributed symmetrically with respect to the center line of the base plate 1 .
- a parallel connecting wall 2b and a left-right symmetrical mounting wall 2a protruding to one side relative to the base plate 1 are two parts, a first angled portion 2c is formed between the connecting wall 2b and the mounting wall 2a, and the mounting wall 2a
- a second corner portion 2d is formed between the substrate 1 and the first corner portion 2c and the angle between the two sides of the second corner portion 2d is not less than 90°;
- step S3 Simultaneously squeeze the first folded corner portion 2c and the second folded corner portion 2d on the other side of the plurality of base grooves 2 in step S2 through another set of second pressing roller assemblies that are mirror-symmetrical with the second pressing roller assembly Press and bend, so that the inner turning parts 3a and the outer turning parts 3b are symmetrically formed on the opposite sides of the several base grooves 2, so that the distance between the outer turning parts 3b on both sides is smaller than the length of the connecting wall 2b.
- a plurality of installation grooves 3 are formed on the base plate 1 with the distance between the two side walls gradually decreasing from the inside to the outside;
- the distance between the two parts of the pressure rollers in the third pressure roller assembly By adjusting the distance between the two parts of the pressure rollers in the third pressure roller assembly, the distance between the two parts of the pressure rollers becomes smaller, and from the outside to the inside, adjust the distance between the two parts of the pressure rollers in step S5 on the other side of the installation groove 3 on both sides.
- the substrate 1 is subjected to extrusion and bending processing to bend the two parts of the substrate 1 from here to the side of the mounting groove 3 to form a turning and bending portion 4a located on both sides of the substrate 1 symmetrically;
- Steps S5-S6 are repeated to form several sets of symmetrical cross rotation angles 4b on both sides of the substrate 1 symmetrically until all the installation slot units 4 are formed, and at the same time, both sides of the main body of the substrate 1 are bent in the same direction Surrounding the preliminary forming rod forming the inner hollow, the two ends located at the outermost side of the base plate 1 abut against each other or form a gap;
- Embodiment 4 Based on the cold-bending process method of the special-shaped rod with mounting groove 3 described in Embodiment 1, it is further preferred that the material of the substrate 1 is Q235, Q355 or Q460, which has the advantages of low cost, high strength, ductility and bending. The advantage of good folding performance.
- the abutment or gap formed by the two ends of the steel plate is welded by high-frequency welding, which has a small heat-affected zone of the welding seam and a fast heating speed, which can greatly improve the welding speed and welding speed.
- the quality of the seam, and the strip steel without pickling, shot peening and trimming can be used as the blank, and the alloy steel, high alloy steel and non-ferrous metal pipes can be welded at the same time, which greatly reduces the unit power consumption.
- a set of welding equipment can be used to produce various Metal profiled rods in various sizes.
- the shaping operation is performed on the welded and formed special-shaped rod.
- a device with a mold hole suitable for the cross-sectional shape of the required special-shaped rod can be used to perform the final finishing process on the special-shaped rod, so that the final obtained special-shaped rod with mounting grooves is obtained.
- the size and shape of the rod and the positional relationship between the installation grooves 3 are more precise, which facilitates more precise positioning and installation with other components.
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Abstract
一种带安装槽（3）的异形杆的冷弯成型方法，包含以下步骤：S1、形成基槽（2）；S2、形成安装槽（3）；S3、形成转向弯折部（4a）；S4、在基板（1）上重复步骤S1-S3，直至基板（1）上的安装槽单元（4）全部成型，基板（1）的两端部互相靠近抵靠贴合或形成间隙；S5、最后通过焊接的方式将基板（1）的两端部连接为一体，形成带安装槽（3）的异形杆。
Description
本发明涉及钢管冷弯成型领域，具体为一种安装槽的冷弯成型方法和包含有该安装槽异形杆的冷弯成型方法。
冷弯成型是通过顺序配置的多道次成型轧辊，将金属板带材不断地进行横向弯曲，以制成特定断面型材的工艺技术。冷弯成型是一种节材、节能、高效、先进和适用的金属成型工艺，是板带材深度加工的一个重要领域，辊式冷弯成型具有生产效率高，产品质量好，对材料的性能影响小，易于实现生产自动化，适合大规模化生产作业，适合制作冷弯型钢的材质品种繁多，原料来源丰富。冷弯成型设备可生产出一般热轧难以生产的复杂断面、品种多样的冷弯型材，从而在金属消耗最少的情况下，获得最大的刚性和强度；在大规模生产中，成型辊的费用比冲模少，而使用寿命却比冲模长得多。其中辊弯成型工艺又是冷弯型钢的主要加工方法，它是通过一组纵向排列的轧辊，将平整的原板逐渐变形，使之达到适合使用要求的形状；而且冷弯成型的产品表面光洁，外观好，尺寸精确，长度也可以根据需要灵活调整，全部按定尺或倍尺供应，提高材料的利用率；生产中还可与冲孔等工序相配合，以满足不同的需要。
在申请公布号为CN110871219A的发明专利申请文件中公开的一种高强形钢方矩形管的冷弯成型工艺，用以将高强钢板带加工成高强型钢方矩形管，根据方矩形管的边长尺寸，沿高强钢板带宽度方向，将高强钢板带划分为左上边段、左边段、下边段、右边段和右上边段，依次进行如下步骤：将左上边段和右上边段弯折到规定角度；将左边段和右边段弯折到规定角度；同时弯折左上边段、左边段、下边段、右边段和右上边段至规定角度；对左上边段和右上边段进行焊接，并同时弯折左上边段和右上边段保证左上边段和右上边段为对准状态；对半成型高强型钢方矩形管进行整形。
安装槽作为一种机械制造领域和工业建筑领域常见的安装配合结构，具有良好的导向和配合锁紧等作用，同时由于安装槽自身形状中带有三角形结构的特性，使得设置有安装槽的杆件其支撑能力、抗弯折能力能够得到有效加强，被广泛应用于各类产品中。
如授权公告号为CN201963652U中国实用新型专利文件中公开的一种安装槽立柱的连接结构，包括安装槽立柱、连接板，所述安装槽立柱的侧面设有安装槽，所述连接板一端设有榫头，所述榫头与所述安装槽相匹配。本实用新型由于采用了上述技术方案，通过连接板上的榫头与安装槽立柱的安装槽的配合可将多块连接板连接，安装简便。
本发明的目的是在于提供一种在基板通过冷弯成型工艺快速高效形成燕尾形状安装槽的方法，同时还提供了一种带有该安装槽异形杆的冷弯成型方法。
本发明提供了一种安装槽以及带有该安装槽异形杆的冷弯成型方法，能够有效避免冷弯过程中钢板发生断裂，精确定位各个安装槽并且提高加工成型效率和精度。
本发明的上述技术目的是通过以下技术方案得以实现的：
一种带安装槽异形杆的冷弯成型方法，其特征在于：所述带安装槽异形杆的冷弯成型方法包含以下步骤：
S1、形成基槽：在基板上通过第一压辊组件处理形成向基板一侧凸起的基槽，所述基槽包含有与基板相平行的连接壁和分别连接所述连接壁两端与两侧基板的安装壁，所述连接壁与安装壁之间形成有第一折角部，所述安装壁与基板之间形成有第二折角部；
S2、形成安装槽：通过第二压辊组件对与基槽上同一安装壁相连的第一折角部和第二折角部进行挤压弯折处理，所述第二压辊组件包含有相对所述安装壁互相交错设置的内辊和外辊，弯折处理时，使所述内辊设在第一折角部由内向外施压形成内回转部，所述外辊设在第二折角部由内向外施压形成外回转部，从而将基槽制成安装槽。
作为对本发明的优选，所述带安装槽异形杆的冷弯成型方法还包括以下步骤：S3、形成转向弯折部：将与安装槽上连接板两端相连接的基板主体利用第三压辊组件进行挤压弯折处理形成回转交叉角，在回转交叉角与外回转角之间形成转向弯折部；位于一个安装槽两侧的转向弯折部、交叉回转角、连接于交叉回转角上的部分基板与该安装槽共同形成异形杆上的安装槽单元。
作为对本发明的优选，所述带安装槽异形杆的冷弯成型方法还包括以下步骤：S4、在所述基板上重复所述步骤S1-S3，直至基板上的安装槽单元全部成型，基板的两端部互相靠近抵靠贴合或形成间隙。
作为对本发明的优选，在所述基板的两端部抵靠贴合或形成间隙处通过焊接的方式将两端部连接为一体，形成带安装槽异形杆。
作为对本发明的优选，取最终所需成型的异形杆中所包含的安装槽的数量为整数N，基板的宽度为D，则所述每个安装槽单元中所包含处理的基板宽度为D/N；在步骤S1前增加步骤S1a，所述步骤S1a如下：
S1a、划分加工段：将基板标记分为N段宽度为D/N的加工段，在基板上选取一处加工段，在所述加工段的中心处通过第一压辊组件的处理定位成型基槽；所述交叉回转角的大小为180°/N。
作为对本发明的优选，所述步骤S2中的第二压辊组件中包含有互相对称的两对内外压辊，先通过位于第二压辊组件一侧的一对内辊外辊对位于基槽一侧的第一折角部和第二折角部进行挤压弯折处理，在基槽的一侧形成内回转部和外回转部；再通过位于所述第二压辊组件另一侧的另一对内辊外辊对位于基槽另一侧的第一折角部和第二折角部进行挤压弯折处理，在该基槽的另一侧形成内回转部和外回转部。
作为对本发明的优选，所述第一压辊组件包含有若干压辊，各个压辊之间的间距可变，对基板由中心向两侧进行对称的挤压弯折处理，在基板上同时形成相对于基板中心线左右对称的若干安装槽。
作为对本发明的优选，所述第三压辊组件中包含左右对称的一对压辊并且两部分压辊之间的间距可变，通过第三压辊组件对基板由外侧向基板中心挤压弯折处理形成各个与安装槽相连接的交叉回转角，同时形成安装槽单元。
作为对本发明的优选，所述第一压辊组件、第二压辊组件和第三压辊组件均设置为多道次，逐步进行挤压弯折处理形成所述安装槽单元。
作为对本发明的优选，在所述冷弯成型方法的最后增加设置对异形杆的整形变形的步骤。
综上所述，本发明能够实现以下多项有益效果：
1.
所述安装槽冷弯成型工艺方法中，利用压辊挤压弯折加工基板制造安装槽的方法，相较于冷拔成型工艺，其所需原材料不需要为一种初步成型的管体，大大减少了原材料在运输储存过程中所占用的空间，提高了运输存储效率，降低该过程中的支出成本；相较于普通弯折工艺，不需要对钢板进行加热处理并且能够有效防止钢板在弯折角位置发生断裂损坏。
2.
所述安装槽冷弯成型工艺方法中，首先利用压辊在基板上成型出作为安装槽制造基础的基槽，便于在形成基槽以后对其位置和形状尺寸进行初步定位和测量，降低在后续成型过程中所产生的累积误差。
3.
所述安装槽冷弯成型工艺方法中，直接通过一种截面形状为圆弧形的凸辊作为第二压辊组件对所述基槽进行弯折加工处理，同时第二压辊组件中的压辊相对于基槽一侧的两个弯折角交错设置，在一次成型过程中使得基槽的弯折角呈圆弧形，减少了加工步骤节约了成本，同时在弯折过程中有效减少了钢板内部所形成产生的的应力，使得弯折成型出的异形杆件形状更为精确。
4.
所述的一种带安装槽异形杆冷弯成型工艺方法中对基板上的基槽及安装槽单元采用逐个冷弯的方式进行成型，能够精确保证成型出的每一个安装槽单元的形状尺寸以及两个安装槽之间的间距大小。
5.
所述的一种带安装槽异形杆冷弯成型工艺方法中，在制造成型作为安装槽制造基础的基槽时，采用由基板的中心部向两侧加工成型出相对于基板的中心轴向左右对称的基槽，使得成型出的基槽之间的位置更为精确，同时也保证了加工时基板受力的平衡，避免了基板自身发生倾斜或是偏移导致成型出形状尺寸不合格的基槽。
6.
所述的一种带安装槽异形杆冷弯成型工艺方法中采取了由基板的两端向中心进行挤压弯折处理在基板上对称形成转向弯折部，保证了加工时基板受力的平衡，避免了基板自身发生倾斜或是偏移导致成型出形状尺寸不合格的转向回转部；同时该形成转向弯折部的方法使得每一次作为加工基础的基板部均位于同一平面上，大大降低了加工成型的难度。
7.
对冷弯处理过程结束后的异形杆通过修整设备进行处理，通过将异形杆穿过带有精确截面形状的模具中的整形孔，对异形杆进一步进行定位修整，减少挤压弯折过程中带入的形状误差，提升产品的标准化程度。
图1为带安装槽异形杆截面示意图；
图2为在基槽各部分结构示意图；
图3为在基槽在第二压辊组件作用下受力示意图；
图4为在安装槽各部分结构示意图；
图5为在安装槽单元跟部分结构示意图；
图6为整形模具孔截面结构示意图；
图7为各主要部分成型顺序示意图；
图8为实施例3所对应的带安装槽异形杆冷弯成型工艺方法流程示意图。
图中：
1——基板；
2——基槽，2a——安装壁，2b——连接壁，2c——第一折角部，2d——第二折角部；
3——安装槽，3a——内回转部，3b——外回转部；
4——安装槽单元，4a——专项弯折部，4b——交叉回转角。
以下具体实施例仅仅是对本发明的解释，其并不是对本发明的限制，本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改，但只要在本发明的权利要求范围内都受到专利法的保护。
须知，本说明书附图所绘的结构、比例、大小等，均仅用以配合说明书所揭示的内容，以供熟悉此技术的人士了解与阅读，并非用以限定本发明可实施的限定条件，故不具技术上的实质意义，任何结构的修饰、比例关系的改变或大小的调整，在不影响本发明所能产生的功效及所能达成的目的下，均应仍落在本发明所揭示的技术内容能涵盖的范围内。同时，本说明书中所引用的如“上”、“下”、“左”、“右”、“中间”等的用语，亦仅为便于叙述明了，而非用以限定本发明可实施的范围，其相对关系的改变或调整，在无实质变更技术内容下，当亦视为本发明可实施的范畴。
本方案是通过以下技术手段实现的：
实施例1：一种带安装槽3异形杆的冷弯成型工艺方法，包含以下步骤：
S1a、选取一块长度为L，宽度为D的钢制原料基板1，用于加工成型高度为L的带安装槽3异形杆。当最终所需成型的异形杆中所包含的安装槽3的数量为整数N时，则所述每个安装槽单元4中所包含处理的基板1宽度为D/N，故将基板1标记分为N段宽度为D/N的加工段，在基板1上选取一处加工段，在所述加工段的中心处通过第一压辊组件的处理定位成型基槽2。
S1、在基板1上所选取的加工段的中部通过多道次布置的第一压辊组件逐步挤压弯折处理形成向基板1一侧凸起的基槽2，所述基槽2包含有与基板1相平行的连接壁2b和分别连接所述连接壁2b两端与两侧基板1的安装壁2a，所述连接壁2b与安装壁2a之间形成有第一折角部2c，所述安装壁2a与基板1之间形成有第二折角部2d；具体的，将所述第一折角部2c和第二折角部2d均弯折加工成90°。
S2、通过第二压辊组件对与基槽2上同一安装壁2a相连的第一折角部2c和第二折角部2d进行挤压弯折处理。所述第二压辊组件包含有相对所述安装壁2a互相交错设置的内辊和外辊，所述内辊和外辊回转轴线互相平行且不再同一直线上，弯折处理时，使所述内辊设在第一折角部2c由内向外施压形成内回转部3a，所述外辊设在第二折角部2d由内向外施压形成外回转部3b，所述内辊对第一折角部2c施加的作用力与外辊对第二折角部2d施加的作用力方向相反互相平行且不再同一直线上。对基槽2的两侧均通过第二压辊组件进行处理从而将基槽2制成安装槽3，其中内回转部3a和外回转部3b两侧壁面之间的夹角呈锐角，使得所述安装槽3呈一种宽度由内向外间距逐渐变小的形状。所述第二压辊组件中的内辊和外辊表面呈圆弧形，使得成型出的内回转部3a和外回转部3b中的弯折角均为一种圆角，有效减小了基板1内部的应力大小，防止成型过程中基板1弯折处发生断裂。
S3、形成转向弯折部4a：将与安装槽3上连接板两端相连接的基板1主体利用多道次设置的第三压辊组件进行挤压弯折处理逐步形成回转交叉角，所述交叉回转角4b的大小为180°/N，在回转交叉角与外回转角之间形成转向弯折部4a；位于一个安装槽3两侧的转向弯折部4a、交叉回转角4b、连接于交叉回转角4b上的部分基板1与该安装槽3共同形成异形杆上的安装槽单元4。
S4、重复步骤S1-S3，在基板1上成型完成全部的安装槽单元4，同时在各个交叉回转角4b的作用下，基板1两侧端部互相靠近直至贴合抵靠或是形成极小的间隙。
S5、通过焊接的方式将基板1两侧端部固定连接为一体，成型出带有安装槽3的异形杆。
S6、将所成型出的异形杆的形状进一步修整加工，获得形状更规则且强度更高的异形杆。
实施例2：一种带安装槽3异形杆的冷弯成型工艺方法，其特征在于：所述冷弯成型工艺方法包含以下步骤：
S1、在基板1上通过第一压辊组件处理形成向一侧凸起的基槽2，所述基槽2包含有与基板1相平行的连接壁2b和相对于基板1向一侧凸起的并且左右对称的安装壁2a两部分，所述连接壁2b与安装壁2a之间形成有第一折角部2c，所述安装壁2a与基板1之间形成有第二折角部2d，所述第一折角部2c以及第二折角部2d中的两边之间的夹角均不小于90°；
S2、通过一组包含有互相交错设置内辊和外辊的第二压辊组件对位于基槽2一侧第一折角部2c和第二折角部2d进行挤压弯折处理，使所述内辊贴合处理第一折角部2c形成内回转部3a，所述外辊贴合处理第二折角部2d形成外回转部3b，所述内回转部3a以及外回转部3b中两边之间的夹角均小于90°；
S3、通过与所述第二压辊组件镜像对称设置的另一组第二压辊组件对位于所述基槽2另一侧的第一折角部2c和第二折角部2d进行挤压弯折处理，使基槽2在对侧形成与该侧对称的内回转部3a以及外回转部3b，使得位于两侧的外回转部3b之间距离小于连接壁2b的长度，形成一种两侧壁面之间距离由内向外逐渐变小的安装槽3；
S4、重复步骤S1-S3，在所述基板1上形成若干安装槽3；
S5、在位于基板1上的靠外两侧部通过包含有对称压辊的第三压辊组件进行挤压弯折处理使基板1靠外两侧部同时向安装槽3一侧发生弯折形成位于基板1两侧相对称的转向弯折部4a；
S6、通过调节第三压辊组件中两部分压辊之间的间距使两部分压辊之间的间距变小，由外侧向内对步骤S5中所述位于两侧安装槽3另一侧的基板1通过挤压弯折处理使两部分基板1从此处向安装槽3一侧发生弯折形成位于基板1两侧相对称的转向弯折部4a；
S7、重复步骤S5-S6，在基板1的两侧两两对称形成若干组对称的交叉回转角4b，直至全部安装槽单元4成型，同时所述基板1主体的两侧向同一方向发生弯折包围形成内部中空的初步成型杆，位于基板1最外侧的两端部互相抵靠贴合或形成缝隙；
S8、对基板1的两端部通过焊接的方式连接成一体。
实施例3：一种带安装槽3异形杆的冷弯成型工艺方法，其特征在于：所述冷弯成型工艺方法包含以下步骤：
S1、在基板1上通过第一压辊组件处理同时形成向一侧凸起并且相对于基板1中心线的左右对称分布的若干个基槽2，所述基槽2均包含有与基板1相平行的连接壁2b和相对于基板1向一侧凸起的并且左右对称的安装壁2a两部分，所述连接壁2b与安装壁2a之间形成有第一折角部2c，所述安装壁2a与基板1之间形成有第二折角部2d，所述第一折角部2c以及第二折角部2d中的两边之间的夹角均不小于90°；
S2、通过一组包含有多对互相交错设置内辊和外辊的第二压辊组件对位于若干个基槽2同一侧的第一折角部2c和第二折角部2d同时进行挤压弯折处理，使所述内辊贴合处理第一折角部2c形成内回转部3a，所述外辊贴合处理第二折角部2d形成外回转部3b，所述内回转部3a以及外回转部3b中两边之间的夹角均小于90°；
S3、通过与所述第二压辊组件镜像对称的另一组第二压辊组件对步骤S2中所述若干基槽2另一侧的第一折角部2c和第二折角部2d同时进行挤压弯折处理，使所述若干个基槽2在对侧对称形成的内回转部3a以及外回转部3b，使得位于两侧的外回转部3b之间距离小于连接壁2b的长度，在所述基板1上形成两侧壁面之间距离由内向外逐渐变小的若干个安装槽3；
S4、调节所述第一压辊组件中对称压辊之间的间距以及相对称的两组第二压辊组件之间的间距并且重复步骤S1-S3，在所述基板1上由中心向两侧逐步对称形成若干安装槽3，直至基板1上的全部安装槽3成型；
S5、在位于基板1上的靠外两侧部通过包含有对称压辊的第三压辊组件进行挤压弯折处理使基板1靠外两侧部同时向安装槽3一侧发生弯折形成位于基板1两侧相对称的转向弯折部4a；
S6、通过调节第三压辊组件中两部分压辊之间的间距使两部分压辊之间的间距变小，由外侧向内对步骤S5中所述位于两侧安装槽3另一侧的基板1通过挤压弯折处理使两部分基板1从此处向安装槽3一侧发生弯折形成位于基板1两侧相对称的转向弯折部4a；
S7、重复步骤S5-S6，在基板1的两侧两两对称形成若干组对称的交叉回转角4b，直至全部安装槽单元4成型，同时所述基板1主体的两侧向同一方向发生弯折包围形成内部中空的初步成型杆，位于基板1最外侧的两端部互相抵靠贴合或形成缝隙；
S8、对基板1的两端部通过焊接的方式连接成一体。
实施例4：在实施例1中所述的带安装槽3异形杆冷弯成型工艺方法的基础上进一步优选，所述基板1材料采用Q235、Q355或Q460，具有成本低，强度高，延展弯折性能好的优点。在异形杆最终成型阶段，对钢板两端部所形成的的抵靠处或间隙采用高频焊接的方式进行焊接，具有焊缝热影响区小，加热速度快，因而能大大提高焊接速度和焊缝质量，而且可用未经酸洗、喷丸和切边的带钢作坯料，同时可焊接合金钢、高合金钢和有色金属管材，大大降低单位耗电量，同时采用一套焊接设备可生产各种尺寸规格的金属异形杆。
进一步优选，对焊接成型的异形杆进行整形操作，具体可利用一种带与有所需异形杆截面形状相适应的模具孔的设备对异形杆进行最终修整处理，使得最终获得的带安装槽异形杆的尺寸造型以及安装槽3之间的位置关系更为精准，便于与其它零部件进行更为精确的定位安装。
以上所述，仅为本发明的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到各种等效的修改或替换，这些修改或替换都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应以权利要求的保护范围为准。
Claims (10)
- 一种带安装槽异形杆的冷弯成型方法，其特征在于：所述带安装槽异形杆的冷弯成型方法包含以下步骤：S1、形成基槽：在基板上通过第一压辊组件处理形成向基板一侧凸起的基槽，所述基槽包含有与基板相平行的连接壁和分别连接所述连接壁两端与两侧基板的安装壁，所述连接壁与安装壁之间形成有第一折角部，所述安装壁与基板之间形成有第二折角部；S2、形成安装槽：通过第二压辊组件对与基槽上同一安装壁相连的第一折角部和第二折角部进行挤压弯折处理，所述第二压辊组件包含有相对所述安装壁互相交错设置的内辊和外辊，弯折处理时，使所述内辊设在第一折角部由内向外施压形成内回转部，所述外辊设在第二折角部由内向外施压形成外回转部，从而将基槽制成安装槽。
- 根据权利要求1所述的带安装槽异形杆的冷弯成型方法，其特征在于：还包括以下步骤：S3、形成转向弯折部：将与安装槽上连接板两端相连接的基板主体利用第三压辊组件进行挤压弯折处理形成回转交叉角，在回转交叉角与外回转部之间形成转向弯折部；位于一个安装槽两侧的转向弯折部、交叉回转角、连接于交叉回转角上的部分基板与该安装槽共同形成异形杆上的安装槽单元。
- 根据权利要求2所述的带安装槽异形杆的冷弯成型方法，其特征在于：还包括以下步骤：S4、在所述基板上重复所述步骤S1-S3，直至基板上的安装槽单元全部成型，基板的两端部互相靠近抵靠贴合或形成间隙。
- 根据权利要求3所述的带安装槽异形杆的冷弯成型方法，其特征在于：在所述基板的两端部抵靠贴合或形成间隙处通过焊接的方式将两端部连接为一体，形成带安装槽异形杆。
- 根据权利要求2所述的带安装槽异形杆的冷弯成型方法，其特征在于：取最终所需成型的异形杆中所包含的安装槽的数量为整数N，基板的宽度为D，则所述每个安装槽单元中所包含处理的基板宽度为D/N；在步骤S1前增加步骤S1a，所述步骤S1a如下：S1a、划分加工段：将基板标记分为N段宽度为D/N的加工段，在基板上选取一处加工段，在所述加工段的中心处通过第一压辊组件的处理定位成型基槽；所述交叉回转角的大小为180°/N。
- 根据权利要求1所述的带安装槽异形杆的冷弯成型方法，其特征在于：所述步骤S2中的第二压辊组件中包含有互相对称的两对内外压辊，先通过位于第二压辊组件一侧的一对内辊外辊对位于基槽一侧的第一折角部和第二折角部进行挤压弯折处理，在基槽的一侧形成内回转部和外回转部；再通过位于所述第二压辊组件另一侧的另一对内辊外辊对位于基槽另一侧的第一折角部和第二折角部进行挤压弯折处理，在该基槽的另一侧形成内回转部和外回转部。
- 根据权利要求1所述的带安装槽异形杆的冷弯成型方法，其特征在于：所述第一压辊组件包含有若干压辊，各个压辊之间的间距可变，对基板由中心向两侧进行对称的挤压弯折处理，在基板上同时形成相对于基板中心线左右对称的若干安装槽。
- 根据权利要求6所述的带安装槽异形杆的冷弯成型方法，其特征在于：所述第三压辊组件中包含左右对称的一对压辊并且两部分压辊之间的间距可变，通过第三压辊组件对基板由外侧向基板中心挤压弯折处理形成各个与安装槽相连接的交叉回转角，同时形成安装槽单元。
- 根据权利要求1所述的带安装槽异形杆的冷弯成型方法，其特征在于：所述第一压辊组件、第二压辊组件和第三压辊组件均设置为多道次，逐步进行挤压弯折处理形成所述安装槽单元。
- 根据权利要求1所述的带安装槽异形杆的冷弯成型方法，其特征在于：在所述冷弯成型方法的最后增加设置对异形杆的整形变形的步骤。
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