A method of manufacturing raznoformnyh sheet items

 

The invention relates to the processing of metals by pressure and can be used, for example, in the manufacture of panels, hatches and other sheet parts with thickened edges, taking into account their reduced strength in the heat-affected zone during welding with the neighboring parts. A method of manufacturing raznoformnyh sheet products includes the creation of shear deformation in the direction of the force action on the workpiece flat strikers in the flat sheet blank of constant thickness, while they conduct pre-stamping a flat sheet metal blank into a hollow semi-finished product with a punch in the shape of a truncated cone. The resulting intermediate product is placed in the package between the two forming elements, which are made ravnovesnymi in the axial direction from an outer diameter of Daboutand with vnutriplitnyi work surfaces in contact with the corresponding surfaces of the semi-finished product. The opposite surface of the latter for all products in terms of perform in the form of truncated cones. Total height in the axial direction of the packet received from the formative elements and prefabricated take constant and equal to (0,2-0,3)th material is thinner in thickness in the part of the product with the formation of the transitional zones of thickening. The technical result of the invention is to eliminate said drawbacks nearest analogue in the manufacture of raznoformnyh sheets and billets, increase the utilization of metal, as well as reducing the complexity of the machining in the manufacture of products. 5 Il.

The invention relates to the processing of metals by pressure and can be used, for example, in the manufacture of panels, hatches and other sheet parts with thickened edges, taking into account their reduced strength in the heat-affected zone during welding with the neighboring parts.

Known technical solution for manufacturing raznoformnyh sheet items due to the formation of bulges on the edges of the sheets by precipitation of a metal, for example, a work roll in a closed cavity between the flat base and the clamp strap using a hydraulic clamping device made in the form of a system of rollers located on both sides of the sheet opposite the working roller [1]. The disadvantage of this technical solution is the complexity of the equipment for the precipitation of metal with the presence of independent drives the workpiece clamp, precipitation of metal and neobhodimosti invention to the technical essence and the achieved effect is a method of manufacturing raznoformnyh sheet items, when creating a shear deformation in the workpiece in the direction of the force action on the workpiece produces a thickness in the sheet, the variance of 2.0 or more times [2].However, the observed thickness receive, first, in the hollow sheet product, and not in a flat sheet blank and, secondly, this thickness are due to thinning of the source material and not due to its thickening, which significantly limits the ability of the method on the prototype.

Technical result achieved with the use of the invention is to eliminate said drawbacks of the prototype when making raznoformnyh sheets and blanks, increase the utilization of metal, and reducing the complexity of the machining in the manufacture of products.

The achievement of the technical result from the use of the developed invention is provided that a method of manufacturing raznoformnyh sheet products includes the creation of shear deformation in the direction of the force action flat strikers in the flat sheet blank of constant thickness, is placed in the package between two deformable formative elements and settling in the container between the flat is artelino stamping a flat sheet metal blank into a hollow semi-finished product with a punch in the shape of a truncated cone, generatrix of which incline at an angleto its axis according to:= arcsin(So/Sy), and the small base of the truncated cone diameter d have over a large base diameter D height HPFinstalled by the formula: HPF= [(By+2Bp)cos-So(1-sin))]/sinin the package between the two formative elements put the resulting intermediate product, forming elements are ravnovesnymi in the axial direction from an outer diameter of Daboutand with vnutriplitnyi work surfaces in contact with the corresponding surfaces of the semi-finished product, and the opposite surface of the latter in terms of perform in the form of truncated cones with diameters of the bases D and D and a height between HPFand the total height Hin the axial direction of the packet received from the formative elements and prefabricated take constant and equal to: H= (0,2-0,3)Do, pono Sothe semi-finished product thickness in the part of Syproducts with the formation of the transitional zones of thickening from Soto Sylinearly on plots of widthpaccording to the formula: Bp= Rncosand Sy= So/sinwhere So- the original thickness of the material; Sythe thickness of the product;
Inp- the width of the transition zone thickness;
By- the width of the thickened part of the product;
H- total thickness of the shaping elements with the material;
HPF- the height of the punch in the material;
Daboutthe diameter of the container tube Boykov, semi-finished and formative elements;
D - diameter of the large base of the truncated cone;
d - diameter of the small base of the truncated cone;
the angle of inclination of the wall of the semi-finished product to the axis of the device;
Rn- the outer radius of the bend murine part of the semi-finished product.

The invention is illustrated by drawings, which show:
in Fig. 1 is a longitudinal section of a device for thickening the edges of the sheets in the initial position;
in Fig.2 - the same in position before stamping;
in Fig.3 - ormaiztegi elements of the device;
in Fig.5 - calculation scheme for determining parameters thickening of leaves.

According Fig. 1-5, the method of manufacturing raznoformnyh products is carried out as follows. First stamp the sheet in the usual stamps or multi-forming machine in equal thickness was cake mix 1 (see Fig. 1) in a bowl diameter To a thickness of the flange, bottom and murine parts are the same and equal to the original thickness of the blank Sabout.

After that, the semi-finished product 1 is collected with a pre-made (forged or cast) formative elements 2 and 3 in the package diameter Daboutand total thickness Hand place it on the lower die 4, is attached to the press table 5. When working stroke of the press first goes down outside the press slide 6 c of the container 7, and then the inner slide of the press (conventionally not shown) with the upper brisk 8 to contact with the upper homeoprotein element 2 (see Fig.2). Further lowering of the press slide with the upper brisk 8 leads to plastic deformation of the shaping elements 2 and 3 with the semi-finished product 1 and in the lowest position of the upper firing pin 8 they adopt the view according to Fig.3, resulting in fortuantely part 12 and bottom part 13 of the semi-finished product 1 (being in a pressed state between the planar sections forming elements 9 and 10) is practically not deformed. Murine part 14 of the semi-finished product 1 with its lower flange part 12 relative to the bottom part 13 is plastically deformed in the thickness in the portion 15 of the articles 11 due to shear deformation in the direction of force plastically deformed package of formative elements 2 and 3 with the semi-finished product 1 (see Fig.3). After the making of the product 11 external press slide 6 with the container 7 report the move to the extreme upper position and then raise up flat head 8. Remaining on the plate 4 deformirovanie forming elements 9 and 10 together with a stamped product 11 is removed from the working area of the press: the first to expose them to new formative elements 2 and 3, and article 11 for subsequent machining, the metal for forming elements can serve fusible plastically deformable metals, for example, an alloy of wood (TPL=60oC), the alloy Lord Guti (TPL=45oC), the alloy Lipovica (TPL= 70oC) and others[3]. For the proposed method of manufacturing raznoformnyh products the use of low-melting metals with zinc additives in [4] has a number of technological advantages.

First, it is cheaper than other alloys, because it contains less is below 100 VAoWith and therefore the melting of the working environment of the stamped package with the product and to make new formative items, you can use boiling water.

Thirdly, the content of low-melting metal [4] zinc in 1.0, 2.0 and 3.0% provides hardness of Brinell respectively 13.9, 15.1 and 17,0 HB [4] that allows the use of this alloy for stamping raznoformnyh products with a wide range of mechanical properties of sheet blanks.

Thus for the implementation of the developed method does not require hard copies of the forms of products and therefore performance of equal thickness was prefabricated in razdolina product is carried out using a shear deformation, the direction and magnitude of which set covering the prefabricated forming elements 2 and 3.

When the diameter of the container 7, the upper and lower forging dies 8 and 4, as well as semi-finished product 1 with forming elements 2 and 3, is equal to Daboutthe total height Hformative elements 2 and 3, together with the thickness of the flange of the semi-finished product 1 should be taken within the
H= (0,20,3)Do, (1)
so Kochetkov forming elements 2, 3 with the semi-finished product 1 and, as a consequence, unmanaged thickening products, and when H>0,3Dois inappropriate increase efforts deformation of the considered packet.

Settlement scheme in Fig.5 allows you to set the appropriate parameters of the method of manufacturing raznoformnyh products from the material of constant thickness (Sabout= onst).

Due to the fact that murine portion 14 of the semi-finished product 1 with the original thickness Saboutinclined to the axis of the device (or, equivalently, to the direction of force on the semi-finished product 1) anglethe wall thickness Sysemi-finished product in this direction (see segment "dg") will be:
Sy= dg = So/sin(2).

The value of intermediate thickness Saccording Fig.5 is written as
,
where, as expected, when b = 0 have a thickness in the bottom part of the product
S= So(1+0/tg= So(4)
and when= 90-(i.e. at the beginning of the third method for solving equation (3) for angles of inclination of the wall of the semi-finished product 1 to the axis of the device=30o, 45o, 60oshows that the transition thickness Saboutto Syand thickness Syto Sabout(see plot S= f(for=30o, 45oand 60oin Fig.5) at the outer radius murine part of the semi-finished product 1 with its bottom and flange parts Rn= Sabout(and also when the inner radius RNR= 0) occurs gradually and almost linearly on plots of width
Bp= Sosin= Sosin(90-) = Socos(6)
To establish the geometric parameters of the semi-finished product 1 and formative elements 2 and 3, it is necessary to determine the height of the punch HPFin the material 1, which according to Fig.5 can be represented by a dependency:
HPF= OA-OB = (By+2Bp)/tg-(Oo-So)
or, keeping in mind that tg= sin/cos,Oo= oBp)cos-So(1-sin)]/sin(7)
The data presented allow to set the geometric parameters as the original sheet and semi-finished product 1 and formative elements 2 and 3 to obtain raznoformnyh products round, square etc. form in plan.

Consider the example of a proposed manufacturing method of service outlet round shape in plan when the outer and inner diameters his thickening of the Dn=200 mm and DNR= 180 mm (width thickening Iny=(Dn-DNR)/2=(200-180)/2=10 mm) and the width of the flange InFL= 5 mm of the aluminum alloy sheet Amg6m (in= 34 kgf/mm2) thickness Sabout=2 mm when it is thickening up to Sy=4 mm (see Fig.1, 2 and 5) using formative elements 2 and 3 of fusible metal [4] zinc additive in 1% (C. F. e= 7 kgf/mm2).
The semi-finished product 1 and massing 2 and 3 in the form of truncated cones according to Fig.1,2 and 5 must have a wall angleto the axis of the product, the value of which is determined by the formula (2):
sin.
Thus the width of the transition zone Inpset (when Rn= Sabout=2 mm) according to the formula (6):

Thus the width of the zone of thickening of the product 11 is defined by the outer and inner diameters D= Dn+2Inp= 200+21,73= 203,46 mm and d=DNR-2Inp=180-21,73= 176,54 mm (or), and the outer diameter of the semi-finished product 1 (and hence of the container 7) is
Dabout=D+2Inf=203,46+25=213,46 mm

The height of the punch in the material 1 according to the formula (7) is:

The geometric parameters of the product 11 is almost completely determine the appropriate parameters of the semi-finished product 1 except that the parallel lines defining the thickening of Syin the sheet thickness Saboutdirect parallel to each other, but at an angleto the axis of symmetry of the product of the points 0'and 0", followed by pairing them with the appropriate lines in the bottom and the flange parts of the semifinished product 11 of radius Rn=Saboutfrom points 0' and 0".

Yu surface of the upper shaping element 2, moreover, the outer surface of the latter must be in the form of a truncated cone at its outer diameter equal to Daboutsmall and large grounds (diameters which are respectively will be D and D) must defend from each other in height at a distance of HPFand the corresponding parameters of the inner surface of the shaping element 2 is determined by the parameters of the outer surface of the semifinished product 1 in contact with the molding element 2.

Similarly determines the geometry of the lower shaping element 3 through the corresponding data of the working surfaces of the semi-finished product 1.

To obtain a semi-finished product 1 in the form of a truncated cone ([5], S. 90, formula number 14) define the workpiece diameter Dinthat stamp lead in a metal matrix (according to [5], S. 314, Fig.276), and then of the fusible metal [4] is made of molding elements 2 and 3, gather them with cake mix 1 package, which is placed on the lower die 4, and when working stroke of the press rebuff top striker 8 in the container 7. The product 11 is sent on subsequent machining and molding elements 9 and 10 to be melted into new items 2 and 3.

Press power, sing container in terms of Fto=/4D2oand tensile strength of the material formingC. F. e= 7 kgf/mm2i.e.

PCR=FtoAboutC. F. E.= 0,785213,57=317688 kgf=317,7 THC
Thus for the given data set as the geometric parameters of the blank for forming the intermediate product, the intermediate product, forming elements and die tooling to implement the proposed method of manufacturing raznoformnyh products and power equipment parameters for its implementation.

Similarly, are considered way and nonaxisymmetric products of various shapes in the plan.

Sources of information
1. Auth. St. USSR 168863, the IPC 21 D, B 23, publ. 22.11.1963.The stamp for the formation of bulges on the edges of leaves. Sizov E. C., and others

2. AV. St. USSR 1061889, B 21 D 22/20, B 47, publ. 23.12.83. Method of forming hollow parts from flat sheet stock. Sizov E. C.

3. H. M. Munasipov. Research and development of low-melting alloys and non-metallic compositions for fastening pieces of the blades when they are machined. Pelagonisko, O. A. Moscow, Y. M. Leontiev).

5. B. N. Romanovsky. Handbook of cold stamping. - Leningrad: Mashinostroenie, 1973.


Claims

A method of manufacturing raznoformnyh sheet items, including the creation of shear deformation in the direction of the force action flat strikers in the flat sheet blank of constant thickness, is placed in the package between two deformable formative elements and settling in the container between the planar strikers with a concomitant change of the initial thickness to the desired thickness of the product, characterized in that conduct pre-stamping a flat sheet metal blank into a hollow semi-finished product with a punch in the shape of a truncated cone forming which incline at an angleto its axis according to
= arcsin(So/Sy),
moreover, the small base of the truncated cone diameter d have over a large base diameter D height HPFinstalled by the formula
HPF= [(By+2Bp)cos-So(1-sin))]/sinin the axial direction of the packet received from the formative elements and prefabricated take constant and equal to
H= (0,2-0,3)Do,
after the settling of the received packet is performed in a container with a diameter of Daboutby converting the original thickness Sothe semi-finished product thickness in the part of Syproducts with the formation of the transitional zones of thickening from Soto Sylinearly on plots of widthpaccording to the formula
Bp= Rncosand Sy= So/sin,
where So- the original thickness of the material;
Sythe thickness of the product;
Inp- the width of the transition zone thickness;
By- the width of the thickened part of the product;
H- total thickness of thermometer container, crimp Boykov, semi-finished and formative elements;
D - diameter of the large base of the truncated cone;
d - diameter of the small base of the truncated cone;
the angle of inclination of the wall of the semi-finished product to the axis of the device;
rn- the outer radius of the bend murine part of the semi-finished product.

 

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