Method for shaping double-curvature sheet parts

FIELD: plastic working of metals, namely processes for bending, finishing and controlling contour of bent sheet parts.

SUBSTANCE: method comprises steps of shaping double-curvature sheet parts by two transitions; at first transition forming cylindrical or cone curvature across blank without thinning it while under-bending blank by value equal to 1/3 of predetermined curvature of part in the same direction; at second transition further deforming blank and thinning it in direction normal relative to direction of blank deforming at first transition during process of rotary local or successive local deforming; selecting upper deforming member whose curvature is less than predetermined one in cross and longitudinal directions at least by springing value; controlling contour by means of gages in cross sections of blank.

EFFECT: lowered time period of bending piece blank, reduced labor consumption and bending effort, lowered power consumption of process.

4 cl, 4 dwg, 1 tbl

 

The invention relates to the processing of metals by pressure, namely, universal flexible ways, debugging, and control over the shape of bent sheet parts.

Known and widespread traditional methods and devices for flexible sheet blanks single and double curvature presses (see, for example, the patents of the Russian Federation No. 1779430 from 07.05.90, No. 1794532 from 03.06.91, No. 1801660 from 17.09.90, and others). The disadvantages of these methods include low productivity and a large range of a variety of die tooling (up to 50 sets of dies on press and mass 5-20 ton per set).

In recent years, are the development of methods flexible sheet of double curvature components in the longitudinal and transverse direction consistent local deformation (within) on the universal stamps (See. Kuklin O.S, Levshakov V.M. Shaping elements torispherical structures. Abstracts of international conference "Morintech-2001". volume 1. SPb, SIC "Morinth", 2001), however, the ability of these processes is limited at present details only spherical and torispherical shape. More productive (3-4 times) in comparison with rotary presses methods for flexible sheets for plate bending machines, but their technological capabilities are also limited parts, mainly cylindrical and conical shape. However, with the use of PR is laying on rotary machines can produce parts of double curvature pausevideo and saddle-type form, but only with a small curvature (Cm. Chipilin PM, Zefirov IV Processing vessel steels. L., "Shipbuilding", 1972).

The most promising for forming sheet parts of various shapes are processes rotary-local deformation (RLD) roller deforming elements in the form of an upper pressure and a lower drive rollers (See. patents of the Russian Federation No. 2102170 from 18.01.93, No. 2129929 from 06.08.97, No. 2191082 from 24.08.2000 year). These processes compared to flexible on presses and rotary bending machines (rollers) provide a significant reduction in metal consumption and energy intensity of processes (by 2-3 orders of magnitude) due to the localization of the lesion plastic deformation (Cm. Alexandrov V.L., E, Gorbach, Kuklin O.S, Shebarshin VP "High breakthrough technologies bending and straightening". Bulletin of shipbuilding technology. 1998, No. 4).

Closest to the claimed technical solution is the method of forming the double curvature components, including the shaping of the workpiece consecutive mouse clicks for the two navigating the patent RF №2194587, which is taken as a prototype. However, this method makes it possible to obtain only the items that are members of the torispherical shell, and in addition, the need for flexible process multiple applications of control frames or set of templates to control the shapes of the child is her double curvature makes it a little productive.

The objective of the present invention is to improve the performance of the process of formation and expansion of its technological capabilities, including the new principles within and RLD and traditional presses and rollers. The solution to this problem is provided by achieving a technical result as reducing the complexity and energy consumption in the process of formation of double curvature components.

This result is achieved by the combination of features present in the independent claim of the invention the method of forming sheet blanks of double curvature, which has the following differences:

- on the first transition creates a curvature in the transverse direction of the workpiece without thinning, cylindrical or conical shape and nedogibi one third from the predetermined curvature of the workpiece in the same direction;

- on the second transition is subsequent deformation with the thinning of the workpiece in a perpendicular direction with respect to the direction of deformation on the first transition, the rotational-local or series of local deformation at the top of deforming element is selected with a curvature less than the specified in the transverse and longitudinal directions by at least the amount of springback, and control forms of exercise ø what blogName cross sections of the workpiece.

In the particular case of the proposed method the curvature of the workpiece on the first transition attach to rotary bending machines - rollers or presses in the universal-bending molds for cylindrical bending with a simplified evaluation control the shape of the blank on the total deflection of the line or cross pattern and the final control of the shape of the parts are on the second transition.

The second particular case of the basting lines flexible on the first transition is performed in the cross-templates installed on the test, the horizontal plane by connecting the points with approximately uniform curvature in cross sections under templates.

In another particular case, the effort of forming the second transition change is proportional to the square root of the value of the thinning of the workpiece.

Creating an initial curvature in the transverse direction without thinning the workpiece allows the most time-consuming part forming with the least amount of time and energy, because the thinning of the workpiece requires increased efforts deformation up to 10 or more times (See. Popov E.A. fundamentals of theory of sheet metal forming. M., engineering, 1977; Kuklin O.S and other Modern technological equipment hull plating shops. Part 1. L., CRI "RUMB", 1985).

Nedohin procurement allows the manufacturer shall establish and further the deformation necessary for forming a sheet of double curvature components thinning of the workpiece, which is obtained by extraction of the workpiece under the action of the upper deforming element (roller, punch), with double curvature. In the present method such deformation will be carried out at reduced deflections and for the most part not on the entire surface of the workpiece, which also reduces the intensity and complexity of the process. For deformation of the parts on the second transition of the curvature of the top of the deforming element is chosen is less than the specified at least by the amount of springback of the material, which eliminates razlivku already reached curvature at the initial stage of deformation.

In addition, the initial curvature of the workpiece can be performed on a rotating bending machines or in their absence in the universal stamps for cylindrical bending. This is a simplified control over the shape of the workpiece by the magnitude of the achieved deflection line or cross pattern. The most informative part of the formation is carried out on the most productive equipment and the time and cost of process control are also reduced.

The effort of forming the second transition at a rotary-local or sequentially-local deformation of the surface of the workpiece, it is recommended to change proportionally to the square root of the value with the value. Due to this will be achieved at the lowest thinning and deformation force. The highest value of thinning Δs of the workpiece is determined by the largest sum of transverse and longitudinal curvature on the well-known law of nsimemory material:

Δs=ε12,

where ε1- deformation strain in the transverse direction of the workpiece;

ε2- deformation strain in the longitudinal direction of the workpiece.

Deformation in the billet, deformed without thinning, identifies common dependencies

where s is the thickness of the workpiece;

R1is the radius of the workpiece in the transverse direction;

R2 is the radius of the workpiece in mutually perpendicular direction.

Then

Empirically, on the basis of the carried out according to the plans of the Ministry of industry and science of the Russian Federation for basic research (final report on the research GCLI-086-2002) found that

the effort of shaping a sheet of double curvature components is directly proportional to the square root of the magnitude of thinning harvest ();

- thinning along the length or width of the local deformation is distributed according to the law of a circle with a zero value at the opposite edges of the workpiece;

the basting line bending can produce the most is simply widely used control templates specifies the cross-section bent parts.

This allows us, with sufficient practical accuracy, producing the molding of parts with thinning that most effectively implemented when rotary-local (RLD) or sequentially-local (within) the deformation.

The essence of the invention is illustrated by the following schemes:

Figure 1 is a blank sheet parts pausevideo form before bending in the transverse direction on the first transition;

Figure 2 is a blank sheet parts pausevideo shape after bending on the first transition;

Figure 3 blank sheet parts of a saddle-node shape before bending in the transverse direction on the first transition;

4 is a blank sheet parts of a saddle-node shape after bending on the first transition;

5 is a distribution chart thinning Δs along the length of section lΔsthe workpiece in the rotary-local or series of local deformation.

Method of forming sheet-metal part double curvature as follows. Sheet stock, which scan parts respectively pausevideo (figure 1) or saddle-type form (figure 3), prepared for the initial bending of the workpiece 1 in the transverse direction. For this templates 2 terminal cross-sections 3 are aligned in the control of dps is Scoti on horizon lines 4 and the workpiece intended line bending on the greatest curvature 5 and then on related lines of curvature 6. The initial deformation of the workpiece 1 is in the transverse direction of the cylindrical surface, although with variable given radius R1section and may be any means of deformation, not giving thinning, when bending a cylindrical or conical surface, for example, plate bending rolls, press the universal stamp, rotary-local bending rollers.

After the initial bending in the transverse direction on the surface of the workpiece 1 (2, 4) planned area 7, where a double curvature in the transverse direction R1and in the longitudinal direction R2, which is in the perpendicular direction with respect to the original curve. As in this case, a thinning of the workpiece, the deformation implement or rotary-local deformation on the machines and the machines, or sequentially-local deformation (see the above sources). The control of the shape of the bent parts carry on the second transition of the deformation to the traditional method of using templates 2 and 8 (figure 2 and 4).

The optimal thinning procurement Δs in the process of local deformation, as shown by studies (see above report on R & d), determines the force local FORMOSAT the project, which is directly proportional to the square root of the value of the thinning. The amount of thinning Δs along the line of deformation plot billet double curvature length lΔs(2, 4) is changed according to the law of the circle (figure 5). For example, the highest value of thinning Δs decreases twice the length ofthis is followed by more rapid drop to Δs=0.

Testing of the proposed method was performed shipyard JSC “Almaz” in the manufacture of a sheet of double curvature components for a module in the cabin of new electric trains (see above report on R & d).

Differences in morphology sheet parts various forms are as follows:

- when pausevideo and the like form an area of double curvature, requiring thinning of the workpiece, is usually in the middle of the billet (figure 2);

- when a saddle-node form an area of double curvature is located at the edges of the workpiece and on the reverse side with respect to the initial bending in the transverse direction of the workpiece (figure 4).

The effect depending on the applied methods of formation, observed in the present description, shown in the table below for the average sheet of low-alloy steel sizes 12×2000×8000 mm pausevideo forms in relation to about the radovanu, available at JSC “Severnaya Verf” and intended for installation at the plant. The standard time taken by the current in shipbuilding standards ("Flexible shell plates and profile in a cold state. The integrated standards of the time. Individual and small-scale production. Part 1. No. 742-3401-151-82).

Table.

Piece time of formation of the sheet pausevideo form of the proposed method and various combination of bending equipment
The initial deformation in the transverse direction in a cylindrical formSubsequent deformation methods RLD and withinTotal piece flexible, min.
Flexible rollers 30×10000, “Nichimen, Japan force 2000 TCFlexible RLD on the machine by the force of 30 IGS TC-30K, Russia186+180=366
Flexible rollers,

The same
Flexible within the press force 800 TC AMR TA, Ukraine186+428=614
Flexible in the press with force 800 TC AMR TA, UkraineFlexible within the press force 800 TC AMR TA, Ukraine235+428=663
Flexible RLD on a machine with CNC AGPM-25 force of 25 TC, FSUE CRIST, RussiaFlexible RLD on a machine with CNC AGPM-25 force of 25 TC, FSUE CRIST,Russia 194+130=324
Flexible rollers 30×10000, “Nichimen, Japan force 2000 TCFlexible RLD on a machine with CNC AGPM-25 force of 25 TC, FSUE CRIST, Russia186+130=316

The table below shows that the greatest effect is achieved for the initial deformation is applied bending rollers, and for the subsequent deformation method RLD on automated bending-straightening machine, which is achieved not only the reduction in unit time flexible (~2 times), but also reduced up to 4 times the complexity flexible by reducing to 1 person staff and reduce more than 16 times the efforts of flexible, which provides a lower energy process 6-10 times.

1. Method of forming a sheet of double curvature components, including forming blanks for the two transitions, characterized in that the first transition creates a curvature in the transverse direction of the workpiece without thinning cylindrical or conical shape and nedogibi one third from the predetermined curvature of the workpiece in the same direction, and the second transition is subsequent deformation with the thinning of the workpiece in a perpendicular direction with respect to the direction of deformation on the first transition, the rotational-local or sequentially-local strain is I, when the upper deforming element is selected with a curvature that is less than the specified in the transverse and longitudinal directions, at least on the amount of springback, while monitoring forms provide templates for the cross sections of the workpiece.

2. Method of forming a sheet of double curvature components according to claim 1, characterized in that the curvature of the workpiece on the first transition attach to rotary bending machines - rollers or presses in the universal-bending molds for cylindrical bending with a simplified evaluation control the shape of the blank on the total deflection of the line or cross pattern and the final control of the shape of the parts are on the second transition.

3. Method of forming a sheet of double curvature components according to claim 1, characterized in that the basting lines flexible on the first transition is performed in the transverse patterns established by controlling the horizontal plane, by connecting the points with approximately uniform curvature in cross sections under templates.

4. Method of forming a sheet of double curvature components according to claim 1, characterized in that the effort of forming the second transition change is proportional to the square root of the value of the thinning of the workpiece.



 

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FIELD: plastic working of metals, namely processes for bending, finishing and controlling contour of bent sheet parts.

SUBSTANCE: method comprises steps of shaping double-curvature sheet parts by two transitions; at first transition forming cylindrical or cone curvature across blank without thinning it while under-bending blank by value equal to 1/3 of predetermined curvature of part in the same direction; at second transition further deforming blank and thinning it in direction normal relative to direction of blank deforming at first transition during process of rotary local or successive local deforming; selecting upper deforming member whose curvature is less than predetermined one in cross and longitudinal directions at least by springing value; controlling contour by means of gages in cross sections of blank.

EFFECT: lowered time period of bending piece blank, reduced labor consumption and bending effort, lowered power consumption of process.

4 cl, 4 dwg, 1 tbl

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SUBSTANCE: method is realized due to applying successive local bending efforts during one or several transitions along bending lines and performing rotary local deforming between engaging deforming members. At least one pressure member is in the form of roller with curvature radius in cross direction less than curvature radius of part in the same direction. Axis for applying bending efforts is directed along lines normal relative to bending lines in plane and to plane of bent blank. Bending efforts are applied beginning from shortest butt cross edge of blank. Above mentioned bending lines divide cross section of blank by even number of pieces whose length is equal to bending pitch or proportional to it. Lengthwise edges of grooves are selected as near as possible to curvature lines of part surface with maximum and minimum curvature radius in each point.

EFFECT: lowered labor consumption of process for shaping sheet parts.

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EFFECT: enhanced accuracy of preset curvilinear surfaces of structure, simplified manufacturing process due to reduced number of transitions.

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EFFECT: lowered labor consumption of manufacturing process.

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