Bending method by right angle with small radius

FIELD: plastic working of metals, namely processes and equipment for bending by right angle with small radius.

SUBSTANCE: method comprises steps of performing first stage for bending flange by relatively large radius; performing second stage for deforming blank by means of punch moving in direction from edge of flange to its radius in parallel relative to die surface; selecting surface shape of deforming punch and its sizes according to condition of creating effect of metal "pushing in" to zone for forming small radius.

EFFECT: improved quality of bent products.

2 dwg

 

The invention relates to the processing of metals by pressure, in particular for bending sheet metal with a small radius (less than the thickness of the workpiece). It can be used in the automotive industry as the first operation in the Assembly process of facing car parts from maloplastichnye alloys.

A method of obtaining bent flange on all transactions which applies an elastic environment to reduce the tensile stresses on the outer surface of the workpiece. The method allows to obtain a small bend radius and can be used with universal equipment. However, the application of elastic environment inevitably leads to a low tool life and the complexity of the design of the stamp (Patent US 6865917, CL 21D 22/10, published. 15.03.2005).

A method of obtaining a right angle with a small radius, based on the increase in compressive stress in the deformation zone through the creation of active friction forces. The method consists of two stages. In the first stage is a conventional flexible at a right angle with a large radius. In the second stage, the workpiece is deformed by the punch, moving horizontally or at an acute angle to the horizon. The result is a part with a high surface quality. Here describes how, with one stage. In one of them the tool moves at an angle to the horizon, AB another tool rotates around its axis (Patent US 6928848, CL B21D 39/02, published. 16.08.2005). In these methods the main drawback is the necessity of implementing the tool movement other than vertical, besides their use for parts having a curved edge, very difficult. The method described in this patent, is the prototype of the developed method.

The traditional process of assembling the facing parts of automobiles (flexible flange on the perimeter of the outer panel, such as the hood, trunk and doors, consists of three successive operations: flexible flange of the outer panel 90, 135 and 180 degrees. Its application to the details of maloplastichnye alloys (e.g. aluminum) leads to the appearance of cracks. Currently there are no methods of facing car parts from maloplastichnye alloys that match collectively to all modern requirements: the deformation without cracks and breaks, small bend radius, the applicability to curved edges, high quality front surface, the use of generic hardware and easy industrial implementation.

The quality of the details obtained in the first operation (bending 90 degrees), completely determines the quality of the final details, i.e. if there was obtained a high quality bent flange, the execution of subsequent operations will not lead to the of effektov. The invention is aimed at obtaining high-quality bent flange with a small bend radius. The use of the invention instead of the first operation (usual floppy) in the traditional Assembly process makes it possible to satisfy all the requirements listed above.

The method consists of two stages. The first stage (figure 1) is a simple bending of the flange at 90 degrees with a relatively large radius (more than two thicknesses of the material). Here, the workpiece 1 is pressed by the tool 2 to the matrix 4 having a radial passage 5, and the punch 3 deforms the workpiece 1. In the second stage (figure 2), the workpiece is turned over and is forming a small radius. Here, the workpiece 1 is pressed against the tool 7 matrix 6 having a radial passage 9 of the desired size and surface 11, which moves parallel to the plug 8 having a deforming surface 10 that is required for the initial clamping of the edges of the workpiece 1 to the surface 11 of the matrix 6. Upon further movement of the plug 8 having friction force between the workpiece 1 and the matrix 6, which create resistance to sliding of the workpiece surface 11 and there is an effect called "zataskivanija" metal in the zone of formation of small radius due to active friction forces. This results in the deformation zone have significant compressive stresses that can improve plasticines the ü metal and deforming the workpiece in the future without the risk of cracks and breaks. The plug 8 in the second stage may be of any shape surface 11, stealing empirically.

Figure 1 - sequence deformation of the flange of the outer panel detail at the first stage in the context.

Figure 2 - sequence deformation of the flange of the outer panel detail at the second stage in the context.

How flexible workpiece at a right angle with a small radius, including two-stage flexible workpiece, the first of which carry out the bending of the flange on a relatively large radius, and the second is the formation of small radius, characterized in that in the second stage, the workpiece is deformed by the punch, moving in the direction from the edge of the flange to its radius parallel to the surface of the matrix, in accordance with the sequence of deformation of the flange, are presented in figure 2, the shape of the surface deforming punch and its dimensions are picked on the basis of the conditions creating the effect of "zataskivanija" metal in the region of formation of small radius.



 

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