Method of producing thin-wall shell with curvilinear work surfaces

FIELD: process engineering.

SUBSTANCE: invention relates to machine building and can be used in producing shell structures with curvilinear work surfaces. Flat thin-wall preform is pressed towards shaping surface of detachable tool. Note here that, simultaneously, curvilinear section with curvilinear work surfaces are formed along with two-layer shaped stiffness ribs jointing the latter together that are produced from preform fragments not involved in forming curvilinear sections of the shell. Shell thickness is made equal to that of preform, while detachable lower die is removed through open zone on the shell extreme edge side.

EFFECT: higher accuracy of shells and efficiency of their production.

6 cl, 16 dwg

 

The invention relates to mechanical engineering and can be used in the design and production of various shell structures, including complex spatial curvilinear work surfaces, including spherical, parabolic, hyperbolic, elliptical, cylindrical, conical, and also combined. Such surfaces are used in receiving and transmitting antennas, reflective devices, membranes spacecraft, fairings, and other elements of the aircraft. The proposed solution can be used for various containers, appliances, art, etc.

For the manufacture of shell structures with curved working surfaces widely used technology stamping of thin sheet materials [1]. At the same time as the technological equipment used universal or special pressing equipment and tools that are used are special stamps, consisting, usually, of the matrix and punch [1]. Traditional punching technology has several disadvantages: press equipment is very bulky, not environmentally friendly, and stamps time-consuming to manufacture. At the same time, due to the complexity of the coordination working poverkhnostyami and punches, not always ensure the required precision stamped parts. In the drawing the workpiece material, the thickness of the shell is obtained uneven and, therefore, neravnopolochny. To ensure the required strength and stiffness of such membranes enhance their additional structural elements.

In some cases, it is preferable electro-stamping [2]. At the same time as the equipment is used, the pulse current generator and as a tool - the process unit that includes only the matrix or just the punch, so the manufacturing accuracy can be substantially improved. Eliminated and a number of other disadvantages associated with conventional stamping: solving environmental problems, increasing efficiency and productivity. This method can be adopted for the prototype.

However, to avoid the uneven thickness of the shell, especially in the case of deep drawing, when the magnetic-pulse stamping is not possible. Not, also provide the required rigidity and strength of the casing. In addition, deep stamping, in which plastic deformation is subjected to a large amount of workpiece material, accompanied by increased energy consumption.

The objective of the proposed technical solution is the software with which labilnosti the thickness of the thin-walled shell, especially in the locations of its working surfaces, while reducing the thickness of the flat blanks, which, in turn, leads to weight reduction of the shell. Another aim of the invention is the possibility of manufacturing complex form of spatial thin-walled shells with high accuracy the location of their working surfaces and with high production efficiency.

These goals are achieved by the fact that the flat thin-walled workpiece is formed into force on the workpiece in the direction of the shaping surface of the removable tool while simultaneously form a curved section with a curved work surfaces and connecting them double-layer shaped ribs, which form from fragments of the workpiece, not involved in the formation of the curved sections of the shell, the shell thickness of the perform equal to the thickness of the workpiece, and a removable matrix is extracted through an open area with the perimeter edge of the shell. The height of the ribs, view their profile, as well as the number and location relative to the curved working surfaces depend on the shape of curved surfaces, the dimensions of shells and other specific requirements of thin-walled curved shell. In the manufacture of Obolo is to complicated forms with varying degrees of curvature forming the shell is produced in stages. First flat thin-walled workpiece is rolled into the form of a shell, the edges of which combine and connect to each other inside the shell is placed a removable tool with a forming surface on which is formed into the shell with the formation of curved sections and profiled ribs. To increase the strength and stiffness of the shell layers of profiled ribs interconnected. When profiled ribs protruding beyond the maximum allowable dimensions of the shell, press to curved sections of the shell and interconnected layers of profiled ribs and curved sections of the shell. To obtain a closed thin-walled shell with a curved border edge of one of the open shells with curved sections combine her with the right border edge of the other open shell with curved sections and connect them together. To ensure high quality thin-walled shell with a curved sections simultaneously improving the efficiency of its production of billets, the connection edges of the shell and the connection edge of the open edges of the shells produce electro influence.

The essence of the method is illustrated in the drawings figure 1 is a-16.

In figure 1, 2 shown in reaktsionnoi communication two projections of the thin-walled shell with a working surface, made in the form of a hemisphere with six external profiled ribs.

Figure 3 shows a cross-section of the shell plane passing through the center of the spherical surface.

Figure 4, 5 shown in the projection due two projections of the thin-walled shell with a working surface made in the form of a hemisphere with six inner profiled ribs

Figure 6, 7 shown in projection due two projections of the thin-walled shell complicated shape: cylindrical part of the shell ends of the hemispherical part of it with six profiled ribs.

On Fig, 9 shown in projection due two projections of the thin-walled shell complicated shape: conical portion of the shell ends of the hemispherical part of it with six profiled ribs.

In Fig 10, 11 shown in projection due two projections of the thin-walled shell with a working surface made in the form of a hemisphere with six external profiled ribs, pressed against the spherical portions of the external surface of the shell.

On Fig, 13 shown in the projection due two projections of the thin-walled shell complicated shape: cylindrical section of the shell hemispherical ends its plot with six profiled ribs, pressed against the spherical phase is m external surface of the shell.

On Fig, 15 shown in projection due two projections of the thin-walled shell complicated shape: conical section of the shell hemispherical ends its plot with six profiled ribs, pressed against the spherical portions of the external surface of the shell.

On Fig shown closed thin-walled spherical shell, obtained by overlapping edge zones of the two hemispherical thin-walled shells with reinforcing ribs pressed against the spherical surfaces of each of the hemispherical shells, one of which is made directly from a flat thin-walled workpiece, and the second of shells, folded from a flat thin-walled workpiece.

For the manufacture of thin-walled curved shell use the blank, which is cut out from a flat thin-walled material, such as aluminum foil. The workpiece feature between the molding surface of a removable tool and, for example, a planar inductor, electrically connected to the pulse current generator. By passing an impulse of alternating current through the inductor in the workpiece produces a counter. As a result of interaction of the electromagnetic fields of the currents of the inductor and workpiece past with great speed hits the molding surface of the removable tool in tegopoulos shell 1, in which simultaneously formed into curved areas 2 with curved, for example, a spherical working surface 3 and connecting their two-layer shaped ribs 4. The thickness of the shell as in the locations of the curved sections 2 and layer 5 profiled ribs 4 is equal to the thickness of the flat blanks. Removable tool is extracted through an open area with the perimeter edge 6 of the shell 1. In the manufacture of shells complicated forms with varying degrees of curvature forming blanks produced in stages: first from a flat thin-walled workpiece roll shell 7, for example, in the form of a cylinder 8 with a given curvature, the edges 10 of the shell 7 combine and connect to each other. Inside the shell is placed a removable matrix, which is formed into the shell with the formation of curvilinear sections 2 and profiled ribs 4. Layers 5 profiled ribs 4 are connected with electro, laser, spot welding, adhesive or other means. Similarly interconnected layers 5 profiled ribs 4 and the curved section 2 of the shell 1.

To obtain a closed thin-walled shell 11 with a curved border edge 6 of one of the open shell 12 with a curved sections 2 combined with razmernoi her edge edge 6 other open shell 13 with a curved sections 2 and connect them with each other

Experimental samples of thin-walled shells were made of aluminum foil having a thickness of 0.15 mm, the Radius of curvature plots with spherical surfaces varied from 15 to 50 mm, the Obtained membranes have gained and has maintained a defined shape. Layers of ribs was performed with predetermined gaps between them in layers, and virtually no gaps. When running the shell with ribs, pressed to its curved sections, the shape of the shell are not visually changed, the rigidity is relatively high, and appearance meets the requirements of the design.

Implementation of the proposed method:

- to ensure a constant thickness of the shell, including its working parts;

to provide additional strength and rigidity to the membrane by formation of a profiled ribs made of the same workpiece during a single operation;

to ensure high precision in the formation of working curvilinear surfaces by eliminating one of the elements of die tooling;

- reduce process cycle by eliminating intermediate operations;

to accelerate the production of membranes and reduce the consumption of energy required for forming membranes, due to the use of high-efficiency equipment.

All this allows to improve the quality of Obolo the EC and the efficiency of their production.

Sources of information

1. Romanovsky VP Reference cold stamping. M: mechanical engineering, 1971.

2. Ively, Simpatic, Ltheta. Handbook of magnetic pulse treatment of metals. Publisher at the Kharkov State University. Publishing Association "high school", 1977. 55 C. (prototype).

1. A method of manufacturing a thin-walled shell with a curved working surfaces, comprising forming force removable tool on a flat thin-walled workpiece toward the shaping surface of the removable tool, characterized in that the moulding is produced while forming curved sections with curved work surfaces and connecting them double-layer corrugated ribs that form of fragments of the workpiece, not involved in the formation of the curved parts of the shell, with the shell thickness of the perform equal to the thickness of the workpiece, and a removable tool forming surface is extracted through an open area with the perimeter edge of the shell.

2. The method according to claim 1, characterized in that the flat thin-walled workpiece is rolled into the form of a shell, the edges of which combine and connect to each other inside the shell is placed a removable tool with a forming surface on which oraut shell with the formation of curved sections and profiled ribs.

3. The method according to claim 1, characterized in that the layers are profiled ribs are connected.

4. The method according to claim 1, characterized in that the profiled ribs pressed against the curved sections of the shell and interconnected layers of profiled ribs and curved sections of the shell.

5. The method according to claim 1, characterized in that the edge the edge of one open shells with curved sections combine her with the right border edge of the other open shell with curved parts, connect them together and get a closed thin-walled shell with a curved sections.

6. The method according to one of claims 1, 2, 5, characterized in that the billets, the connection edges of the shell and the connection edge of the open edges of the shells produce electro influence.



 

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