Method and device for production of large-sized ribbed panels

FIELD: process engineering.

SUBSTANCE: invention relates to metal forming and can be used in production of ribbed panels intended for bodies of compartments, bulkheads, wings and other parts of aircraft and spacecraft. Heated blank is strained at the rate of 0.01-10 mm/s, in steps over the sections, with gradual forming of the entire surface. Area of said sections is at least two times smaller than that of said blank. Straining is executed at the device to be secured in die unit for isothermal die forming. Proposed device comprises top and bottom plates, heaters, female die, male dies with cavities shaped and sized to panel ribs and at least two male die holders. The latter displace in guide columns. It includes sliding thrust plates with drive. One male die is rigidly fixed in male die holder. Other male dies are fitted in their holders and spring-loaded and can displace in direction of forming force application.

EFFECT: enhanced processing performances.

2 cl, 5 dwg

 

The invention relates to the processing of metals by pressure and can be used in the manufacture of panels with unilateral and bilateral fins.

Ribbed panels find application in engineering for manufacturing, in particular, enclosures, compartments, partitions, wings and other panels aviation and spacecraft. Such panels must have a high strength, stability and minimum weight, so they are made of high-strength hard under normal conditions of metals and alloys mechanical processing.

There is a method of creep-forming bulky ribbed panels (Forging and stamping: a Handbook. 4 so/ Ed. Tip: E.I. Semenov (PREV.) and others - M.: Mashinostroenie, 1986, - Vol.2. Hot stamping /Ed. by E.I. Semenov, 1986. 592 S., ill., s-463). The method improves the utilization rate of the metal, improves the operating characteristics of ribbed panels, however, require significant power influences in forming the blank of high-strength hard material, having a powerful press equipment.

Closest to the proposed method, is a Method of forming panels with unilateral relief" (see A.S. SU 1248718, bull. No. 29 from 07.08. 1986). Using this method it is possible to make flat ribbed panels of aluminum alloy is Bob. After heating the die and the workpiece to 400...500°C is first a preliminary forming, and after installation in the special stamp of the liner between the preformed blanks is the final stamping with a certain exposure time, given the strength of the deformation and the average specific pressure.

The advantage of this method is to improve the quality of ribbed panels and durability of die tooling.

The disadvantages of the prototype are limited technological opportunities only unilateral relief, the need to use powerful hydraulic presses for the production of large-size panels of spheroidal hard materials, as well as the time spent on cooling and re-heating of the die block, billet with a liner that substantially increases energy expenditure and reduces performance.

A device in the form of a die block structural diagram of which is shown in p.150, RES. (Engineering. Encyclopedia of 40 tons/ Ed. tip: K.V. Frolov (PREV.) and others - M.: mechanical engineering. M 38 Technology and procurement industries. So III-2 / I. Acaro, R.A. Andrievski, A.F. Arzhanov and others; Under the General Ed. Ms. V. Manuilov, 1996, 736 C., Il.). Die block provides isothermal conditions stampout the use of a stamp, which it is installed. Stamp, mounted in the die block has a flaw in the design, which is that the die tool produces simultaneously forming on the entire surface contact with the flat workpiece. The forming is performed without taking into account the speed of movement of the deforming tool and viscous properties of the workpiece material. For this reason, it requires considerable force, so the industry are small sections of ribbed panels, which are by welding with each other get bulky ribbed panel of high-strength hard metals.

This increases the complexity of manufacture and decreases the quality of the product.

The closest structure is the device AS. SU 1248718, bull. No. 29 from 07.08.1986, consisting of upper and lower halves of the die, each of which is made streams for centration halves stamp, upper stamp is placed in the case, directing the inner surface of which is in the process of forming contacts with the rail outer surface of the lower half of the stamp. With the help of the device forming is carried out in two stages: pre with simultaneous forming of two blanks and receiving unilateral relief forms nedostupova parts semi-finished products, and then after the installation of special liner between the billet re-heating to a temperature of forming the final forming.

The disadvantage of this device is the possibility of forming on the entire surface of the workpieces that to obtain large-size panels requires powerful processing equipment, resulting in lower technological capabilities of the stamping process, and the need for cooling of the die and workpiece and re-heating. This reduces efficiency and increases energy consumption.

The objective of the proposed technical solution is the expansion of technological capabilities by regulating specific pressure variation in the conditions of creep under load depending on the speed of deformation and deformation of parts of the flat blanks for her one setup with the specified parameter of damage to the panel.

To solve this problem is proposed a method of manufacturing a bulky ribbed panels, including the deformation of the heated billet, which is carried out at the same temperature with exposure under the force of the impact, the deformation of the workpiece is carried out with a speed of from 0.01 to 10 mm/s series plots, the area of which, at least in DV is times smaller than the area of the workpiece.

Device for the production of large ribbed panels, designed for mounting the die block for isothermal forging, comprising upper and lower plates, heating elements, the matrix and punches executed with the cavity shape and dimensions of the ribs ribbed panel, the device is equipped with at least two peasantization mounted for movement on guide columns, through which they are connected with the upper plate, punches with cavities on the shape and dimensions of the ribs of ribbed panels and slip resistant straps with the mechanism of their movement, with one of the punches rigidly fixed to the lower pancontinental, other punches are installed in peasantization can move in the direction of application of force stamping and spring-loaded, sliding resistant strap is made with possibility of accommodation through the mechanism of their movement between peasantization and between the upper plate and the upper peasantization to ensure impact on the blank by the punch mounted for movement.

Figure 1 shows a honeycomb panel with ribs;

figure 2 shows the package stamp at the beginning of the deformation of the workpiece;

figure 3 shows the package stamp at the first stage formais the change of the Central section of the blank;

figure 4 shows the package stamp in the second stage of deformation of other portions of the workpiece;

figure 5 Dana design pack stamp on the final stage of forming the marginal areas of the blank.

The method is as follows.

In block stamp mounted on a hydraulic press, and fix pack placed between peasantization slip resistant straps. In the stamp stack the sheet and carry out heating of the package with the workpiece to the desired temperature isothermal forging. Isothermal forging panel is carried out with a range of velocities of the upper stamp from 0.01 mm/s to 10 mm/sec Power load P=qF create depending on the calculated and experimental values of specific pressure q and the corresponding speed of deformation of the V0. Specific pressure q is determined by the results of experimental or theoretical studies depending on the speed of deformation, taking into account the damage to the metal.

The forming carried out in stages. The number of stages of deformation depends on the power of a hydraulic press, mechanical and plastic properties of the workpiece material, the overall dimensions of the panel, the speed and degree of deformation, regulated damaging material. At one stage forms the small change ribbed panels with simultaneous exposure tool stamp on the entire surface of the workpiece. To obtain large ribbed panels produce the forming of individual sections of the workpiece. The position of the parts of the stamp before deformation is shown in figure 2. The Central punch 6 is rigidly connected with peasantization 8, while the punches 3, 9, 4 and 7 have the opportunity longitudinal movement by the amount of introduction of the plug 6 into the workpiece material. Thus, a force on the workpiece may be exercised only by the punch 6.

In the first step, forming subjected to the median point of the work piece 14 (see figure 3) using a punch 6. After the deformation force is removed, and between the bottom 8 and the top 5 peasantization moving forward thrust of the strap 17 by using an eccentric rotary device 16 and the handles 15. The newly created calculated force on other sites billet new sections of the punches 4 and 7 with a specified exposure time (see figure 4). When this happens move poisonedwaters 8 on guide columns 18 to contact with the upper peasantization 5, which established the punches 3 and 9. Punches 3 and 9 do not participate in the forming of the workpiece, so as to have the ability to move relative to poisonedwaters 5. In the process of forming new areas of the workpiece Central punch 6 is coprecos is owenii with molded at the first stage of loading cells protecting them from possible distortion in the process of forming new areas of the workpiece. In the last step, moving forward thrust of the strap 17 between the upper peasantization 5 and the upper plate 1 with the eccentric rotator handles 16 and 15, followed by forming the remaining edge areas of the workpiece (see figure 5). When this happens move passonately 8 and 5 on guide columns 18 to contact with the upper plate 1, and the punches 3 and 9, based in the surface of the upper plate 1, are introduced into the workpiece 14, while the other punches are in contact with the previously formed cells, protecting them from possible distortion. Gradual deformation ensures complete filling of the metal streams stamp without the use of special gaskets and repeated cooling and heating of the die block with the workpiece.

By the way, who is using this service stamp, the calculated value of power punching is reduced three times and stamping exercise for one set of billet hydraulic press. The complexity of manufacturing large-sized panel is significantly reduced when using the proposed method by reducing the heating time insulated snap-in three razai abolition of welding operations sections of the panel. Indeed, by a known method it is necessary to formastat three sections of the panel, placing three consecutive blanks in the die and heating each with a stamp.

For details of the responsible destination damaging material should not exceed ω=0,2. In this case, it is expedient to carry out the forming at speeds of deformation that does not exceed V0=0.1 mm/s For parts with higher damage rate of deformation can be increased to V0=10 mm/s

For implementing the method uses a device consisting of the top 1 and the bottom 13 of the plates. On the bottom plate for thermal insulation is used asbestos gasket 12 on which you installed the heaters 11 and the matrix 10. On the top plate are pressed column guides 18 which move pancontinental 5 and 8. To reduce the eccentricity of the force stamping on the yoke press and prevent misalignment when forming the workpiece 14 in the lower pancontinental 8 and the upper pancontinental 5 punches 4 and 7, 3 and 9 have the same contact area with the workpiece and constant calculated power variation. Between peasantization 5 and 8 are placed in the frontal direction moving the stop rail 17, the same sliding thrust of the strap 17 is installed in the transverse direction between the point what soedertaelje 5 and the upper plate 1. Removing and installing a sliding stop bars 17 is eccentrics 16 by turning the handles 15. The punch 6 is pressed into pancontinental 8, and the punches 3, 9, 4 and 7 in peasantization 5 and 8 can move under the action of elastic elements 2 and force shaping.

The design of the device allows you to change the number of stages of loading on the workpiece. If, for example, it is necessary to reduce the magnitude of the forces shaping flat blanks, instead of two passonately at the top of the stamp are fixed three purandaradasa and three sets of sliding stop bars, which gives the possibility to increase the number of stages of loading up to four.

When forming blanks from less durable materials, the proposed device allows forming the entire workpiece during removal from the package sliding stop bars.

An example implementation of the method.

It is necessary to make large ribbed panel of aluminium alloy AMg6 with bilateral fins and unit cell dimensions a=50 mm, the thickness of the rib b=10 mm and a depth of wells 5 mm (see figure 1) on a hydraulic press force of 5 mn. The number of cells n=12×10=120. The dimensions of the panel: A=730 mm; B=610 mm Initial thickness of the blank h0=35 mm, end h=30 mm for double sided fins, the depth of penetration of the punches ∆ H=5 mm

P and conducting experimental and theoretical studies have shown the influence of speed of implementation tool V 0the value of specific pressure q at the heating temperature of 450°C alloy AMg6. The research results are summarized in the table.

The estimated strength of the deformation of one ribbed cells respectively equal to 100.5 kN; 117,250 kN; 124,000 of 127.5 kN and kN.

To obtain panel (see figure 1) with 120 cells requires the power of forming in a single operation variation, respectively: 12,06 mn; 14,07 mn; 14,88 mn; and 15.3 mn.

Table
The dependence of the surface pressure q on the speed of deformation of V under isothermal forging aluminum alloy AMg6 at a temperature of 450±2°C
MaterialThe speed of movement of the tool in mm/s
0,010,11,010
Aluminum alloy AMg6The value of the specific pressure, MPa
40,246,949,651,0

From these calculations of the modes of deformation of the workpiece to obtain a large ribbed panel is visible, if there is a hydraulic press with a capacity of 5 mn is impossible to obtain a honeycomb panel with a size of 730×610 mm by a known method. The proposed method for three stages of forming such a panel can be made on the existing hydraulic press, if the first and subsequent stages of isothermal forging to produce 40 cells. Power punching in a single operation, respectively, will be equal to: as 4.02 mn; 4,69 mn; 4,96 mn; 5,10 mn.

For panels a responsible destination damaging material after stamping should not exceed the rate of damage w=0,2. In this case, it is expedient to carry out the forming at speeds of deformation that does not exceed V0=0.1 mm/s, i.e. create a load not more 4,69 mn. For panels, which during operation is possible, a higher level of damage, can be isothermal forging load 4,96 mn and more. Thus, the proposed method extends the technological capabilities of manufacturing large ribbed panels, significantly reduces the complexity of the process and the energy consumption for the heating device and the workpiece.

1. Method of manufacturing large ribbed panels, including the deformation of the heated billet, which is carried out at a temperature of isothermal forging with vyd what Ricoy under power influence characterized in that the deformation is carried out with a speed of from 0.01 to 10 mm/s series plots of the workpiece, the area of which at least two times smaller than the area of the workpiece, with the gradual forming the entire surface of the workpiece.

2. Device for the production of large ribbed panels, designed for mounting the die block for isothermal forging, comprising upper and lower plates, heating elements, a matrix and a punch made with cavities on the shape and dimensions of the ribs of ribbed panels, characterized in that it is provided with at least two peasantization mounted for movement on guide columns, through which they are connected with the upper plate, punches with cavities on the shape and dimensions of the ribs of ribbed panels and slip resistant straps with the mechanism of their movement, with one punch rigidly fixed to the lower pancontinental, the other punches established in peasantization can move in the direction of stamping and spring-loaded, sliding resistant strap is made with possibility of accommodation through the mechanism of their movement between peasantization and between the upper plate and the upper peasantization to ensure impact on the blank what uranami, installed with the ability to move.



 

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