Progressive forming apparatus, process and process design method for engine boss components

Abstract

The application discloses a kind of progressive forming device, process and process design method of engine boss component, belong to aerospace equipment technical field, the progressive forming process of engine boss component includes the following steps: S1.to high-temperature alloy material is preheated;S2.high-temperature alloy strip after preheating is handled by progressive die, and the boss component is prepared.The process method disclosed in the application effectively solves the problems existing in the traditional processing method by the continuity of production and high-speed production rhythm of progressive die, combined with material heating temperature control system.The process method has the advantages of improving production efficiency, reducing cost, improving product precision and consistency, and reducing deformation risk, etc., and can realize high-quality, high-efficiency boss product production.

Description

Technical Field

[0001] This invention belongs to the field of aerospace equipment manufacturing technology, and particularly relates to a progressive forming device, process, and process design method for engine mount components for aerospace applications. Background Technology

[0002] The boss is a component in aerospace engines; its structure can be found in [reference needed]. Figures 5-7 The material used is GH3044, a solid solution strengthened nickel-based oxidation-resistant high-temperature alloy. In working environments below 900℃, this material exhibits high plasticity and thermal strength, making it ideal for manufacturing main combustion chamber and afterburner components for aero-engines to ensure their reliability during long-term operation. The material has a tensile strength of 685 MPa and an elongation of 40%. As a crucial component in aero-engines, the boss requires high precision. Because this product requires welding, the permissible deviation in its surface position is less than 0.1 mm. Furthermore, due to the special material used, mold forming presents certain challenges. Traditional manufacturing methods typically involve: first, using 3D printing equipment to create a blank, then machining it using a CNC machining center to remove excess metal, ultimately obtaining the final boss product.

[0003] The above-mentioned traditional processing methods for manufacturing boss products have the following problems:

[0004] 1. Poor formability: High-temperature alloy materials have poor formability and can only be machined by CNC machining centers, resulting in high manufacturing costs. Furthermore, manufacturing the boss requires numerous related processes and necessitates the use of expensive advanced equipment, further increasing processing costs.

[0005] 2. Low production efficiency: Traditional 3D printing methods require laying metal powder layer by layer on a worktable and using laser sintering to form the shape, which makes the processing time long and thus reduces production efficiency.

[0006] 3. Unstable product precision and poor consistency: High temperatures during processing and sintering can cause product deformation, affecting dimensional accuracy. Furthermore, alignment errors during each of the multi-stage processing steps also lead to poor product consistency. While traditional production methods can meet product usage requirements, they significantly impact subsequent final assembly and increase the difficulty of cost control.

[0007] In summary, traditional machining methods for manufacturing bosses suffer from the aforementioned problems, including poor formability of high-temperature alloy materials, low production efficiency, and inconsistent product precision and uniformity. These issues not only increase manufacturing costs but also complicate subsequent assembly processes and the difficulty of controlling product costs. Summary of the Invention

[0008] To address the problems existing in the prior art, this invention provides a progressive forming device, process, and process design method for engine mount components that solves the problems of unstable product precision, poor consistency, high manufacturing cost, and high efficiency associated with traditional processing methods for mount products.

[0009] This invention is implemented as follows: a progressive forming process for an engine boss component, characterized by comprising the following steps:

[0010] S1. Preheating treatment of high-temperature alloy materials;

[0011] S2. The high-temperature alloy strip after preheating is processed by a progressive die to obtain a boss component. The progressive die processes the high-temperature alloy strip by stretching, punching, extrusion and cutting.

[0012] The preheating treatment is performed at the inlet end of the high-temperature alloy material feeding into the progressive die.

[0013] In the above technical solution, preferably, the progressive die's processing steps for the preheated high-temperature alloy strip include:

[0014] 1) Stretch forming: forming the convex cylindrical part of the boss component;

[0015] 2) Stretch and flip-up forming: forming the flip-up flange part;

[0016] 3) Stretching and straightening the profile: The flange portion undergoes shaping treatment;

[0017] 4) Punching: Use a punch to cut away the top surface of the convex cylindrical part to form a through hole;

[0018] 5) Extrusion flanging: Using a punch to correct the through hole;

[0019] 6) Cutting: to obtain the finished product of the boss component.

[0020] This invention proposes a novel process method that utilizes the continuous production and high-speed production cycle of progressive dies, combined with a material heating and temperature control system, offering the following advantages and effects:

[0021] 1. Improved Production Efficiency: This process utilizes progressive dies and high-speed production cycles to achieve continuous production, thereby significantly improving the production efficiency of punch mount products. Compared to traditional methods involving 3D printing and CNC machining, this process can complete the production process much faster, reducing production time and delivery cycles.

[0022] 2. Cost Reduction: The new process reduces associated steps and required equipment by employing continuous production and high-speed production cycles, thereby lowering the cost of manufacturing the boss product. Simultaneously, this method effectively controls product dimensional accuracy, reducing adjustments and corrections during subsequent assembly, further reducing overall costs.

[0023] 3. Improved Product Precision and Consistency: The new process method, through experimental measurement, determined the optimal ambient temperature for stamping high-temperature alloy materials. By providing a specific temperature environment, the impact of heat on the raw material steel sheet was effectively controlled, ensuring that the forming of the stretched portion of the product met performance requirements. Therefore, this process method improves product precision and consistency, ensuring that each boss product meets specifications.

[0024] 4. Reduced Deformation Risk: The new process utilizes a material heating temperature control system, which reduces the risk of thermal deformation during processing and stamping by controlling the heat supply. This helps maintain the product's shape stability and dimensional accuracy, improving its reliability and durability.

[0025] In summary, the new process effectively solves the problems existing in traditional processing methods by combining continuous production with high-speed production cycles using progressive dies and a material heating and temperature control system. This process offers advantages such as improved production efficiency, reduced costs, enhanced product precision and consistency, and reduced deformation risks, enabling the production of high-quality, high-efficiency punch products.

[0026] Another objective of this invention is to provide a design method for a progressive forming process of an engine boss component, characterized by comprising the following steps:

[0027] S1. Determine the geometric parameters of the sample;

[0028] S2. Obtain the material physical properties parameters of the material formed at different temperatures through experiments;

[0029] S3. Design modification and experimental verification: Tensile forming tests were conducted on the sample at different temperatures, and the minimum number of stretching cycles and the scene temperature at the minimum number of stretching cycles were taken as the preheating temperature.

[0030] A third objective of this invention is to provide a progressive forming apparatus for an engine boss component, characterized by comprising a progressive die and a preheating assembly; the progressive die having an inlet end and an outlet end, the progressive die being used for stamping and forming high-temperature alloy materials; the preheating assembly being disposed at the inlet end of the progressive die, the preheating assembly being provided with a heating module for preheating the high-temperature alloy materials before they enter the progressive die.

[0031] In the above technical solution, preferably, the heating module includes a lower heating module and an upper heating module, and a preheating seam is provided between the lower heating module and the upper heating module to allow the high-temperature alloy material to pass through.

[0032] In the above technical solution, preferably, the lower heating module includes a lower mold body and a heating pipe embedded inside the lower mold body, the upper heating module includes an upper mold body and a heating pipe embedded inside the upper mold body, and the preheating seam is formed between the lower mold body and the upper mold body.

[0033] In the above technical solution, preferably, the heating tubes are arranged in rows along the seam surface of the preheating seam.

[0034] In the above technical solution, preferably, the heating element is an electric heating element, and the heating element is connected to a thermostat for controlling the temperature of the electric heating element. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the progressive forming device for the engine boss component in this invention;

[0036] Figure 2 This is a schematic diagram of the preheating component in this invention;

[0037] Figure 3 This is a schematic diagram of the progressive forming process of the engine boss component in this invention.

[0038] Figure 4 This is a schematic diagram of the punch structure in this invention;

[0039] Figures 5-7 This is a structural schematic diagram of the boss component product in this invention; Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0041] To address the problems of unstable product precision, poor consistency, high manufacturing costs, and low efficiency associated with traditional machining methods for engine mount components, this invention provides a progressive forming apparatus, process, and process design method for engine mount components. This process method offers advantages such as improved production efficiency, reduced costs, enhanced product precision and consistency, and reduced deformation risk, enabling the production of high-quality, high-efficiency engine mount products. To further illustrate the structure of this invention, a detailed description is provided below in conjunction with the accompanying drawings:

[0042] Example 1

[0043] A progressive forming apparatus for an engine boss component, please refer to [link / reference]. Figure 1 It includes progressive die 1 and preheating assembly.

[0044] Progressive dies have an inlet and an outlet end and are used for stamping and forming high-temperature alloy materials. A progressive die is a multi-station die consisting of multiple workstations or processes, each with different cutting, stamping, or shape-changing functions. Each time the die performs a pressing operation, the material gradually completes the various processes in consecutive workstations, ultimately forming the final product. Because the cutting or forming operations at each workstation are performed step-by-step, it is called a progressive die.

[0045] Progressive machining is a stamping process that uses progressive dies. In progressive machining, sheet metal or strip steel passes through different workstations of the progressive die, undergoing continuous stamping and deformation operations to ultimately obtain the formed part. Each workstation is responsible for completing specific processing steps, such as shearing, punching, bending, stretching, and punching bosses. By sequentially performing each process, progressive machining can efficiently achieve continuous production, improving production efficiency and ensuring product precision and consistency. Progressive dies enable high-speed, high-precision, and high-efficiency production, increasing the automation level of the production line, reducing costs, and also providing good consistency and repeatability.

[0046] The preheating assembly is located at the feed end of the progressive die, and its interior contains a heating module for preheating the high-temperature alloy material before it enters the progressive die. This heating module includes a lower heating module and an upper heating module, with a preheating slit between the two modules to allow the high-temperature alloy material to pass through.

[0047] The lower heating module consists of a lower mold body 2 and heating tubes 4 embedded within it, while the upper heating module consists of an upper mold body 3 and heating tubes embedded within it. A preheating seam is formed between the lower and upper mold bodies, so that the heating tubes are arranged in rows along the seam surface, and the heating tubes are horizontally positioned with their axes perpendicular to the feeding direction of the high-temperature alloy material. The heating tubes are electric heating tubes, which are connected to a temperature controller 5 to control their temperature.

[0048] Furthermore, the lower and upper mold bodies can be mounted and fixed to the lower mold base of the progressive die using a dedicated bracket. The heating element is connected to the power supply via power interface 6. The lower and upper mold bodies are hexahedral in shape, appearing as plate-like components of a certain thickness. Pads are installed on both sides between the lower and upper mold bodies to form a preheating gap between them. The heating element can be inserted into the lower and upper mold bodies through openings on their sides.

[0049] In short, a preheating assembly is a device installed at the feed end of a progressive die, comprising a lower heating module and an upper heating module with a preheating slit between them. The lower heating module consists of a lower die body and internal heating tubes, while the upper heating module consists of an upper die body and internal heating tubes. These heating tubes are electric heating tubes, and the temperature is controlled by a thermostat connected to them. The function of this preheating assembly is to preheat the high-temperature alloy material before it enters the progressive die.

[0050] This device utilizes the continuous production and high-speed production cycle of progressive dies to combine the heat generated during the continuous stretching of high-temperature alloy materials with the thermal energy of the material heating and temperature control system added to the front of the progressive die. This provides a special temperature environment for the raw material steel plate, and the optimal ambient temperature for stamping high-temperature alloy materials is determined through experimental measurements to ensure that the forming of the stretched part of the product meets the product performance requirements.

[0051] The working principle of this device is as follows: First, plug the power interface into a 220V socket and set the temperature using the temperature regulator. Once the power is on, the heating elements begin to heat up. The heating elements are distributed in two rows, forming a closed heating cavity. During the production process, the raw material steel plate is passed through the heating cavity for heating and then enters the mold for production.

[0052] The temperature field generated within the progressive die and the protrusion shaping structure of the die's upper forming block can alter the springback of the product, thereby ensuring dimensional requirements. During stretching at the product's front station, the resulting temperature field provides specific conditions for subsequent forming and shaping. At room temperature, high-temperature alloys exhibit significant springback, typically requiring experimental determination of the appropriate springback correction amount for dimensional compensation. However, controlling the springback of high-temperature alloys within a specific temperature field necessitates adding evenly distributed protrusions to the punch structure of the upper forming block and the correction surface block. These protrusions are spaced 0.25 mm apart and 0.05 mm high. When designing the dimensions of the upper forming and correction surface blocks, they are designed as lower tolerance dimensions based on theoretical data, i.e., a forming gap of 1.4 mm. The punch structure is as follows... Figure 4 As shown, after the mold closes, the protrusions are evenly distributed on the surface of the punch. The protrusions on the surface of the punch will be pressed into the surface of the material. The material surface will form a local compression tendency around each protrusion, causing the surrounding material to harden. The entire surface is subjected to compression. Due to the fine structural design of the protrusions relative to the surface of the punch, while ensuring the stamping surface shape of the material, the entire surface of the product can be hardened, thereby eliminating internal stress and achieving springback control to meet dimensional requirements.

[0053] Example 2

[0054] A method for designing a progressive forming process for an engine boss component includes the following steps:

[0055] S1. Determine the geometric parameters of the sample; In this embodiment, the semi-finished process part of the product is a stretching cylinder with an inner diameter of 7.6 mm and a height of 12 mm.

[0056] S2. Obtain the material physical properties parameters of the material formed at different temperatures through experiments;

[0057] S3. Design modification and experimental verification: Tensile forming tests were conducted on the sample at different temperatures, and the minimum number of stretching cycles and the scene temperature at the minimum number of stretching cycles were taken as the preheating temperature.

[0058] In existing technology, the tensile coefficient of material forming at different temperatures is calculated experimentally, and the number of stretching cycles is initially determined:

[0059] Based on material physical property parameters and relative thickness ,in For material thickness, This refers to the outer diameter of the sheet material.

[0060] Calculate the tensile coefficient in the first step , ;

[0061] A series of tensile coefficient values ​​were obtained using methods such as table lookup. , , , … ;

[0062] The diameter change at each step is calculated using the elongation coefficient value, for example... 0, ... until the product size requirements are met; according to the design manual and calculation formula, the stretching process of this product requires at least 8 stretching steps to meet the product size requirements.

[0063] This method involves taking values ​​for the stretching of the punch and die every two steps, reducing and determining the number of stretching steps for the die. A large number of material physical property parameters within the temperature field are collected. In this embodiment, the material physical property parameters include detailed tensile properties, density, thermal conductivity, coefficient of thermal expansion, specific heat capacity, elastic modulus, Poisson's ratio, and material fracture properties. These parameters are obtained experimentally or from specification manuals. By taking values ​​for the stretching of the punch and die every two steps, the number of stretching steps is ultimately reduced to five, and the resulting stretching coefficients are compiled into a database.

[0064] Example 3

[0065] For a progressive forming process of an engine boss component, please refer to [link / reference]. Figure 2 This includes the following steps:

[0066] S1. Preheating treatment of high-temperature alloy materials;

[0067] S2. The preheated high-temperature alloy strip is processed using a progressive die to produce a boss component. The progressive die processing of the preheated high-temperature alloy strip includes stamping and stretching as well as stamping and shearing. Further specific processing steps include:

[0068] 1) Stretch forming: This process forms the cylindrical part of the boss component in the shape of a protrusion, ensuring the height and dimensional accuracy requirements of the cylindrical part. Specifically, pre-punching is performed first, forming two 4mm diameter holes on the strip after stamping. Then, the strip is fed backward by one step to align the holes with the position of the first set of guide pins. When the mold closes, the guide structure guides the pins, followed by a ring cutting process, i.e., cutting two semicircular rings on the strip. The next step is to cut two more semicircles rotated 90 degrees at the same position. The distance between these two sets of rings is 1.9mm, forming two strip threads. The next step is to stretch a circular protrusion in the middle of the rings. To achieve the required dimensions, the protrusion needs to be stretched five times, ultimately reaching the required size.

[0069] 2) Stretch and flip-up forming: forming the flip-up flange section. The material on both sides of the stretch flange is flipped upward to form a semi-circular arc shape.

[0070] 3) Stretching and straightening the surface: The flange part is shaped. After the original upward forming process, a shaping process is added to ensure the springback variable during product forming, that is, the arc dimension requirement is achieved through two forming processes in the mold.

[0071] 4) Punching: Use a punch to cut away the top surface of the convex cylindrical part to form a through hole. The diameter of the punch is designed to be 0.05mm smaller than the original hole diameter.

[0072] 5) Extrusion flanging: Using a punch to correct the through hole. The punch size needs to be designed to be within tolerance of the dimensions required by the drawing. After the inner hole is corrected by flanging, there will be shrinkage, so the size range must be controlled within the tolerance range.

[0073] 6) Cutting: to obtain the finished product of the boss component.

[0074] The above processes can be summarized as follows, as shown in the diagram: pre-punching, ring cutting, ring cutting, first stretching, second stretching, third stretching, fourth stretching, fifth stretching, upward forming, surface correction, top surface cutting, inner hole correction, and cutting.

[0075] This design method adds a material heating and temperature control system to the front of the progressive die, providing a special temperature environment for the high-temperature alloy material before it enters the die for forming, thereby achieving the best stamping effect and ensuring that the forming of the stretched part of the product meets the performance requirements.

[0076] In summary, this design method adds evenly distributed protrusions to the punches of the forming block and the correction and shaping block on the mold, thereby controlling springback by eliminating internal stress in the material and ensuring product dimensional requirements.

[0077] This design method significantly reduces manufacturing costs by replacing all previous processes such as 3D printing, CNC turning, and CNC machining centers with automated production using progressive dies. Manufacturing costs are reduced by more than five times, with a daily production capacity of approximately 15,000 pieces. Compared to the traditional method, which can only produce 150 pieces per day, production efficiency is increased by more than 100 times.

[0078] This design method produces products with high precision and consistency. Through progressive die positioning, the positioning accuracy of each process reaches 0.02mm, eliminating repeated clamping and alignment deviations. This ensures the product's dimensional accuracy requirements meet customer needs. It replaces traditional machining processes, improving product quality, precision, and dimensional consistency while also increasing production efficiency.

[0079] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A progressive forming process for an engine boss component, characterized in that, Includes the following steps: S1. Preheating treatment of high-temperature alloy strip; S2. The high-temperature alloy strip after preheating is processed by a progressive die to obtain a boss component. The progressive die processes the high-temperature alloy strip by stretching, punching, extrusion and cutting. The preheating treatment is performed at the inlet end of the high-temperature alloy strip feeding into the progressive die; The chemical material of the high-temperature alloy strip is GH3044 solid solution strengthened nickel-based oxidation-resistant high-temperature alloy. The stretching includes stretch forming, stretching and turning, and stretching and correcting the profile; the extrusion includes extrusion and flanging; and the progressive die process for the preheated high-temperature alloy strip includes: 1) Stretch forming: forming the convex cylindrical part of the boss component; 2) Stretch and flip-up forming: forming the flip-up flange part; 3) Stretching and straightening the profile: The flange portion undergoes shaping treatment; 4) Punching: Use a punch to cut away the top surface of the convex cylindrical part to form a through hole; 5) Extrusion flanging: Using a punch to correct the through hole; 6) Cutting: to obtain the finished boss component; Evenly distributed protrusions are added to the punch structure of the upturning block in the stretching and upturning forming step and the correction surface block in the stretching and correction surface step.

2. A design method for a progressive forming process of the engine boss component according to claim 1, characterized in that... Includes the following steps: S1. Determine the geometric parameters of the sample; S2. Obtain the material physical properties parameters of the material formed at different temperatures through experiments; S3. Design modification and experimental verification: Tensile forming tests were conducted on the sample at different temperatures, and the minimum number of stretching cycles and the scene temperature at the minimum number of stretching cycles were taken as the preheating temperature.

3. A progressive forming apparatus for an engine boss component, referring to the progressive forming process of the engine boss component as described in claim 1, characterized in that... include: A progressive die, having an infeed end and an outlet end, is used for stamping and forming high-temperature alloy strip; A preheating assembly is provided at the feed end of the progressive die, and the preheating assembly is provided with a heating module for preheating the high-temperature alloy strip before it enters the progressive die.

4. The progressive forming apparatus for an engine boss component according to claim 3, characterized in that: The heating module includes a lower heating module and an upper heating module, and a preheating seam is provided between the lower heating module and the upper heating module to allow the high-temperature alloy strip to pass through.

5. The progressive forming apparatus for an engine boss component according to claim 4, characterized in that: The lower heating module includes a lower mold body and a heating tube embedded inside the lower mold body, and the upper heating module includes an upper mold body and a heating tube embedded inside the upper mold body. The preheating seam is formed between the lower mold body and the upper mold body.

6. The progressive forming apparatus for an engine boss component according to claim 5, characterized in that: The heating tubes are arranged in rows along the surface of the preheating seam.

7. The progressive forming apparatus for an engine boss component according to claim 6, characterized in that: The heating element is an electric heating element, and the heating element is connected to a thermostat for controlling the temperature of the electric heating element.

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