U-shaped bumper trial-manufacturing processing method

Abstract

The U-shaped bumper trial-manufacturing machining method comprises the steps that a bumper is divided into a first part and a second part, the first part comprises upper side plates of two side plates of the bumper, and the second part comprises lower side plates and a bottom plate of the two side plates of the bumper; the depth of the U-shaped groove of the second part is set to be 150 to 300 mm; two matched first-generation wood blanks are arranged according to the first part, and a matched second-generation wood blank is arranged according to the second part; processing the second-generation wood blank into a B surface of a second part; the two first-generation wood blanks are fixed to the end faces of the two lower side plates of the second-generation wood blank correspondingly; the two first-generation wood blanks are machined to form the B face of the first part; and the A face of the bumper is machined. The method has the advantages that the B face of the bumper is machined in a split mode, all parts of the B face of the second part can be machined in place, the machining efficiency of trial-manufactured workpieces is improved, and the research, development and manufacturing cycle of a whole vehicle is shortened.

Description

Technical Field

[0001] The invention relates to the technical field of trial production and processing, in particular to a trial production and processing method for a U-shaped bumper. Background Art

[0002] Before a car becomes a commercial vehicle and is put on the market, the vehicle structure is designed in the early stage. According to the data design structure, a vehicle model is made in a 1:1 ratio using CNC machining center equipment. The rear and front bumpers are trial-produced as single pieces. After processing, the vehicle model is debugged and assembled.

[0003] The rear guard and the front guard are U-shaped structures. Due to the limitation of the U-shaped structure, the positioning holes and assembly structures on the B surface of the rear guard and the front guard will collide with the main shaft of the equipment when processed with short tools. Even if the positioning holes and assembly feature parts are processed at the maximum swing angle of the five-axis machining center, especially the positioning holes near the bottom corner, they cannot be fully processed. The only way is to reduce the number of positioning holes, or change the design position of the positioning holes, or the parts that cannot be processed will be processed by the operator using manual tools later. However, manual processing efficiency is very low, and the processing accuracy and quality cannot be guaranteed. It cannot meet the assembly matching accuracy of the whole vehicle, and increases the labor intensity and working time of model matching and assembly processes.

[0004] The height from the high point of the B surface of the rear U-shaped structure to the low point of the U-shaped bottom is 600mm. If all milling is to be done, only a 300mm long tool can be used to meet the processing requirements. However, the use of long tools for processing is limited in cutting feed and spindle speed. Compared with short tools, the processing efficiency of long tools is very low, and the quality of the workpiece is also affected. Summary of the invention

[0005] In order to solve at least one of the above technical problems, the present invention provides a U-shaped bumper trial production method, which divides the bumper into a first part and a second part, first processes the second part, and then glues the first generation wood blank to the second part to process the first part, so that all parts of the workpiece can be processed in place.

[0006] The present invention solves the technical problem by adopting the following technical solution:

[0007] A U-shaped bumper trial production method comprises the following steps:

[0008] Step 1, dividing the bumper into a first part and a second part, wherein the first part includes the upper side panels of the two side panels of the bumper, and the second part includes the lower side panels and the bottom panel of the two side panels of the bumper; the depth of the U-shaped groove of the second part is set to 150-300 mm;

[0009] Step 2, setting two first-generation wooden blanks that match each other according to the first part, and setting two second-generation wooden blanks that match each other according to the second part;

[0010] Step 3, processing the second-generation wooden blank into the second part of the B surface;

[0011] Step 4, fix the two first-generation wooden blanks to the end surfaces of the two lower side panels of the second-generation wooden blank respectively;

[0012] Step 5: Process the two first-generation wooden blanks to obtain the B side of the first part;

[0013] Step 6: Process the A side of the bumper.

[0014] Furthermore, the second generation wooden blank is configured as a U-shaped blank or two L-shaped blanks, so that the shape of the second generation wooden blank matches the shape of the second part.

[0015] Furthermore, the bumper is divided into a first part and a second part by a first plane, and the first plane is arranged parallel to the bottom of the U-shaped groove.

[0016] Furthermore, the depth of the U-shaped groove of the second part is set to 150-200 mm, and each part of the B surface of the second part can be processed in place by using a short tool.

[0017] Furthermore, the first generation wooden blank is provided with two first positioning holes, and the end surface of each lower side panel of the second part is provided with two second positioning holes matched with the first positioning holes. The two first positioning holes and the two second positioning holes are positioned by two positioning pins, and the length of the positioning pins is not greater than the sum of the depths of the first positioning hole and the second positioning hole, so as to prevent slippage of the first generation wooden blank during bonding.

[0018] Further, the method of processing the second-generation wooden blank into the second part of the B surface includes:

[0019] Step 301, with the end surfaces of the two lower side plates of the second-generation wooden blank facing downward, the second-generation wooden blank is mounted on a first fixture, and the A surface of the second-generation wooden blank is roughly processed;

[0020] Step 302, installing the bottom of the U-shaped groove of the second-generation wooden blank on the second fixture, and rough-machining the B surface of the second-generation wooden blank;

[0021] Step 303: finish-process the B surface of the second-generation wooden blank, and process second positioning holes on the end surfaces of the two lower side panels.

[0022] Further, the method of processing the first-generation wooden blank into the first part of the B surface includes:

[0023] Step 401, processing two first positioning holes at the bottom of two first-generation wooden blanks;

[0024] Step 402: insert four positioning pins into four second positioning holes respectively;

[0025] Step 403, coating the end surfaces of the two lower side panels of the second generation wood blank with wood substitute glue, and respectively sleeve the two first positioning holes of the two first generation wood blanks on the corresponding positioning pins, so that the first generation wood blank fits the end surface of the lower side panel of the second generation wood blank;

[0026] Step 501, rough processing is performed on the A surface and the B surface of two first-generation wooden blanks;

[0027] Step 502: Finishing the B surfaces of the two first-generation wooden blanks.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] (1) The U-shaped bumper is divided into two parts, the B side of the second part is first machined, and then the first-generation wood blank is bonded to the second part and the B side of the first part is machined. This can reduce the depth of the second part of the U-shape and realize the split processing of the B side of the bumper. This solves the problem that the B side structure of large U-shaped workpieces such as the front and rear bumpers cannot be machined in place, and the operator needs to manually process the assembly positioning holes and assembly feature parts. This improves the processing efficiency of the trial-produced workpieces and shortens the vehicle R&D and manufacturing cycle.

[0030] (2) When machining the first and second B surfaces, the same fixture is used to clamp them. The machining program of the five-axis machining center can maintain the same coordinate system, and the quality is the same as that of machining the bumper B surface in one piece.

[0031] (3) After the entire B side of the bumper is processed, the bumper is turned over and the entire A side of the bumper is processed. This can achieve integrated processing of the A side of the bumper, improve processing accuracy, and meet the surface quality requirements of the exterior parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to better understand the above and other purposes, features, advantages and functions of the present invention, reference may be made to the embodiments shown in the accompanying drawings. The same reference numerals in the accompanying drawings refer to the same components. It should be understood by those skilled in the art that the accompanying drawings are intended to schematically illustrate the preferred embodiments of the present invention and have no limiting effect on the scope of the present invention, and the components in the drawings are not drawn to scale.

[0033] Figure 1 The figure is a flow chart of the trial production method of the U-shaped bumper of the present invention.

[0034] Figure 2 The figure is a process diagram of the trial production method of the U-shaped bumper of the present invention.

[0035] Figure 3 It is a schematic diagram of the second part of the structure of the U-shaped bumper of the present invention.

[0036] In the figure: 1-bumper; 11-first part; 12-second part; 121-lower side plate; 1211-second positioning hole; 122-bottom plate; 1221-assembly positioning hole; 1222-mounting hole; 1223-mounting groove; 21-first generation wooden blank; 22-second generation wooden blank; 3-second fixture. DETAILED DESCRIPTION

[0037] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the exemplary embodiments of the present invention are described below in conjunction with the accompanying drawings, including various details of the embodiments of the present invention to facilitate understanding, which should be considered as merely exemplary. Therefore, it should be recognized by those of ordinary skill in the art that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for the sake of clarity and conciseness, the description of well-known functions and structures is omitted in the following description.

[0038] In the description of the present invention, it should be noted that the term "including" and its variations represent open inclusion, that is, "including but not limited to". The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance. In addition, in the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0039] The present invention provides a U-shaped bumper trial production method, referring to Figure 1 and Figure 2 As shown, the following steps are included:

[0040] Step 1, dividing the bumper 1 into a first part 11 and a second part 12, wherein the first part 11 includes an upper side plate of two side plates of the bumper 1, and the second part 12 includes a lower side plate 121 and a bottom plate 122 of two side plates of the bumper 1; the depth of the U-shaped groove of the second part 12 is set to 150-300 mm;

[0041] Step 2: two first-generation wooden blanks 21 are arranged according to the first part 11, and two second-generation wooden blanks 22 are arranged according to the second part 12;

[0042] Step 3, processing the second generation wooden blank 22 to obtain the B surface of the second part 12;

[0043] Step 4, fix the two first-generation wooden blanks 21 to the end surfaces of the two lower side plates 121 of the second-generation wooden blank 22 respectively;

[0044] Step 5, processing the two first-generation wooden blanks 21 to obtain the B surface of the first part 11;

[0045] Step 6: Process the A side of the bumper 1.

[0046] The U-shaped bumper 1 includes two side panels and a bottom panel 122, and the two side panels and the bottom panel 122 form a U-shaped structure. The bumper 1 is divided into a first part 11 and a second part 12, and the two side panels are divided into an upper side panel and a lower side panel 121. The two upper side panels form the first part 11, and the two lower side panels 121 and the bottom panel 122 still form a U-shaped structure to form the second part 12. The depth of the U-shaped groove of the second part 12 is set to 150-300mm, preferably, the depth of the U-shaped groove of the second part 12 is set to 150-200mm. For example, the depth of the U-shaped groove of the second part 12 can be set to 150mm, 160mm, 170mm, 180mm, 190mm, 200mm, 210mm, 220mm, 230mm, 240mm, 250mm, 260mm, 270mm, 280mm, 290mm or 300mm, etc. The U-shaped bumper 1 can be segmented according to the 3D data of the U-shaped bumper 1 to determine the appropriate depth of the U-shaped groove of the second part 12. In this way, when the second-generation wooden blank 22 is processed into the B surface of the second part 12 by the five-axis machining center, the short tool can also be inserted into the bottom of the U-shaped groove of the second-generation wooden blank 22, so as to process the bottom of the U-shaped groove of the second-generation wooden blank 22 and the lower side plate 121 near the bottom, that is, all parts of the B surface of the second part 12 can be processed in place; after the first-generation wooden blank 21 is bonded, the short tool can still be inserted into the depth corresponding to the bottom of the first-generation wooden blank 21, and the entire B surface of the first-generation wooden blank 21 can be processed, that is, the short tool can be inserted into the depth of the dividing surface between the first part 11 and the second part 12, and the first-generation wooden blank 21 can be processed into the B surface of the first part 11.

[0047] The method completes the processing of the B surface of the first part 11 and the B surface of the second part 12 in sequence, that is, completes the processing of the entire B surface of the bumper 1. The B surface of the first part 11 and the B surface of the second part 12 can be clamped by the same fixture. The processing program of the five-axis machining center can maintain the same coordinate system and use the same coordinate origin to make the processing datum consistent, making the processing programming simpler, and the quality is the same as that of the B surface of the bumper 1 being processed in one piece. After the entire B surface of the bumper 1 is processed, the bumper 1 is turned over and the entire A surface of the bumper 1 is processed, which can achieve the integrated processing of the A surface of the bumper 1, improve the processing accuracy, and meet the surface quality requirements of the appearance parts.

[0048] The second generation wood blank 22 can be directly made of U-shaped blank or formed into a U-shape by gluing two L-shaped blanks, or it can be made of 1500mm*500mm*100mm standard generation wood boards gluing into a U-shape. In this way, the shape of the second generation wood blank 22 matches the shape of the second part 12, and the processing is more convenient and quick.

[0049] In one embodiment, the bumper 1 is divided into a first part 11 and a second part 12 by a first plane, and the first plane is arranged parallel to the bottom of the U-shaped groove. The bumper 1 is divided by the first plane so that the heights of the two lower side plates 121 of the second part 12 are substantially the same. When processing the two lower side plates 121 of the second part 12, the tool moves up and down by approximately the same distance, which is conducive to the preparation of the processing program and improves the processing efficiency.

[0050] In one embodiment, reference Figure 3 As shown, the first generation wooden blank 21 is provided with two first positioning holes, and the end face of each lower side plate 121 of the second part 12 is provided with two second positioning holes 1211 matched with the first positioning holes, and the two first positioning holes and the two second positioning holes 1211 are positioned by two positioning pins, and the length of the positioning pins is not greater than the sum of the depths of the first positioning hole and the second positioning hole 1211.

[0051] The first part 11 and the second part 12 are positioned by two positioning holes and positioning pins. When the first-generation wooden blank 21 is bonded to the end face of the lower side plate 121 of the second-generation wooden blank 22, the first-generation wooden blank 21 can be prevented from slipping, and the first-generation wooden blank 21 can be prevented from being cut or being cut when processing the first-generation wooden blank 21, so as to keep the relative position of the first-generation wooden blank 21 and the second part 12 stable. After the B surface of the second part 12 is processed, the B surface of the first-generation wooden blank 21 can be finely processed based on the first positioning hole, that is, based on the second positioning hole 1211, and the first part 11 and the second part 12 are clamped by the same second fixture 3. When processing the first-generation wooden blank 21 and the second-generation wooden blank 22, the processing program of the five-axis machining center can maintain the same coordinate system and use the same coordinate origin, so that the processing reference is consistent and the processing programming is simpler.

[0052] The length of the positioning pin is not greater than the sum of the depths of the first positioning hole and the second positioning hole 1211, so that the bottom surface of the first generation wooden blank 21 and the end surface of the lower side plate 121 of the second generation wooden blank 22 can be fitted together, so that the end surface center of the first positioning hole and the end surface center of the second positioning hole 1211 basically coincide with each other.

[0053] The A surface is the appearance surface, and the B surface has installation points reserved for installing other parts, such as assembly positioning holes 1221, installation holes 1222, installation grooves 1223, etc. The surface roughness of the A surface and the B surface must meet the corresponding requirements. According to the split first part 11 and the second part 12, processing processes can be formulated respectively.

[0054] In one embodiment, the method of processing the second-generation wood blank 22 to form the B surface of the second part 12 includes:

[0055] Step 301, with the end surfaces of the two lower side plates 121 of the second-generation wooden blank 22 facing downward, the second-generation wooden blank 22 is mounted on a first fixture, and the A surface of the second-generation wooden blank 22 is roughly processed;

[0056] Step 302, installing the bottom of the U-shaped groove of the second-generation wooden blank 22 on the second fixture 3, and rough-machining the B surface of the second-generation wooden blank 22;

[0057] Step 303 , finish-processing the B surface of the second-generation wooden blank 22 , and processing the second positioning holes 1211 on the end surfaces of the two lower side panels 121 .

[0058] First, the A surface of the second-generation wooden blank 22 is rough-processed, and then the B surface of the second-generation wooden blank 22 is rough-processed and fine-processed, so as to complete the fine processing of the B surface of the second part 12. At the same time, the second-generation wooden blank 22 is kept installed on the second clamp 3, and the first-generation wooden blank 21 can be directly bonded to the end surface of the lower side plate 121 of the second-generation wooden blank 22, thereby simplifying the processing technology and improving the processing efficiency.

[0059] In one embodiment, the method of processing the first generation wood blank 21 to obtain the B surface of the first part 11 includes:

[0060] Step 401, processing two first positioning holes at the bottom of two first-generation wooden blanks 21;

[0061] Step 402, insert four positioning pins into the four second positioning holes 1211 respectively;

[0062] Step 403, coating the end surfaces of the two lower side plates 121 of the second generation wood blank 22 with wood substitute glue, and respectively sleeve the two first positioning holes of the two first generation wood blanks 21 on the corresponding positioning pins, so that the first generation wood blank 21 fits the end surface of the lower side plate 121 of the second generation wood blank 22;

[0063] Step 501, rough processing is performed on the A surface and the B surface of the two first-generation wooden blanks 21;

[0064] Step 502 , finish processing the B surfaces of the two first-generation wooden blanks 21 .

[0065] According to the relative positions of the two second positioning holes 1211, the first positioning holes are processed at the bottom of the two first-generation wood blanks 21. The two second positioning holes 1211 are roughly arranged in the middle of the end face of the lower side plate 121. The distance between the two first positioning holes of the first-generation wood blank 21 can be measured with a ruler, and the two first positioning holes are processed in the middle position of the first-generation wood blank 21. When the first-generation wood blank 21 is fixed to the end face of the lower side plate 121 of the second-generation wood blank 22, the first-generation wood blank 21 is positioned by positioning pins so that the processing coordinate system of the first-generation wood blank 21 is consistent with the processing coordinate system of the second-generation wood blank 22, and the wood blank 21 is fixed by bonding with wood substitute glue. After waiting for the wood substitute glue to solidify, the first-generation wood blank 21 can be roughly processed, and then the B surface of the first part 11 can be finely processed. After completing the fine processing of the B surface of the first part 11, the entire bumper 1 can be turned over, and the turned-over bumper 1 is installed on the first fixture, and the entire A surface of the bumper 1 is finely processed.

[0066] The U-shaped bumper 1 is divided into two parts, the B surface of the second part 12 is first finely processed, and then the first-generation wooden blank 21 is bonded to the second part 12, and the B surface of the first part 11 is finely processed. The split processing of the B surface of the bumper 1 can be realized. When using a short tool for processing, the assembly positioning hole 1221 and other assembly feature parts of the B surface can be processed in place, which can also improve the processing efficiency and shorten the research and development trial processing time of the whole vehicle model, which is 20% higher than the overall clamping processing efficiency. At the same time, when processing the B surface of the first part 11 and the B surface of the second part 12, the same fixture is used for clamping, and the processing program of the five-axis machining center can maintain the same coordinate system, which is the same as the quality of the integrated processing of the B surface of the bumper 1, reducing the errors caused by the use of CNC machining technology to split the components and test and assemble them separately, and can also effectively reduce personnel costs and equipment costs.

[0067] After the entire B surface of the bumper 1 is processed, the bumper 1 is turned over and the entire A surface of the bumper 1 is processed, which can realize the integrated processing of the A surface of the bumper 1, improve the processing accuracy, and meet the surface quality requirements of the appearance parts. The B surface of the bumper 1 is first processed separately, and then the A surface is processed as a whole, which can ensure the processing accuracy and the overall structure of the shape, and the workpiece performance can meet the appearance display and dynamic test requirements at the same time.

[0068] The method can be applied to the trial production of U-shaped front bumpers and U-shaped rear bumpers, as well as other large U-shaped workpieces and complex workpieces with undercuts. It can solve the problem that the B-side structure of large U-shaped workpieces such as front bumpers and rear bumpers cannot be processed in place, and operators need to manually process the assembly positioning holes 1221 and other assembly feature parts. It can improve the processing efficiency of trial production workpieces and shorten the research and development and manufacturing cycle of complete vehicles.

[0069] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A U-shaped bumper trial production method, characterized in that: The following steps are involved: Step 1, dividing the bumper into a first part and a second part, wherein the first part includes the upper side panels of the two side panels of the bumper, and the second part includes the lower side panels and the bottom panel of the two side panels of the bumper; the depth of the U-shaped groove of the second part is set to 150-300 mm; Step 2, setting two first-generation wooden blanks that match each other according to the first part, and setting two second-generation wooden blanks that match each other according to the second part; Step 3, processing the second-generation wooden blank into the second part of the B surface; Step 4, fix the two first-generation wooden blanks to the end surfaces of the two lower side panels of the second-generation wooden blank respectively; Step 5: Process the two first-generation wooden blanks to obtain the B side of the first part; Step 6: Process the A side of the bumper.

2. The U-shaped bumper trial production method according to claim 1, characterized in that: The second generation wooden blank is configured as a U-shaped blank or two L-shaped blanks.

3. The U-shaped bumper trial production method according to claim 1, characterized in that: The bumper is divided into a first part and a second part by a first plane, and the first plane is arranged parallel to the bottom of the U-shaped groove.

4. The U-shaped bumper trial production method according to claim 1, characterized in that: The depth of the second U-shaped groove is set to 150-200 mm.

5. The U-shaped bumper trial production method according to claim 1, characterized in that: The first generation wooden blank is provided with two first positioning holes, and the end surface of each lower side panel of the second part is provided with two second positioning holes matched with the first positioning holes, the two first positioning holes and the two second positioning holes are positioned by two positioning pins, and the length of the positioning pins is not greater than the sum of the depths of the first positioning holes and the second positioning holes.

6. The U-shaped bumper trial production method according to claim 5, characterized in that: The method of processing the second-generation wooden blank into the B side of the second part includes: Step 301, with the end surfaces of the two lower side plates of the second-generation wooden blank facing downward, the second-generation wooden blank is mounted on a first fixture, and the A surface of the second-generation wooden blank is roughly processed; Step 302, installing the bottom of the U-shaped groove of the second-generation wooden blank on the second fixture, and rough-machining the B surface of the second-generation wooden blank; Step 303: finish-process the B surface of the second-generation wooden blank, and process second positioning holes on the end surfaces of the two lower side panels.

7. The U-shaped bumper trial production method according to claim 6, characterized in that: The method of processing the first-generation wooden blank into the B side of the first part includes: Step 401, processing two first positioning holes at the bottom of two first-generation wooden blanks; Step 402: insert four positioning pins into four second positioning holes respectively; Step 403, coating the end surfaces of the two lower side panels of the second generation wood blank with wood substitute glue, and respectively sleeve the two first positioning holes of the two first generation wood blanks on the corresponding positioning pins, so that the first generation wood blank fits the end surface of the lower side panel of the second generation wood blank; Step 501, rough processing is performed on the A surface and the B surface of two first-generation wooden blanks; Step 502: Finishing the B surfaces of the two first-generation wooden blanks.

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