A forming method and mold for unequal cross-section tube beam

Abstract

The present application relates to a forming die for a tube beam of unequal cross-section, which includes: a male die structure, which includes: a core rod, with mounting round blocks at both ends and a molding surface on it; a rotating ring, which is sleeved and rotatably connected to the mounting round block and a connecting rod on it; a female die structure, which includes: two pressing blocks, which are located between the two mounting round blocks and are respectively connected to the two connecting rods, and a first pressurizing chamber for containing liquid is provided in the pressing block; a pressure insert, which is connected to the two pressing blocks and a second pressurizing chamber for containing liquid is provided inside it. Since the female die structure is a universal structure and only the male die structure is a special structure, when facing different products, it is only necessary to replace the core rod in the male die structure, thereby reducing the production cost of the product and improving the universality of the die; in addition, due to the rotation of the pressure insert, universal processing of sheet materials and tube blanks is realized.

Description

Technical Field

[0001] The present application relates to the technical field of processing torsion tube beams, and in particular to a forming method and a mold for tube beams of unequal cross-sections. Background Art

[0002] At present, torsion tube beams have been widely used in A-class and A0-class vehicles due to their simple structure, small space occupation and low cost. For torsion tube beam structures, the biggest problem in current development and application is fatigue cracking. Under extreme conditions such as wheel reverse bounce and rotary torque reverse loading, the service conditions of torsion tube beams are poor. Fatigue cracking is the biggest challenge of torsion tube beam structures. Therefore, fatigue cracking resistance is the key to the design of torsion tube beam structures, so they are generally designed as torsion tube beams with unequal cross-sections.

[0003] In some related technologies, in the processing of bent tube beams of unequal cross-sections of automobile frames, internal high pressure or stamping + coil welding is generally used for manufacturing and processing. For internal high pressure, products with complex cross-sections need to be preformed and then internal high pressure forming. The number of mold sets is at least two, and the molds are basically special molds; it has the following problems:

[0004] Two sets of special molds are needed, the product requires many stamping processes, and the male and female molds between the various processes cannot be shared, so the versatility is poor.

[0005] In other related technologies, the equipment used includes a die set, a pipe bending mechanism, a hydraulic system and a sealing mechanism arranged at both ends of the die set; the die set is used to clamp and bulge the pipe to be processed, and the hydraulic system provides bulging internal pressure for the pipe to be processed; the die set includes a first die and a second die arranged opposite to each other; the pipe bending mechanism includes a rotatable bending arm, and when the bending arm rotates, the first die and the second die are driven to rotate synchronously; the second die is provided with a pipe bending groove, and as the second die rotates, the pipe bending groove acts on the pipe to bend it; the double action of bulging and pipe bending is realized on one device; however, there are the following problems:

[0006] This method is mainly used for the forming of closed heterogeneous cross-section tubular beams. The initial blank is a closed tubular beam. The internal high pressure requires that the initial blank must be a closed tubular beam to ensure that the internal pressure is applied uniformly everywhere. This method is not applicable to the initial blank that is a flat plate. Summary of the invention

[0007] The embodiment of the present application provides a forming method and a mold for a tubular beam of unequal cross-section, so as to solve the problem that the male and female molds cannot be shared between various processes in the related art and the versatility is poor.

[0008] In a first aspect, a forming die for a tube beam of unequal cross-section is provided, comprising:

[0009] The male mold structure comprises:

[0010] - a mandrel having mounting blocks at both ends and a profiled surface;

[0011] - a rotating ring, which is sleeved and rotatably connected to the mounting round block and on which a connecting rod is provided;

[0012] The die structure comprises:

[0013] - two pressing blocks, which are located between the two mounting round blocks and are respectively connected to the two connecting rods, and the pressing blocks are provided with a first pressurized chamber for containing liquid;

[0014] - a pressure insert, which is connected to the two pressure blocks and has a second pressure chamber for containing liquid inside.

[0015] In some embodiments, a solution channel communicating with the first pressurized chamber is provided in the connecting rod;

[0016] The pressure insert is connected with a liquid containing pipe which is in communication with the second pressurizing chamber; the first pressurizing chamber is not in communication with the second pressurizing chamber.

[0017] In some embodiments, the mandrel comprises:

[0018] Two process supplementary sections, which are respectively connected to the two mounting round blocks;

[0019] A plurality of profile segments are selectively detachably connected to two process supplementary segments.

[0020] In some embodiments, a positioning pin is provided on the process supplement section.

[0021] In some embodiments, the pressure insert includes two parts, a first part and a second part are connected to form an arc; or,

[0022] The pressure insert comprises two parts, and a designed angle is formed between the first part and the second part.

[0023] In some embodiments, a limiting fixing block is provided at one end of the mounting round block away from the core rod.

[0024] In some embodiments, a first tooth surface is provided on the outer circumference of the mounting round block, a mounting groove is provided in the rotating circle, and a planetary gear meshing with the first tooth surface is provided in the mounting groove; the connecting rod passes through the planetary gear and is rotationally connected to the planetary gear; or,

[0025] The rotating circle is in sliding contact with the mounting round block.

[0026] In some embodiments, a driving member is further included;

[0027] The outer surface of the rotating ring is provided with a second tooth surface for meshing, and the driving member is meshed with the second tooth surface; or,

[0028] An intermediate rod is fixedly connected to the end surface of the rotating circle, and the driving member is fixedly connected to the end surface of the rotating circle through the intermediate rod.

[0029] In a second aspect, a method for forming a tubular beam of unequal cross-section is provided, which comprises the following steps:

[0030] Design the corresponding mandrel according to the product structure and make the forming mold of the tube beam with different cross sections;

[0031] The bottom of the sheet or tube is fitted with the pressure insert, and one side of the sheet or tube is in contact with the mandrel;

[0032] Flushing liquid into the first pressurizing chamber and the second pressurizing chamber to pressurize the sheet or tube blank so that the sheet or tube blank is partially deformed and fits the core rod;

[0033] Depressurizing the first pressurized chamber and the second pressurized chamber, and rotating the pressurized insert using a rotating ring;

[0034] Flushing liquid into the first pressurizing chamber and the second pressurizing chamber to pressurize the remaining part of the sheet or tube blank;

[0035] Repeat the above steps to complete the forming of the entire sheet or tube.

[0036] In some embodiments, during the process of injecting liquid into the first pressurized chamber and the second pressurized chamber for pressurization, the two rotating circles are controlled to rotate in opposite directions.

[0037] The beneficial effects of the technical solution provided by this application include:

[0038] The embodiment of the present application provides a forming method and mold for tubular beams of unequal cross-sections. Since the die structure is a universal structure and only the punch structure is a special structure, when facing different products, it is only necessary to replace the core rod in the punch structure, which can further reduce the product production cost, improve the mold commonality rate, and provide a new process for the production of tubular beams.

[0039] In addition, due to the setting of the pressure insert and the pressure block, the product forming is achieved by controlling the pressure in the first pressurized chamber and the second pressurized chamber. During operation, a part of the sheet material or the tube contacts the core rod first. After the extrusion of this part is completed, the first pressurized chamber and the second pressurized chamber are depressurized, and the pressure insert is rotated by the rotating ring, the connecting rod and the mounting round block to pressurize the remaining part. Finally, the forming of the rear pipe beam is completed to adapt to the materials of the sheet material and the tube blank. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0041] Figure 1 A schematic diagram of the structure of a mandrel provided in an embodiment of the present application;

[0042] Figure 2 A schematic structural diagram of a forming die for a tubular beam of unequal cross-section provided in an embodiment of the present application;

[0043] Figure 3 A cross-sectional schematic diagram of the connection between the pressing block and the pressure insert provided in an embodiment of the present application;

[0044] Figure 4 The specific connection form of the rotating circle and the mounting round block provided in the embodiment of the present application;

[0045] Figure 5 A schematic diagram of the connection between the connecting rod and the planetary gear provided in an embodiment of the present application.

[0046] In the figure: 1, core rod; 100, process supplement section; 101, profile section; 2, mounting round block; 3, rotating circle; 4, connecting rod; 5, pressure block; 6, first pressurized chamber; 7, pressure insert; 8, second pressurized chamber; 9, liquid containing tube; 10, limit fixing block; 11, first tooth surface; 12, planetary gear. DETAILED DESCRIPTION

[0047] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0048] The embodiment of the present application provides a forming method and a mold for a tubular beam of unequal cross-section, so as to solve the problem that the male and female molds cannot be shared between various processes in the related art and the versatility is poor.

[0049] See also Figure 1-Figure 3A forming die for a tubular beam of unequal cross-section comprises: a male die structure and a female die structure; wherein the male die structure comprises: a core rod 1, a mounting round block 2, a connecting rod 4 and a rotating ring 3; mounting round blocks 2 are provided at both ends of the core rod 1, and a molding surface is provided thereon; the rotating ring 3 is sleeved and rotatably connected to the mounting round block 2, and a connecting rod 4 is provided thereon.

[0050] The die structure includes: two pressing blocks 5, which are located between the two mounting round blocks 2 and are respectively connected to the two connecting rods 4, and a first pressurized chamber 6 for containing liquid is provided in the pressing block 5; a pressure insert 7, which is connected to the two pressing blocks 5 and has a second pressurized chamber 8 for containing liquid inside.

[0051] When in use: fit the bottom of the sheet or tube blank with the pressure insert 7, and make one side of the sheet or tube blank contact with the core rod 1; inject liquid into the first pressurizing chamber 6 and the second pressurizing chamber 8 to pressurize, so that the sheet or tube blank is partially compressed and deformed to fit the core rod 1; release the pressure in the first pressurizing chamber 6 and the second pressurizing chamber 8, and rotate the pressure insert 7 by using the rotating ring 3; inject liquid into the first pressurizing chamber 6 and the second pressurizing chamber 8 to pressurize the rest of the sheet or tube blank; repeat the above steps to complete the forming of the entire sheet or tube blank.

[0052] Thus, through the above structure, since the die structure is a universal structure and only the convex structure is a special structure, when facing different products, only the core rod 1 in the convex structure needs to be replaced, which can further reduce the production cost of the product, improve the universality of the mold, and provide a new process for the production of pipe beams. The profile of the core rod 1 is adapted to the shape of the pipe beams of different cross-sections required, and different pipe beams have different corresponding profiles.

[0053] In addition, due to the setting of the pressure insert 7 and the pressure block 5, the product molding is realized by controlling the pressure of the first pressurized chamber 6 and the second pressurized chamber 8. During operation, a portion of the sheet material or the tube first contacts the core rod 1, and after the extrusion of this portion is completed and the core rod 1 is completely fitted; the first pressurized chamber 6 and the second pressurized chamber 8 are depressurized, and then the pressure insert 7 is rotated by the rotating ring 3, the connecting rod 4 and the mounting round block 2 to pressurize the remaining portion, and finally the sheet material or the tube completely covers and fits the core rod 1, completing the molding of the tube beam to adapt to the material of the sheet material and the tube blank. The core rod 1 does not rotate during the above process.

[0054] In some related technologies, the pressurization and depressurization of the pressing block 5 and the pressure insert 7 can be controlled by the same pipeline; they can also be controlled separately. In this embodiment, separate control is used as a preferred solution, which can be referred to Figure 3 As shown:

[0055] The connecting rod 4 is provided with a solution channel connected to the first pressurized chamber 6; since the connecting rod 4 has multiple channels, pressurization and pressure relief can be achieved; the pressure insert 7 is connected to a liquid-containing tube 9 connected to the second pressurized chamber 8, and the first pressurized chamber 6 is not connected to the second pressurized chamber 8. The liquid-containing tube 9 has multiple channels that can realize liquid inlet and outlet, pressurization and pressure relief.

[0056] By setting a solution channel in the connecting rod 4, there is no need to set up an additional pipeline, thereby simplifying the structure; the first pressurized chamber 6 and the second pressurized chamber 8 are not connected, so better control can be achieved, so that the pressure block 5 is first used to pressurize the first pressurized chamber 6 of the pressure block 5, so that the pressure insert 7 is pressed down and fits to the surface of the core rod 1, and then the second pressurized chamber 8 of the pressure insert 7 is pressurized. At the same time, the same pressure is applied to the first pressurized chamber 6 of the pressure block 5 to ensure that the pressure insert 7 is always tightly fitted to the surface of the core rod 1 to prevent liquid leakage. Under the action of pressure, the sheet or tube blank slowly fits onto the core rod to achieve product molding.

[0057] In some preferred embodiments, since the male mold structure is a dedicated structure, the following settings are made to facilitate replacement when facing different products:

[0058] The mandrel 1 comprises: two process supplementary sections 100 and a plurality of profile sections 101; the two process supplementary sections 100 are respectively connected to two mounting round blocks 2; and the plurality of profile sections 101 are selectively connected to the two process supplementary sections 100 in a detachable manner. The detachable connection may be in the form of connection holes provided on the process supplementary sections 100 and the plurality of profile sections 101, and fastening screws provided in the connection holes; a groove provided on the process supplementary section 100, a convex block matching the groove provided on the profile section 101, and a pin passing through the process supplementary section 100 and the convex block in the groove.

[0059] Therefore, the profile segment 101 can be quickly replaced through the above structure, further reducing the cost of the special punch and improving the versatility.

[0060] Furthermore, in order to prevent the sheet material or the tube blank from shifting during the pressing and forming process, a positioning pin is provided on the process supplement section 100 .

[0061] In some preferred embodiments, in order to facilitate the movement of the pressure insert 7 during the rotation process and facilitate the pressure insert 7 to quickly fit and contact the sheet or tube blank, the following settings are made:

[0062] In the first type, the pressure insert 7 includes two parts, a first part and a second part are connected to form an arc, and the sizes of the first part and the second part are completely the same or different.

[0063] The second type is that the pressure insert 7 includes two parts, and a design angle is formed between the first part and the second part. The design angle is a right angle or an acute angle according to the actual setting. The hard rubber support used by the pressure insert 7 can withstand a certain pressure.

[0064] In some preferred embodiments, in order to prevent the mandrel 1 from rotating and fix the mandrel 1, the following settings are made:

[0065] A limit fixing block 10 is provided at one end of the installation round block 2 away from the core rod 1. The limit fixing block 10 can be fixed with corresponding tooling, and the tooling here is not limited, as long as it can fix the limit fixing block 10.

[0066] In some preferred embodiments, to realize the rotation of the rotating circle 3, refer to Figure 4 and Figure 5 Give the specific structure:

[0067] The first one is that a first tooth surface 11 is provided on the outer circumference of the mounting round block 2, a mounting groove is provided in the rotating circle 3, and a planetary gear 12 meshing with the first tooth surface 11 is provided in the mounting groove; the connecting rod 4 passes through the planetary gear 12 and is rotationally connected with the planetary gear 12.

[0068] When rotating, the planetary gear 12 rotates along the first tooth surface 11. Such a structure utilizes the meshing between teeth to achieve controllable rotation each time, so as to facilitate segmented pressing.

[0069] The second type is that the rotating circle 3 is in sliding contact with the mounting round block 2. This form can certainly also be realized, but it is not as effective as the first structure and is used as an alternative form.

[0070] In some preferred embodiments, a power source is necessary to realize the rotation of the rotating circle 3. Two forms of the power source are given below:

[0071] The first type also includes a driving member, and the outer surface of the rotating ring 3 is provided with a second tooth surface for meshing, and the driving member meshes with the second tooth surface through a transmission gear.

[0072] The second type is that an intermediate rod is fixedly connected to the end surface of the rotating circle 3, and the driving member is fixedly connected to the end surface of the rotating circle 3 through the intermediate rod.

[0073] Both of the above forms can drive the rotating ring 3 to rotate to achieve indexing. It should be understood that the power for deformation comes from the pressure generated by the liquid introduced into the pressure block 5 and the pressure insert 7, and the rotating ring 3 provides the power for rotation after each extrusion deformation.

[0074] The present application also proposes a method for forming a tubular beam of unequal cross-section, comprising the following steps:

[0075] Design a corresponding core rod 1 according to the product structure, and make a forming mold for a tube beam of unequal cross-section; fit the bottom of the sheet or tube blank with the pressure insert 7, and make one side of the sheet or tube blank contact with the core rod 1; inject liquid into the first pressurizing chamber 6 and the second pressurizing chamber 8 to pressurize the sheet or tube blank so that part of it is compressed and deformed to fit the core rod 1; release the pressure in the first pressurizing chamber 6 and the second pressurizing chamber 8, and rotate the pressure insert 7 by using the rotating ring 3; inject liquid into the first pressurizing chamber 6 and the second pressurizing chamber 8 to pressurize the rest of the sheet or tube blank; repeat the above steps to complete the forming of the entire sheet or tube blank.

[0076] The following is a detailed description:

[0077] Firstly, a corresponding process supplement is designed according to the product structure, a corresponding core rod 1 is processed according to the process supplement, and the core rod 1 is connected to the mounting round block 2.

[0078] At the initial moment, the sheet or tube blank is positioned by relying on the positioning pins on the process supplement section 100, and the lower pressure block 5 and the lower pressure insert 7 are both at the bottom of the sheet, playing a certain supporting role, and the gap between them is zero; at this time, the first pressurizing chamber 6 of the pressure block 5 is pressurized to make the pressure insert 7 move closer to the core rod 1 and fit to the surface of the core rod.

[0079] Then, the second pressurized chamber 8 of the pressure insert 7 is pressurized, and the same pressure is applied to the second pressurized chamber 8 of the pressure block 5, to ensure that the pressure insert 7 is always tightly attached to the surface of the mandrel 1 to prevent liquid leakage. Under the action of pressure, the sheet tube slowly fits onto the punch of the mandrel 1 to achieve product molding.

[0080] When the forming process is completed, the first pressurized chamber 6 and the second pressurized chamber 8 are depressurized at the same time. After the pressure relief is completed, the driving member drives the rotating circle 3 to rotate the square pressure block 5 and the pressure insert 7 to a certain angle, and then the next forming process is carried out. When the rotating circle 3 rotates 180° each, the forming of the entire product can be completed. After the entire forming process is completed, the first pressurized chamber 6 and the second pressurized chamber 8 are discharged, and the formed pipe beam is taken out, and the desired product can be obtained through subsequent welding.

[0081] In summary, the use of the above device can further reduce product production costs, improve the commonality of molds, and provide a new process for the production of pipe beams.

[0082] In the description of the present application, it should be noted that the terms "upper", "lower", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application. Unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be a connection between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to the specific circumstances.

[0083] It should be noted that, in this application, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the presence of other identical elements in the process, method, article or device including the elements.

[0084] The above description is only a specific implementation of the present application, so that those skilled in the art can understand or implement the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest range consistent with the principles and novel features applied for herein.

Claims

1. A forming die for a tube beam of unequal cross-section, characterized in that: It includes: The male mold structure comprises: - a mandrel (1) having mounting blocks (2) at both ends and a profiled surface; - a rotating ring (3), which is sleeved and rotatably connected to the mounting round block (2) and on which a connecting rod (4) is provided; A first tooth surface (11) is provided on the outer circumference of the mounting round block (2); a mounting groove is provided in the rotating circle (3); a planetary gear (12) meshing with the first tooth surface (11) is provided in the mounting groove; the connecting rod (4) passes through the planetary gear (12) and is rotationally connected to the planetary gear (12); Or, the rotating circle (3) is in sliding contact with the mounting round block (2); The die structure comprises: - two pressing blocks (5), which are located between the two mounting round blocks (2) and are respectively connected to the two connecting rods (4), and a first pressurizing chamber (6) for containing liquid is provided in the pressing block (5); - A pressure insert (7) which is connected to the two pressure blocks (5) and has a second pressure chamber (8) inside for containing liquid.

2. The forming die for the unequal cross-section tubular beam according to claim 1, characterized in that: The connecting rod (4) is provided with a solution channel communicating with the first pressurizing chamber (6); The pressure insert (7) is connected to a liquid containing pipe (9) which is in communication with the second pressurizing chamber (8); the first pressurizing chamber (6) is not in communication with the second pressurizing chamber (8).

3. The forming die for the unequal cross-section tube beam according to claim 1, characterized in that: The mandrel (1) comprises: Two process supplementary sections (100), which are respectively connected to the two mounting round blocks (2); A plurality of profile segments (101) are selectively detachably connected to two process supplementary segments (100).

4. The forming die for the unequal cross-section tubular beam according to claim 3, characterized in that: The process supplement section (100) is provided with a positioning pin.

5. The forming die for the unequal cross-section tube beam according to claim 1, characterized in that: The pressure insert (7) comprises two parts, a first part and a second part are connected to form an arc; or, The pressure insert (7) comprises two parts, and a designed angle is formed between the first part and the second part.

6. The forming die for the unequal cross-section tube beam according to claim 1, characterized in that: A limiting fixing block (10) is provided at one end of the mounting round block (2) away from the core rod (1).

7. The forming die for the unequal cross-section tube beam according to claim 1, characterized in that: Also includes a drive member; The outer surface of the rotating ring (3) is provided with a second tooth surface for meshing, and the driving member meshes with the second tooth surface; or, An intermediate rod is fixedly connected to the end surface of the rotating circle (3), and the driving member is fixedly connected to the end surface of the rotating circle (3) via the intermediate rod.

8. A method for forming a tubular beam of unequal cross-section, characterized in that: It includes the following steps: Designing a corresponding core rod (1) according to the product structure, and manufacturing a forming mold for the unequal cross-section tube beam as claimed in any one of claims 1 to 7; The bottom of the sheet material or the tube blank is fitted with the pressure insert (7), and one side of the sheet material or the tube blank is in contact with the mandrel (1); Flushing liquid into the first pressurizing chamber (6) and the second pressurizing chamber (8) to apply pressure, so that the sheet material or the tube blank is partially deformed under pressure to fit the core rod (1); Relieving the pressure in the first pressurized chamber (6) and the second pressurized chamber (8), and rotating the pressure insert (7) using the rotating ring (3); Flushing liquid into the first pressurizing chamber (6) and the second pressurizing chamber (8) to pressurize the remaining part of the sheet material or the tube blank; Repeat the above steps to complete the forming of the entire sheet or tube.

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