A high-precision diaphragm precision stamping forming process method

Abstract

The application provides a high-precision diaphragm precision stamping forming process method, which comprises the following steps: cutting to obtain a diaphragm blank; stamping and blanking and preforming a wave surface on the diaphragm blank; making the outer contour size of the preformed diaphragm and the R angle and wave height of the wave surface meet the preforming size requirements, and ensuring that the planes between the wave surfaces of the preformed diaphragm are wrinkle-free; performing wave surface correction on the preformed diaphragm, so that the R angle and wave height of the diaphragm wave surface meet the wave surface size and precision requirements of the diaphragm product; and processing the outer contour of the diaphragm after the wave surface correction, so that the outer contour of the diaphragm meets the outer contour size and precision requirements of the diaphragm product, and the diaphragm product is obtained. The application effectively solves the problems of poor wave surface forming precision and wrinkle generation of a high-precision diaphragm with a wave surface and a small deformation area when the stretching ratio is close to the limit, and improves the qualified rate and production efficiency of diaphragm forming.

Description

A high-precision diaphragm precision stamping process Technical Field

[0001] This invention relates to the field of diaphragm forming technology, and in particular to a high-precision diaphragm precision stamping forming process. Background Technology

[0002] As a sensitive element in pressure regulating devices used to sense outlet pressure, the diaphragm requires extremely high precision in terms of its corrugated surface dimensions and outer diameter to ensure stable and reliable operation.

[0003] The diaphragm of the voltage regulator is usually made of high-elastic alloy, and the diaphragm waveform deformation is small (less than 6%). After deformation, the rebound is large, and the height of the waveform is not easy to control. At the same time, the stretch ratio at the waveform deformation point is large, close to the material's elongation at break, and the area of ​​the planar part in the middle of the waveform is large, making it difficult to control the deformation in the middle area and easily causing wrinkles.

[0004] Existing pressure regulator diaphragm forming processes typically employ composite precision blanking technology, which involves blanking and one-time forming. This process has the following drawbacks:

[0005] The process requires the use of high-precision blanking dies and precise calculation of springback to compensate the blanking dies accordingly. Due to the performance fluctuations of the diaphragm raw materials, the compensated blanking die parameters and springback compensation amount cannot be applied to all batches of raw materials, resulting in poor process stability and an inability to guarantee the pass rate of diaphragm forming. Summary of the Invention

[0006] The technical problem solved by this invention is to overcome the shortcomings of the prior art and provide a high-precision diaphragm precision stamping process, which effectively solves the problem of poor forming accuracy of the waveform surface of the pressure regulator diaphragm when the stretch ratio is close to the limit and the deformation area is small.

[0007] The technical solution of this invention is:

[0008] A high-precision diaphragm precision stamping process, wherein the diaphragm is a wave-shaped diaphragm with a flat central area, includes the following steps:

[0009] (1) Shearing to obtain the diaphragm blank;

[0010] (2) Stamping blanking and preforming of the diaphragm blank; ensuring that the outer contour dimensions of the preformed diaphragm and the R angle and wave height of the wave surface meet the preforming size requirements, and ensuring that there are no wrinkles between the wave surfaces of the preformed diaphragm.

[0011] (3) The preformed diaphragm is shaped to ensure that the R-angle and wave height of the diaphragm wave surface meet the wave surface size and accuracy requirements of the diaphragm product;

[0012] (4) The outer contour of the diaphragm after the waveform surface is shaped is processed so that the outer contour of the diaphragm meets the outer contour size and accuracy requirements of the diaphragm product, and the diaphragm product is obtained.

[0013] Preferably, in step (2), the diaphragm blank is punched and preformed with a corrugated surface, which is specifically completed by a punch press and a preforming mold. The preforming mold includes an upper preforming mold and a lower preforming mold. The lower preforming mold is made of polyurethane rubber material and its processing surface is a plane. The outer edge of the upper preforming mold is a cutting tool, and the processing surface is provided with a corrugated surface for preforming the diaphragm blank. Under the punching force applied by the punch press, the upper preforming mold punches the diaphragm blank placed on the lower preforming mold, punches out the outer contour through the outer edge, and completes the preforming of the corrugated surface through the processing surface.

[0014] Preferably, the stamping pressure for blanking and preforming the corrugated surface of the diaphragm blank is 400KN~630KN.

[0015] Preferably, in step (3), the preformed film is shaped to form a waveform surface, which is specifically accomplished by a hydraulic press and a shaping mold. The shaping mold includes a shaping male mold and a shaping female mold. The processing surfaces of the shaping male mold and the shaping female mold are respectively provided with waveforms for shaping the waveform surface of the preformed film. Pressure is applied to the preformed film by the hydraulic press and the shaping mold. After the shaping male mold and the shaping female mold are closed, the pressure is maintained for a period of time to complete the waveform surface shaping of the film.

[0016] Preferably, the pressure applied to the preformed diaphragm during the waveform surface correction is 6MPa~10MPa.

[0017] Preferably, the pressure is maintained for 8s to 10s when the preformed diaphragm is shaped to correct its waveform.

[0018] Preferably, in the process of corrugating the preformed diaphragm, a guide sleeve is provided on the outside of the forming mold to prevent the diaphragm from sliding.

[0019] Preferably, the waveform dimensions of the preforming upper mold and the straightening mold compensate for the springback of the diaphragm material.

[0020] Preferably, the radius (R) of the preformed upper mold processing surface waveform is 0.8 to 0.9 times the radius (R) of the diaphragm product waveform surface, and the wave height of the preformed upper mold processing surface waveform is equal to the wave height of the diaphragm product waveform surface.

[0021] Preferably, the outer contour dimension of the preformed diaphragm is 1.1 to 1.2 times the outer contour dimension of the diaphragm product.

[0022] The advantages of this invention compared to the prior art are:

[0023] This invention pre-forms a pressure regulator diaphragm by punching, ensuring the waveform meets initial dimensional requirements and preventing wrinkles between the waveform surfaces. The pre-formed diaphragm is then precisely calibrated using a calibrating mold that compensates for springback, ensuring the waveform meets dimensional and accuracy requirements. Finally, the calibrated diaphragm undergoes precision machining of its outer contour to guarantee dimensional accuracy. This invention can be applied to different batches of raw materials, and the forming dimensions are unaffected by fluctuations in raw material properties, resulting in high product consistency and significantly improving the pass rate and production efficiency of high-precision waveform diaphragm forming. Attached Figure Description

[0024] Figure 1 is a schematic diagram of the high-precision diaphragm precision stamping process of the present invention.

[0025] Figure 2 is a schematic diagram of the high-precision diaphragm structure of the present invention;

[0026] Figure 3 is a schematic diagram of the high-precision diaphragm punching preforming process of the present invention;

[0027] Figure 4 is a schematic diagram of the high-precision diaphragm alignment process of the present invention;

[0028] Figure 5 is a schematic diagram of the machining process of the high-precision diaphragm shape according to the present invention. Detailed Implementation

[0029] The features and advantages of the present invention will become clearer and more explicit through the following detailed description.

[0030] In one specific embodiment, the raw material of the diaphragm is 3J21 high elastic alloy, the diaphragm product is a round diaphragm, as shown in Figure 2, the diaphragm thickness is 0.2mm, the wave height of the waveform is 0.6mm, the R angle is R1mm, the waveform is in the range of one-half to one-sixth of the radius of the circle, and the external dimensions are required to be Φ39±0.1mm.

[0031] A high-precision diaphragm precision stamping process, as shown in Figure 1, includes the following steps:

[0032] (1) Shearing to obtain the diaphragm blank;

[0033] Specifically, a shearing machine is used to cut the diaphragm material to obtain a 70mm×70mm square diaphragm blank, ensuring that the four corners of the blank are perpendicular;

[0034] (2) The diaphragm blank is punched and blanked and the corrugated surface is pre-formed so that the outer dimensions of the diaphragm are close to the final forming dimensions, the R angle and wave height of the corrugated surface meet the pre-forming dimension requirements, and the plane between the corrugated surfaces of the diaphragm is wrinkle-free.

[0035] Specifically, as shown in Figure 3, the female die of the punching preforming die is a polyurethane rubber punching die 3 with a flat surface, and the male die is a cutting template 1. The film blank 2 is placed on the polyurethane rubber punching die 3 and punched preforming is performed using an open double column press.

[0036] Furthermore, the punching pressure of the pre-forming punch is 400KN~630KN. During the pre-forming punch, the cutting template 1 is embedded in the polyurethane rubber die 3 to complete the blanking of the pre-formed film. The depth of the cutting template 1 embedded in the polyurethane rubber die 3 is 0.5mm.

[0037] Furthermore, the cutting template 1 is prepared according to the dimensional parameters of the preformed membrane, and the outline dimension of the cutting template 1 is Φ40±0.5mm and the thickness is 3mm;

[0038] Furthermore, since the waveform surface of the diaphragm will spring back after preforming, the mold needs to be compensated accordingly based on the amount of springback so that the waveform surface of the preformed diaphragm meets the requirements of the preformed wave height and R angle. The R angle of the waveform surface of the preformed diaphragm is 0.8 to 0.9 times that of the waveform surface R angle of the diaphragm product. Since the diaphragm will spring back after punching, the waveform surface wave height of the preformed male mold is set to the waveform surface wave height of the diaphragm product.

[0039] The pre-formed diaphragm has an external dimension of Φ40±0.5mm, a waveform R angle of R3mm, and a wave height of 0.5mm.

[0040] (3) The pre-formed diaphragm is shaped with a high-precision steel mold using a hydraulic press so that the wave height and R angle of the waveform surface meet the dimensional accuracy requirements of the diaphragm product.

[0041] Specifically, as shown in Figure 4, rigid male and female molds 4 and 6 are used to correct the shape of the pre-formed diaphragm 7. The male and female molds are compensated according to the springback amount so that the size and accuracy of the diaphragm after stamping and correction meet the requirements.

[0042] Furthermore, the high-precision stamping and shaping pressure is 6~10MPa. After the male and female molds are closed, pressure is maintained for 8~10s, thereby maintaining the consistency of the corrugated surface forming of the diaphragm product and avoiding inconsistencies in the final forming size due to hydraulic press pressure fluctuations. At the same time, it can ensure the consistency of the forming size of different batches of raw materials.

[0043] Furthermore, a guide sleeve 5 is installed on the outside of the mold during the calibration process to prevent the diaphragm from shifting during the stamping process, thereby improving the calibration accuracy.

[0044] The calibrated diaphragm waveform has an R-angle of R1mm and a wave height of 0.6mm, which meets the waveform size and accuracy requirements of the diaphragm product.

[0045] (4) Process the outer contour of the diaphragm to meet the size and precision requirements of the diaphragm product.

[0046] Specifically, the outer dimensions of the rectified diaphragm are machined using a lathe, as shown in Figure 5. A special fixture with the same waveform as the diaphragm is prepared. The diaphragm is placed in a special clamping fixture and first, its shape is positioned. It is then pressed onto the positioning mandrel 8 by the clamping device 10. The diaphragm's corrugated surface is used for positioning. During the cutting process, the clamping force of the clamping device 10 and the friction of the diaphragm against the clamping device 10 and the positioning mandrel 8 are used to ensure that the diaphragm does not rotate during the cutting process. At the same time, the positioning mandrel 8 is positioned by the lathe fixture positioning element 9. The fixture is aligned before cutting to ensure that the runout of the clamping end face is not greater than 0.02 mm. The machining allowance and feed rate are controlled during the cutting process until the outer diameter of the diaphragm meets the accuracy requirements.

[0047] The contents not described in detail in this specification are common knowledge to those skilled in the art.

Claims

1. A high-precision diaphragm precision stamping process, wherein the diaphragm is a wave-shaped diaphragm with a flat central area, characterized in that, The process includes the following steps: (1) cutting to obtain the diaphragm blank; (2) stamping and blanking the diaphragm blank and preforming the waveform surface; ensuring that the outer contour dimensions of the preformed diaphragm, as well as the R angle and wave height of the waveform surface, meet the preforming dimension requirements and that the plane between the waveform surfaces of the preformed diaphragm is wrinkle-free; (3) correcting the waveform surface of the preformed diaphragm so that the R angle and wave height of the waveform surface meet the waveform surface dimensions and accuracy requirements of the diaphragm product; (4) processing the outer contour of the diaphragm after waveform surface correction so that the outer contour of the diaphragm meets the outer contour dimensions and accuracy requirements of the diaphragm product, thereby obtaining the diaphragm. Product; In step (2), the diaphragm blank is punched and preformed with a corrugated surface, which is specifically completed by a punch press and a preforming mold. The preforming mold includes a preforming upper mold and a preforming lower mold. The preforming lower mold is made of polyurethane rubber material and its processing surface is a plane. The outer edge of the preforming upper mold is a cutting tool, and the processing surface is provided with a corrugated surface for preforming the diaphragm blank. Under the punching force applied by the punch press, the preforming upper mold punches the diaphragm blank placed on the preforming lower mold, punches out the outer contour through the outer edge, and completes the preforming of the corrugated surface through the processing surface.

2. The high-precision diaphragm precision stamping forming process method according to claim 1, characterized in that, The stamping pressure for blanking and preforming the corrugated surface of the diaphragm blank is 400KN~630KN.

3. The high-precision diaphragm precision stamping forming process method according to claim 1, characterized in that, In step (3), the preformed film is shaped to form a waveform surface. This is done by a hydraulic press and a shaping mold. The shaping mold includes a shaping male mold and a shaping female mold. The processing surfaces of the shaping male mold and the shaping female mold are respectively set with waveforms to shape the waveform surface of the preformed film. Pressure is applied to the preformed film by the hydraulic press and the shaping mold. After the shaping male mold and the shaping female mold are closed, the pressure is maintained for a period of time to complete the waveform surface shaping of the film.

4. The high-precision diaphragm precision stamping forming process method according to claim 3, characterized in that, The preformed diaphragm is subjected to waveform surface correction, and the pressure applied to the preformed diaphragm is 6MPa~10MPa.

5. The high-precision diaphragm precision stamping forming process method according to claim 4, characterized in that, The preformed diaphragm is subjected to waveform surface correction, and the pressure is maintained for 8s~10s.

6. The high-precision diaphragm precision stamping forming process method according to claim 5, characterized in that, The preformed diaphragm is shaped to a waveform surface, and a guide sleeve is provided on the outside of the shaping mold to prevent the diaphragm from sliding.

7. The high-precision diaphragm precision stamping forming process method according to claim 6, characterized in that, The waveform dimensions of the preforming upper mold and the straightening mold compensate for the springback of the diaphragm material.

8. A high-precision diaphragm precision stamping forming process according to any one of claims 1 to 7, characterized in that, The radius (R) of the preformed upper mold processing surface waveform is 0.8 to 0.9 times that of the diaphragm product waveform surface, and the wave height of the preformed upper mold processing surface waveform is equal to the wave height of the diaphragm product waveform surface.

9. A high-precision diaphragm precision stamping forming process according to any one of claims 1 to 7, characterized in that, The outer contour dimension of the preformed diaphragm is 1.1 to 1.2 times the outer contour dimension of the diaphragm product.

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