An automated production line for hot forming of aerospace aluminum alloy and its production process

Abstract

This invention provides an automated production line and process for the warm forming of aerospace aluminum alloys. The production line includes a solution treatment furnace, a transfer device, a hot press, a stamping die, and an aging furnace. The heated sheet metal from the outlet of the solution treatment furnace is transferred to the hot press via the transfer device. A robotic arm is mounted on the side of the hot press near the solution treatment furnace via a robotic arm beam. The robotic arm moves back and forth between the solution treatment furnace, the transfer device, the hot press, and the aging furnace, conveying the sheet metal into the mold cavity of the stamping die. The transfer device includes a transfer frame for transferring the sheet metal, an end effector, and an insulating shell mounted on the end effector. This invention solves the problem of sudden temperature drops during aluminum alloy transfer by using a transfer device with an insulating function, achieving warm forming of aluminum alloys. Compared to hot forming and W-forming production lines, it eliminates the aging process for aluminum alloys, greatly improving production efficiency.

Description

Technical Field

[0001] This invention mainly relates to the field of aluminum alloy hot forming technology for large aerospace components, specifically to an automated production line and production process for warm stamping forming of aerospace aluminum alloys. Background Technology

[0002] With the gradual maturation of domestic aviation technology, the localization of large, thin-walled aerospace structural components such as engine lips is imperative. However, due to the high strength and low elastic modulus of aerospace aluminum alloys, room temperature forming results in low plasticity, making it difficult to form complex components. In recent years, warm forming has been proposed, heating the material to 200-300℃ to improve its dislocation migration ability and reduce its deformation resistance, ultimately enabling the forming of complex components. However, in actual production, uneven cooling of the sheet metal leads to significant thermal stress and springback, preventing the industrial application of warm forming of aluminum alloys.

[0003] A published Chinese invention patent, application number CN105834268A, entitled "Hot Stamping Forming Production Line for Aluminum Alloy Sheets," was filed on March 28, 2016. It employs a box furnace with a rolling mechanism to directly heat both sides of the sheet material with flame spraying. However, the furnace structure is complex, and the heating temperature of the sheet material is uneven, making mass production in industry difficult. Furthermore, this material cannot be practically applied industrially to large aerospace components. Summary of the Invention

[0004] To address the aforementioned deficiencies in the prior art, this invention provides an automated production line for the warm forming of aerospace aluminum alloys, comprising a solution treatment furnace 7, a transfer device, a hot press 8, a stamping die 9, and an aging furnace. The discharge end of the solution treatment furnace 7 transfers the heated sheet metal to the hot press 8 via the transfer device. A robotic arm 10 is mounted on the side of the hot press 8 near the solution treatment furnace 7 via a robotic arm beam 5. The robotic arm 10 moves back and forth between the solution treatment furnace 7, the transfer device, the hot press 8, and the aging furnace, and conveys the sheet metal into the mold cavity of the stamping die 9.

[0005] The transfer device includes a transfer frame 11 for transferring sheet metal, an end effector, and an insulation shell 13 installed on the end effector. The end effector includes a connecting plate 6, a longitudinal beam 4, an aluminum tube 2, and a clamp 1. The top of the connecting plate 6 is mounted on a robot arm 10, and the bottom is fixed on a pair of parallel longitudinal beams 4. The aluminum tube 2 is vertical and passes through the longitudinal beams 4 and is fixed by an aluminum tube fixing seat 3. Clamps 1 for clamping sheet metal are also installed at both ends of the aluminum tube 2.

[0006] Preferably, the aluminum tube 2 is provided in two types: a long aluminum rod and a short aluminum rod. The outer circumference of the plate is clamped by clamps 1 installed at both ends of the long aluminum rod, and the inner circumference of the plate is clamped by clamps 1 installed at both ends of the short aluminum rod.

[0007] Preferably, there are three long aluminum rods at equal intervals, two short aluminum rods at equal intervals, and long aluminum rods and short aluminum rods are spaced apart.

[0008] Preferably, the heat insulation shell 13 is installed at the bottom of the longitudinal beam 4 and the transverse beam 5, and is fixed inside by multiple round rods. The temperature of the heat insulation shell 13 is controlled at 200-300 degrees Celsius. The inner side of the heat insulation shell 13 is coated with a thermal barrier coating and is equipped with a temperature sensor for multi-point temperature measurement.

[0009] Preferably, the stamping die 9 is provided with a cooling system, which includes a cooling pipe disposed in the lower die 12. Both ends of the cooling pipe pass through the lower die 12 and the amount of water entering and exiting is controlled by a water valve.

[0010] Preferably, the solution treatment furnace 7 is a roller furnace or a box furnace, and is equipped with a circulating fan, with a heating rate of 25-200℃ / min and a maximum heating temperature of 400-700℃.

[0011] Preferably, the end effector is made of aluminum-magnesium alloy or carbon fiber composite material.

[0012] A production process for an automated production line for the hot forming of aerospace aluminum alloys includes the following steps:

[0013] Step S1: Solution heat treatment:

[0014] The sheet material is heated in a solution heating furnace at 500-550℃ and held at that temperature for 10-50 minutes, while the transfer device is placed close to the solution heating furnace.

[0015] Step S2: Clamping the sheet metal:

[0016] After the heat treatment in step S1, the plate is moved to the furnace opening by a transfer device. The robot arm is started, and the lowering end picker grabs the plate. The plate is picked up and put into the heat preservation shell within 0-10 seconds.

[0017] Step S3: Transfer the sheet metal and feed it into the mold cavity:

[0018] After step S2, the sheet metal moves to the stamping die within 1-20 seconds via the transfer device. At this time, the mechanical gripper transfers the aluminum alloy sheet metal into the die cavity within 0-5 seconds. The transfer device then exits from the hot press, and the transfer ends at a temperature of 450-500℃.

[0019] Step S4: Hot stamping forming:

[0020] After step S3, the hot press descends, and the mold closes in 2-10 seconds, followed by pressure holding and cooling.

[0021] The first stage press descends at a speed of 250-500 mm / s, and the second stage press descends at a speed of 50-100 mm / s. The purpose is to control the forming rate, regulate the dynamic recovery and recrystallization behavior of aluminum alloy components during the forming process, and optimize the performance of the material during the forming process.

[0022] Step S5: Mold holding pressure and cooling:

[0023] The holding pressure is 2-15 MPa, and the holding time is 5-30 seconds;

[0024] Step S6: Time-sensitive processing:

[0025] The sheet metal is transferred to an aging furnace, heated to 120-200℃, held for 2-20 minutes, with a heating rate of 5-15℃ / min and a cooling rate of 5-15℃ / min. The purpose is to reduce deformation of large components during the heating and cooling process.

[0026] The beneficial effects of this invention are as follows: By using a transfer device with heat preservation function, the problem of sudden temperature drop during the transfer of aluminum alloy is solved, and the warm forming of aluminum alloy is realized. Compared with hot forming and W forming production lines, the aging treatment process of aluminum alloy is eliminated, which greatly improves production efficiency. Attached Figure Description

[0027] Figure 1 This is a structural diagram of the present invention, in which the heat preservation shell, aging furnace and solution treatment furnace have the same structure and are not shown;

[0028] Figure 2 This is a structural diagram of the end effector in this invention;

[0029] Figure 3 This is an assembly diagram of the end effector and the insulation shell in this invention;

[0030] Figure 4 This is a structural diagram of the cooling system in this invention;

[0031] In the picture,

[0032] 1. Clamping clamp; 2. Aluminum tube; 3. Aluminum tube fixing seat; 4. Longitudinal beam; 5. Cross beam; 6. Connecting plate; 7. Solution treatment furnace; 8. Hot press; 9. Stamping die; 10. Robot arm; 11. Transfer frame; 12. Lower die; 13. Insulation shell. Detailed Implementation

[0033] To enable those skilled in the art to better understand the technical solutions of the present invention and to make the above-mentioned features, objectives, and advantages of the present invention clearer and easier to understand, the present invention will be further described below with reference to embodiments. These embodiments are for illustrative purposes only and are not intended to limit the scope of the present invention.

[0034] like Figure 1-4 As shown, the present invention includes: a solution treatment furnace 7, a transfer device, a hot press 8, a stamping die 9, and an aging furnace. The discharge end of the solution treatment furnace 7 transfers the heated sheet metal to the hot press 8 through the transfer device. A robot arm 10 is installed on the side of the hot press 8 near the solution treatment furnace 7 via a robot arm beam 5. The robot arm 10 moves back and forth between the solution treatment furnace 7, the transfer device, the hot press 8, and the aging furnace, and conveys the sheet metal into the mold cavity of the stamping die 9.

[0035] The transfer device includes a transfer frame 11 for transferring sheet metal, an end effector, and an insulation shell 13 installed on the end effector. The end effector includes a connecting plate 6, a longitudinal beam 4, an aluminum tube 2, and a clamp 1. The top of the connecting plate 6 is mounted on a robot arm 10, and the bottom is fixed on a pair of parallel longitudinal beams 4. The aluminum tube 2 is vertical and passes through the longitudinal beams 4 and is fixed by an aluminum tube fixing seat 3. Clamps 1 for clamping sheet metal are also installed at both ends of the aluminum tube 2.

[0036] In this embodiment, the aluminum tube 2 is preferably provided in two types: a long aluminum rod and a short aluminum rod. The outer circumference of the plate is clamped by clamps 1 installed at both ends of the long aluminum rod, and the inner circumference of the plate is clamped by clamps 1 installed at both ends of the short aluminum rod.

[0037] In this embodiment, preferably, three long aluminum rods are arranged at equal intervals, two short aluminum rods are arranged at equal intervals, and the long aluminum rods and short aluminum rods are arranged alternately.

[0038] The above structure is designed so that, since the sheet metal is a ring, it is necessary to ensure smooth transfer and prevent deformation during transportation. Therefore, two aluminum rods of different lengths are used to achieve this purpose.

[0039] In this embodiment, preferably, the heat insulation shell 13 is installed at the bottom of the longitudinal beam 4 and the transverse beam 5, and is fixed inside by multiple round rods. The temperature of the heat insulation shell 13 is controlled at 200-300 degrees Celsius. The inner side of the heat insulation shell 13 is coated with a thermal barrier coating and is equipped with a temperature sensor for multi-point temperature measurement.

[0040] The purpose of setting up the above structure is to reduce heat loss to the insulation box and reduce the heating power of the insulation box. By controlling the opening and closing status and power of the heating device, the sheet material is maintained at the set temperature, thereby improving the stability of the structural component performance.

[0041] In this embodiment, preferably, a cooling system is provided inside the stamping die 9. The cooling system includes a cooling pipe disposed inside the lower die 12. Both ends of the cooling pipe pass through the lower die 12 and the amount of water entering and exiting is controlled by water valves.

[0042] The above structure includes a cooling system inside the mold, with the cooling water temperature ranging from 0 to 50 degrees Celsius. This is also to prevent thermal stress deformation caused by excessively high temperatures during the hot press molding process.

[0043] In this embodiment, the solution treatment furnace 7 is preferably a roller furnace or a box furnace, and is equipped with a circulating fan, with a heating rate of 25-200℃ / min and a maximum heating temperature of 400-700℃.

[0044] With the above structure, a roller continuous furnace is convenient for industrial mass production, while a multi-layer box furnace is convenient for small-batch trial production.

[0045] In this embodiment, the end effector is preferably made of aluminum-magnesium alloy or carbon fiber composite material.

[0046] The above structure eliminates the vibration caused by the large inertia of the end effector due to the excessive size of large aerospace components, thus improving the accuracy of sheet metal feeding. The end effector removes the sheet metal from the heating furnace and quickly moves it to the die for stamping.

[0047] A production process for an automated production line for the hot forming of aerospace aluminum alloys includes the following steps:

[0048] Step S1: Solution heat treatment:

[0049] The sheet material is heated in a solution heating furnace at 500-550℃ and held at that temperature for 10-50 minutes, while the transfer device is placed close to the solution heating furnace.

[0050] Step S2: Clamping the sheet metal:

[0051] After the heat treatment in step S1, the plate is moved to the furnace opening by a transfer device. The robot arm is started, and the lowering end picker grabs the plate. The plate is picked up and put into the heat preservation shell within 0-10 seconds.

[0052] Step S3: Transfer the sheet metal and feed it into the mold cavity.

[0053] After step S2, the sheet metal moves to the stamping die within 1-20 seconds via the transfer device. At this time, the mechanical gripper transfers the aluminum alloy sheet metal into the die cavity within 0-5 seconds. The transfer device then exits from the hot press, and the transfer ends at a temperature of 450-500℃.

[0054] Step S4: Hot stamping

[0055] After step S3, the hot press descends, and the mold closes in 2-10 seconds, followed by pressure holding and cooling.

[0056] The first stage press descends at a speed of 250-500 mm / s, and the second stage press descends at a speed of 50-100 mm / s. The purpose is to control the forming rate, regulate the dynamic recovery and recrystallization behavior of aluminum alloy components during the forming process, and optimize the performance of the material during the forming process.

[0057] Step S5: Mold holding pressure and cooling:

[0058] The holding pressure is 2-15 MPa, and the holding time is 5-30 seconds;

[0059] Step S6: Time-sensitive processing:

[0060] The sheet metal is transferred to an aging furnace, heated to 120-200℃, held for 2-20 minutes, with a heating rate of 5-15℃ / min and a cooling rate of 5-15℃ / min. The purpose is to reduce deformation of large components during the heating and cooling process.

[0061] The above embodiments are merely illustrative of the principles and effects of this patent application and are not intended to limit this patent application. Any person skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of this patent application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this patent application shall still be covered by the claims of this patent application.

Claims

1. A production process for an automated production line for the warm forming of aerospace aluminum alloys, characterized in that... Therefore, the automated production line includes: The solution treatment furnace (7), the transfer device, the hot press (8), the stamping die (9) and the aging furnace are provided. The discharge end of the solution treatment furnace (7) is transferred to the hot press (8) through the transfer device. The hot press (8) is equipped with a robot arm (10) on the side of the hot press (8) near the solution treatment furnace (7) through the robot arm beam (5). The robot arm (10) moves back and forth between the solution treatment furnace (7), the transfer device, the hot press (8) and the aging furnace, and transports the sheet material into the mold cavity of the stamping die (9). The transfer device includes a transfer frame (11) for transferring sheet metal, an end effector, and an insulation shell (13) installed on the end effector. The end effector includes a connecting plate (6), a longitudinal beam (4), an aluminum tube (2), and clamps (1). The top of the connecting plate (6) is mounted on a robot (10), and the bottom is fixed on a pair of parallel longitudinal beams (4). The aluminum tube (2) is vertical and passes through the longitudinal beams (4) and is fixed by an aluminum tube fixing seat (3). Clamps (1) for clamping sheet metal are also installed at both ends of the aluminum tube (2). The aluminum tube (2) is provided in two types: long aluminum rod and short aluminum rod. The outer circumference of the sheet is clamped by clamps (1) installed at both ends of the long aluminum rod, and the inner circumference of the sheet is clamped by clamps (1) installed at both ends of the short aluminum rod. The long aluminum rods are arranged in three equal intervals, and the short aluminum rods are arranged in two equal intervals, with the long aluminum rods and short aluminum rods arranged alternately; the heat insulation shell (13) is installed at the bottom of the longitudinal beam (4) and the transverse beam (5), and is fixed inside by multiple round rods. The temperature of the heat insulation shell (13) is controlled at 200-300 degrees Celsius. The inner side of the heat insulation shell (13) is coated with a thermal barrier coating and is equipped with a temperature sensor for multi-point temperature measurement; The stamping die (9) is equipped with a cooling system, which includes a cooling pipe installed in the lower die (12). Both ends of the cooling pipe pass through the lower die (12) and the amount of water entering and exiting is controlled by a water valve. The solution treatment furnace (7) is a roller furnace or a box furnace, and is equipped with a circulating fan with a heating rate of 25-200℃ / min. The end effector is made of aluminum-magnesium alloy or carbon fiber composite material; The production process includes the following steps: Step S1: Solution heat treatment: The sheet material is heated in a solution treatment furnace at 500-550℃ and held at that temperature for 10-50 minutes, while the transfer device is placed close to the solution treatment furnace. Step S2: Clamping the sheet metal: Start the robotic arm, lower the end gripper to pick up the sheet metal, and within 10 seconds, lift the sheet metal and put it into the insulation shell; Step S3: Transfer the sheet metal and send it into the mold cavity: The sheet metal is moved to the stamping die by the transfer device within 20 seconds. At this time, the clamp transfers the sheet metal into the die cavity within 5 seconds, and the transfer device withdraws from the hot press. Step S4: Hot stamping forming: As the hot press descends, the stamping die closes within 2-10 seconds, followed by pressure holding and cooling. The first section of the hot press has a downward speed of 250-500 mm / s, and the second section has a downward speed of 50-100 mm / s. Step S5: Mold holding pressure and cooling: The holding pressure is 2-15 MPa, and the holding time is 5-30 seconds; Step S6: Time-sensitive processing: The sheet material is transferred to an aging furnace, where the heating temperature is 120-200℃, the heating rate is 5-15℃ / min, and the cooling rate is 5-15℃ / min.

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