Laser shock forming device and method for complex shape skin of electric locomotive

Abstract

The application discloses a kind of electric locomotive complex shape skin laser impact forming device, including solid laser, laser controller, laser ranging sensor, part clamping robot, part clamping robot control system, water spraying robot, water spraying robot control system, high-speed laser profiler detection device, first forming plate fastening arc clamping plate, second forming plate fastening arc clamping plate, third forming plate fastening arc clamping plate, data acquisition card, computer integrated control system, laser focal point indicator and forming simulation system.The application also discloses a kind of electric locomotive complex shape skin laser impact forming method, based on laser impact forming numerical simulation plug-in, corresponding forming data is obtained;Different forming areas are clamped and different process parameters are applied respectively, to realize excess-free laser impact forming;Finally, the adhesive remaining on the surface of the formed skin is removed.The application accurately forms the complex shape skin of locomotive, and forms residual compressive stress with a certain depth.

Description

Technical Field

[0001] This invention relates to the field of laser shock forming technology, and more specifically, to a laser shock forming apparatus and method for complex-shaped skin of an electric locomotive. Background Technology

[0002] With the rapid increase in international demand for high-speed trains, my country's high-speed train exports are gradually expanding. These exports need to meet the diverse technical requirements of different countries in terms of railway traction, track structure, and transportation organization. my country's exported high-speed trains are characterized by "small batches, multiple varieties, and customization." The processing method for small-batch high-speed train head skins is mostly a combination of machine and manual hammering, a semi-manual process. This method is heavily influenced by human experience, resulting in poor precision and dimensional limitations. For the forming of complex head skins for a particular train model, it is necessary to divide the train into multiple areas, hammer each area separately, and then weld these small skin pieces together to form a complex, variable-section, spatially twisted skin. This leads to long production cycles, poor forming precision, high labor intensity, and an increased number of skins required. Deformation and residual tensile stress are easily generated during welding, affecting assembly accuracy and the fatigue life of structural components. Traditional forming processes can no longer fully meet the processing requirements of these skin parts.

[0003] In existing technologies, laser shock forming is a new moldless forming technology that uses the shock wave pressure generated by laser action to deform materials. It utilizes the force effect of high-amplitude shock wave pressure induced by high-energy short-pulse lasers to achieve plastic forming of metal sheets. It is not constrained by part size and can achieve rapid moldless forming of large-sized, complex-shaped parts. It features high forming limits, high forming flexibility, and high speed and efficiency. Research on laser shock forming technology for high-speed train front skin has broken through key manufacturing technologies for processing complex-shaped skin parts, and can be extended to the processing and forming of body panels for other rail transit vehicles. This has significant practical implications for improving the forming quality and fatigue life of components. Summary of the Invention

[0004] The purpose of this invention is to propose a laser shock forming method for electric locomotive skin, in order to solve the problems of the existing high-speed train head skin processing technology being a semi-manual processing method, with long production cycle, poor forming accuracy, and high labor intensity.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] A laser shock forming device for complex-shaped skin of electric locomotives includes a solid-state laser, a laser controller, a laser rangefinder, a parts clamping robot, a parts clamping robot control system, a water-spraying robot, a water-spraying robot control system, a high-speed laser profilometer detection device, a first forming plate fastening arc clamp, a second forming plate fastening arc clamp, a third forming plate fastening arc clamp, a data acquisition card, a computer integrated control system, a laser focus indicator, and a forming simulation system. The first, second, and third forming plate fastening arc clamps are respectively fastened to different positions on the sheet to be formed by bolts, and the sheet to be formed is fastened to the parts clamping robot. The laser focus indicator works with the parts clamping robot to ensure that the laser shock position of the sheet to be formed is always at the laser focus position. The high-speed laser profilometer detection device can monitor the forming shape of the sheet to be formed in real time. The laser controller, forming simulation system, high-speed laser profilometer detection device, and laser rangefinder transmit data to the computer integrated control system through the data acquisition card.

[0007] Preferably, the water spraying robot acts as a constraint layer. After the forming plate is formed, the water pressure is adjusted by the water spraying robot control system to apply water pressure to the residual adhesive on the surface of the forming plate, and the water pressure is used to remove the adhesive residue of the black tape in the energy absorption layer.

[0008] Preferably, the fastening positions of the first forming plate fastening arc-shaped clamp, the second forming plate fastening arc-shaped clamp, and the third forming plate fastening arc-shaped clamp on the plate to be formed are determined based on the initial welding and splicing position of the complex-shaped skin.

[0009] Preferably, the laser rangefinder measures the distance between the laser impact position and the reference base surface in real time, and transmits the data to the computer integrated control system in real time through the data acquisition card, thereby moving the workpiece to the laser focus position.

[0010] Preferably, the forming simulation system has a built-in laser shock forming numerical simulation plugin. Based on the forming simulation system, the relationship between the laser shock forming trend, elongation and process parameters is formed. Combined with the computer integrated control system and the high-speed laser profilometer detection device, it can realize the zero-margin laser shock forming of complex skin parts.

[0011] Preferably, the solid-state laser, laser controller, and computer-integrated control system enable variable-parameter laser shock forming.

[0012] Furthermore, this invention also proposes a method for laser shock forming of complex-shaped skin of electric locomotives, employing the laser shock forming apparatus for complex-shaped skin of electric locomotives as described above, and including the following steps:

[0013] s1. In the forming simulation system, based on the laser shock forming numerical simulation plugin, the inherent strain distribution data under different laser process parameters are obtained. The inherent strain and preload are applied using a Fortran subroutine to obtain the correspondence between different process parameters and preload and the forming trend of the sheet, and the correspondence between the sheet elongation and the process parameters.

[0014] s2. Based on the different forming areas of the complex skin and the initial welding position of the complex skin, four areas are set up. The plates to be formed are clamped and fixed at the connection between the four areas by the first forming plate fastening arc clamp, the second forming plate fastening arc clamp, and the third forming plate fastening arc clamp respectively.

[0015] s3. Variable parameter laser shock forming process is adopted for different areas of complex skin. According to the forming curvature of the sheet in different areas, the pulse width is changed in different action areas, thereby changing the laser shock wave action time. At the same time, according to the correspondence between the sheet elongation and the process parameters, the size of the actual sheet is reduced accordingly based on the elongation, so as to realize the zero-margin laser shock forming process of skin.

[0016] s4. During the laser shock forming process, a high-speed laser contour measuring device is used to detect the forming accuracy of the skin. The forming data is fed back to the computer integrated control system in real time. In this system, the forming data is compared with the theoretical data model. If it is within the required range of shape and size error, the laser shock forming process is terminated.

[0017] s5. The location of residual adhesive on the sheet metal parts is removed by spraying water with a water-spraying robot to remove the residual adhesive on the skin surface after laser impact forming.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] The laser shock forming method for electric locomotive skin of this invention provides precise and controllable laser shock process parameters and laser shock position. Multiple laser shocks can be performed at the same location, resulting in high part forming accuracy and high part forming flexibility. It can form single-curvature shapes, double-curvature shapes, bending areas, non-straight generatrix areas, parts of equal thickness, parts of varying thickness, and ribbed parts. Furthermore, the laser shock forming process generates residual compressive stress of a certain depth along the thickness direction of the part, which strengthens the sheet metal and significantly improves its fatigue life. Attached Figure Description

[0020] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the device structure of the present invention.

[0022] Figure 2 This is a flowchart of the method of the present invention.

[0023] Figure 3 This is a schematic diagram of the laser shock forming numerical simulation plugin of the present invention.

[0024] Figure 4 This is the inherent strain distribution cloud map of the present invention.

[0025] Figure 5 This is a cloud diagram of the laser shock forming of the skin of the present invention.

[0026] Figure 6 This is a schematic diagram of the clamping and fixing of the complex-shaped skin part of the present invention.

[0027] In the diagram: 1. Computer integrated control system; 2. Forming simulation system; 3. Part clamping robot control system; 4. Part clamping robot; 5. Data acquisition card; 6. Laser focus indicator; 7. Laser rangefinder; 8. Laser controller; 9. Solid-state laser; 10. High-speed laser profilometer detection device; 11. Water spraying robot control system; 12. Water spraying robot; 13. Plate to be formed. Detailed Implementation

[0028] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0029] Furthermore, in the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0030] Example 1

[0031] like Figure 1 As shown, a preferred embodiment of the present invention provides a laser shock forming apparatus for complex-shaped skin of an electric locomotive.

[0032] The device includes: a solid-state laser 9, a laser controller 9, a laser rangefinder 7, a parts clamping robot 4, a parts clamping robot control system 3, a water-spraying robot 12, a water-spraying robot control system 11, a high-speed laser profilometer detection device 10, a first forming plate fastening arc clamp, a second forming plate fastening arc clamp, a third forming plate fastening arc clamp, a data acquisition card 5, a computer integrated control system 1, a laser focus indicator 6, and a forming simulation system 2.

[0033] Furthermore, the laser focus indicator 6 works in conjunction with the part clamping robot 4 to ensure that the laser impact position of the plate to be formed 13 is always at the laser focus position. The high-speed laser profiler detection device 10 can monitor the forming shape of the plate to be formed 13 in real time. The laser controller 9, the forming simulation system 2, the high-speed laser profiler detection device 10, and the laser range sensor 7 transmit data to the computer integrated control system 1 through the data acquisition card 5.

[0034] Furthermore, the first forming plate fastening arc-shaped clamp, the second forming plate fastening arc-shaped clamp, and the third forming plate fastening arc-shaped clamp are fastened to different positions on the plate to be formed by bolts. The fastening positions are determined according to the initial welding and splicing position of the complex skin. The plate to be formed is fastened to the part clamping robot 4 by the first forming plate fastening arc-shaped clamp, the second forming plate fastening arc-shaped clamp, and the third forming plate fastening arc-shaped clamp.

[0035] Furthermore, the water spraying robot 12 acts as a constraint layer. After the forming plate is formed, the water pressure is adjusted by the water spraying robot control system 11 to act on the residual adhesive on the surface of the forming plate, and the water pressure is used to remove the adhesive residue of the black tape of the energy absorption layer.

[0036] Furthermore, the laser rangefinder 7 measures the distance between the laser impact position and the reference base surface in real time, and transmits the data to the computer integrated control system 1 in real time through the data acquisition card 5, and moves the workpiece to the laser focus position.

[0037] Furthermore, the forming simulation system 2 incorporates a laser shock forming numerical simulation plugin. Based on the forming simulation system, it establishes the relationship between laser shock forming trends, elongation, and process parameters. Combined with the computer integrated control system 1 and the high-speed laser profilometer detection device 10, it can achieve zero-margin laser shock forming of complex skin parts.

[0038] Furthermore, the solid-state laser 9, the laser controller 8, and the computer integrated control system 1 can realize variable parameter laser shock forming processing.

[0039] Example 2

[0040] like Figures 2-5The preferred embodiment of the present invention provides a method for laser shock forming of complex-shaped skin of an electric locomotive, employing the laser shock forming apparatus for complex-shaped skin of an electric locomotive as described in Embodiment 1, and includes the following steps:

[0041] s1. Aluminum alloy 5083 was selected as the material for the complex skin part. The sheet metal is 1.1m long, 0.3m wide, and 4mm thick. The laser energy is 5J, the spot size is 3mm, the laser frequency is 10Hz, and the spot overlap rate is 30%. In the forming simulation system, based on the laser shock forming numerical simulation plug-in, such as... Figure 3 As shown, the inherent strain distribution data under different laser process parameters were obtained, such as... Figure 4 As shown, Fortran subroutines were used to apply inherent strain and preload, obtaining the correspondence between different process parameters and preload and the forming trend of the sheet metal, and the correspondence between sheet metal elongation and process parameters, as shown in the figure. Figure 5 As shown.

[0042] s2. Based on the different forming areas and initial welding positions of the complex-shaped skin, four areas are set. The plates to be formed are clamped and fixed at the connection points between the four areas using the first forming plate clamping arc-shaped clamp, the second forming plate clamping arc-shaped clamp, and the third forming plate clamping arc-shaped clamp. The fixing positions are as follows: Figure 6 As shown.

[0043] s3. Variable parameter laser shock forming process is adopted for different areas of complex skin. According to the forming curvature of the sheet in different areas, the pulse width is changed in different action areas, thereby changing the laser shock wave action time. At the same time, according to the correspondence between the sheet elongation and process parameters, the size of the actual sheet is reduced accordingly based on the elongation, so as to realize the zero-margin laser shock forming process of skin.

[0044] s4. During the laser shock forming process, a high-speed laser contour measuring device 10 is used to detect the skin forming accuracy and feeds the forming data back to the computer integrated control system 1 in real time. In this system, the forming data is compared with the theoretical data model. If it is within the required range of shape and size error, the laser shock forming process ends.

[0045] s5. The location of residual adhesive on the sheet metal part is removed by water spraying robot 12 to remove the residual adhesive on the skin surface after laser impact forming.

[0046] In summary, the laser shock forming method for electric locomotive skin described in this embodiment of the invention offers precise and controllable laser shock process parameters and laser shock positions. Multiple laser shocks can be performed at the same location, resulting in high part forming accuracy and flexibility. It can form single-curvature shapes, double-curvature shapes, bending areas, non-straight generatrix areas, parts of equal thickness, parts of varying thickness, and ribbed parts. Furthermore, the laser shock forming process generates residual compressive stress of a certain depth along the part's thickness, strengthening the sheet metal and significantly improving its fatigue life.

[0047] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for laser shock forming of complex-shaped skin for electric locomotives, characterized in that, A laser shock forming device for complex-shaped skin of electric locomotives was adopted; The device includes a solid-state laser, a laser controller, a laser rangefinder, a parts clamping robot, a parts clamping robot control system, a water-spraying robot, a water-spraying robot control system, a high-speed laser profilometer detection device, a first forming plate fastening arc-shaped clamp, a second forming plate fastening arc-shaped clamp, a third forming plate fastening arc-shaped clamp, a data acquisition card, a computer integrated control system, a laser focus indicator, and a forming simulation system. The first forming plate fastening arc-shaped clamp, the second forming plate fastening arc-shaped clamp, and the third forming plate fastening arc-shaped clamp are fastened to different positions on the plate to be formed by bolts, and the plate to be formed is fastened to the parts clamping robot. The laser focus indicator works with the parts clamping robot to ensure that the laser impact position of the plate to be formed is always at the laser focus position. The high-speed laser profilometer detection device can monitor the forming shape of the plate to be formed in real time. The laser controller, the forming simulation system, the high-speed laser profilometer detection device, and the laser rangefinder transmit data to the computer integrated control system through the data acquisition card. The fastening positions of the first forming plate fastening arc-shaped clamp, the second forming plate fastening arc-shaped clamp, and the third forming plate fastening arc-shaped clamp on the plate to be formed are determined based on the initial welding and splicing position of the complex skin. The forming simulation system has a built-in laser shock forming numerical simulation plugin. Based on the forming simulation system, the relationship between laser shock forming trend, elongation and process parameters is formed. Combined with the computer integrated control system and high-speed laser profilometer detection device, it can realize zero-margin laser shock forming of complex skin. The method includes the following steps: s1. In the forming simulation system, based on the laser shock forming numerical simulation plugin, the inherent strain distribution data under different laser process parameters are obtained. The inherent strain and preload are applied using a Fortran subroutine to obtain the correspondence between different process parameters and preload and the forming trend of the sheet, and the correspondence between the sheet elongation and the process parameters. s2. Based on the different forming areas of the complex skin and the initial welding position of the complex skin, four areas are set up. The plates to be formed are clamped and fixed at the connection between the four areas by the first forming plate fastening arc clamp, the second forming plate fastening arc clamp, and the third forming plate fastening arc clamp respectively. s3. Variable parameter laser shock forming process is adopted for different areas of complex skin. According to the forming curvature of the sheet in different areas, the pulse width is changed in different action areas, thereby changing the laser shock wave action time. At the same time, according to the correspondence between the sheet elongation and the process parameters, the size of the actual sheet is reduced accordingly based on the elongation, so as to realize the zero-margin laser shock forming process of skin. s4. During the laser shock forming process, a high-speed laser contour measuring device is used to detect the forming accuracy of the skin. The forming data is fed back to the computer integrated control system in real time. In this system, the forming data is compared with the theoretical data model. If it is within the required range of shape and size error, the laser shock forming process is terminated. s5. The location of residual adhesive on the sheet metal parts is removed by spraying water with a water-spraying robot to remove the residual adhesive on the skin surface after laser impact forming.

2. The laser shock forming method for complex-shaped skin of electric locomotives according to claim 1, characterized in that, The water spraying robot acts as a constraint layer. After the forming plate is formed, the water pressure is adjusted by the water spraying robot control system to apply water pressure to the residual adhesive on the surface of the forming plate, and the water pressure is used to remove the adhesive residue of the black tape in the energy absorption layer.

3. The laser shock forming method for complex-shaped skin of electric locomotives according to claim 1, characterized in that, The laser rangefinder sensor measures the distance between the laser impact point and the reference base in real time. The data is then transmitted to the computer integrated control system via a data acquisition card, which moves the workpiece to the laser focus position.

4. The laser shock forming method for complex-shaped skin of electric locomotives according to claim 1, characterized in that, Solid-state lasers, laser controllers, and computer-integrated control systems enable variable-parameter laser shock forming processes.

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