A composite bending roll forming device and method for non-closed cross-section profiles

Abstract

The present invention discloses a composite bending roll forming device and method for non-closed cross-section profiles, comprising a cross-section shape forming roller group, a final axis bending forming roller group and a driving roller; the axis bending forming roller group comprises two bending rollers arranged on the left and right sides of the non-closed cross-section profile, whose two rotating axes are parallel to each other, the rotating axes of the two bending rollers are perpendicular to the advancing direction of the plate, which is defined as the y-axis direction, and their motion trajectories are respectively controlled by two groups of control motors, and the axis bending change of the target component is achieved by causing a certain displacement change of the two axis bending forming rollers; the present invention is a matching process parameter analysis method for the axis bending forming system of non-closed cross-section profiles based on multiple rollers, which gives full play to the system's adjustment of the motion trajectory of the rollers, so that the cross-section characteristics and the axis bending can meet the forming requirements without replacing the device.

Description

Technical Field

[0001] The invention belongs to the technical field of roll bending forming of non-closed cross-section type materials, and in particular relates to a roller design and parameter analysis method for roll composite bending forming. Background Art

[0002] Lightweighting is the current development trend of industrial products. On the one hand, lightweighting is achieved by replacing lightweight materials, and on the other hand, lightweighting is achieved by replacing solid structures with frame structures. Profiles can effectively replace solid components to meet production quality requirements.

[0003] Traditional profile production technologies include stamping, rolling, roll bending, and bending. The above processes have long production cycles and are highly dependent on manual debugging, making continuous production impossible. In addition, the molds need to be replaced to meet different forming angles. The mold costs are high, and the labor costs of replacing molds are high, which seriously restricts production efficiency. As an emerging forming technology, roll forming technology performs a multi-pass small-angle continuous bending forming process on the sheet. During the forming process, the bending angles of various parts of the sheet are not the same, and there is a smooth transition between each forming angle. This technology is a cold-bending technology that is energy-saving and environmentally friendly. It can meet the production needs of different fields, including profiles with complex cross-sections of variable width and depth.

[0004] At present, the research on roller pressing technology is not yet mature, and there is still a disadvantage that the shape characteristics of the products produced in a single time are single. Summary of the invention

[0005] The present invention mainly aims at the deficiencies of the prior art and the demand for one-time continuous forming of spatial profile components, and provides a composite bending roll forming device and method for non-closed cross-section profiles, which improves the forming efficiency and completes the forming requirements of the cross-sectional shape and the axis bending in two dimensions at one time.

[0006] The present invention adopts the following technical solutions:

[0007] A composite bending roll forming device for non-closed cross-section profiles comprises a cross-section shape forming roller group, a final-pass axis bending forming roller group and a driving roller; the cross-section shape forming roller group comprises a multi-pass forming roller group sequentially arranged on the upper and lower sides of the non-closed cross-section profile; the axis bending forming roller group comprises two bending rollers arranged on the left and right sides of the non-closed cross-section profile, the two rotating axes of which are parallel to each other, the rotating axes of the two bending rollers are perpendicular to the advancing direction of the plate, which is defined as the y-axis direction, and the motion trajectories of the two bending rollers are controlled by two groups of control motors respectively, and the axis bending change of the target component is achieved by causing a certain displacement change of the two axis bending forming rollers: the translational displacement x1 of the bending roller located on the inner side of the axis bending curve in the x-axis direction is equal to (Rr 弯曲 )(1-cosθ);

[0008] Translational displacement of the bending roller outside the axis bending curve in the x-axis direction:

[0009] x2=U+r 弯曲 (1-cosθ)=(R+H)(1-cosθ)+r 弯曲 (1-cosθ);

[0010] Translational displacement in the z-axis direction z2=(R+H)sinθ-D+r 成形 ; The sheet forward direction is defined as the z-axis direction; the inner bending radius is R, the bending angle is θ, the translation displacement is x1, the translation displacement of the outer bending roller is x2, z2, the profile width is H, the distance between the initial center position of the bending roller and the center position of the adjacent cross-sectional feature forming roller is D, and the radius of the bending roller is r 弯曲 , the radius of the previous forming roller is r 成形 .

[0011] In the composite bending roll forming device for non-closed cross-section profiles, in the cross-section shape forming roller group, the forming angles of each roller group gradually increase according to the forming sequence. The multi-pass roller group ensures that the axis of the blank is always in a straight line during the forming process. On the other hand, the rollers with different bending forming angles in different passes are used to gradually form the forming cross-section of the target component by continuously changing the small angle. The upper roller in the forming roller group rotates counterclockwise, and the lower roller rotates clockwise. The upper and lower roller groups fit each other.

[0012] In the composite bending roll forming device for non-closed cross-section profiles, the cross-section shape forming roller set rotates around its own axis at a certain speed in the Y-axis / Z-axis plane to complete the cross-section forming of the target component.

[0013] In the composite bending roll forming device for non-closed cross-section profiles, the axis bending forming roller group moves linearly up and down and / or left and right in the X-axis / Z-axis plane to complete the axis bending forming of the target component.

[0014] In the composite bending roll forming device for non-closed cross-section profiles, the driving roller rotates around its own axis at a certain speed in the Y-axis / Z-axis plane, providing support and driving force for the profile forming process.

[0015] According to any of the above-mentioned forming process parameter analysis methods for the composite bending roll forming device for non-closed cross-section profiles, the method comprises the following steps:

[0016] The first step is to extract the bending angle and geometric axis of the profile bending member;

[0017] The second step is to design the roller parameters according to the bending forming angle and design the bending roller forming trajectory according to the geometric axis;

[0018] The third step is to establish the geometric parameters of the bending section, including the inner bending radius R, the bending angle θ, the translation displacement x1 of the inner bending roller, the translation displacement x2, z2 of the outer bending roller, the profile width H, the distance D between the initial center position of the bending roller and the center position of the adjacent section feature forming roller, and the radius r of the bending roller. 弯曲 , the radius of the previous forming roller r 成形 The quantitative relationship between them.

[0019] The forming process parameter analysis method, the specific method of the third step is:

[0020] The translation displacement of the inner bending roller in the x-axis direction is x1 = (Rr 弯曲 )(1-cosθ);

[0021] Translational displacement of the outer bending roller in the x-axis direction:

[0022] x2=U+r 弯曲 (1-cosθ)=(R+H)(1-cosθ)+r 弯曲 (1-cosθ);

[0023] Translational displacement in the z-axis direction z2=(R+H)sinθ-D+r 成形 .

[0024] Beneficial effects:

[0025] The present invention is a supporting process parameter analysis method for a non-closed cross-section profile axis bending forming system based on multiple rollers, which gives full play to the system's adjustment of the motion trajectory of the rollers, thereby achieving cross-sectional characteristics and axis bending to meet forming requirements without replacing the device; the method of the present invention is simple and feasible, improves production efficiency to a certain extent, and has important application value and obvious economic benefits in engineering fields such as aviation, aerospace, automobiles, and rail transportation. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 , schematic diagram of the roll bending forming device;

[0027] Figure 2 , schematic diagram of the final bending roller and the driving roller;

[0028] Figure 3 , schematic diagram of the motion trajectory of the last roller group;

[0029] Figure 4 , schematic diagram of roll bending forming process parameters;

[0030] Figure 5 , examples of profile bending and forming components;

[0031] Figure 6 , schematic diagram of example roller motion trajectory;

[0032] A1 forming roller, B bending roller, B1 bending roller one, B2 bending roller two, C driving roller; DETAILED DESCRIPTION

[0033] The present invention is described in detail below in conjunction with specific embodiments.

[0034] refer to Figure 1 , a composite bending roll forming device for non-closed cross-section profiles, including cross-section shape forming rollers, final-pass axis bending forming rollers and drive rollers; the cross-section shape forming roller group includes multi-pass rollers, which on the one hand ensure that the axis of the blank is always in a straight line during the forming process, and on the other hand, use rollers with different bending forming angles in different passes to gradually form the target component forming cross-section with small angles continuously. The forming angles of adjacent rollers are slightly different, and the forming angles of each roller group gradually increase in the forming order, which can effectively avoid deformity caused by excessive stress concentration. Figure 1 Middle: The upper roller of the forming roller rotates counterclockwise, and the lower roller rotates clockwise. The upper and lower rollers fit each other, and the plate moves along the positive direction of the z axis in the figure through friction. The forming angle of each forming roller increases gradually along the positive direction of the z axis, and the difference between the forming angles of the two adjacent rollers is small. After the last pass, the plate completes the forming requirement of the target angle.

[0035] The axis bending forming roller consists of two rollers, each of which is controlled by two sets of control motors to control its movement trajectory. The axis bending change requirements of the target component are achieved by causing the two axis bending forming rollers to undergo a certain displacement change. The transmission roller supports and transmits traction power to the plate. The forward driving force of the plate is provided by the friction force generated by the transmission roller and the plate. The gap between the transmission roller and the plate needs to be controlled within a limited range. Figure 2-3 As shown in the figure, the component with cross-sectional features is then bent in the xz plane by the bending rollers. The two bending rollers are located on both sides of the component, and their rotation direction is consistent with the forward direction of the plate. The bending roller 1 rotates counterclockwise in the xz plane, and the driving roller of the bending roller 2 supports the movement of the component in the forward direction. Figure 4 During the bending process shown in the figure, the center position of the bending roller 1 is from the original position O1' to O1, and the center position of the bending roller 2 is from the original position O2' to O2. R - inner bending radius, θ - bending angle, x 1— The translation displacement of the inner bending roller, x2, z2—the translation displacement of the outer bending roller, H—profile width, D—the distance between the initial center position of the bending roller and the center position of the adjacent section feature forming roller, r 弯曲 —Bending roller radius, r 成形 —Radius of the forming roller in the previous pass.

[0036] like Figure 5 As shown, the non-closed cross-section profile of this embodiment is composed of three straight sections and two arc sections with different bending angles and different bending radii, θ1 and R1 are the bending forming angle and bending forming radius of arc section 1, and θ2 and R2 are the bending forming angle and bending forming radius of arc section 2. In this embodiment, a multi-roller rolling bending forming device is used, including a cross-section shape forming roller group, a bending roller group, a transmission roller, etc. The rollers move in space driven by a servo motor.

[0037] The bending forming process parameter analysis method of the composite bending roll forming device for the non-closed cross-section profile member of this embodiment is as follows:

[0038] The first step is to extract the geometric parameters of the target component profile, including the final section forming angle and the side bending angle;

[0039] In the second step, according to the final cross-sectional forming angle, the number of forming rollers is first determined, and then the forming angle of each group of rollers is determined according to the angle calculation formula to complete the structural design of the rollers. In this embodiment, the final cross-sectional forming angle is 90°, and the number of forming rollers is calculated to be 5 groups, and the forming angles of each group are 22°, 42°, 60°, 75°, and 90° in sequence, and the upper and lower rollers fit each other.

[0040] The third step is to plan the trajectory of the bending roller group according to the bending angle of the target component axis. Assuming that the axis bending angle θ1 of the target formed profile component is 60°, θ2 is 45°, the inner bending radius R1 of the plate is 400mm, R2 is 900mm, the cross-sectional width H of the target formed component is 120mm, and the radius of the last roller group of the forming roller group is r 成形 The bending roller radius r is 100 mm. 弯曲 The distance D between the initial center position of the bending roller and the center position of the adjacent cross-sectional feature forming roller is 50 mm. The geometric parameters of the bending section, including the inner bending radius R, the bending angle θ, the translation displacement x1 of the inner bending roller, the translation displacement x2 and z2 of the outer bending roller, the profile width H, the distance D between the initial center position of the bending roller and the center position of the adjacent cross-sectional feature forming roller, and the radius r of the bending roller are established. 弯曲 , the radius of the previous forming roller r 成形 The quantitative relationship between them is as follows:

[0041] (1) Forming arc segment 1: Before forming arc segment 1, the roller remains in the initial position and only rotates. After the straight segment is formed, the arc segment 1 is formed. Figure 6 As shown in the figure, the forming process of the forming arc segment 1 is marked as ①, and the bending roller 1 is used as the inner roller, which is translated along the positive direction of the x-axis to position 3:

[0042] x1=(R1-r 弯曲 )(1-cosθ1)=(400mm-50mm)(1-cos60°)

[0043] Bending roller 2 is used as the outer roller and moves to position 4. The translation displacement along the positive direction of the z-axis is:

[0044] z2=(R1+H)sinθ1-D+r 成形 =(400mm+100mm)sin60°-250mm+100mm

[0045] Translational displacement along the positive x-axis:

[0046] x2=U+r(1-cosθ1)=(R+H)(1-cosθ1)+r 弯曲 (1-cosθ1)

[0047] =(400mm+100mm)(1-cos60°)+50mm(1-cos60°)

[0048] After completing the forming of arc segment 1, the roller needs to return to its initial position. Figure 6 As shown, that is, process ② is marked in the figure, the bending roller 1 is restored from position 3 to position 1, and the bending roller 2 is restored from position 4 to position 2;

[0049] (2) Forming arc segment 2: Figure 6 As shown, the forming process of arc segment 2 is marked as process ③, and the bending roller 1 is used as the outer roller and moves to position 5, with a translation displacement along the positive direction of the z axis:

[0050] z3=(R2+H)sinθ2-D+r 成形 =(900mm+100mm)sin45°-250mm+100mm

[0051] Translational displacement along the positive x-axis:

[0052] x3=U+r(1-cosθ2)=(R+H)(1-cosθ2)+r 弯曲 (1-cosθ2)

[0053] =(900mm+100mm)(1-cos45°)+50mm(1-cos45°)

[0054] Bending roller 2 is used as the inner roller and moves along the positive direction of the x-axis to position 6:

[0055] x4=(R2-r 弯曲 )(1-cosθ2)=(900mm-50mm)(1-cos45°)

[0056] After the arc segment 2 is formed, the roller returns to its original position to form the straight segment. Figure 6 In the process marked ④, bending roller 1 is restored from position 5 to position 1, and bending roller 2 is restored from position 6 to position 2.

[0057] It should be understood that those skilled in the art can make improvements or changes based on the above description, and all these improvements and changes should fall within the scope of protection of the appended claims of the present invention.

Claims

1. A composite bending roll forming device for non-closed cross-section profiles, characterized in that: It includes a cross-sectional shape forming roller group, a final-pass axis bending forming roller group and a driving roller; the cross-sectional shape forming roller group includes a multi-pass forming roller group sequentially arranged on the upper and lower sides of the non-closed cross-sectional profile; the axis bending forming roller group includes two bending rollers arranged on the left and right sides of the non-closed cross-sectional profile with two rotating axes parallel to each other, the rotating axes of the two bending rollers are perpendicular to the advancing direction of the plate, defined as the y-axis direction, and their motion trajectories are controlled by two groups of control motors respectively, and the axis bending change of the target component is achieved by causing a certain displacement change of the two axis bending forming rollers: the translational displacement x1 of the bending roller located on the inner side of the axis bending curve in the x-axis direction = (Rr 弯曲 )(1-cosθ); Translational displacement of the bending roller outside the axis bending curve in the x-axis direction: x2=U+r 弯曲 (1-cosθ)=(R+H)(1-cosθ)+r 弯曲 (1-cosθ); Translational displacement in the z-axis direction z2=(R+H)sinθ-D+r 成形 ; The sheet forward direction is defined as the z-axis direction; the inner bending radius is R, the bending angle is θ, the translation displacement is x1, the translation displacement of the outer bending roller is x2, z2, the profile width is H, the distance between the initial center position of the bending roller and the center position of the adjacent cross-sectional feature forming roller is D, and the radius of the bending roller is r 弯曲 , the radius of the previous forming roller is r 成形 .

2. The composite bending roll forming device for non-closed cross-section profiles according to claim 1 is characterized in that: In the cross-sectional shape forming roller group, the forming angle of each roller group gradually increases according to the forming sequence. On the one hand, the multi-pass roller group ensures that the axis of the blank is always in a straight line during the forming process. On the other hand, the rollers with different bending forming angles in different passes are used to gradually form the forming cross-section of the target component with small angles. The upper roller in the forming roller group rotates counterclockwise, and the lower roller rotates clockwise, and the upper and lower roller groups fit each other.

3. The composite bending roll forming device for non-closed cross-section profiles according to claim 1, characterized in that: The cross-sectional shape forming roller group rotates around its own axis at a certain speed in the Y-axis / Z-axis plane to complete the cross-sectional forming of the target component.

4. The composite bending roll forming device for non-closed cross-section profiles according to claim 1, characterized in that: The axis bending forming roller group moves up and down and / or left and right in a straight line in the X-axis / Z-axis plane to complete the axis bending forming of the target component.

5. The composite bending roll forming device for non-closed cross-section profiles according to claim 1, characterized in that: The transmission roller rotates around its own axis at a certain speed in the Y-axis / Z-axis plane, providing support and driving force for the profile forming process.

6. The forming process parameter analysis method of the non-closed cross-section profile composite bending roll forming device according to any one of claims 1 to 5, characterized in that: The following steps are involved: The first step is to extract the bending angle and geometric axis of the profile bending member; The second step is to design the roller parameters according to the bending forming angle and design the bending roller forming trajectory according to the geometric axis; The third step is to establish the geometric parameters of the bending section, including the inner bending radius R, the bending angle θ, the translation displacement x1 of the inner bending roller, the translation displacement x2, z2 of the outer bending roller, the profile width H, the distance D between the initial center position of the bending roller and the center position of the adjacent section feature forming roller, and the radius r of the bending roller. 弯曲 , the radius of the previous forming roller r 成形 The quantitative relationship between them.

7. The forming process parameter analysis method according to claim 6, characterized in that: The specific method of the third step is: The translation displacement of the inner bending roller in the x-axis direction is x1 = (Rr 弯曲 )(1-cosθ); Translational displacement of the outer bending roller in the x-axis direction: x2=U+r 弯曲 (1-cosθ)=(R+H)(1-cosθ)+r 弯曲 (1-cosθ); Translational displacement in the z-axis direction z2=(R+H)sinθ-D+r 成形 .

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