A 3D moldless forming system and process for thin material sheets
By using linear constraint units in the XYZ coordinate system and flexible metal wire cores, the problem of surface pits in low-hardness thin sheet materials during multi-point moldless forming was solved, achieving high-precision linear clamping and deformation fitting.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- JIANGSU FANRUN ELECTRONICS
- Filing Date
- 2023-08-31
- Publication Date
- 2026-06-09
AI Technical Summary
In multi-point moldless forming technology, low-hardness thin sheet materials are prone to point extrusion during processing, resulting in multiple local point pits on the surface, affecting processing accuracy and surface smoothness.
The linear constraint unit in the XYZ coordinate system includes upper and lower symmetrical linear constraint components. The upper and lower constraint lines are formed by a flexible metal core and a flexible outer sheath. Combined with independently lifting constraint wheels and floating beams, the linear clamping and precise deformation of the thin plate are achieved, avoiding point contact.
Linear contact was achieved on the surface of the thin sheet, preventing the formation of pits on the surface, while improving the fitting degree of the deformation curve and the processing accuracy.
Smart Images
Figure CN117161190B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of moldless molding. Background Technology
[0002] Multi-point moldless forming technology is a new type of manufacturing technology. It replaces the traditional integral stamping die with a series of regularly arranged point displacement bodies that can move up and down, so as to achieve moldless and flexible forming of sheet metal. However, when processing low-hardness thin sheet materials (such as thin copper sheets), these multi-point forming point displacement bodies will form point extrusion on the local areas of the low-hardness thin sheet material, so as to form multiple local point pits on the surface of the sheet being processed, thereby affecting the processing accuracy and surface smoothness. Summary of the Invention
[0003] Purpose of the invention: In order to overcome the shortcomings of the existing technology, the present invention provides a 3D moldless forming system and process for thin sheets, which avoids the formation of dot-shaped pits due to dot-shaped extrusion on the surface of the thin sheet being processed.
[0004] Technical solution: To achieve the above objectives, the present invention provides a 3D moldless forming system for thin sheet materials, which includes an XYZ coordinate system and a plurality of linear constraint units distributed in an equidistant array along the Y direction. Each linear constraint unit is composed of an upper linear constraint component and a lower linear constraint component that are structurally symmetrical.
[0005] It also includes a thin plate to be 3D formed, the thin plate being horizontal and sandwiched between each upper linear constraint component and each lower linear constraint component.
[0006] Furthermore, the upper linear constraint component includes an upper constraint line extending horizontally along the X direction, the lower side of which contacts the upper surface line of the thin plate along the X direction; several upper linear constraint wheels are equidistantly distributed along the X direction on the upper side of the upper constraint line, the annular groove on the outer periphery of each upper linear constraint wheel is tangent to the upper constraint line roller, and the several upper linear constraint wheels are rotatably mounted on several upper roller supports, with an upper lifter above each upper roller support, thereby realizing the independent lifting of each upper linear constraint wheel.
[0007] Furthermore, the upper linear constraint assembly also includes an upper floating beam extending along the X direction, and the linear drive device independently controls the upper floating beam to float along the X direction; the upper end of each upper lift is fixedly connected to the upper floating beam.
[0008] Furthermore, both ends of the upper constraint line are integrally connected to upper length compensation lines extending in an upward direction. Each upper length compensation line is connected to an upper tension spring at its end. The upper tension spring exerts tension on the upper length compensation line, thereby keeping both the upper constraint line and the upper length compensation line taut.
[0009] Furthermore, the lower linear constraint component includes a lower constraint line extending horizontally along the X direction, with the upper side of the lower constraint line contacting the lower surface line of the thin plate along the X direction; a number of lower constraint wheels are distributed in an equidistant array along the lower side of the lower constraint line, and the annular groove on the outer circumference of each lower constraint wheel is tangent to the lower constraint line roller. The number of lower constraint wheels are rotatably mounted on a number of lower roller supports, and there is a lower lifter under each lower roller support, thereby realizing the independent lifting and lowering of each lower constraint wheel.
[0010] Furthermore, the lower linear constraint assembly also includes a lower floating beam extending along the X direction, and the linear drive device independently controls the lower floating beam to float along the X direction; the lower end of each lower lifter is fixedly connected to the lower floating beam.
[0011] Furthermore, both ends of the lower constraint line are integrally connected to a lower length compensation line extending in a downward direction. The end of each lower length compensation line b is connected to a lower tension spring, which exerts a tension force on the lower length compensation line, thereby making both the lower constraint line and the lower length compensation line taut.
[0012] Furthermore, a horizontally oriented thin plate is sandwiched between several upper constraint lines and several lower constraint lines.
[0013] Furthermore, the upper and lower constraint lines consist of a flexible metal core and a flexible outer sheath.
[0014] Furthermore, a working method for a 3D moldless molding system for thin sheets:
[0015] In any set of linear constraint units, the thin plate is constrained into a straight line extending along the X direction by the linearly clamped portion of the horizontal upper constraint line and the horizontal lower constraint line. The precise lifting and lowering movements of each upper and lower constraint wheel are independently controlled. At the same time, during the process of independently controlling the precise lifting and lowering movements of each upper and lower constraint wheel, any corresponding upper and lower constraint wheels always lift and lower synchronously. The clamped portion between the upper and lower constraint lines deforms by following the synchronous fluctuations of the upper and lower constraint lines. At the same time, the upper and lower floating beams are controlled to synchronously translate and float along the X direction, so that the deformation curve of the linearly clamped portion of the thin plate is repeatedly fitted.
[0016] Beneficial effects: The structure of this invention is simple. The contact between this solution and the surface of the thin sheet is a line contact, which protects the surface of the processed thin sheet better than the traditional point contact. At the same time, it avoids the formation of multiple point-like pits on the surface. Meanwhile, the upper and lower constraint lines are composed of a flexible metal core and a flexible outer sheath. The flexible outer sheath also helps to avoid the formation of local dents on the surface of the thin sheet.
[0017] At the same time, the upper and lower constraint wheels, which correspond to each other, are precisely offset along the X direction. Simultaneously, they also perform synchronous and precise vertical displacement and roll constraint fitting along the length of the upper and lower constraint lines, respectively. This makes the upper and lower constraint lines fit the expected shape better under the repeated fitting constraints of the upper and lower constraint wheels, thereby making the deformation curve of the linearly clamped part of the thin plate fit the pre-set curve shape better. Attached Figure Description
[0018] Appendix Figure 1 This is a schematic diagram of the overall structure of this solution;
[0019] Appendix Figure 2 For the appendix Figure 1 A side view along the X-line of sight;
[0020] Appendix Figure 3 For the appendix Figure 1 A front view along the Y-axis;
[0021] Appendix Figure 4 This is a schematic diagram showing the portion of the thin plate that is linearly clamped but has not yet undergone bending deformation.
[0022] Appendix Figure 5 This is a schematic diagram showing that the portion of the thin plate being linearly clamped has undergone glass-like undulating deformation.
[0023] Appendix Figure 6 This is a schematic diagram of the interaction between a single set of upper linear constraint components and a thin plate;
[0024] Appendix Figure 7 This is a schematic diagram of a single-group linear constraint component structure.
[0025] Appendix Figure 8 This is a schematic diagram of the cross-sections of the upper and lower constraint lines. Detailed Implementation
[0026] The invention will now be further described with reference to the accompanying drawings.
[0027] As attached Figures 1 to 8 The illustrated 3D moldless molding system for thin sheets, such as Figure 1 Let there be an XYZ coordinate system, which includes a number of linear constraint units 12 distributed in an equidistant array along the Y direction. Each linear constraint unit 12 is composed of an upper linear constraint component 12.1 and a lower linear constraint component 12.2 that are structurally symmetrical.
[0028] It also includes a thin plate 11 to be 3D formed, such as a copper plate with a thickness of less than 3mm. Before processing, the thin plate 11 is horizontal and sandwiched between each upper linear constraint component 12.1 and each lower linear constraint component 12.2, such as... Figure 2 and Figure 3 As shown.
[0029] The structure of the upper linear constraint component 12.1 is as follows:
[0030] like Figure 3 and 7 As shown, the upper linear constraint assembly 12.1 includes an upper constraint line 2.1 extending horizontally along the X direction. The lower side of the upper constraint line 2.1 is in line contact with the upper surface of the thin plate 11 along the X direction. Several upper linear constraint wheels 10.1 are equidistantly distributed along the X direction on the upper side of the upper constraint line 2.1. The annular groove 6 on the outer periphery of each upper linear constraint wheel 10.1 is tangent to the upper constraint line 2.1. Several upper linear constraint wheels 10.1 are rotatably mounted on several upper roller supports 9.1. An upper lifter 8.1 is provided above each upper roller support 9.1. The end of the lifting rod 7.1 of each upper lifter 8.1 is fixedly connected to an upper roller support 9.1 below, thereby realizing the independent lifting of each upper linear constraint wheel 10.1.
[0031] The upper linear constraint assembly 12.1 also includes an upper floating beam 5.1 extending along the X direction, and the linear drive device independently controls the upper floating beam 5.1 to float along the X direction; the upper end of each upper lifter 8.1 is fixedly connected to the upper floating beam 5.1;
[0032] Both ends of the upper constraint line 2.1 are integrally connected to upper length compensation lines 2a extending in an upward oblique direction. Each upper length compensation line 2a is connected to an upper tension spring 1.1 at its end. The upper tension spring 1.1 exerts tension on the upper length compensation line 2a, thereby keeping both the upper constraint line 2.1 and the upper length compensation line 2a taut. In the subsequent working process, when the upper constraint line 2.1 undergoes bending deformation, the length of the upper constraint line 2.1 will increase due to bending. The upper constraint line 2.1 itself is rigid in the length direction, so the upper length compensation line 2a plays the role of compensating for the length of the upper constraint line 2.1.
[0033] The upper linear constraint assembly 12.1 also includes an upper linear expansion joint 4.1 along the X direction. The upper linear expansion joint 4.1 has an upper floating beam 5.1 fixedly connected to the end of the upper linear expansion rod 3.1, thereby driving the upper floating beam 5.1 to make precise floating displacement along the X direction.
[0034] like Figure 1 It also includes a fixed upper structural beam 14.1 extending along the Y direction, and each upper linear expansion joint 4.1 on a number of linear constraint units 12 distributed in an equidistant array along the Y direction is fixed on the upper structural beam 14.1;
[0035] It also includes a fixed upper spring connecting bracket 13.1, and the other end of each upper tension spring 1.1 is fixedly connected to the upper spring connecting bracket 13.1.
[0036] The structure of the lower linear constraint component 12.2 is as follows:
[0037] The lower linear constraint assembly 12.2 includes a lower constraint line 2.2 extending horizontally along the X direction. The upper side of the lower constraint line 2.2 is in line contact with the lower surface of the thin plate 11 along the X direction. A plurality of lower constraint wheels 10.2 are distributed in an equidistant array along the X direction on the lower side of the lower constraint line 2.2. The annular groove 6 on the outer periphery of each lower constraint wheel 10.2 is tangent to the lower constraint line 2.2. The plurality of lower constraint wheels 10.2 are rotatably mounted on a plurality of lower roller supports 9.2. A lower lifter 8.2 is provided below each lower roller support 9.2. The end of the b lifting rod 7.2 of each lower lifter 8.2 is fixedly connected to a lower roller support 9.2 above, thereby realizing the independent lifting of each lower constraint wheel 10.2.
[0038] The lower linear constraint assembly 12.2 also includes a lower floating beam 5.2 extending along the X direction, and the linear drive device independently controls the lower floating beam 5.2 to float along the X direction; the lower end of each lower lifter 8.2 is fixedly connected to the lower floating beam 5.2;
[0039] Both ends of the lower constraint line 2.2 are integrally connected to a lower length compensation line 2b extending in a downward direction. The end of each lower length compensation line 2b is connected to a lower tension spring 1.2, which exerts tension on the lower length compensation line 2b, thus keeping both the lower constraint line 2.2 and the lower length compensation line 2b taut. In the subsequent working process, when the lower constraint line 2.2 undergoes bending deformation, the length of the lower constraint line 2.2 will increase due to bending. The lower constraint line 2.2 itself is rigid in the length direction, so the lower length compensation line 2b plays the role of compensating for the length of the lower constraint line 2.2.
[0040] The lower linear constraint assembly 12.2 also includes a lower linear expansion joint 4.2 along the X direction. The lower linear expansion joint 4.2 has a lower floating beam 5.2 fixedly connected to the end of the lower linear expansion rod 3.2, thereby driving the lower floating beam 5.2 to float and displace along the X direction.
[0041] It also includes a fixed lower structural beam 14.2 extending along the Y direction, and each lower linear expansion joint 4.2 on a number of linear constraint units 12 distributed in an equidistant array along the Y direction is fixed on the lower structural beam 14.2;
[0042] It also includes a fixedly installed lower spring connecting bracket 13.2, and the other end of each lower tension spring 1.2 is fixedly connected to the lower spring connecting bracket 13.2.
[0043] Overall, the initially horizontal thin plate 11 is sandwiched between several upper constraint lines 2.1 and several lower constraint lines 2.2; as... Figure 7As shown, the upper constraint line 2.1 and the lower constraint line 2.2 are composed of a flexible metal core 21 and a flexible outer sheath 22; the flexible outer sheath 22 avoids forming local dents on the surface of the thin plate 11.
[0044] Specific processes and working principles:
[0045] In the initial state, the horizontally oriented, easily deformable thin plate 11, which has not yet undergone deformation, is sandwiched between each upper linear constraint component 12.1 and each lower linear constraint component 12.2. The following analysis will focus on any one of the groups of linear constraint elements 12 that are equidistantly arrayed along the Y direction:
[0046] In any set of linear constraint units 12, a deformable line segment extending along the X direction on the surface of the horizontal thin plate 11 is sandwiched between the horizontal upper constraint line 2.1 and the horizontal lower constraint line 2.2; the linearly clamped portion of the thin plate 11 by the horizontal upper constraint line 2.1 and the horizontal lower constraint line 2.2 is constrained into a straight line extending along the X direction, as shown below. Figure 3 and Figure 4 ;
[0047] By independently controlling the precise lifting and lowering movements of each upper constraint wheel 10.1 and each lower constraint wheel 10.2, the upper constraint line 2.1 and the lower constraint line 2.2 are transformed from straight lines into undulating wave-like lines. Simultaneously, during this precise lifting and lowering process, any corresponding upper constraint wheel 10.1 and lower constraint wheel 10.2 move synchronously, ensuring that the undulations of the upper constraint line 2.1 and the lower constraint line 2.2 at any position along the X-direction remain consistent. This results in perfectly identical wave shapes generated by the upper constraint line 2.1 and the lower constraint line 2.2, guaranteeing that the clamped portion between the upper constraint line 2.1 and the lower constraint line 2.2 moves synchronously with them. This achieves undulating deformation constraint on the linearly clamped portion of the thin plate 11, causing the linearly clamped portion of the thin plate 11 to deform into a pre-set curved shape. Figure 5 As shown;
[0048] To improve the accuracy of the undulating deformation constraint on the linearly clamped portion of the thin plate 11, while independently controlling the precise lifting and lowering movements of each upper linear constraint wheel 10.1 and each lower linear constraint wheel 10.2, the upper floating beam 5.1 and the lower floating beam 5.2 are controlled to synchronously translate and float along the X direction. This allows each upper linear constraint wheel 10.1 and the lower linear constraint wheel 10.2 to undergo precise lateral offset while experiencing precise up-and-down undulating changes, such as... Figure 5While the upper constraint wheel 10.1 and the lower constraint wheel 10.2, which are corresponding to each other, are precisely offset in the X direction, they also synchronously and precisely move up and down, and roll and constrain along the length direction of the upper constraint line 2.1 and the lower constraint line 2.2 respectively. This makes the upper constraint line 2.1 and the lower constraint line 2.2 fit the expected shape better under the repeated fitting constraints of the upper constraint wheel 10.1 and the lower constraint wheel 10.2, and thus make the deformation curve of the linearly clamped part of the thin plate 11 fit the pre-set curve shape better.
[0049] The above analysis is based on the working principle of a single group of linear constraint units 12.
[0050] Since several sets of linear constraint units 12 are equidistantly distributed along the Y direction, and each set of linear constraint units 12 can operate independently in terms of structure, under the common constraint of several linear constraint units 12 equidistantly distributed along the Y direction, the thin plate 11 can eventually deform into an arbitrary three-dimensional undulating shape. Theoretically, a thin-walled product with an arbitrary three-dimensional shape can be obtained.
[0051] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.
Claims
1. A 3D moldless forming system for thin sheets, comprising an XYZ coordinate system, characterized in that: It includes several linear constraint units (12) distributed in an equidistant array along the Y direction. Each linear constraint unit (12) is composed of an upper linear constraint component (12.1) and a lower linear constraint component (12.2) that are structurally symmetrical. It also includes a thin plate (11) to be 3D formed, the thin plate (11) being horizontal and sandwiched between each upper linear constraint component (12.1) and each lower linear constraint component (12.2); The upper linear constraint assembly (12.1) includes an upper constraint line (2.1) extending horizontally along the X direction. The lower side of the upper constraint line (2.1) is in line contact with the upper surface of the thin plate (11) along the X direction. Several upper linear constraint wheels (10.1) are equidistantly arranged on the upper side of the upper constraint line (2.1) along the X direction. The annular groove (6) on the outer periphery of each upper linear constraint wheel (10.1) is tangent to the roller of the upper constraint line (2.1). Several upper linear constraint wheels (10.1) are rotatably mounted on several upper roller supports (9.1). There is an upper lifter (8.1) above each upper roller support (9.1), thereby realizing the independent lifting of each upper linear constraint wheel (10.1). The upper linear constraint assembly (12.1) also includes an upper floating beam (5.1) extending along the X direction, and the linear drive device independently controls the upper floating beam (5.1) to float along the X direction; the upper end of each upper lifter (8.1) is fixedly connected to the upper floating beam (5.1). Both ends of the upper constraint line (2.1) are integrally connected to an upper length compensation line (2a) extending in an upward direction. The end of each upper length compensation line (2a) is connected to an upper tension spring (1.1). The upper tension spring (1.1) exerts tension on the upper length compensation line (2a), thereby making both the upper constraint line (2.1) and the upper length compensation line (2a) taut. The lower linear constraint assembly (12.2) includes a lower constraint line (2.2) extending horizontally along the X direction. The upper side of the lower constraint line (2.2) is in contact with the lower surface of the thin plate (11) along the X direction. A number of lower constraint wheels (10.2) are distributed in an equidistant array along the X direction on the lower side of the lower constraint line (2.2). The annular groove (6) on the outer periphery of each lower constraint wheel (10.2) is tangent to the roller of the lower constraint line (2.2). The number of lower constraint wheels (10.2) are rotatably mounted on a number of lower roller supports (9.2). There is a lower lifter (8.2) under each lower roller support (9.2), thereby realizing the independent lifting of each lower constraint wheel (10.2). The lower linear constraint assembly (12.2) also includes a lower floating beam (5.2) extending along the X direction, and the linear drive device independently controls the lower floating beam (5.2) to float along the X direction; the lower end of each lower lifter (8.2) is fixedly connected to the lower floating beam (5.2).
2. The 3D moldless forming system for thin sheets according to claim 1, characterized in that: Both ends of the lower constraint line (2.2) are integrally connected to a lower length compensation line (2b) extending in a downward direction. The end of each lower length compensation line (2b) is connected to a lower tension spring (1.2). The lower tension spring (1.2) exerts a tension force on the lower length compensation line (2b), thereby making both the lower constraint line (2.2) and the lower length compensation line (2b) taut.
3. The 3D moldless forming system for thin sheets according to claim 2, characterized in that: A horizontally oriented thin plate (11) is sandwiched between several upper constraint lines (2.1) and several lower constraint lines (2.2).
4. The 3D moldless forming system for thin sheets according to claim 3, characterized in that: The upper constraint line (2.1) and the lower constraint line (2.2) consist of a flexible metal core (21) and a flexible outer sheath (22).
5. The working method of the 3D moldless forming system for thin sheets according to claim 4, characterized in that: In any set of linear constraint units (12), the thin plate (11) is constrained into a straight line extending along the X direction by the linear clamping part of the horizontal upper constraint line (2.1) and the horizontal lower constraint line (2.2); the precise lifting and lowering movements of each upper constraint wheel (10.1) and each lower constraint wheel (10.2) are independently controlled. At the same time, during the precise lifting and lowering movements of each upper constraint wheel (10.1) and each lower constraint wheel (10.2) are independently controlled, the corresponding upper constraint wheel (10.1) and lower constraint wheel (10.2) always lift and lower synchronously. The clamped part between the upper constraint line (2.1) and the lower constraint line (2.2) deforms synchronously with the undulation of the upper constraint line (2.1) and the lower constraint line (2.2). At the same time, the upper floating beam (5.1) and the lower floating beam (5.2) are controlled to move synchronously along the X direction, so that the deformation curve of the linearly clamped part of the thin plate (11) is repeatedly fitted.