Processing method for forming large-size variable curvature RCS test bracket

Abstract

The present invention provides a process for forming a large-scale variable-curvature RCS test bracket, comprising the following steps: selecting metal plates to be processed based on the corresponding dimensions of each left and right side plate; fabricating a corresponding curvature detection tool, a punch, and a die according to the external shape of the RCS test bracket; placing each metal plate to be processed between the corresponding punch and die, and pressing the metal plate into a left / right side plate with the corresponding forming curvature; detecting the maximum distance h between the left / right side plate and the detection tool; welding multiple left plates to their corresponding symmetrically arranged right sides to form corresponding bracket units; securing the multiple bracket units with fasteners, and welding the joints between adjacent bracket units to form a bracket blank; and machining the bracket blank to obtain the RCS test bracket. This process reduces the amount of cutting required in subsequent processing, saving processing time and lowering costs.

Description

Technical Field

[0001] The present invention relates to the technical field of RCS brackets, and more particularly to a process for forming a large-size variable-curvature RCS test bracket. Background Art

[0002] Many countries attach great importance to the research and development of stealth technology. Competition in the stealth field is becoming increasingly fierce, with new technologies and new ideas emerging continuously. With the continuous development of stealth technology, the RCS (Radar Cross Section) value of targets is decreasing, making target detection increasingly difficult. Furthermore, the limitations of sensor bandwidth make anti-stealth extremely challenging. Clearly understanding the electromagnetic scattering characteristics of different targets in various postures and electromagnetic environments, obtaining corresponding target electromagnetic scattering characteristic data, and then analyzing and deriving the target scattering center distribution, is of great significance for targeted anti-stealth design.

[0003] RCS testing is primarily categorized into indoor and outdoor field testing, depending on target size. To minimize the impact of ground clutter, the target must be mounted at a specific height using a bracket. Using a turntable or two-dimensional rotating top, the target's various postures are simulated to determine the target's RCS at various azimuth and elevation angles. Therefore, a bracket is essential for RCS testing, and its stability, low scattering, reliability, and safety are crucial to RCS accuracy.

[0004] Commonly used brackets and support technologies include rope suspension, inflatable bag brackets, and polystyrene foam brackets. However, with the development of target characteristics, target identification, and stealth technology, there is a need for radiation phase measurement, low RCS measurement, and two-dimensional imaging measurement. This requires the bracket itself to have a very low RCS and the radiation phase of the scattered signal from the bracket to be stable during the test to cancel the background. However, these brackets and support technologies are no longer able to meet these requirements.

[0005] To minimize the impact on the target's RCS during RCS testing, the bracket must possess excellent safety, reliability, and scattering properties. These brackets must meet requirements such as high strength, rigidity, and low scattering. Typically, these brackets are over ten meters tall, with an outer surface of variable curvature. Due to their large size and complex surface, the current manufacturing process for these brackets is typically one-piece casting. This requires large molds, resulting in high manufacturing costs and low efficiency. Summary of the Invention

[0006] (1) Technical issues to be resolved

[0007] The technical problem to be solved by the present invention is that the existing RCS test bracket is generally manufactured by an integral casting method, which requires a large mold size, resulting in high manufacturing cost and low efficiency.

[0008] (2) Technical solution

[0009] To achieve the above object, the technical solution adopted by the present invention is:

[0010] A process for forming a large-sized variable-curvature RCS test bracket is provided. The RCS test bracket includes a plurality of bracket units with different curvatures connected in sequence along its length. Each bracket unit is composed of a left plate and a right plate with corresponding curvatures and symmetrically arranged. The process includes the following steps:

[0011] Step 1: Select metal plates of corresponding sizes to be processed based on the corresponding sizes of the left and right plates, determine the corresponding forming curvatures of the metal plates to be processed based on the external shape of the RCS test bracket, and manufacture corresponding curvature detection tools, punches, and die according to the respective forming curvatures;

[0012] Step 2: placing each metal plate to be processed between a corresponding male die and a female die, wherein the male die and the female die cooperate to press the metal plate to be processed into a left plate / right plate with a corresponding forming curvature;

[0013] Step 3: Use the corresponding inspection tool to check the curvature of the left / right panel. Measure the maximum distance h between the surface of the left / right panel close to the inspection tool and the surface of the inspection tool close to the left / right panel. If h > 5 mm, repeat step 2 until h ≤ 5 mm, then proceed to step 4.

[0014] Step 4: Weld the multiple left panels to their corresponding symmetrically arranged right panels to form corresponding bracket units, fix the multiple bracket units together with fasteners, and weld the connecting seams between two adjacent bracket units to form a bracket embryo;

[0015] Step 5: machining the scaffold embryo to obtain a scaffold for RCS testing.

[0016] Preferably, the step one further comprises:

[0017] A grid coordinate system is established based on the xy rectangular coordinate system of the metal plate surface to be processed. The horizontal axis of the grid coordinate system is parallel to the x-axis, and the angle between the vertical axis of the grid coordinate system and the y-axis is the inclination angle of the RCS test bracket. The length f of each grid on the horizontal axis is equal, and the width e of each grid on the vertical axis is equal.

[0018] According to the width e and length f of the grid, a convex mold with a width e and a length f is made, and a concave mold with a width e and a length f is made.

[0019] Preferably, the width of the grid is one fiftieth to one twentieth of the width of the metal plate to be processed, and / or the length of the grid is one fiftieth to one twentieth of the length of the metal plate to be processed.

[0020] Preferably, the steps of making corresponding curvature detection tools, male dies and female dies according to the respective molding curvatures include:

[0021] At the end of the left / right side plate with a total length of s, a DD segment with a length of f, an EE segment with a distance d from the DD segment, and an FF segment with a distance d from the EE segment are provided, where d = s / 3 - f;

[0022] According to the curvature of the DD segment, EE segment and FF segment, detection tools, punches and die with corresponding curvatures are made, among which: the detection tool corresponding to the curvature of the DD segment is tool a, the corresponding punch is punch a, and the corresponding die is die a; the detection tool corresponding to the curvature of the EE segment is tool b, the corresponding punch is punch b, and the corresponding die is die b; the detection tool corresponding to the curvature of the FF segment is tool c, the corresponding punch is punch c, and the corresponding die is die c.

[0023] Preferably, the second step includes:

[0024] The metal plate to be processed is divided into segments D, E and F along the longitudinal axis according to their lengths, and the following steps are performed in sequence: the punch a and the die a are used to press the segments D, E and F, the punch b and the die b are used to press the segments E and F, and the punch c and the die c are used to press the segment F, so as to press the metal plate to be processed into a left plate / right plate with a corresponding forming curvature.

[0025] Preferably, before step three:

[0026] Observe the surface of the left / right panel with the naked eye. If there are obvious bulges on the surface of the left / right panel, use the corresponding punch and die to press the bulge until there is no obvious bulge on the left / right panel.

[0027] Preferably, step three includes: fitting tool a to segment D, fitting tool b to segment E, and fitting tool c to segment F, and respectively measuring the maximum distance h between the surface of segment D close to tool a and the surface of tool a close to segment D, the maximum distance h between the surface of segment E close to tool b and the surface of tool b close to segment E, and the maximum distance h between the surface of segment F close to tool c and the surface of tool c close to segment F.

[0028] Preferably, the fasteners are bolts and / or pins.

[0029] Preferably, the step 2 further includes:

[0030] The metal plate to be processed is placed on the support seat, and the metal plate to be processed is placed between the corresponding punch and die, and the metal plate to be processed is moved along its width direction. The punch and die cooperate to press the metal plate to be processed into a left plate / right plate with a corresponding forming curvature.

[0031] (3) Beneficial effects

[0032] The above technical solution of the present invention has at least the following advantages:

[0033] 1. The process method provided by the present invention divides a large-sized RCS test bracket into multiple small-sized left and right side plates, which are connected to form the bracket. The metal plate to be processed is pressed by the cooperation of the punch and the die to form a left side plate / right side plate corresponding to the strain curvature; the corresponding left side plate and right side plate are then connected to form a bracket unit, and finally the bracket unit is connected to form an RCS test bracket. Compared with the existing RCS test bracket forming method, the process method provided by the present invention does not require a large mold. The corresponding components are pressed into shape and then assembled by the cooperation of the punch and the die, which can reduce the amount of cutting in subsequent processing, save processing time, and reduce costs. Moreover, the process parameters can be flexibly adjusted according to the requirements of RCS test brackets with different curvatures. The corresponding parameters of the punch and the die can be widely adapted and highly efficient.

[0034] 2. The RCS test bracket manufactured by the process method provided by the present invention can not only meet the load requirements of the test target, but also has good scattering performance, can realize the connection of different parts, and can be applied to RCS tests of different targets. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0036] Figure 1 A schematic diagram of the structure of an RCS test bracket provided in an embodiment of the present invention;

[0037] Figure 2 A schematic diagram of a grid coordinate system provided by an embodiment of the present invention;

[0038] Figure 3 A schematic structural diagram of a detection tool, a male mold, and a female mold provided in an embodiment of the present invention;

[0039] Figure 4 One of the implementation steps of the process method provided in the embodiment of the present invention;

[0040] Figure 5FIG2 is a second diagram of the implementation steps of the process method provided in an embodiment of the present invention;

[0041] Figure 6 FIG3 is a diagram of the implementation steps of the process method provided in an embodiment of the present invention;

[0042] Figure 7 FIG4 is a fourth diagram of the implementation steps of the process method provided in an embodiment of the present invention;

[0043] Figure 8 FIG5 is a fifth diagram of the implementation steps of the process method provided in an embodiment of the present invention.

[0044] The reference numerals in the figures are:

[0045] 1. RCS test bracket; 2. Metal plate to be processed; 3. Tool a; 4. Tool b; 5. Tool c; 6. Die a; 7. Punch a; 8. Die b; 9. Punch b; 10. Die c; 11. Punch c; 12. Support seat; 13. Support pad. DETAILED DESCRIPTION

[0046] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0047] It should be noted that when an element is referred to as being “fixed to” or “disposed on” another element, it may be directly located on the other element or indirectly located on the other element. When an element is referred to as being “connected to” another element, it may be directly connected to the other element or indirectly connected to the other element.

[0048] It should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention, and do not indicate that the device or element must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it should not be understood as a limitation on the present invention.

[0049] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating relative importance or the number of technical features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined. The following is a more detailed description of the specific implementation of the present invention in conjunction with specific embodiments:

[0050] like Figure 1 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 7 and Figure 8 As shown, an embodiment of the present invention provides a process method for forming a large-sized variable curvature RCS test bracket, and provides a process method for forming a large-sized variable curvature RCS test bracket. The RCS test bracket 1 includes a plurality of bracket units with different curvatures connected in sequence along its length direction (in this embodiment, the RCS test bracket 1 is preferably divided into three bracket units with different curvatures along its length direction, which are respectively as follows Figure 1 As shown in the bracket unit A, bracket unit B and bracket unit C), each bracket unit is composed of a left plate and a right plate connected by corresponding curvatures and symmetrically arranged; Figure 1 In the embodiment shown, the bracket unit A is composed of a first side panel A1 and a second side panel A2 connected together and having corresponding curvatures and being symmetrically arranged; the bracket unit B is composed of a third side panel B1 and a fourth side panel B2 connected together and having corresponding curvatures and being symmetrically arranged; and the bracket unit C is composed of a fifth side panel C1 and a sixth side panel C2 connected together and having corresponding curvatures and being symmetrically arranged. The process method includes the following steps:

[0051] Step 1: Based on the corresponding dimensions of the left side panels (including the first side panel A1, the third side panel B1, and the fifth side panel C1 in this embodiment) and the right side panels (including the second side panel A2, the fourth side panel B2, and the sixth side panel C2 in this embodiment), select the corresponding sizes of the metal plates 2 to be processed. Based on the external shape of the RCS test bracket 1, determine the corresponding forming curvature of each metal plate 2 to be processed. According to each forming curvature, produce the corresponding curvature detection tool, punch, and die.

[0052] Step 2: Place each metal plate to be processed between the corresponding punch and die. The punch and die cooperate to press the metal plate to be processed into a left plate / right plate with a corresponding forming curvature.

[0053] Step 3: Use the corresponding inspection tool to check the curvature of the left / right panel. Measure the maximum distance h between the surface of the left / right panel close to the inspection tool and the surface of the inspection tool close to the left / right panel. If h > 5mm, repeat step 2 until h ≤ 5mm, then proceed to step 4.

[0054] Step 4: Weld the multiple left panels to their corresponding symmetrically arranged right panels to form corresponding bracket units. Fasteners secure the multiple bracket units together, and weld the seams between adjacent bracket units to form the bracket body. The welds at the seams are not subject to stress; their primary function is to conceal the seams, ensuring a continuous, smooth surface for the RCS test bracket 1 and preventing radar signal reflection. Specifically, the fasteners are bolts or pins. These fasteners are the primary load-bearing components of the RCS test bracket 1.

[0055] Step 5: Machining the stent embryo to obtain the RCS test stent 1. Through machining, the RCS test stent 1 with higher surface forming accuracy is obtained.

[0056] The processing steps for the first side panel A1, the second side panel A2, the third side panel B1, the fourth side panel B2, the fifth side panel C1, and the sixth side panel C2 are the same. The processing steps for the third side panel B1 are used as an example for description. The specific steps are as follows:

[0057] like Figure 2 As shown, first, a metal plate 2 to be processed with a length of L, a width of W, and a thickness of H is prepared, and a grid coordinate system is established based on the xy rectangular coordinate system of the surface of the metal plate 2 to be processed. A marker pen and a ruler are used to divide the surface of the metal plate 2 to be processed into grids. The horizontal axis of the grid coordinate system is parallel to the x-axis (along the horizontal axis, from left to right, each grid segment is named A1 segment, B1 segment...N1 segment and O1 segment in sequence), and the angle between the longitudinal axis of the grid coordinate system and the y-axis is the inclination angle of the RCS test bracket (along the longitudinal axis, from bottom to top, each grid segment is named A1 segment, A2 segment...A19 segment and A20 segment in sequence), wherein the length f of each grid on the horizontal axis is equal, and the width e of each grid on the longitudinal axis is equal; specifically, the width e of the grid is one-fiftieth to one-twentieth of the width of the metal plate 2 to be processed, and / or, the length f of the grid is one-fiftieth to one-twentieth of the length of the metal plate 2 to be processed.

[0058] According to the width e and length f of the grid, a convex mold with a width e and a length f is made, and a concave mold with a width e and a length f is made. Specifically, Figure 3 As shown, a DD segment with a length of f, an EE segment with a distance d from the DD segment, and an FF segment with a distance d from the EE segment are provided at the end of the left side plate / right side plate with a total length of s, wherein d = s / 3 - f, d ≥ 0;

[0059] According to the curvature of the DD segment, EE segment and FF segment, detection tools, punches and die with corresponding curvatures are made, among which: the detection tool corresponding to the curvature of the DD segment is tool a3, the corresponding punch is punch a7, and the corresponding die is die a6; the detection tool corresponding to the curvature of the EE segment is tool b4, the corresponding punch is punch b9, and the corresponding die is die b8; the detection tool corresponding to the curvature of the FF segment is tool c5, the corresponding punch is punch c11, and the corresponding die is die c10.

[0060] like Figures 4 to 6As shown, the metal plate to be processed is placed on the support seat 12, and the metal plate to be processed is placed between the corresponding male and female dies, and the metal plate to be processed is moved along its width direction. The male and female dies cooperate to press the metal plate to be processed into a left plate / right plate with a corresponding forming curvature. Specifically, as Figure 3 As shown, the metal plate to be processed is divided into segments D, E, and F along the longitudinal axis, and the following steps are performed in sequence: the punch a7 and the die a6 cooperate to press segments D, E, and F. More specifically, the gridded metal plate 2 to be processed is placed on the support seat 12, and the die a6 is placed on the support pad 13. Die a6 is positioned at a certain position below the grid line A1 segment. The punch a7 is moved above the grid line A1 segment. The distance between the die a6 and the grid line A1 segment is determined by the surface shape of the RCS test bracket 1. The punch a7 is aligned with the grid line A1 segment and presses the metal plate 2 to be processed downward until it is in full contact with the die a6. Using the same method, grid lines B1 to O1, A2 to O2, A3 to O3... are processed in sequence until all grid lines are processed; next, the punch b9 and the die b8 are used to press the E and F segments; more specifically, the die a8 is placed at a certain position below the grid line A7 segment, and the punch a9 is moved to the top of the grid line A7 segment. The distance between the die a8 and the grid line A7 segment is determined by the surface shape of the RCS test bracket 1. The punch a9 is aligned with the grid line A7 segment and presses the metal plate 2 to be processed downward until it is in full contact with the die a8. Following the same method, process grid lines B7 to O7, A8 to O8, A9 to O9, and so on, all the way to grid line O20. Next, use punch c11 and die c10 to press segment F. Die a10 is positioned below grid line A7, and punch a11 is moved above grid line A14. The distance between die a10 and grid line A14 is determined by the surface shape of the RCS test bracket 1. Punch a11 is aligned with grid line A14 and presses down on the metal plate 2 to be processed until it makes full contact with die a10. Following the same method, process grid lines B14 to O14, A15 to O15, A16 to O16, and so on, all the way to grid line O20.

[0061] Observe the surface of the left / right panel with the naked eye. If there are obvious bulges on the surface of the left / right panel, use the corresponding punch and die to press the bulge until there is no obvious bulge on the left / right panel.

[0062] like Figure 7 and Figure 8 As shown, Figure 8The image on the right side of the center is an enlarged view of area G on the left. Tool a3 is attached to segment D, tool b4 is attached to segment E, and tool c5 is attached to segment F. The maximum distance h between the surface of segment D near tool a3 and the surface of tool a3 near segment D, the maximum distance h between the surface of segment E near tool b4 and the surface of tool b4 near segment E, and the maximum distance h between the surface of segment F near tool c5 and the surface of tool c5 near segment F are measured. If h > 5 mm, repeat the pressing process until h ≤ 5 mm.

[0063] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A process for forming a large-size variable curvature RCS test bracket, characterized in that: The RCS test bracket includes a plurality of bracket units with different curvatures connected in sequence along its length, each bracket unit being composed of a left plate and a right plate with corresponding curvatures and symmetrically arranged. The process method includes the following steps: Step 1: According to the corresponding sizes of the left and right plates, select the metal plates to be processed of the corresponding sizes, determine the forming curvatures of the metal plates to be processed according to the external shape of the RCS test bracket, and make corresponding curvature detection tools, punches and concave dies according to the forming curvatures; establish a grid coordinate system based on the xy rectangular coordinate system of the surface of the metal plate to be processed, wherein the horizontal axis of the grid coordinate system is parallel to the x-axis, and the angle between the vertical axis of the grid coordinate system and the y-axis is the inclination angle of the RCS test bracket, wherein the length f of each grid on the horizontal axis is equal, and the width e of each grid on the vertical axis is equal; according to the width e and length f of the grid, make a punch with a width e and a length f, so as to and making a die with a width of e and a length of f; setting a DD segment with a length of f, an EE segment with a distance d from the DD segment, and an FF segment with a distance d from the EE segment at the end of the left plate / right plate with a total length of s, where d=s / 3-f; making detection tools, punches, and die with corresponding curvatures according to the curvatures of the DD segment, the EE segment, and the FF segment, where: the detection tool corresponding to the curvature of the DD segment is tool a, the corresponding punch is punch a, and the corresponding die is die a; the detection tool corresponding to the curvature of the EE segment is tool b, the corresponding punch is punch b, and the corresponding die is die b; the detection tool corresponding to the curvature of the FF segment is tool c, the corresponding punch is punch c, and the corresponding die is die c; Step 2: placing each metal plate to be processed between a corresponding male die and a female die, wherein the male die and the female die cooperate to press the metal plate to be processed into a left plate / right plate with a corresponding forming curvature; Step 3: Use the corresponding inspection tool to check the curvature of the left / right panel. Measure the maximum distance h between the surface of the left / right panel close to the inspection tool and the surface of the inspection tool close to the left / right panel. If h > 5 mm, repeat step 2 until h ≤ 5 mm, then proceed to step 4. Step 4: Weld the multiple left panels to their corresponding symmetrically arranged right panels to form corresponding bracket units, fix the multiple bracket units together with fasteners, and weld the connecting seams between two adjacent bracket units to form a bracket embryo; Step 5: machining the scaffold embryo to obtain a scaffold for RCS testing.

2. The process for forming a large-size variable curvature RCS test bracket according to claim 1, characterized in that: The width of the grid is 1 / 50 to 1 / 20 of the width of the metal plate to be processed, and / or the length of the grid is 1 / 50 to 1 / 20 of the length of the metal plate to be processed.

3. The process for forming a large-size variable curvature RCS test stent according to claim 1, characterized in that: The second step includes: The metal plate to be processed is divided into segments D, E and F along the longitudinal axis according to their lengths, and the following steps are performed in sequence: the punch a and the die a are used to press the segments D, E and F, the punch b and the die b are used to press the segments E and F, and the punch c and the die c are used to press the segment F, so as to press the metal plate to be processed into a left plate / right plate with a corresponding forming curvature.

4. The process for forming a large-size variable curvature RCS test stent according to claim 1, characterized in that: Before step 3: Observe the surface of the left / right panel with the naked eye. If there are obvious bulges on the surface of the left / right panel, use the corresponding punch and die to press the bulge until there is no obvious bulge on the left / right panel.

5. The process for forming a large-size variable curvature RCS test bracket according to claim 3, characterized in that: The step three includes: fitting tool a to segment D, fitting tool b to segment E, and fitting tool c to segment F, and respectively measuring the maximum distance h between the surface of segment D close to tool a and the surface of tool a close to segment D, the maximum distance h between the surface of segment E close to tool b and the surface of tool b close to segment E, and the maximum distance h between the surface of segment F close to tool c and the surface of tool c close to segment F.

6. The process for forming a large-size variable curvature RCS test bracket according to claim 1, characterized in that: The fasteners are bolts and / or pins.

7. The process for forming a large-size variable curvature RCS test stent according to claim 1, characterized in that: The second step also includes: The metal plate to be processed is placed on the support seat, and the metal plate to be processed is placed between the corresponding punch and die, and the metal plate to be processed is moved along its width direction. The punch and die cooperate to press the metal plate to be processed into a left plate / right plate with a corresponding forming curvature.

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