Flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures

Abstract

The application discloses a flexible ultrasonic roll forming device and method for ultrathin-wall micro-surface structure, which comprises: driving feature gear, driven light surface gear, flexible pad, driving ultrasonic vibration system, servo power system, roll gear pressure adjusting system and device base; the forming method comprises the following steps: (1) stress relief annealing after foil rolling, selecting the hardness and thickness of the flexible pad; (2) adjusting the pressure parameters between the driving and driven gears; (3) setting the ultrasonic vibration parameters; (3) setting the gear rotating speed; (4) putting the foil, flexible pad and lubricant into the material guide port, and starting the device for roll forming. The device and method can only use one gear with a feature structure for forming, the equipment cost is reduced, and the process flexibility is improved. The flexible pad can dynamically compensate the micro-error of the parallelism of the driving and driven shafts, and avoids forming distortion and rupture. Under the action of ultrasonic vibration, the mold adhesion degree of the ultrathin-wall micro-surface structure is increased, and the forming precision is improved.

Description

Technical Field

[0001] This invention relates to advanced manufacturing technology for improving the quality and efficiency of manufacturing ultrathin-walled micro-surface structures, and particularly to a flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures. Background Technology

[0002] At present, the trends of energy saving, friction reduction, functional integration and lightweighting of mechanical equipment are becoming increasingly intense. Due to the excellent waterproof, stain-resistant and drag-reducing properties of micro-surface structures, the demand for ultra-thin wall micro-surface structure parts is increasing. Ultra-thin wall micro-surface structure parts are widely used in microfluidic pipeline transmission, honeycomb structures, chemical reactors, etc. However, due to the influence of size effect, the following problems exist in the manufacturing of ultra-thin wall micro-surface structures: (1) There are many types of micro-surface structures and their shapes are varied. Each structure requires a set of rolling equipment, which is expensive; (2) The foil thickness is small. The slight error in the parallelism of the main and driven roller teeth during the rolling process will lead to the distortion and breakage of the ultra-thin wall micro-surface structure; (3) The heterogeneity of individual grains has a great influence. The longitudinal and transverse characteristics of ultra-thin wall micro-surface structures have large dispersion; (4) Both the main and driven roller teeth adopt ultrasonic vibration. The ultrasonic vibration system is complex and expensive; (5) The microscopic damage during the forming of ultra-thin wall micro-surface structures is large. They are prone to breakage and deformation in later use and have low fatigue life.

[0003] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0004] The purpose of this invention is to provide a flexible ultrasonic roll forming device for ultra-thin wall micro-surface structures, which can achieve precise forming of high aspect ratio micro-surface structures using only one roller tooth with characteristic microstructures. At the same time, it utilizes the acoustic softening effect of longitudinal ultrasonic vibration to promote the rotation and deformation of heterogeneous grains in the foil, thereby significantly improving the forming accuracy and efficiency of micro-surface structures.

[0005] To achieve the above objectives, embodiments of the present invention provide a flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures, characterized in that the device comprises: active feature roller teeth, driven smooth roller teeth, a flexible pad, an active ultrasonic vibration system, a servo power system, a roller tooth pressure adjustment system, and a device base;

[0006] The active feature roller tooth consists of two parts: a fixed shaft with a diameter of 10-30 mm and a length of 10-50 mm at both ends, and an intermediate feature gear with a diameter of 50-300 mm and a width of 10-50 mm. The feature gear has microstructures with a length of 1-15 mm, a width of 1-15 mm, a depth of 1-10 mm, or a height of 1-10 mm on its surface. The fillet radius at the connection between the fixed shaft and the feature gear is 10-30 mm.

[0007] The driven smooth roller tooth consists of two parts: a fixed shaft with a diameter of 10-50 mm and a length of 10-100 mm at both ends, and a smooth roller with a diameter of 50-300 mm and a width of 10-500 mm in the middle. The radius of the fillet at the connection between the fixed shaft and the smooth roller is 10-50 mm.

[0008] The flexible pad is a polyurethane rubber pad with a hardness of 10~90HA, a thickness of 5~20mm, a width of 10~500mm, and a length of 100~500mm.

[0009] The active ultrasonic vibration system consists of an ultrasonic generator, a transducer, and an amplitude transformer. The ultrasonic generator transmits electrical energy to the transducer through a carbon brush ring. The end of the amplitude transformer is coupled to the end face of the fixed shaft of the active feature roller tooth. The ultrasonic vibration direction of the active feature roller tooth is along the radial direction of the roller tooth.

[0010] The servo power system includes a servo motor and a controller. The servo motor drives the active feature roller to rotate through a rubber synchronous belt. The servo power system is connected to the device base.

[0011] The pressure regulation system between the roller teeth includes an air compressor, a cylinder, a driven roller tooth fixing frame, and a precision slide rail. The cylinder is connected to the driven roller tooth fixing frame, and the driven roller tooth fixing frame is connected to the device base through the precision slide rail.

[0012] The method of using the flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures is characterized by comprising the following steps:

[0013] Step 1: Cold roll 20% to 50% of the foil material with a width of 10~50mm, a length of 50~300mm, and a thickness of 30~300μm, and then perform stress-relieving annealing heat treatment at a temperature of 200~400℃ for 1~5h, and select a flexible pad.

[0014] Step 2: Turn on the roller tooth pressure adjustment system and set the roller tooth pressure value to 50~3000N;

[0015] Step 3: Turn on the active ultrasonic vibration system and set the ultrasonic vibration frequency to 10~30kHz and the amplitude to 1~30μm;

[0016] Step 4: Turn on the servo power system and set the active feature roller tooth linear speed to 1~30mm / s;

[0017] Step 5: After applying lubricant to the upper and lower surfaces of the foil, it is bonded together with the flexible pad. The foil and flexible pad are placed into the feed inlet from bottom to top and then rolled into shape.

[0018] In one or more embodiments of the present invention, the method for selecting the flexible pad is as follows: when the yield strength of the foil is 100~300MPa and the thickness is 30~150μm, the flexible pad is a polyurethane rubber pad with a thickness of 5~10mm and a hardness of 10~30HA; when the yield strength of the foil is 300~500MPa and the thickness is 150~250μm, the flexible pad is a polyurethane rubber pad with a thickness of 10~15mm and a hardness of 30~50HA; when the yield strength of the foil is 500~800MPa and the thickness is 250~300μm, the flexible pad is a polyurethane rubber pad with a thickness of 15~20mm and a hardness of 50~90HA.

[0019] In one or more embodiments of the present invention, the microstructure of the active feature gear surface is a single discontinuous structure.

[0020] In one or more embodiments of the present invention, the microstructure of the active feature gear surface is a plurality of continuous structures.

[0021] In one or more embodiments of the present invention, the lubricant is vegetable oil, animal oil, or MoS2.

[0022] Compared with existing technologies, this invention proposes a novel process utilizing feature roller teeth + flexible pads + ultrasonic vibration, which has the following advantages: 1. Each micro-surface structure model requires only one rigid active feature roller tooth, significantly improving process flexibility and reducing equipment costs. 2. The free deformation of the flexible pad promotes micro-structure adhesion to the mold, improving forming accuracy. 3. The flexible pad with specific hardness can adaptively adjust the parallelism of the master and driven roller tooth shafts, avoiding forming distortion and breakage of the ultra-thin-walled micro-surface structure caused by slight deviations in the master and driven roller tooth shafts. 4. Ultrasonic vibration produces optimal acoustic softening effect on the foil during roll forming, enhancing dislocation kinetic energy and significantly reducing the yield strength and microscopic damage of the foil. Therefore, the method of this invention is particularly suitable for the efficient, high-quality, and controllable manufacturing of ultra-thin-walled micro-surface structures. Attached Figure Description

[0023] Figure 1 This is a comparison diagram of a flexible ultrasonic roll forming method for ultrathin-walled micro-surface structures according to an embodiment of the present invention and a conventional method;

[0024] Figure 2This is a schematic diagram of a flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures according to an embodiment of the present invention;

[0025] Figure 3 This is a schematic diagram of an active feature roller tooth according to an embodiment of the present invention.

[0026] The following are the labels in the diagram: 1. Active feature roller tooth, 101. Fixed shaft, 102. Feature gear, 103. Corner radius, 104. Microstructure, 2. Driven smooth roller tooth, 3. Flexible pad, 4. Active ultrasonic vibration system, 5. Servo power system, 6. Roller tooth pressure adjustment system, 601. Cylinder, 602. Air compressor, 603. Precision slide rail, 604. Driven roller tooth fixing frame, 7. Device base, 8. Foil. Detailed Implementation

[0027] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments.

[0028] Unless otherwise expressly stated, throughout the specification and claims, the term "comprising" or its variations such as "including" or "comprises" shall be understood to include the stated elements or components without excluding other elements or other components.

[0029] like Figures 1-3 As shown, a flexible ultrasonic roll forming device for ultrathin wall micro-surface structures according to a preferred embodiment of the present invention is characterized in that the device comprises: 1 active feature roller teeth, 2 driven smooth roller teeth, 3 flexible pad, 4 active ultrasonic vibration system, 5 servo power system, 6 roller tooth pressure adjustment system and 7 device base;

[0030] The active feature roller tooth consists of two parts: a fixed shaft (101) with a diameter of 10-30 mm and a length of 10-50 mm at both ends, and a feature gear (102) with a diameter of 50-300 mm and a width of 10-50 mm. The feature gear has a microstructure (104) with a length of 1-15 mm, a width of 1-15 mm, a depth of 1-10 mm, or a height of 1-10 mm on its surface. The fillet radius (103) at the connection between the fixed shaft (101) and the feature gear (102) is 10-30 mm.

[0031] The two driven smooth roller teeth are composed of two fixed shafts with a diameter of 10~50mm and a length of 10~100mm at both ends, and a smooth roller with a diameter of 50~300mm and a width of 10~500mm in the middle. The radius of the fillet at the connection between the fixed shaft and the smooth roller is 10~50mm.

[0032] The three flexible pads are polyurethane rubber pads with a hardness of 10~90HA, a thickness of 5~20mm, a width of 10~500mm, and a length of 100~500mm.

[0033] The four active ultrasonic vibration systems consist of an ultrasonic generator, a transducer, and an amplitude transformer. The ultrasonic generator transmits electrical energy to the transducer through a carbon brush ring. The end of the amplitude transformer is coupled to the end face of the fixed shaft of the active roller tooth. The ultrasonic vibration direction of the active characteristic roller tooth is along the radial direction of the roller tooth.

[0034] The 5-servo power system includes a servo motor and a controller. The servo motor drives the active feature roller to rotate through a rubber synchronous belt. The servo power system is connected to the device base.

[0035] The 6-roller inter-tooth pressure adjustment system includes a 601 cylinder, a 602 air compressor, a 603 precision slide rail, and a 604 driven roller tooth fixing frame. The 601 cylinder is connected to the 604 driven roller tooth fixing frame, and the 604 driven roller tooth fixing frame is connected to the 7 device base through the 603 precision slide rail.

[0036] The method of using the flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures is characterized by comprising the following steps:

[0037] Step 1: Cold roll 8 foil materials with a width of 10~50mm, a length of 50~300mm, and a thickness of 30~300μm by 20%~50%, and then perform stress-relieving annealing heat treatment by holding at 200~400℃ for 1~5h, and select 3 flexible pads.

[0038] Step 2: Turn on the 6-roller inter-tooth pressure adjustment system and set the inter-tooth pressure value to 50~3000N;

[0039] Step 3: Turn on the 4-active ultrasonic vibration system and set the ultrasonic vibration frequency to 10~30kHz and the amplitude to 1~30μm;

[0040] Step 4: Turn on the 5-servo power system and set the linear speed of the 1 active feature roller tooth to 1~30mm / s;

[0041] Step 5: After applying lubricant to the upper and lower surfaces of the 8 foils, bond them together with the 3 flexible pads. Place the 8 foils and 3 flexible pads into the feed inlet from bottom to top, and roll them into shape.

[0042] The method for selecting the three flexible pads is as follows: when the yield strength of the foil is 100~300MPa and the thickness is 30~150μm, the flexible pad is a polyurethane rubber pad with a thickness of 5~10mm and a hardness of 10~30HA; when the yield strength of the foil is 300~500MPa and the thickness is 150~250μm, the flexible pad is a polyurethane rubber pad with a thickness of 10~15mm and a hardness of 30~50HA; when the yield strength of the foil is 500~800MPa and the thickness is 250~300μm, the flexible pad is a polyurethane rubber pad with a thickness of 15~20mm and a hardness of 50~90HA.

[0043] The microstructure on the surface of the active characteristic gear is a single discontinuous structure.

[0044] The microstructure on the surface of the active feature gear is a series of continuous structures.

[0045] The lubricant is vegetable oil, animal oil, or MoS2.

[0046] Example 1

[0047] Taking the preparation of 50 TA1 ultrathin-walled micro-surface structures, each with a length of 80 mm, a width of 25 mm, and a thickness of 100 μm, as an example, the implementation process of the method for preparing ultrathin-walled micro-surface structures according to the present invention is illustrated. The microstructure consists of multiple continuous microgrooves with a length of 2 mm, a width of 1 mm, and a depth of 1 mm, as detailed below:

[0048] Step 1: The TA1 foil with a width of 25mm, a length of 170mm, and a thickness of 100μm is cold rolled by 25%, and then subjected to stress-relief annealing heat treatment at 400℃ for 3h. The yield strength is measured to be 450MPa. A polyurethane rubber pad with a thickness of 10mm and a hardness of 30HA is selected.

[0049] Step 2: Turn on the roller tooth pressure adjustment system and set the roller tooth pressure value to 500N;

[0050] Step 3: Turn on the active ultrasonic vibration system and set the ultrasonic vibration frequency to 20kHz and the amplitude to 20μm;

[0051] Step 4: Turn on the servo power system and set the linear speed of the active feature roller teeth to 10mm / s;

[0052] Step 5: After coating the upper and lower surfaces of the foil with vegetable oil, bond it together with the polyurethane rubber pad. Place the foil and the flexible pad into the feed inlet from bottom to top, and roll it into shape.

[0053] Comparative Example 1

[0054] Using traditional methods:

[0055] Step 1: Clean the TA1 foil with a width of 25mm, a length of 170mm, and a thickness of 100μm;

[0056] Step 2: Start the roll bending forming device, with a roll bending forming speed of 10mm / s;

[0057] Step 3: Roll bending.

[0058] Comparison results

[0059]

[0060] This invention proposes a novel device combining active feature roller teeth, a flexible pad, and an ultrasonic vibration system. Based on the microstructure and thickness of the foil, specific ultrasonic vibration parameters, compressive stress state, and roller bending speed are set. Under ultrasonic vibration, the foil absorbs a significant amount of energy, dislocation kinetic energy increases substantially, and some hard-oriented grains rotate and deform under impact vibration, greatly improving forming uniformity and foil plasticity. Simultaneously, the flexible pad dynamically compensates for minute deviations in the shafts of the active and driven roller teeth, significantly eliminating forming distortion and cracking defects. Furthermore, during the forming process, the ultra-thin wall micro-surface structure adheres to the mold under high-frequency impact, enhancing forming uniformity. Therefore, as shown in Table 1, the method of this invention significantly reduces microstructure forming angle deviation compared to traditional methods, resulting in a substantial improvement in product dimensional accuracy and strength.

[0061] The foregoing description of specific exemplary embodiments of the invention is for illustrative and explanatory purposes. These descriptions are not intended to limit the invention to the precise forms disclosed, and it will be apparent that many changes and variations can be made in accordance with the foregoing teachings. The exemplary embodiments were chosen and described in order to explain the specific principles of the invention and its practical application, thereby enabling those skilled in the art to implement and utilize various different exemplary embodiments of the invention, as well as various different choices and variations. The scope of the invention is intended to be defined by the claims and their equivalents.

Claims

1. A flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures, characterized in that, The device includes: active feature roller teeth, driven smooth roller teeth, flexible pad, active ultrasonic vibration system, servo power system, roller tooth pressure adjustment system, and device base; The active feature roller tooth consists of two parts: a fixed shaft with a diameter of 10-30 mm and a length of 10-50 mm at both ends, and an intermediate feature gear with a diameter of 50-300 mm and a width of 10-50 mm. The feature gear has microstructures with a length of 1-15 mm, a width of 1-15 mm, a depth of 1-10 mm, or a height of 1-10 mm on its surface. The fillet radius at the connection between the fixed shaft and the feature gear is 10-30 mm. The driven smooth roller tooth consists of two parts: a fixed shaft with a diameter of 10-50 mm and a length of 10-100 mm at both ends, and a smooth roller with a diameter of 50-300 mm and a width of 10-500 mm in the middle. The radius of the fillet at the connection between the fixed shaft and the smooth roller is 10-50 mm. The flexible pad is a polyurethane rubber pad with a hardness of 10~90HA, a thickness of 5~20mm, a width of 10~500mm, and a length of 100~500mm. The active ultrasonic vibration system consists of an ultrasonic generator, a transducer, and an amplitude transformer. The ultrasonic generator transmits electrical energy to the transducer through a carbon brush ring. The end of the amplitude transformer is coupled to the end face of the fixed shaft of the active feature roller tooth. The ultrasonic vibration direction of the active feature roller tooth is along the radial direction of the roller tooth. The servo power system includes a servo motor and a controller. The servo motor drives the active feature roller to rotate through a rubber synchronous belt. The servo power system is connected to the device base. The pressure regulation system between the roller teeth includes an air compressor, a cylinder, a driven roller tooth fixing frame, and a precision slide rail. The cylinder is connected to the driven roller tooth fixing frame, and the driven roller tooth fixing frame is connected to the device base through the precision slide rail. The method of using the flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures is characterized by comprising the following steps: Step 1: Cold roll 20% to 50% of the foil material with a width of 10~50mm, a length of 50~300mm, and a thickness of 30~300μm, and then perform stress-relieving annealing heat treatment at a temperature of 200~400℃ for 1~5h, and select a flexible pad. Step 2: Turn on the roller tooth pressure adjustment system and set the roller tooth pressure value to 50~3000N; Step 3: Turn on the active ultrasonic vibration system and set the ultrasonic vibration frequency to 10~30kHz and the amplitude to 1~30μm; Step 4: Turn on the servo power system and set the active feature roller tooth linear speed to 1~30mm / s; Step 5: After applying lubricant to the upper and lower surfaces of the foil, it is bonded together with the flexible pad. The foil and flexible pad are placed into the feed inlet from bottom to top and then rolled into shape.

2. The flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures according to claim 1, characterized in that: The method for selecting the flexible pad is as follows: when the yield strength of the foil is 100~300MPa and the thickness is 30~150μm, the flexible pad is a polyurethane rubber pad with a thickness of 5~10mm and a hardness of 10~30HA; when the yield strength of the foil is 300~500MPa and the thickness is 150~250μm, the flexible pad is a polyurethane rubber pad with a thickness of 10~15mm and a hardness of 30~50HA; when the yield strength of the foil is 500~800MPa and the thickness is 250~300μm, the flexible pad is a polyurethane rubber pad with a thickness of 15~20mm and a hardness of 50~90HA.

3. The flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures according to claim 1, characterized in that: The microstructure on the surface of the active feature gear is a single, discontinuous structure.

4. The flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures according to claim 1, characterized in that: The microstructure on the surface of the active feature gear is a series of continuous structures.

5. The flexible ultrasonic roll forming device for ultrathin-walled micro-surface structures according to claim 1, characterized in that: The lubricant is vegetable oil, animal oil, or MoS2.

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