A device and method for two-way ultrasonic vibration assisted roll forming of ultra-thin-walled corrugated microstructures

Abstract

The application discloses a kind of two-way ultrasonic vibration auxiliary roll bending forming device and method of super-thin-wall corrugated microstructure, device includes: roll tooth module, ultrasonic vibration module, servo power module, eccentric fine adjustment module, roll tooth inter pressure regulating module and base module;Forming method includes: (1) foil cold rolling is then recrystallized heat treatment;(2) adjusting roll tooth shaft parallelism, setting roll tooth inter pressure parameter;(3) setting ultrasonic vibration parameter (3) setting roll tooth rotating speed;(4) foil is placed into guide inlet, roll bending forming.The device and method of the application can be according to foil microstructure in transverse and longitudinal two directions high-frequency rolling hard orientation grain, promote grain rotation deformation, produce significant ultrasonic softening effect, greatly reduce the rebound angle of super-thin-wall corrugated microstructure and its dispersion, improve part fatigue strength.

Description

Technical Field

[0001] This invention relates to advanced manufacturing technology for improving the quality and efficiency of manufacturing ultrathin-walled corrugated microstructures, and in particular to a bidirectional ultrasonic vibration-assisted roll bending forming device and method for ultrathin-walled corrugated microstructures. Background Technology

[0002] Currently, with the increasing trend of energy conservation, friction reduction, and lightweight development in mechanical equipment, the demand for ultra-thin-walled corrugated microstructure parts is growing. Ultra-thin-walled corrugated microstructure parts are widely used in aircraft wing surfaces, microfluidic pipelines, wind turbine blades, honeycomb structures, chemical reactors, etc. However, due to the influence of size effects, the manufacturing of ultra-thin-walled corrugated microstructures has the following problems: (1) The foil thickness is small, and the slight error of the main and driven roller teeth shafts during the roll forming process will lead to the forming distortion and breakage of the corrugated microstructure; (2) The heterogeneity of individual grains has a large impact, and the longitudinal and transverse characteristics of ultra-thin-walled corrugated microstructures have large dispersion; (3) The existing combination process of roll forming + pressure straightening has low production efficiency; (4) The microstructure parameters of the foil and the ultrasonic vibration parameters have low matching degree, making it difficult to exert the best acoustic softening effect of ultrasonic vibration; (5) The microscopic damage during the forming of ultra-thin-walled corrugated microstructures is large, and they are prone to breakage and deformation in later use, resulting in 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 bidirectional ultrasonic vibration-assisted roll forming device and method for ultrathin-walled corrugated microstructures. This device can create a compressive stress state in the forming area during forming, while simultaneously utilizing the coordinated action of longitudinal and transverse ultrasonic vibrations to flexibly roll heterogeneous grains in three dimensions, significantly improving the plasticity and forming uniformity of the foil. Furthermore, the ultrasonic vibration field, matched to the microstructure of the foil, generates an optimal acoustic softening effect, reducing the yield strength and microscopic damage of the foil. High-frequency impact strengthening of the corrugated microstructure using an ultrasonic energy field improves the fatigue strength of the microstructure, achieving efficient and controllable manufacturing of the shape and performance of the ultrathin-walled corrugated microstructure.

[0005] To achieve the above objectives, embodiments of the present invention provide a bidirectional ultrasonic vibration-assisted roll bending forming device and method for ultra-thin-walled corrugated microstructures, characterized in that the device comprises: a roll tooth module, a bidirectional ultrasonic vibration module, a servo power module, an eccentric fine-tuning module, a roll tooth pressure adjustment module, and a substrate module;

[0006] The roller gear module includes a driving roller gear and a driven roller gear. The driving roller gear 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 roller gear with a diameter of 60-200 mm and a width of 5-30 mm. The roller gear has a side length of 1-5 mm, an included angle of 110-120°, and 20-40 teeth. The radius of the fillet at the connection between the fixed shaft and the roller gear is 10-30 mm. The driven roller gear consists of two parts: a fixed shaft with a diameter of 20-40 mm and a length of 20-60 mm at both ends, and an intermediate roller gear. The roller gear of the driven roller gear has the same shape as the roller gear of the driving roller gear. The radius of the fillet at the connection between the fixed shaft and the roller gear is 20-50 mm.

[0007] The bidirectional ultrasonic vibration module includes an active radial ultrasonic vibration system and a driven axial ultrasonic vibration system. The active radial 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 roller tooth. The ultrasonic vibration direction of the active roller tooth is along the radial direction of the roller tooth. The driven axial 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 driven roller tooth. The ultrasonic vibration direction of the driven roller tooth is along the axial direction of the roller tooth.

[0008] The servo power module includes a servo motor and a controller. The servo motor drives the active roller to rotate through a rubber synchronous belt. The servo power module is connected to the base module.

[0009] The eccentric fine adjustment module consists of a fixed block, a fine-pitch adjusting screw with a pitch of 0.1 to 1 mm, an arc-shaped adjusting block with a radius of 100 to 300 mm, a driven roller tooth fixing frame, and a precision slide rail. The arc-shaped adjusting block is connected to the driven roller tooth fixing frame, and the driven roller tooth fixing frame is connected to the base module through the precision slide rail.

[0010] The pressure regulating module between the roller teeth includes an air compressor and a cylinder, and the cylinder is connected to the driven roller tooth fixing frame.

[0011] The method of using the bidirectional ultrasonic vibration-assisted roll bending forming device for ultra-thin-wall corrugated microstructures is characterized by comprising the following steps:

[0012] Step 1: Cold roll a foil with a width of 5-30 mm, a length of 50-300 mm, and a thickness of 50-200 μm by 10%-30%, and then perform recrystallization annealing treatment at a temperature of 300-800℃ for 1-3 hours to make the number of grains in the thickness direction of the foil 8-15.

[0013] Step 2: Activate the eccentricity fine-tuning module and set the parallelism of the main and driven roller tooth shafts to 10-100μm;

[0014] Step 3: Turn on the roller tooth pressure adjustment module and set the roller tooth pressure value to 100~1000N;

[0015] Step 4: Turn on the ultrasonic vibration system, set the vibration frequency of the active radial ultrasonic vibration system to 10-30kHz and the amplitude to 5-15μm, and the vibration frequency of the driven axial ultrasonic vibration system to 20-30kHz and the amplitude to 15-30μm.

[0016] Step 5: Turn on the servo power module and set the active roller tooth linear speed to 1-30 mm / s;

[0017] Step 6: Place the foil into the feed inlet and roll it into shape.

[0018] In one or more embodiments of the present invention, the eccentricity fine-tuning module is used in combination with a laser parallelism measuring instrument.

[0019] Compared with existing technologies, this invention: 1. Proposes using bidirectional ultrasonic vibration (transverse and longitudinal) under compressive stress to flexibly roll heterogeneous grains in three dimensions, promoting dislocation migration and significantly improving the plasticity and microstructure uniformity of the foil. 2. Applying a specific bidirectional ultrasonic vibration field based on the microstructure characteristics of the foil to achieve optimal acoustic softening during roll forming, significantly reducing the yield strength of the foil, minimizing microscopic damage, and increasing the service life of the ultra-thin-walled corrugated microstructure. 3. Utilizing a combination of an eccentric fine-tuning module and a laser parallelism measuring instrument to precisely adjust the parallelism of the master and driven roller teeth, avoiding distortion and breakage of the ultra-thin-walled corrugated microstructure caused by minute deviations in the master and driven roller teeth. 4. Applying a small amount of inter-roller pressure during roll forming, creating a compressive stress state in the bending area while reducing minor warping defects in the ultra-thin-walled corrugated microstructure. 5. Under the impact of bidirectional ultrasonic vibration, a hardened layer forms on the surface of the ultra-thin-walled corrugated microstructure, significantly improving the product's fatigue resistance and performance uniformity. Therefore, the method of the present invention is particularly suitable for the efficient, high-quality, and controllable fabrication of ultrathin-walled microstructures. Attached Figure Description

[0020] Figure 1 This is a comparison diagram of a bidirectional ultrasonic vibration-assisted roll bending forming method for ultrathin-walled corrugated microstructures according to an embodiment of the present invention and a conventional method;

[0021] Figure 2 This is a schematic diagram of a bidirectional ultrasonic vibration-assisted roller bending forming device for an ultrathin-walled corrugated microstructure according to an embodiment of the present invention.

[0022] Figure 3 This is a schematic diagram of the active roller teeth according to an embodiment of the present invention;

[0023] Figure 4 This is a schematic diagram of the eccentric fine-tuning module according to an embodiment of the present invention.

[0024] The following are the labels in the diagram: 1. Roller tooth module, 101. Active roller tooth, 101A. Fixed shaft, 101B. Roller gear, 101B1. Roller tooth side length, 101B2. Roller tooth included angle, 101C. Corner radius, 102. Driven roller tooth, 2. Bidirectional ultrasonic vibration module, 201. Active radial ultrasonic vibration system, 202. Driven axial ultrasonic vibration system, 3. Servo power module, 4. Eccentric fine adjustment module, 401. Fixing block, 402. Fine thread adjusting screw, 403. Arc-shaped adjusting block, 404. Driven roller tooth fixing frame, 405. Precision slide rail, 5. Roller tooth pressure adjustment module, 501. Cylinder, 502. Air compressor, 6. Base module. Detailed Implementation

[0025] 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.

[0026] 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.

[0027] like Figures 1-4 As shown, a bidirectional ultrasonic vibration-assisted roller bending forming device and method for ultra-thin-walled corrugated microstructures according to a preferred embodiment of the present invention is characterized in that the device comprises: 1 roller tooth module, 2 bidirectional ultrasonic vibration module, 3 servo power module, 4 eccentric fine adjustment module, 5 roller tooth pressure adjustment module and 6 base module.

[0028] The roller gear module includes a 101 driving roller gear and a 102 driven roller gear. The 101 driving roller gear consists of two parts: a 101A fixed shaft with a diameter of 10-30mm at both ends and a length of 10-50mm, and a middle 101B roller gear with a diameter of 60-200mm and a width of 5-30mm. The side length of the 101B1 roller gear is 1-5mm, the included angle of the 101B2 roller gear is 110-120°, and the number of roller teeth is 20-40. The radius of the fillet at the connection between the 101A fixed shaft and the 101B roller gear is 10-30mm. The 102 driven roller gear consists of two parts: a fixed shaft with a diameter of 20-40mm at both ends and a length of 20-60mm, and a middle roller gear. The roller gear of the driven roller gear has the same shape as the roller gear of the driving roller gear. The radius of the fillet at the connection between the fixed shaft and the roller gear is 20-50mm.

[0029] The two bidirectional ultrasonic vibration modules include an active radial ultrasonic vibration system (201) and a driven axial ultrasonic vibration system (202). The active radial ultrasonic vibration system (201) 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 roller tooth (101). The ultrasonic vibration direction of the active roller tooth (101) is along the radial direction of the roller tooth. The driven axial ultrasonic vibration system (202) 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 driven roller tooth (102). The ultrasonic vibration direction of the driven roller tooth (102) is along the axial direction of the roller tooth.

[0030] The 3 servo power modules include a servo motor and a controller. The servo motor drives the active roller teeth to rotate through a rubber synchronous belt. The 3 servo power modules are connected to the 6 base modules.

[0031] The 4 eccentric fine adjustment modules consist of a 401 fixing block, a 402 fine-pitch adjusting screw with a pitch of 0.1 to 1 mm, a 403 arc-shaped adjusting block with a radius of 100 to 300 mm, a 404 driven roller tooth fixing frame, and a 405 precision slide rail. The 403 arc-shaped adjusting block is connected to the 404 driven roller tooth fixing frame, and the 404 driven roller tooth fixing frame is connected to the 6 base module through the 405 precision slide rail.

[0032] The 5-roller inter-tooth pressure regulating module includes a 502 air compressor and a 501 cylinder, with the 501 cylinder connected to a 404 driven roller tooth fixing frame.

[0033] The method of using the bidirectional ultrasonic vibration-assisted roll bending forming device for ultra-thin-wall corrugated microstructures is characterized by comprising the following steps:

[0034] Step 1: Cold roll a foil with a width of 5-30 mm, a length of 50-300 mm, and a thickness of 50-200 μm by 10%-30%, and then perform recrystallization annealing treatment at a temperature of 300-800℃ for 1-3 hours to make the number of grains in the thickness direction of the foil 8-15.

[0035] Step 2: Turn on the 4-eccentricity fine adjustment module. The eccentricity fine adjustment module is used in combination with the laser parallelism measuring instrument. Set the parallelism of the main and driven roller tooth shafts to 10-100μm.

[0036] Step 3: Turn on the 5-roller inter-tooth pressure adjustment module and set the inter-tooth pressure value to 100~1000N;

[0037] Step 4: Turn on the 2 bidirectional ultrasonic vibration modules, set the vibration frequency of the 201 active radial ultrasonic vibration system to 10-30kHz and the amplitude to 5-15μm, and the vibration frequency of the 202 driven axial ultrasonic vibration system to 20-30kHz and the amplitude to 15-30μm.

[0038] Step 5: Turn on the 3 servo power module and set the linear speed of the 101 active roller tooth to 1~30mm / s;

[0039] Step 6: Place the foil into the feed inlet and roll it into shape.

[0040] Example 1

[0041] Taking 100 pieces of Ti-6Al-4V ultrathin-walled corrugated microstructures, each with a length of 100 mm, a width of 20 mm, and a thickness of 80 μm, as an example, the implementation process of preparing ultrathin-walled corrugated microstructures by the method of the present invention is described in detail below:

[0042] Step 1: The Ti-6Al-4V foil with a width of 30mm, a length of 150mm, and a thickness of 80μm is cold rolled by 15%, and then subjected to recrystallization annealing at 700℃ for 2h. The resulting grain size is about 8μm, and the number of grains in the thickness direction of the foil is about 10.

[0043] Step 2: Activate the 4-eccentricity fine-tuning module and, with the help of a parallelism measuring instrument, set the parallelism of the main and driven roller tooth shafts to 10μm;

[0044] Step 3: Turn on the 5-roller inter-tooth pressure adjustment module and set the inter-tooth pressure value to 200N;

[0045] Step 4: Turn on the 2 bidirectional ultrasonic vibration modules, set the vibration frequency of the 201 active radial ultrasonic vibration system to 20kHz and the amplitude to 12μm, and the vibration frequency of the 202 driven axial ultrasonic vibration system to 30kHz and the amplitude to 20μm.

[0046] Step 5: Turn on the 3 servo power module and set the linear speed of the 101 active roller teeth to 5mm / s;

[0047] Step 6: Place the foil into the feed inlet and roll it into shape.

[0048] Comparative Example 1

[0049] Using traditional methods:

[0050] Step 1: Clean the Ti-6Al-4V foil with a width of 30mm, a length of 150mm, and a thickness of 80μm;

[0051] Step 2: Start the roll bending forming device, with a roll bending forming speed of 5mm / s;

[0052] Step 3: Roll bending.

[0053] Comparison results

[0054] Table 1 Comparison between the method of the present invention and the traditional method

[0055] Method type Forming angle time Forming angle dispersion Is it twisted / broken? Hardness of the deformation zone This invention 121° 2.5 hours 3° none 340HV10 / 20 Traditional methods 129° 4 hours 12° 26% defect rate 315HV10 / 20

[0056] The method of this invention sets specific bidirectional ultrasonic vibration field parameters, compressive stress state, and roll forming speed based on the microstructure and thickness of the foil. Under this longitudinal and transverse ultrasonic vibration, the Ti-6Al-4V foil with a t / d of 10 absorbs a significant amount of ultrasonic vibration energy, resulting in a substantial increase in dislocation kinetic energy. Simultaneously, the bidirectional ultrasonic vibration in both the longitudinal and transverse directions performs flexible high-frequency rolling of heterogeneous grains in three dimensions, significantly improving the forming uniformity and plasticity of the ultrathin-walled corrugated microstructure. Furthermore, during the forming process, the ultrathin-walled corrugated microstructure undergoes surface hardening under high-frequency impact, resulting in a significant enhancement in strength and fatigue resistance. Therefore, as shown in Table 1, the method of this invention greatly improves the forming angle accuracy and forming zone hardness of the ultrathin-walled corrugated microstructure compared to traditional methods, resulting in a significant improvement in product dimensional accuracy and strength.

[0057] 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 bidirectional ultrasonic vibration-assisted roller bending forming device for ultrathin-walled corrugated microstructures, characterized in that, The device includes: a roller tooth module, a bidirectional ultrasonic vibration module, a servo power module, an eccentric fine adjustment module, a roller tooth pressure adjustment module, and a base module. The roller gear module includes a driving roller gear and a driven roller gear. The driving roller gear 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 roller gear with a diameter of 60-200 mm and a width of 5-30 mm. The roller gear has a side length of 1-5 mm, an included angle of 110-120°, and 20-40 teeth. The radius of the fillet at the connection between the fixed shaft and the roller gear is 10-30 mm. The driven roller gear consists of two parts: a fixed shaft with a diameter of 20-40 mm and a length of 20-60 mm at both ends, and an intermediate roller gear. The roller gear of the driven roller gear has the same shape as the roller gear of the driving roller gear. The radius of the fillet at the connection between the fixed shaft and the roller gear is 20-50 mm. The bidirectional ultrasonic vibration module includes an active radial ultrasonic vibration system and a driven axial ultrasonic vibration system. The active radial 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 roller tooth. The ultrasonic vibration direction of the active roller tooth is along the radial direction of the roller tooth. The driven axial 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 driven roller tooth. The ultrasonic vibration direction of the driven roller tooth is along the axial direction of the roller tooth. The servo power module includes a servo motor and a controller. The servo motor drives the active roller to rotate through a rubber synchronous belt. The servo power module is connected to the base module. The eccentric fine-tuning module consists of an arc-shaped adjusting block with a radius of 100~300mm, a driven roller tooth fixing frame, and a precision slide rail. The arc-shaped adjusting block is connected to the driven roller tooth fixing frame, and the driven roller tooth fixing frame is connected to the base module through the precision slide rail. The pressure adjustment module between the roller teeth includes an air compressor and a cylinder, with the cylinder connected to the driven roller tooth fixing frame.

2. The forming method of the bidirectional ultrasonic vibration-assisted roll bending forming device for ultra-thin-walled corrugated microstructures according to claim 1, characterized in that, Includes the following steps: Step 1: Cold roll a foil with a width of 5~30mm, a length of 50~300mm, and a thickness of 50~200μm by 10%~30%, and then perform recrystallization annealing treatment at a temperature of 300~800℃ for 1~3h to make the number of grains in the thickness direction of the foil 8~15. Step 2: Activate the eccentricity fine-tuning module and set the parallelism of the main and driven roller tooth shafts to 10~100μm; Step 3: Turn on the roller tooth pressure adjustment module and set the roller tooth pressure value to 100~1000N; Step 4: Turn on the ultrasonic vibration system, set the vibration frequency of the active radial ultrasonic vibration system to 10~30kHz and the amplitude to 5~15μm, and the vibration frequency of the driven axial ultrasonic vibration system to 20~30kHz and the amplitude to 15~30μm. Step 5: Turn on the servo power module and set the active roller tooth linear speed to 1~30mm / s; Step 6: Place the foil into the feed inlet and roll it into shape.

3. The forming method according to claim 2, characterized in that: The aforementioned eccentricity fine-tuning module is used in combination with a laser parallelism measuring instrument.

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