A method for bending forming an aluminum alloy plate with super-large and super-thick dimensions

Abstract

The application relates to a bending forming method for an aluminum alloy thick-walled plate with super-large and super-thick dimensions, and belongs to the field of advanced manufacturing technology. The method comprises the following steps: processing a blank into a plate according to required dimensions; hoisting the plate and placing the plate into the middle of equipment between two shafts, aligning, adjusting the two main shafts to press the plate, rotating the roller shaft to adjust the roller shaft generatrix to be perpendicular to the reference edge of the plate, and keeping the state in the whole forming process; meanwhile, adjusting one of the two side roller shafts to be in contact with the surface of the plate, recording the distance value of the roller shaft at this time, recording the distance data of the roller shaft when the plate is arched, continuously adjusting the roller shaft, and gradually forming the plate curvature, detecting the plate curvature condition by using a sample plate, reducing the gap between the sample plate and the plate, reducing the distance of the shaft each time, and stopping the roller bending when the sample plate and the plate are completely attached. The application realizes the bending forming of the plate with super-large dimensions and a grid by formulating reasonable plate roller bending process parameters, and solves the problem of manual shape correction of the super-large size plate.

Description

Technical Field

[0001] This invention relates to a bending forming method applicable to ultra-large and ultra-thick aluminum alloy thick-walled plates, belonging to the field of advanced manufacturing technology. Background Technology

[0002] The 9.5m launch vehicle cannon section wall panel is extra-large, with a thickness of 45mm. It adopts a method of progressive roll bending followed by mechanical milling to form the inner grid. This is the first time such a large-size and thick wall panel has been processed, and there is a lack of relevant experience and process parameters to support it. Based on previous experience with progressive roll bending wall panels, it is necessary to continuously explore and optimize parameters such as the number of roll bending passes and the amount of pressure applied per pass to finally determine the process parameters.

[0003] There is still a gap in the domestic aerospace field for the processing of ultra-large-sized wall panels by rolling. Various units within the system still use traditional manual methods for shaping after rolling, which cannot meet the precision requirements of ultra-large-sized wall panels. Summary of the Invention

[0004] The technical problem solved by this invention is to overcome the shortcomings of the prior art and propose a bending forming method for ultra-large and ultra-thick aluminum alloy plates with equal thickness, thereby improving product quality and reliability.

[0005] The solution of the present invention is:

[0006] A method for bending and forming ultra-large and ultra-thick aluminum alloy plates with equal wall thickness, comprising:

[0007] The raw material is processed into wall panels according to the required dimensions, ensuring the perpendicularity of the four corners;

[0008] Using a four-axis roller press, the sheet metal is hoisted and placed into the two middle axes of the equipment. After alignment, the two main axes are adjusted to press the sheet metal together. The rollers are rotated to adjust the roller generatrix to be perpendicular to the reference edge of the sheet metal, and this state is maintained throughout the forming process.

[0009] Simultaneously adjust one of the two rollers to contact the wall panel surface, and record the distance value of this roller; tighten the wall panel on the two middle rollers, and then adjust the left roller to contact the wall panel, keeping the left and right rollers H the same, and record the value H at this time; adjust the left roller to a certain amount h, the middle roller starts to roll and drive the wall panel to the right, and stop rolling when the left end of the wall panel is at the center of the middle roller; adjust the right roller to a certain amount (h+h1), and roll the wall panel to the left, and record the value each time;

[0010] Record the roller distance data when the wall panel begins to curve; continue to adjust the roller, and the wall panel curvature gradually takes shape. Use a template to check the curvature of the wall panel. As the gap between the template and the wall panel decreases, the distance of the roller is adjusted each time. Stop rolling when the template and the wall panel are completely in contact.

[0011] Furthermore, the upward distance h1 of the roller before arc initiation is 20-30mm.

[0012] Furthermore, the curvature of the wall panel changes non-linearly from a flat plate to an arc and then to a rolled bend.

[0013] Furthermore, the wall panel begins to curve after at least four roll bends.

[0014] Furthermore, the roller rise distance h1 after the arc is initiated is adjusted by 5-10mm, and after at least 6 rounds of rolling, the arc of the wall panel fits the template.

[0015] Furthermore, the roller rising distance h1 is adjusted to 2-3mm, and the wall panel is formed by at least 4 rolling bends.

[0016] Furthermore, it also includes precision measurement, measuring the straightness of the busbar every 90-100mm along the curvature of the wall panel, and moving the wall panel from left to right along the curvature to detect the curvature.

[0017] Furthermore, the maximum straightness of the busbar is 4mm in the vertical middle part of the wall panel, and the maximum gap between the curvature and the template is 5mm.

[0018] Furthermore, the distance from the ends on both sides is 800-1000mm.

[0019] Furthermore, this also includes panel alignment, which involves tapping the middle part of the panel along the curvature to make the gap between the panel curvature and the template 2-3mm, and the straightness of the generatrix 1-3mm.

[0020] The advantages of this invention compared to the prior art are:

[0021] (1) This invention realizes the bending and forming of ultra-large mesh panels by formulating reasonable wall panel bending process parameters, thus solving the problem of manual shaping of ultra-large wall panels;

[0022] (2) The present invention uses a roll bending forming method to achieve the bending forming of ultra-large size wall panels. This method has high technical maturity and improves product quality and reliability. Attached Figure Description

[0023] Figure 1 This invention relates to the wall panel bending process;

[0024] Figure 2 This is a schematic diagram of the wall panel mounting of the present invention;

[0025] Wherein, 1-upper axis; 2-left axis; 3-left side platform;

[0026] Figure 3 This is a schematic diagram of the roller spacing of the present invention;

[0027] Figure 4This is a schematic diagram of the wall panel bending of the present invention. Detailed Implementation

[0028] The present invention will be further described below with reference to the embodiments.

[0029] A method for bending and forming ultra-large and ultra-thick aluminum alloy plates with equal wall thickness, such as... Figure 1 As shown, it includes:

[0030] (1) Blanking: Aluminum alloy sheet of 6000mm×2500mm×45mm is used for wall panel forming. Water jet cutting is used to process the blank according to the above dimensions to ensure the perpendicularity of the four corners, which is convenient for the subsequent placement of the sheet into the equipment for alignment.

[0031] (2) Feeding and alignment: A four-axis rolling mill is used, the structure of which is as follows: Figure 2 As shown. The two large shafts in the middle are responsible for pressing the sheet metal, rotating and rolling the sheet metal repeatedly left and right. The sheet metal is hoisted and placed into the two middle shafts of the equipment. After alignment, the upper large shaft is adjusted to press the wall panel. The rollers are rotated to adjust their vertical center line to be perpendicular to the long side of the wall panel, and this state is maintained throughout the forming process. The left roller is adjusted to contact the wall panel surface. At this time, the vertical distance H between the center of this roller and the center of the middle large roller is recorded. Simultaneously, the right roller is adjusted to maintain its center distance H from the center of the middle large roller. For example... Figure 3 As shown;

[0032] (3) Roll forming: Simultaneously adjust one of the two rollers on both sides to contact the surface of the wall panel, and record the distance value of this roller; tighten the wall panel onto the two middle rollers, and then adjust the left roller to contact the wall panel, keeping the H values ​​of the left and right rollers the same, and record the value H at this time; adjust the left roller to a certain amount h, and the middle roller will start rolling, driving the wall panel to the right. Stop rolling when the left end of the wall panel is located at the center of the middle roller, and adjust the right roller by a certain amount (h+h1), such as... Figure 4 As shown, roll the panel to the left and adjust the recorded value each time;

[0033] Record the roller distance data when the wall panel begins to curve; continue to adjust the roller, and the wall panel curvature gradually takes shape. Use a template to check the curvature of the wall panel. As the gap between the template and the wall panel decreases, the distance of the roller is adjusted each time. Stop rolling when the template and the wall panel are completely in contact.

[0034] Roll bending parameters determined:

[0035] 1. The roller rise distance h1 (20-30mm) before arc initiation: Panel bending is a process of gradual change in the curvature of the sheet material. From flatness to arc initiation to completion of bending, the curvature change is non-linear. The arc initiation state is crucial and has a significant impact on the entire processing. Insufficient arc initiation will result in more bending passes and longer processing time; excessive arc initiation will cause localized reduction in curvature, requiring repeated adjustments that are difficult to make. Based on the panel size and thickness, a roller rise distance of 20-30mm before arc initiation is reasonable. The panel begins to arc after four bending passes.

[0036] 2. The roller rising distance h1 between the bending passes and the rollers is adjusted by 5-10mm after the initial arc. After 6 bending passes, the curvature of the board basically matches the sample. Subsequently, the roller rising distance h1 is adjusted by 2-3mm, and after 4 bending passes, the curvature of the board basically meets the requirements.

[0037] (4) Precision Measurement: Remove the wall panel and stand it upright. Use a template and a steel ruler to measure the straightness of the generatrix. Place the steel ruler against the surface of the wall panel and measure every 100mm along the curvature of the wall panel. Use the template to measure every 100mm along the vertical direction of the wall panel, and move the template from left to right along the curvature to check the curvature. The measurement results show that the maximum straightness of the generatrix is ​​4mm in the middle of the vertical part of the wall panel. The maximum gap between the curvature and the template is 5mm, and the distance from the ends on both sides is about 800-1000mm.

[0038] (5) Wall panel alignment

[0039] The panel alignment process combines manual and mechanical methods. A top-mounted bed is used to align the busbars. Based on the panel's deformation, it is conveyed to a designated position via a ground-based transport device. The central slider rises to the top, and a side lifting transmission device moves the alignment hydraulic cylinder to a set position. The cylinder's piston rod extends outward to align the busbars. Traditional manual hammering is used to adjust the busbar straightness. The panel's two vertical edges are placed on the ground, and a hammer is used to repeatedly strike the center of the panel along its curvature. After alignment, the gap between the panel's curvature and the template is 2-3mm, and the busbar straightness is 2mm, meeting the accuracy requirements.

[0040] This invention achieves the bending and forming of ultra-large mesh panels by formulating reasonable wall panel rolling process parameters, thus solving the problem of manual shaping of ultra-large wall panels;

[0041] This invention uses a roll bending forming method to achieve the bending forming of ultra-large size wall panels. This method has high technical maturity and improves product quality and reliability.

[0042] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. A method for bending and forming aluminum alloy plates of uniform thickness with ultra-large and ultra-thick dimensions, characterized in that, include: The blank material is processed into a wall panel according to the required dimensions, ensuring the perpendicularity of the four corners. The dimensions of the blank material are 6000mm×2500mm×45mm. Using a four-axis roller press, the sheet metal is hoisted and placed into the two middle axes of the equipment. After alignment, the two middle axes are adjusted to press the sheet metal together. The rollers are rotated to adjust the roller generatrix to be perpendicular to the reference edge of the sheet metal, and this state is maintained throughout the forming process. Simultaneously adjust one of the two rollers to contact the wall panel surface, and record the distance value of this roller. Secure the wall panel to the two middle shafts, then adjust the left roller to contact the wall panel, keeping the distance H on both rollers the same, and record the value H at this point. H is the vertical distance from the center of the roller to the center of the middle shaft. Adjust the left roller to a certain amount h, and the middle shaft will begin to roll, moving the wall panel to the right. Stop rolling when the left end of the wall panel is at the center of the middle shaft. Adjust the right roller to a certain amount (h+h1), rolling the wall panel to the left. Record the value each time, where h is the rising distance of one roller and h1 is the rising distance of the opposite roller. Before the arc begins, the rising distance h1 of the roller is 20-30mm. The wall panel will begin to arc after at least four rolling bends. Record the roller distance data when the wall panel starts to curve; continue to adjust the roller, and the wall panel curvature gradually takes shape. Use a template to check the curvature of the wall panel. After the curve starts, the roller rise distance h1 is adjusted to 5-10mm. After at least 6 rounds of rolling, the wall panel curvature fits the template. Then, the roller rise distance h1 is adjusted to 2-3mm, and after at least 4 rounds of rolling, the wall panel bending is completed.

2. The method for bending and forming ultra-large and ultra-thick aluminum alloy plates with uniform thickness according to claim 1, characterized in that, The curvature of the wall panel changes non-linearly from flat to curved to rolled.

3. The method for bending and forming ultra-large and ultra-thick aluminum alloy plates with uniform thickness according to claim 1, characterized in that, It also includes precision measurement, measuring the straightness of the busbar every 90-100mm along the curvature of the wall panel, and moving the wall panel from left to right along the curvature to detect the curvature.

4. The method for bending and forming ultra-large and ultra-thick aluminum alloy plates with uniform thickness according to claim 3, characterized in that, The maximum straightness of the busbar is 4mm in the vertical middle part of the wall panel, and the maximum gap between the curvature and the template is 5mm.

5. The method for bending and forming ultra-large and ultra-thick aluminum alloy plates with uniform thickness according to claim 1, characterized in that, It also includes wall panel alignment, which involves tapping the middle part of the wall panel along the curvature to make the gap between the wall panel curvature and the template 2-3mm, and the straightness of the generatrix 1-3mm.

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