Progressive flanging and bulk forming method of large thin-walled variable cross-section ring member by local heating

Abstract

A method for locally heated progressive flanging integral forming of a large thin-walled variable cross-section annular component involves first clamping a flanging forming roller and a blank, with the blank clamped by a first upper pressure plate and a first lower mold. Then, the distance between the electromagnetic induction heating coil and the flanging forming roller is adjusted, and the inner edge is progressively flanged using local electromagnetic induction heating to form a complete inner edge shape. Next, the first upper pressure plate and the first lower mold are disassembled, and a second lower mold is installed. The inner edge is clamped and fixed to the upper side of the second lower mold using the second upper pressure plate. Then, the distance between the electromagnetic induction heating coil and the flanging forming roller is adjusted, and the outer edge is progressively rolled using local electromagnetic induction heating to form a complete outer edge shape. Finally, the outer edge is shaped using a rubber-bladed mold and the second lower mold. This invention reduces the number of steps in forming large thin-walled variable cross-section annular components, improves the surface accuracy and microstructure of the formed parts, and has the advantages of labor-saving forming, low cost, stable forming quality, and high flexibility.

Description

Technical Field

[0001] This invention belongs to the field of advanced material forming technology, specifically relating to a method for integral forming of large thin-walled variable cross-section ring components by local heating and progressive flanging. Background Technology

[0002] Large thin-walled variable cross-section ring-shaped components are widely used in key aerospace vehicle models in the aerospace field. For example, the lips of civil airliners and stealth fighters are typical large thin-walled variable cross-section ring-shaped components. These components have the geometric characteristics of large size, thin wall thickness, and variable cross-section. In order to cope with the coupled working conditions of complex loads and high-strength environments, extremely high requirements are placed on the lightweight, shape accuracy, dimensional accuracy, structural strength, microstructure and assembly accuracy of these components. The demand for integrated molding is becoming increasingly urgent.

[0003] However, currently, most large thin-walled variable cross-section ring-shaped components are formed by stamping, requiring large-tonnage, large-size stamping equipment. Furthermore, mold manufacturing is difficult, costly, and inflexible. Under thin-walled, large-deformation conditions, the failure rate of wrinkling and cracking is relatively high, resulting in uneven wall thickness, poor stiffness, and difficulty in guaranteeing surface accuracy. Traditional machining of these components is not only inefficient but also cuts metal fibers and affects the component's microstructure and properties. Some are formed by spinning, which can improve wall thickness uniformity and reduce wrinkling and cracking to some extent. However, this process lacks flexibility; while suitable for forming ring-shaped components with uniform cross-sections, it is unsuitable for forming ring-shaped components with variable cross-sections. At the same time, large spinning machines are expensive, and exports are restricted by foreign countries, posing a significant risk of being "strangled" by foreign technology. Besides integral forming, deep drawing, bulging, or drop forming followed by welding are also commonly used to form these components, resulting in low forming accuracy, uneven wall thickness, increased weld weight, and large adjustments required. The patent with publication number CN 116441619A (title: An integral forming device and method for aircraft engine lips) solves the problem of easy deformation at the tip of the lip when manufacturing lips using existing spin forming equipment. However, due to the limitations of the device and process flexibility, the parts need to be flipped during the forming process, resulting in low repeatability and positioning accuracy, which may lead to out-of-tolerance geometric accuracy of the formed parts. In addition, the device and process are suitable for cold forming processes, and the existing structure cannot accommodate thermal fields or other auxiliary energy field devices, making it difficult to apply to the forming of materials with high deformation resistance and poor room temperature plasticity. In summary, the device and process have limitations in terms of production quality, forming performance, processing range, and application, and cannot meet the process requirements of multi-specification and multi-variety workpieces, and adjustments are troublesome. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the present invention aims to provide a local heating progressive flanging integral forming method for large thin-walled variable cross-section ring components, which effectively reduces the number of process steps in forming large thin-walled variable cross-section ring components, improves the surface accuracy and microstructure properties of the formed parts, and has the advantages of labor-saving forming, low cost, stable forming quality and high flexibility.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] A method for integral forming of a large thin-walled variable cross-section ring component by local heating and progressive flanging involves first forming the inner edge 1-2 by local heating and progressive rolling layer by layer on the blank 1-1, and then forming the outer edge 1-3 by local heating and progressive rolling layer by layer, thus obtaining the large thin-walled variable cross-section ring component 1.

[0007] A method for locally heated progressive flanging integral forming of a large thin-walled variable cross-section annular component includes the following steps:

[0008] Step 1: Clamp the flanging forming roller 5 and connect the flanging forming roller 5 to the robotic arm 4;

[0009] Step 2: Clamp the blank 1-1. The blank 1-1 is clamped by the first upper pressure plate 2 and the first lower mold 3, and kept coaxial.

[0010] Step 3: Adjust the distance L1 between the electromagnetic induction heating coil 6 and the flanging forming roller 5; the electromagnetic induction heating current frequency is f1, the permeability of the blank 1-1 is μ, and the resistivity is ρ. The current penetration depth Δ1 is determined; where η is 3160 when using imperial units and 5030 when using national standard units; then, the heating time t1 required for the billet 1-1 to be heated to temperature T1 is determined using simulation methods; the diameter of the electromagnetic induction heating coil 6 is D, through... The relative circumferential speed v1 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the blank 1-1 is determined; the temperature of the extrusion area between the flanging forming roller 5 and the blank 1-1 is T2; the time required for the blank 1-1 to drop from temperature T1 to temperature T2 is t2. Therefore, the distance L1 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 is determined by L1 = v1t2.

[0011] Step 4: Based on the cross-sectional geometry of the inner edge 1-2, plan the movement trajectory between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the blank 1-1. Local electromagnetic induction heating is used to progressively flanging and forming the inner edge 1-2. The flanging forming roller 5 and the electromagnetic induction heating coil 6 move synchronously along the circumference of the blank 1-1 at a relative speed v1, while simultaneously moving axially downwards and radially inwards, achieving local electromagnetic induction heating for progressive flanging and forming of the inner edge 1-2. The flanging forming roller 5 and the electromagnetic induction heating coil 6 locally heat and roll the blank 1-1 one revolution along the circumference, with a synchronous downward axial pressure of Z1. The inclination angle of the inner edge 1-2 sidewall is α1. The radial movement d1 along the radial direction is calculated when the flanging forming roller 5 and the electromagnetic induction heating coil 6 locally heat and progressively roll the blank 1-1 layer by layer. While performing the above actions, the flanging forming roller 5 and the electromagnetic induction heating coil 6 rotate around the direction of the relative motion speed v1 to ensure that the side wall of the flanging forming roller 5 is in contact with the side wall of the inner edge 1-2, and at the same time, the plane of the electromagnetic induction heating coil 6 is as parallel as possible to the side wall of the inner edge 1-2. The inner edge 1-2 is formed by progressively heating and rolling layer by layer.

[0012] Step 5: Based on the forming properties of the blank 1-1 and the forming depth of the large thin-walled variable cross-section ring component 1, determine the forming passes n1 of the inner edge 1-2; repeat steps 3-4 until the complete shape of the inner edge 1-2 is formed.

[0013] Step 6: Disassemble the first upper pressure plate 2 and the first lower mold 3, install the second lower mold 8, and clamp and fix the inner edge 1-2 to the upper side of the second lower mold 8 through the second upper pressure plate 7 to ensure that the three are coaxial; the robotic arm 4 adjusts the position of the flanging forming roller 5 to the outer plane of the inner edge 1-2.

[0014] Step 7: Adjust the distance L2 between the electromagnetic induction heating coil 6 and the flanging forming roller 5; the electromagnetic induction heating current frequency f2 is adjusted by... The current penetration depth Δ2 is determined, and then the heating time t3 required for the inner edge 1-2 to be heated to temperature T3 is determined using simulation methods; through Determine the relative motion speed v2 between the robotic arm 4 driving the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the inner edge 1-2; the temperature of the extrusion area between the flanging forming roller 5 and the inner edge 1-2 is T4, and the time required for the inner edge 1-2 to drop from temperature T3 to temperature T4 is t4. Therefore, the distance L2 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 is determined by L2 = v2t4.

[0015] Step 8: Based on the cross-sectional geometry of the outer edge 1-3, plan the motion trajectory of the flanging forming roller 5 and the electromagnetic induction heating coil 6. Perform localized electromagnetic induction heating and progressive rolling to flanging and forming the outer edge 1-3. The flanging forming roller 5 and the electromagnetic induction heating coil 6 move synchronously at a relative speed v2 along the circumference of the inner edge 1-2, while simultaneously moving axially downwards and radially outwards, achieving localized electromagnetic induction heating and progressive rolling to flanging and forming the outer edge 1-3. The flanging forming roller 5 and the electromagnetic induction heating coil 6 locally heat and roll the inner edge 1-2 one revolution along the circumference, with a synchronous downward axial pressure of Z2. The inclination angle of the sidewall of the outer edge 1-3 is α2. The radial movement d2 of the flanging forming roller 5 and the electromagnetic induction heating coil 6 is calculated when the inner edge 1-2 is gradually rolled layer by layer with local heating. While performing the above actions, the flanging forming roller 5 and the electromagnetic induction heating coil 6 rotate around the direction of the relative motion velocity v2 to ensure that the side wall of the flanging forming roller 5 is in contact with the side wall of the outer edge 1-3. At the same time, the plane of the electromagnetic induction heating coil 6 is as parallel as possible to the side wall of the outer edge 1-3. The outer edge 1-3 is gradually rolled layer by layer with local heating.

[0016] Step 9: Based on the forming properties of the blank 1-1 and the forming depth of the large thin-walled variable cross-section ring component 1, determine the forming passes n2 of the outer edge 1-3; repeat steps 7-8 until the outer edge 1-3 is formed into a complete shape.

[0017] Step 10: Remove the second upper pressure plate 7, transfer the outer edge 1-3 and the second lower mold 8 to the shaping table; shape the outer edge 1-3 through the rubber bladder shaping mold 9 and the second lower mold 8, open the mold after the pressure holding time t3, remove the rubber bladder shaping mold 9, and take out the large thin-walled variable cross-section ring component 1.

[0018] In step 1, the type of robotic arm 4 is designed according to the process requirements, and ensures that the flanging forming roller 5 can rotate freely along its axis.

[0019] In step 3, based on the requirements of the local heating progressive flanging integral forming process for the real-time temperature and forming rate of the locally heated area, the relative speed v1 of the flanging forming roller 5 and the electromagnetic induction heating coil 6 with the blank 1-1 can be controlled in two ways: constant and real-time variable.

[0020] There are two ways to achieve the constant v1: one is that the robotic arm 4 drives the flanging forming roller 5 and the electromagnetic induction heating coil 6 to move in a circular motion at a constant linear velocity v1; the other is that the first lower mold 3 and the first upper pressure plate 2 drive the blank 1-1 to rotate at a real-time changing angular velocity w1, so as to ensure that the relative motion speed v1 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the blank 1-1 is constant.

[0021] When v1 changes in real time, it needs to be done through The real-time changing heating time t1 required for the billet 1-1 to be heated to temperature T1 is determined, and the heating time t1 required for the billet 1-1 to be heated to temperature T1 is satisfied by adjusting the frequency f1 of the electromagnetic induction heating current. The real-time changing v1 is achieved in two ways: first, the robotic arm 4 drives the flanging forming roller 5 and the electromagnetic induction heating coil control arm 10 to drive the electromagnetic induction heating coil 6 to move in a circular motion at a real-time changing speed v1; second, the first lower mold 3 and the first upper pressure plate 2 drive the billet 1-1 to rotate at a constant angular velocity w1, and the relative motion speed v1 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the billet 1-1 changes in real time.

[0022] In step 3, when v1 remains constant, the flanging forming roller 5 is fixedly connected to the electromagnetic induction heating coil 6 with a distance L1.

[0023] When v1 changes in real time, the distance between the flanging forming roller 5 and the electromagnetic induction heating coil 6 is flexibly adjusted in real time by the robotic arm 4 and the electromagnetic induction heating coil control arm 10 to ensure that the temperature of the flanging forming roller 5 and the extrusion area of ​​the blank 1-1 is T2.

[0024] In step 4, based on the geometry of the inner edge 1-2, if it involves geometric features with varying curvature radius, the robotic arm 4 drives the flanging forming roller 5 to adjust its spatial position in a timely manner to adapt to the geometric features of the inner edge 1-2.

[0025] In step 4, the inclination angle α1 of the inner edge 1-2 sidewalls ranges from 0° to 90°. Therefore, the radial movement d1 of the flanging forming roller 5 and the electromagnetic induction heating coil 6 of each forming layer in the radial direction changes accordingly.

[0026] In step 7, the control method for the relative motion speed v2 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the inner edge 1-2 is the same as in step 3.

[0027] In step 8, based on the geometry of the outer edge 1-3, if it involves geometric features with variable curvature radius, the robotic arm 4 drives the flanging forming roller 5 to adjust its spatial position in a timely manner to adapt to the geometric feature requirements of the outer edge 1-3.

[0028] In step 8, the inclination angle α2 of the outer edge 1-3 sidewalls ranges from 0° to 90°. Therefore, the radial movement d2 of the flanging forming roller 5 and the electromagnetic induction heating coil 6 of each forming layer changes accordingly.

[0029] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0030] This invention integrates progressive rolling flanging with local electromagnetic induction heating, realizing the integral forming of large thin-walled variable cross-section ring components by local electromagnetic induction heating progressive flanging; it provides a method for determining the spacing between the flanging roller and the electromagnetic induction heating coil, as well as a forming method for variable cross-section ring components, to meet the forming requirements of large deformation and variable cross-section of large thin-walled variable cross-section ring components; it can achieve flexible and labor-saving forming, ensuring the shape accuracy and structural stability of the components. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the initial clamping of the device used in this invention.

[0032] Figure 2 This is a schematic diagram of blank 1-1 in an embodiment of the present invention.

[0033] Figure 3 This is a schematic diagram of the first lower mold 3 for forming the inner edge 1-2 in an embodiment of the present invention.

[0034] Figure 4 This is a schematic diagram of the inner edge 1-2 formed according to an embodiment of the present invention.

[0035] Figure 5 This is a schematic diagram of the inner edge 1-2 of an embodiment of the present invention.

[0036] Figure 6 This is a schematic diagram of the initial clamping when forming the outer edges 1-3 in an embodiment of the present invention.

[0037] Figure 7 This is a schematic diagram of the second upper pressure plate 7 during the molding of the outer edges 1-3 in an embodiment of the present invention.

[0038] Figure 8 This is a schematic diagram of the second lower mold 8 when molding the outer edges 1-3 in an embodiment of the present invention.

[0039] Figure 9 This is a schematic diagram of the outer edge 1-3 of an embodiment of the present invention.

[0040] Figure 10 This is a schematic diagram illustrating the calibration process in an embodiment of the present invention. Detailed Implementation

[0041] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0042] In this embodiment, the blank 1-1 is made of 2219 aluminum alloy. The blank 1-1 is used to form a large thin-walled variable cross-section annular component 1, which simultaneously has an inner edge 1-2 and an outer edge 1-3. A method for locally heated progressive flanging integral forming of a large thin-walled variable cross-section annular component includes the following steps:

[0043] Step 1, refer to Figure 1The flanging forming roller 5 is clamped and connected to the robotic arm 4. The type of robotic arm 4 can be designed according to process requirements and ensures that the flanging forming roller 5 can rotate freely along its axis.

[0044] Step 2, refer to Figures 1-3 The blank 1-1 is clamped and held together by the first upper pressure plate 2 and the first lower mold 3, and kept coaxial.

[0045] Step 3, refer to Figures 1-3 Adjust the distance L1 between the electromagnetic induction heating coil 6 and the flanging forming roller 5; the electromagnetic induction heating current frequency is f1, the permeability of the blank 1-1 is μ, and the resistivity is ρ. Determine the current penetration depth Δ1; where η is 3160 when using imperial units and 5030 when using GB units; then, the heating time t1 required for the billet 1-1 to be heated to temperature T1 can be determined using simulation methods; the diameter of the electromagnetic induction heating coil 6 is D, through The relative circumferential speed v1 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the blank 1-1 is determined; the temperature of the extrusion zone between the flanging forming roller 5 and the blank 1-1 is T2; the time required for the blank 1-1 to drop from temperature T1 to temperature T2 is t2. Therefore, the distance L1 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 can be determined by L1 = v1t2.

[0046] Based on the requirements of the local heating progressive flanging integral forming process for the real-time temperature and forming rate of the local heated area, the relative motion speed v1 of the flanging forming roller 5 and the electromagnetic induction heating coil 6 with the blank 1-1 has two control methods: constant and real-time change.

[0047] There are two ways to achieve the constant v1. One is that the robotic arm 4 drives the flanging forming roller 5 and the electromagnetic induction heating coil 6 to move in a circular motion at a constant linear velocity v1. The other is that the first lower mold 3 and the first upper pressure plate 2 drive the blank 1-1 to rotate at a real-time changing angular velocity w1, so as to ensure that the relative motion speed v1 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the blank 1-1 is constant.

[0048] When v1 changes in real time, it needs to be done through The real-time changing heating time t1 required for the billet 1-1 to be heated to temperature T1 is determined, and the heating time t1 required for the billet 1-1 to be heated to temperature T1 is satisfied by adjusting the frequency f1 of the electromagnetic induction heating current. The real-time changing v1 can be achieved in two ways: one is that the robotic arm 4 drives the flanging forming roller 5 and the electromagnetic induction heating coil control arm 10 to drive the electromagnetic induction heating coil 6 to move in a circular motion at a real-time changing speed v1; the other is that the first lower mold 3 and the first upper pressure plate 2 drive the billet 1-1 to rotate at a constant angular velocity w1, and the relative motion speed v1 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the billet 1-1 changes in real time.

[0049] When v1 remains constant, the flanging forming roller 5 and the electromagnetic induction heating coil 6 can be fixedly connected with a distance L1, which simplifies the forming equipment and improves the process stability.

[0050] When v1 changes in real time, the distance between the flanging forming roller 5 and the electromagnetic induction heating coil 6 can be flexibly adjusted in real time by the robotic arm 4 and the electromagnetic induction heating coil control arm 10 to ensure that the temperature of the flanging forming roller 5 and the extrusion area of ​​the blank 1-1 is T2.

[0051] Step 4, refer to Figure 4 and Figure 5 Based on the cross-sectional geometry of the inner edge 1-2, the movement trajectory between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the blank 1-1 is planned, and the inner edge 1-2 is gradually flanged by local electromagnetic induction heating. The flanging forming roller 5 and the electromagnetic induction heating coil 6 move synchronously along the circumference of the blank 1-1 at a relative speed v1, while also moving axially downward and radially inward, to achieve the gradual flanging forming of the inner edge 1-2 by local electromagnetic induction heating. According to the geometry of the inner edge 1-2, if it involves geometric features with varying curvature radii, the robotic arm 4 drives the flanging forming roller 5 to adjust its spatial position in time to adapt to the geometric requirements of the inner edge 1-2. The flanging forming roller 5 and the electromagnetic induction heating coil 6 locally heat and roll the blank 1-1 one revolution along the circumference, with a synchronous downward pressure of Z1 along the axial direction, and the inclination angle of the sidewall of the inner edge 1-2 is α1. The radial movement d1 along the radial direction is calculated when the flanging forming roller 5 and the electromagnetic induction heating coil 6 locally heat and progressively roll the blank 1-1 layer by layer. While performing the above actions, the flanging forming roller 5 and the electromagnetic induction heating coil 6 rotate around the direction of the relative motion speed v1 to ensure that the side wall of the flanging forming roller 5 is in contact with the side wall of the inner edge 1-2, and at the same time, the plane of the electromagnetic induction heating coil 6 is as parallel as possible to the side wall of the inner edge 1-2. The inner edge 1-2 is formed by progressively heating and rolling layer by layer.

[0052] The inclination angle α1 of the inner edge 1-2 sidewalls ranges from 0° to 90°, so the radial movement d1 of the flanging forming roller 5 and the electromagnetic induction heating coil 6 of each forming layer in the radial direction changes accordingly.

[0053] Step 5, refer to Figure 4 and Figure 5 Based on the forming properties of the blank 1-1 and the forming depth of the large thin-walled variable cross-section ring component 1, determine the forming pass n1 of the inner edge 1-2; repeat steps 3-4 until the complete shape of the inner edge 1-2 is formed.

[0054] Step 6, refer to Figures 6-8 Disassemble the first upper pressure plate 2 and the first lower mold 3, install the second lower mold 8, and clamp and fix the inner edge 1-2 to the upper side of the second lower mold 8 through the second upper pressure plate 7 to ensure that the three are coaxial; the robotic arm 4 adjusts the position of the flanging forming roller 5 to the outer plane of the inner edge 1-2;

[0055] Step 7, refer to Figure 6 Adjust the distance L2 between the electromagnetic induction heating coil 6 and the flanging forming roller 5; the electromagnetic induction heating current frequency f2, through After determining the current penetration depth Δ2, simulation methods can be used to determine the heating time t3 required for the inner edge 1-2 to be heated to temperature T3; through Determine the relative motion speed v2 between the robotic arm 4 driving the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the inner edge 1-2; the temperature of the extrusion area between the flanging forming roller 5 and the inner edge 1-2 is T4, and the time required for the inner edge 1-2 to drop from temperature T3 to temperature T4 is t4. Therefore, the distance L2 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 can be determined by L2 = v2t4.

[0056] The control method for the relative motion speed v2 between the flanging forming roller 5 and the electromagnetic induction heating coil 6 and the inner edge 1-2 is the same as in step 3;

[0057] Step 8, refer to Figure 9Based on the cross-sectional geometry of the outer edge 1-3, the motion trajectory of the flanging forming roller 5 and the electromagnetic induction heating coil 6 is planned. Local electromagnetic induction heating is used to progressively roll and flange the outer edge 1-3. The flanging forming roller 5 and the electromagnetic induction heating coil 6 move synchronously at a relative speed v2 along the circumference of the inner edge 1-2, while simultaneously moving axially downwards and radially outwards, achieving local electromagnetic induction heating and progressive rolling of the outer edge 1-3. Depending on the geometry of the outer edge 1-3, if variable curvature radius geometry is involved, the robotic arm 4 drives the flanging forming roller 5 to adjust its spatial position in a timely manner to adapt to the geometric requirements of the outer edge 1-3. The flanging forming roller 5 and the electromagnetic induction heating coil 6 locally heat and roll the inner edge 1-2 one revolution along the circumference, with a synchronous downward axial pressure of Z2. The inclination angle of the sidewall of the outer edge 1-3 is α2. The radial movement d2 of the flanging forming roller 5 and the electromagnetic induction heating coil 6 is calculated when the inner edge 1-2 is gradually rolled layer by layer with local heating. While performing the above actions, the flanging forming roller 5 and the electromagnetic induction heating coil 6 rotate around the direction of the relative motion velocity v2 to ensure that the side wall of the flanging forming roller 5 is in contact with the side wall of the outer edge 1-3. At the same time, the plane of the electromagnetic induction heating coil 6 is as parallel as possible to the side wall of the outer edge 1-3. The outer edge 1-3 is gradually rolled layer by layer with local heating.

[0058] The inclination angle α2 of the outer edge 1-3 sidewalls ranges from 0° to 90°. Therefore, the radial movement d2 of the flanging forming roller 5 and the electromagnetic induction heating coil 6 of each forming layer changes accordingly.

[0059] Step 9, refer to Figure 9 Based on the forming properties of the blank 1-1 and the forming depth of the large thin-walled variable cross-section ring component 1, determine the forming passes n2 of the outer edge 1-3; repeat steps 7-8 until the outer edge 1-3 is formed into a complete shape.

[0060] Step 10, refer to Figure 10 Remove the second upper pressure plate 7, transfer the outer edge 1-3 and the second lower mold 8 to the shaping table; shape the outer edge 1-3 through the rubber bladder shaping mold 9 and the second lower mold 8, open the mold after the pressure holding time t3, remove the rubber bladder shaping mold 9, and take out the large thin-walled variable cross-section ring component 1.

[0061] The beneficial effects of this embodiment: Refer to Figure 1 , 4 Articles 6, 9, and 10 integrate progressive rolling flanging with localized electromagnetic induction heating, achieving integral forming of large, thin-walled, variable-section, difficult-to-deform 2219 aluminum alloy ring components using localized electromagnetic induction heating progressive flanging; (Refer to...) Figure 1 , 6This invention provides a method for determining the spacing between the flanging roller and the electromagnetic induction heating coil, as well as a forming method for 2219 aluminum alloy rings with variable cross-sections, to meet the forming requirements of large deformation and variable cross-section of large thin-walled 2219 aluminum alloy ring components. In this embodiment, the forming method of local heating and progressive flanging and rolling achieves a flexible, labor-saving, and low-cost manufacturing process while ensuring the shape accuracy and structural stability of the components.

Claims

1. A method for locally heated progressive flanging integral forming of a large thin-walled variable cross-section annular component, characterized in that, The inner edge (1-2) is formed by local heating and rolling layer by layer on the blank (1-1), and the outer edge (1-3) is formed by local heating and rolling layer by layer, thus obtaining a large thin-walled variable cross-section ring component (1). The method includes the following steps: Step 1: Clamp the flanging forming roller (5) and connect the flanging forming roller (5) to the robotic arm (4); Step 2, clamp the blank (1-1). The blank (1-1) is clamped by the first upper pressure plate (2) and the first lower mold (3) and kept coaxial. Step 3: Adjust the distance between the electromagnetic induction heating coil (6) and the flanging forming roller (5). L 1; The frequency of the electromagnetic induction heating current is f 1. The magnetic permeability of the billet (1-1) is The resistivity is ,pass Determine the depth of current penetration 1; where imperial units are used, It is 3160; however, when using national standard units, The value is 5030; then, simulation methods are used to determine the temperature at which the billet (1-1) is heated. T 1. Required heating time t 1; The diameter of the electromagnetic induction heating coil (6) is D ,pass Determine the relative circumferential speeds of the flanging forming roller (5) and the electromagnetic induction heating coil (6) with the blank (1-1). v 1; The temperature of the extrusion zone between the flanging forming roller (5) and the blank (1-1) is T 2. The billet (1-1) is heated by temperature. T 1. Temperature dropped to T 2. The required time is t 2, therefore through Determine the distance between the flanging forming roller (5) and the electromagnetic induction heating coil (6). L 1; Step 4: Based on the cross-sectional geometry of the inner edge (1-2), plan the movement trajectory between the flanging forming roller (5) and the electromagnetic induction heating coil (6) and the blank (1-1), and gradually flanging the inner edge (1-2) using local electromagnetic induction heating; the flanging forming roller (5) and the electromagnetic induction heating coil (6) move synchronously at a relative speed. v 1. While moving circumferentially along the blank (1-1), it moves axially downward and radially inward to achieve local electromagnetic induction heating and progressive flanging forming of the inner edge (1-2); the flanging forming roller (5) and the electromagnetic induction heating coil (6) locally heat and roll the blank (1-1) one revolution along the circumferential direction, and the downward pressing amount along the axial direction is... Z 1. The inclination angle of the inner edge (1-2) sidewall is ,pass The radial inward movement of each layer of the progressively rolled blank (1-1) by the flanging forming roller (5) and the electromagnetic induction heating coil (6) was calculated. d 1; The flanging forming roller (5) and the electromagnetic induction heating coil (6) perform relative motion speeds while completing the above actions. v Rotational motion in direction 1 to ensure that the sidewall of the flanging forming roller (5) fits the sidewall of the inner edge (1-2) and the electromagnetic induction heating coil (6) plane is as parallel as possible to the sidewall of the inner edge (1-2); the inner edge (1-2) is gradually formed by local heating layer by layer. Step 5: Based on the forming properties of the blank (1-1) and the forming depth of the large thin-walled variable cross-section ring component (1), determine the forming passes of the inner edge (1-2). n 1; Repeat steps 3-4 until the inner edge (1-2) is formed into a complete shape; Step 6: Disassemble the first upper pressure plate (2) and the first lower mold (3), install the second lower mold (8), and clamp and fix the inner edge (1-2) to the upper side of the second lower mold (8) through the second upper pressure plate (7) to ensure that the three are coaxial; the robotic arm (4) adjusts the position of the flanging forming roller (5) to the outer plane of the inner edge (1-2); Step 7: Adjust the distance between the electromagnetic induction heating coil (6) and the flanging forming roller (5). L 2; Electromagnetic induction heating current frequency f 2. Through Determine the depth of current penetration 2. Then, simulation methods are used to determine the temperature at which the inner edge (1-2) is heated. T 3. Required heating time t 3; through Determine the relative motion speed between the robotic arm (4) driving the flanging forming roller (5) and the electromagnetic induction heating coil (6) and the inner edge (1-2). v 2; The temperature of the extrusion zone between the flanging forming roller (5) and the inner edge (1-2) is T 4. Inner edge (1-2) is determined by temperature. T 3. Temperature dropped to 3 T 4. The required time is t 4, therefore through Determine the distance between the flanging forming roller (5) and the electromagnetic induction heating coil (6). L 2; Step 8: Based on the cross-sectional geometry of the outer edge (1-3), plan the movement trajectory of the flanging forming roller (5) and the electromagnetic induction heating coil (6), and perform local electromagnetic induction heating to progressively roll and form the flanging outer edge (1-3); the flanging forming roller (5) and the electromagnetic induction heating coil (6) move synchronously at a relative speed. v 2. While moving circumferentially along the inner edge (1-2), the outer edge (1-3) is formed by local electromagnetic induction heating and progressive rolling. The forming roller (5) and the electromagnetic induction heating coil (6) locally heat and roll the inner edge (1-2) once along the circumferential direction, and the downward pressing amount along the axial direction is... Z 2; The inclination angle of the outer edge (1-3) sidewall is ,pass The radial movement of the flanging forming roller (5) and the electromagnetic induction heating coil (6) during the local heating and progressive rolling of the inner edge (1-2) of each layer was calculated. d 2; The flanging forming roller (5) and the electromagnetic induction heating coil (6) perform relative motion speeds while completing the above actions. v Rotational motion in two directions to ensure that the sidewall of the flanging forming roller (5) fits the sidewall of the outer edge (1-3) and the electromagnetic induction heating coil (6) is as parallel as possible to the sidewall of the outer edge (1-3); the outer edge (1-3) is formed by gradual local heating and rolling. Step 9: Based on the forming properties of the blank (1-1) and the forming depth of the large thin-walled variable cross-section ring component (1), determine the forming passes of the outer edge (1-3). n 2; Repeat steps 7-8 until the outer edge (1-3) is fully formed; Step 10: Remove the second upper pressure plate (7), transfer the outer edge (1-3) and the second lower mold (8) to the calibration table; calibrate the outer edge (1-3) using the rubber bladder calibration mold (9) and the second lower mold (8), and maintain pressure for a specified time. t 3. After opening the mold, remove the rubber bladder shaping mold (9) and take out the large thin-walled variable cross-section ring component (1).

2. The method according to claim 1, characterized in that: In step 1, the type of robotic arm (4) is designed according to the process requirements, and the flanging forming roller (5) is guaranteed to rotate freely along its axis.

3. The method according to claim 1, characterized in that: Based on the requirements of the local heating progressive flanging integral forming method for the real-time temperature and forming rate of the locally heated area, the relative motion speed v1 between the flanging forming roller (5) and the electromagnetic induction heating coil (6) and the blank (1-1) in step 3 has two control modes: constant and real-time variation. constant v There are two ways to achieve this: one is to use a robotic arm (4) to drive the flanging forming roller (5) and the electromagnetic induction heating coil (6) at a constant linear velocity. v 1. Perform circular motion; 2. The first lower mold (3) and the first upper pressure plate (2) move at real-time varying angular velocities. w 1. Drive the blank (1-1) to rotate to ensure the relative speed of the flanging forming roller (5) and the electromagnetic induction heating coil (6) with the blank (1-1). v 1. Constant; v When changes occur in real time, it is necessary to... The billet (1-1) is heated to a certain temperature. T 1. Required real-time variable heating time t 1. And by adjusting the frequency of the electromagnetic induction heating current. f 1, thereby satisfying the requirement that the billet (1-1) is heated to a certain temperature. T 1. Required heating time t 1; Real-time changes are achieved through two methods. v 1: One is that the robotic arm (4) drives the flanging forming roller (5) and the electromagnetic induction heating coil control arm (10) drives the electromagnetic induction heating coil (6) at a speed that changes in real time. v 1. Perform circular motion; 2. The first lower mold (3) and the first upper pressure plate (2) move at a constant angular velocity. w 1 drives the billet (1-1) to rotate, and the relative speed of the flanging forming roller (5) and the electromagnetic induction heating coil (6) with the billet (1-1) is... v 1. Changes in real time.

4. The method according to claim 3, characterized in that: In step 3 v When the distance between the flange forming roller (5) and the electromagnetic induction heating coil (6) remains constant, the flange forming roller (5) is positioned at a distance of 1. L 1. Fixed connection; v When the temperature changes in real time, the distance between the flanging forming roller (5) and the electromagnetic induction heating coil (6) is flexibly adjusted in real time by the robotic arm (4) and the electromagnetic induction heating coil control arm (10) to ensure that the temperature of the flanging forming roller (5) and the extrusion zone of the blank (1-1) is within a certain range. T 2.

5. The method according to claim 1, characterized in that: In step 4, based on the geometry of the inner edge (1-2), if it involves geometric features of variable curvature radius, the robotic arm (4) drives the flanging forming roller (5) to adjust the spatial position in time to adapt to the geometric feature requirements of the inner edge (1-2).

6. The method according to claim 1, characterized in that: The inclination angle of the inner edge (1-2) sidewall in step 4 The range is ° °, therefore, the flanging forming roller (5) and the electromagnetic induction heating coil (6) of each forming layer move radially inward synchronously. d 1. It changes accordingly.

7. The method according to claim 1, characterized in that: The relative motion speed between the flanging forming roller (5) and the electromagnetic induction heating coil (6) and the inner edge (1-2) in step 7. v The control method for step 2 is the same as that for step 3.

8. The method according to claim 1, characterized in that: In step 8, based on the geometry of the outer edge (1-3), if it involves geometric features of variable curvature radius, the robotic arm (4) drives the flanging forming roller (5) to adjust the spatial position in time to adapt to the geometric feature requirements of the outer edge (1-3).

9. The method according to claim 1, characterized in that: The inclination angle of the outer edge (1-3) sidewall in step 8 The range is ° °, therefore, the flanging forming roller (5) and the electromagnetic induction heating coil (6) of each forming layer move radially outward synchronously. d 2. It changes accordingly.

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