Progressive roll forming method for large thin-walled deep-cavity component with local heating

Abstract

A kind of local heating progressive roll forming method of large thin-walled deep-cavity component with rib, first layer local heating progressive roll forming part deep cavity on blank, then local electromagnetic induction heating synchronous progressive roll forming part first reinforcing rib, part second reinforcing rib,..., until part mth reinforcing rib, finally layer local heating progressive roll forming part flanging, to obtain large thin-walled deep-cavity component with rib;The present application effectively reduces the cost of producing large thin-walled deep-cavity component with rib, improves the quality of forming component, can ensure the overall shape accuracy of component, with the advantages of low production cost, stable forming quality, wide processing range, easy adjustment.

Description

Technical Field

[0001] This invention belongs to the field of advanced material forming technology, specifically relating to a method for local heating and progressive rolling integral forming of large thin-walled, ribbed, deep-cavity components. Background Technology

[0002] With the continuous development of the aerospace industry, the requirements for the performance, reliability, and lightweight of parts are becoming increasingly stringent. There is a trend towards large-scale integration, complex thin-walled construction, and lightweight materials for components. In particular, large thin-walled high-strength aluminum alloy components with ribbed deep cavity features and annular variable cross-section features are widely used in the new generation of aerospace equipment. The key forming difficulty of such components lies in the fact that during integral forming, the large-size thin wall and local abrupt changes cause uneven local strain and strain concentration, which are difficult to comprehensively control under uniform temperature field conditions. Traditional integral forming processing and manufacturing has problems such as high difficulty, unstable performance, low efficiency, and high cost.

[0003] The article "Classification and Manufacturing Technology of Aerospace Gas Cylinders and Tanks" published in the journal *Aerospace Materials and Processes* mentions that currently, both domestically and internationally, superplastic / thermoforming blanks and precision machining are widely used to manufacture ribbed deep-cavity variable-wall-thickness parts. However, the overall technical approach, which relies on variable stiffness design with non-uniform wall thickness and traditional hot pressing / air expansion combined with mechanical cutting processes, suffers from severe thinning and low material utilization. Application number CN202110348063.6 (Precision Forming Method for Large-Size Variable Curvature Thin-Walled Tank Diaphragms) also proposes a spinning manufacturing process for this type of component. However, this process cannot solve the problem of overall shape control for asymmetric thin-walled deep-cavity parts. Moreover, the local ribbed areas are prone to rib-piercing phenomena, making it extremely difficult to control forming accuracy. Furthermore, it also suffers from many other problems such as long design and manufacturing cycles, high costs, and difficulty in guaranteeing forming accuracy and mechanical properties. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the present invention aims to provide a method for local heating and progressive rolling integral forming of large thin-walled ribbed deep cavity components, which effectively reduces the cost of producing large thin-walled ribbed deep cavity components, improves the quality of formed components, and can ensure the overall shape accuracy of components. It has the advantages of low production cost, stable forming quality, wide processing range, and convenient adjustment.

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

[0006] A method for integral forming of large thin-walled ribbed deep cavity components by local heating and progressive rolling is provided. First, the deep cavity 7-1 of the part is formed by local heating and progressive rolling layer by layer on the blank 1. Then, the first reinforcing rib 7-2, the second reinforcing rib 7-3, ..., up to the m-th reinforcing rib of the part are formed by local electromagnetic induction heating and synchronous progressive rolling. Finally, the outer flange 7-4 of the part is formed by local heating and progressive rolling layer by layer, thus obtaining the large thin-walled ribbed deep cavity component 7.

[0007] A method for locally heated progressive rolling integral forming of large, thin-walled, ribbed, deep-cavity components includes the following steps:

[0008] Step 1: Install the deep cavity forming roller 4 and connect the deep cavity forming roller 4 to the robotic arm 5;

[0009] Step 2: Clamp the billet 1. The billet 1 is fixed by the upper pressure plate 2 and the lower mold 3 to ensure that the central axis of the billet 1 coincides with the central axis of the lower mold 3.

[0010] Step 3: Determine the distance L1 between the electromagnetic induction heating coil 6 and the deep cavity forming roller 4; determine the electromagnetic induction heating current frequency f1, the permeability μ and resistivity ρ of the blank 1, and then... Determine the current penetration depth Δ1; where η is 3160 when using imperial units and 5030 when using national standard units; then determine the heating time t1 required for the billet 1 to be heated to temperature T1 using simulation or experimental methods; the diameter of the electromagnetic induction heating coil 6 is D, through... The relative motion speed v1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 and the blank 1 is determined; the temperature of the extrusion area between the deep cavity forming roller 4 and the blank 1 is T2; the time required for the blank 1 to drop from temperature T1 to temperature T2 is t2; therefore, the distance L1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 is determined by L1 = v1t2.

[0011] Step 4: Local electromagnetic induction heating synchronously and progressively roll forming the deep cavity 7-1 of the part; according to the geometry of the deep cavity 7-1, the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 synchronously heat and roll the blank 1 circumferentially at a relative speed v1 while moving axially downward and radially inward; for each circumferential rotation of the deep cavity forming roller 4 and the electromagnetic induction heating coil 6, the synchronous downward pressure along the axial direction is Z1; the inclination angle of the sidewall of the deep cavity 7-1 is α1, through... The radial inward movement d1 of the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 is calculated when the blank 1 is gradually rolled layer by layer under local heating. While performing the above actions, the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 rotate around the relative motion velocity v1 to ensure that the side wall of the deep cavity forming roller 4 is in contact with the side wall of the deep cavity 7-1 of the part, 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 deep cavity 7-1 of the part. The deep cavity 7-1 of the part is formed by gradually rolling layer by layer under local heating.

[0012] Step 5: Based on the material forming properties of blank 1 and the forming depth and sidewall inclination angle α1 of part deep cavity 7-1, determine the number of forming passes n1 of part deep cavity 7-1; repeat steps 3-4 until the complete shape of part deep cavity 7-1 is formed.

[0013] Step 6: Replace the reinforcing rib forming roller 8; disassemble the deep cavity forming roller 4 and install the reinforcing rib forming roller 8; connect the reinforcing rib forming roller 8 to the robotic arm 5; and enable the reinforcing rib forming roller 8 to rotate freely along its axis.

[0014] Step 7: Determine the distance L2 between the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6; determine the electromagnetic induction heating current frequency f2, through... Determine the current penetration depth Δ2, and then use simulation or experimental methods to determine the heating time t3 required for the deep cavity 7-1 of the part to be heated to temperature T3; through The relative motion speed v2 between the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 and the deep cavity 7-1 of the part is determined; the temperature of the extrusion area between the reinforcing rib forming roller 8 and the deep cavity 7-1 of the part is T4; the time required for the deep cavity 7-1 of the part to drop from temperature T3 to temperature T4 is t4. Therefore, the distance L2 between the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 is determined by L2 = v2t4.

[0015] Step 8: Local electromagnetic induction heating synchronously and progressively roll forming the first reinforcing rib 7-2 of the part; according to the geometric shape and size of the first reinforcing rib 7-2, the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 move synchronously along the circumferential direction at a relative motion speed v2 while pressing down in a direction perpendicular to the side wall of the deep cavity 7-1 of the part; when the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 move relative to the deep cavity 7-1 of the part for one revolution, the amount of pressing down in the direction perpendicular to the side wall of the deep cavity 7-1 of the part is Z2;

[0016] Step 9: Determine the number of forming reinforcing ribs n2 based on the depth of the first reinforcing rib 7-2 of the part; repeat step 8 until the shape of the first reinforcing rib 7-2 of the part is formed.

[0017] Step 10: Repeat steps 7-9 to form the m-th reinforcing rib of the part;

[0018] Step 11: If the large thin-walled, ribbed, deep-cavity component 7 does not have the geometry of the outer flange 7-4, proceed to step 12; if it does have the geometry of the outer flange 7-4, then perform local electromagnetic induction heating and synchronous progressive rolling to form the outer flange 7-4; remove the upper pressure plate 2, install the upper mold 9, remove the reinforcing rib forming roller 8, and install the deep cavity forming roller 4; the distance between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 is L1. According to the geometric dimensions of the outer flange 7-4, the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 move in a circular motion with a relative speed v1 with the m-th reinforcing rib of the component, while simultaneously moving axially downward and radially inward; the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 perform one revolution of local heating and progressive rolling along the circumference, and the synchronous downward pressure along the axial direction is Z3; the inclination angle of the side wall of the outer flange 7-4 is α2, through... The radial movement d2 along the radial direction is calculated when the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 perform one revolution of progressive rolling in each local heating stage. While performing the above actions, the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 rotate around the direction of the relative motion velocity v1 to ensure that the side wall of the deep cavity forming roller 4 is in contact with the side wall of the outer flange 7-4 of the part. 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 flange 7-4 of the part. The outer flange 7-4 of the part is formed by progressive rolling in local heating layer by layer.

[0019] Step 12: The robotic arm 5 drives the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 away from the large thin-walled ribbed deep cavity component 7, removes the upper mold 9, and takes out the large thin-walled ribbed deep cavity component 7.

[0020] In step 1, the robotic arm 5 is designed according to process requirements to enable the deep cavity forming roller 4 to rotate freely along its axis.

[0021] In step 3, based on the requirements of the local heating progressive rolling integral forming process for the real-time temperature and forming rate of the locally heated area, the relative motion speed v1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 and the blank 1 can be controlled in two ways: constant and real-time variable.

[0022] There are two ways to achieve the constant v1: one is that the robotic arm 5 drives the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 to move in a circular motion at a constant linear velocity v1; the other is that the lower mold 3 drives the blank 1 to rotate at a real-time changing angular velocity w1 to ensure that the relative motion speed v1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 and the blank 1 remains constant.

[0023] When v1 changes in real time, it needs to be done through The real-time changing heating time t1 required for the billet 1 to be heated to temperature T1 is determined, and the heating time t1 required for the billet 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 5 drives the deep cavity forming roller 4 and the electromagnetic induction heating coil control arm 10 drives the electromagnetic induction heating coil 6 to move in a circular motion at a real-time changing speed v1; second, the upper pressure plate 2 and the lower mold 3 drive the billet 1 to rotate at a constant angular velocity w1, and the relative motion speed v1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 and the billet 1 changes in real time.

[0024] In step 3, when v1 remains constant, the deep cavity forming roller 4 is fixedly connected to the electromagnetic induction heating coil 6 with a distance L1.

[0025] When v1 changes in real time, the distance between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 is flexibly adjusted in real time by the robotic arm 5 and the electromagnetic induction heating coil control arm 10 to ensure that the temperature of the extrusion area between the deep cavity forming roller 4 and the blank 1 is T2.

[0026] In step 4, the inclination angle α1 of the sidewall of the deep cavity 7-1 of the part ranges from 0° to 90°. Therefore, the radial movement d1 of the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 of each forming layer in the radial direction also changes accordingly.

[0027] In step 7, the control method for the relative motion speed v2 between the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 and the deep cavity 7-1 of the part is the same as in step 3.

[0028] In step 11, the inclination angle α2 of the outer flange 7-4 sidewall of the part gradually increases from 0° to 90°, and the radial movement d2 of the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 of each forming layer also changes accordingly.

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

[0030] This invention integrates local electromagnetic induction heating and progressive rolling, realizing the integral forming of large thin-walled, ribbed, deep-cavity components by local electromagnetic induction heating and simultaneous progressive rolling. It provides a method for adjusting the distance between the roller and the electromagnetic induction heating coil according to the forming temperature and process parameters to adapt to the forming requirements of different geometric configurations of large thin-walled, ribbed, deep-cavity components. It can flexibly, labor-savingly, with high quality and low cost form large thin-walled, ribbed, deep-cavity aluminum alloy 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 2This is a schematic diagram of the deep cavity structure 7-1 of a large thin-walled, ribbed deep cavity component 7 according to an embodiment of the present invention.

[0033] Figure 3 This is a schematic diagram of the clamping of the first reinforcing rib 7-2 of the part formed by electromagnetic induction heating synchronous progressive rolling according to an embodiment of the present invention.

[0034] Figure 4 This is a schematic diagram of the second reinforcing rib 7-3 of a large thin-walled, ribbed, deep-cavity component 7 according to an embodiment of the present invention.

[0035] Figure 5 This is a schematic diagram of the clamping of the outer flange 7-4 of the part formed by electromagnetic induction heating synchronous progressive rolling in an embodiment of the present invention.

[0036] Figure 6 This is a schematic diagram of the outer flange 7-4 of a large thin-walled, ribbed, deep-cavity component 7 according to an embodiment of the present invention. Detailed Implementation

[0037] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0038] In this embodiment, the blank 1 is made of 2219 aluminum alloy. The formed large thin-walled ribbed deep cavity component 7 has a deep cavity 7-1, a first reinforcing rib 7-2, a second reinforcing rib 7-3, and an outer flange 7-4.

[0039] A method for locally heated progressive rolling integral forming of large, thin-walled, ribbed, deep-cavity components includes the following steps:

[0040] Step 1, refer to Figure 1 Install the deep cavity forming roller 4, which is connected to the robotic arm 5. The type of robotic arm 5 can be designed according to process requirements, and it can realize the free rotation of the deep cavity forming roller 4 along its axis.

[0041] Step 2, refer to Figure 1 The blank 1 is clamped and fixed by the upper pressure plate 2 and the lower mold 3 to ensure that the central axis of the blank 1 coincides with the central axis of the lower mold 3.

[0042] Step 3, refer to Figure 1 After determining the distance L1 between the electromagnetic induction heating coil 6 and the deep cavity forming roller 4; and after determining the electromagnetic induction heating current frequency f1, the permeability μ and resistivity ρ of the blank 1, the following steps are taken: Determine the current penetration depth Δ1; 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 to be heated to temperature T1 can be determined using simulation or experimental methods; the diameter of the electromagnetic induction heating coil 6 is D, through... The relative motion speed v1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 and the blank 1 is determined; the temperature of the extrusion area between the deep cavity forming roller 4 and the blank 1 is T2; the time required for the blank 1 to drop from temperature T1 to temperature T2 is t2; therefore, the distance L1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 can be determined by L1 = v1t2.

[0043] Based on the requirements of the local heating progressive rolling integral forming process for the real-time temperature and forming rate of the locally heated area, the relative motion speed v1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 and the blank 1 can be controlled in two ways: constant and real-time variable.

[0044] There are two ways to achieve the constant v1: one is that the robotic arm 5 drives the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 to move in a circular motion at a constant linear velocity v1; the other is that the lower mold 3 drives the blank 1 to rotate at a real-time changing angular velocity w1 to ensure that the relative motion speed v1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 and the blank 1 remains constant.

[0045] When v1 changes in real time, it needs to be done through The real-time changing heating time t1 required for the billet 1 to be heated to temperature T1 is determined, and the heating time t1 required for the billet 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 5 drives the deep cavity forming roller 4 and the electromagnetic induction heating coil control arm 10 drives the electromagnetic induction heating coil 6 to move in a circular motion at a real-time changing speed v1; the other is that the upper pressure plate 2 and the lower mold 3 drive the billet 1 to rotate at a constant angular velocity w1, and the relative motion speed v1 between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 and the billet 1 changes in real time.

[0046] When v1 remains constant, the deep cavity forming roller 4 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.

[0047] When v1 changes in real time, the distance between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 can be flexibly adjusted in real time by the robotic arm 5 and the electromagnetic induction heating coil control arm 10 to ensure that the temperature of the deep cavity forming roller 4 and the extrusion area of ​​the blank 1 is T2.

[0048] Step 4, refer to Figure 1 and Figure 2The deep cavity 7-1 of the part is formed by local electromagnetic induction heating and synchronous progressive rolling. Based on the geometry of the deep cavity 7-1, the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 synchronously heat and roll the blank 1 circumferentially at a relative speed v1, while simultaneously moving axially downwards and radially inwards. For each circumferential rotation of the deep cavity forming roller 4 and the electromagnetic induction heating coil 6, the synchronous downward pressure along the axial direction is Z1. The inclination angle of the sidewall of the deep cavity 7-1 is α1. The radial inward movement d1 of the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 is calculated when the blank 1 is gradually rolled layer by layer under local heating. While performing the above actions, the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 rotate around the relative motion velocity v1 to ensure that the side wall of the deep cavity forming roller 4 is in contact with the side wall of the deep cavity 7-1 of the part, 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 deep cavity 7-1 of the part. The deep cavity 7-1 of the part is formed by gradually rolling layer by layer under local heating.

[0049] The inclination angle α1 of the sidewall of the deep cavity 7-1 of the part ranges from 0° to 90°. Therefore, the radial movement d1 of the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 of each forming layer in the radial direction also changes accordingly.

[0050] Step 5, refer to Figure 2 Based on the material forming properties of blank 1 and the forming depth and sidewall inclination angle α1 of part deep cavity 7-1, determine the number of forming passes n1 of part deep cavity 7-1; repeat steps 3-4 until the complete shape of part deep cavity 7-1 is formed.

[0051] Step 6, refer to Figure 3 Replace the reinforcing rib forming roller 8; disassemble the deep cavity forming roller 4 and install the reinforcing rib forming roller 8; connect the reinforcing rib forming roller 8 to the robotic arm 5 to enable the reinforcing rib forming roller 8 to rotate freely along its axis.

[0052] Step 7, refer to Figure 3 Determine the distance L2 between the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6; determine the frequency f2 of the electromagnetic induction heating current, through... After determining the current penetration depth Δ2, the heating time t3 required for the deep cavity 7-1 of the part to be heated to temperature T3 can be determined using simulation or experimental methods; through The relative motion speed v2 between the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 and the deep cavity 7-1 of the part is determined; the temperature of the extrusion area between the reinforcing rib forming roller 8 and the deep cavity 7-1 of the part is T4; the time required for the deep cavity 7-1 of the part to drop from temperature T3 to temperature T4 is t4. Therefore, the distance L2 between the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 can be determined by L2 = v2t4.

[0053] The control method for the relative motion speed v2 between the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 and the deep cavity 7-1 of the part is the same as in step 3;

[0054] Step 8, refer to Figure 3 The first reinforcing rib 7-2 of the part is formed by local electromagnetic induction heating and synchronous progressive rolling. According to the geometric shape and size of the first reinforcing rib 7-2, the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 move synchronously along the circumferential direction at a relative motion speed v2, while pressing down in the direction perpendicular to the side wall of the deep cavity 7-1 of the part. When the reinforcing rib forming roller 8 and the electromagnetic induction heating coil 6 move relative to the deep cavity 7-1 of the part for one revolution, the amount of pressing down in the direction perpendicular to the side wall of the deep cavity 7-1 of the part is Z2.

[0055] Step 9, refer to Figure 3 Based on the depth of the first reinforcing rib 7-2 of the part, determine the number of forming reinforcing rib passes n2; repeat step 8 until the shape of the first reinforcing rib 7-2 of the part is formed;

[0056] Step 10, refer to Figure 4 Repeat steps 7-9 to form the second reinforcing rib 7-3 of the part;

[0057] Step 11, refer to Figure 5 and Figure 6 The process involves localized electromagnetic induction heating and synchronous progressive rolling to form the outer flange 7-4 of the part; disassembling the upper pressure plate 2, installing the upper mold 9, disassembling the reinforcing rib forming roller 8, and installing the deep cavity forming roller 4; the distance between the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 is L1; based on the geometric dimensions of the outer flange 7-4, the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 move in a circular motion relative to the second reinforcing rib 7-3 of the part at a relative speed v1, while simultaneously moving synchronously downward along the axial direction and inward along the radial direction; for each localized progressive rolling turn along the circumference, the synchronous downward pressure along the axial direction is Z3; the inclination angle of the side wall of the outer flange 7-4 is α2, through... The radial movement d2 along the radial direction is calculated when the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 perform one revolution of progressive rolling in each local heating stage. While performing the above actions, the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 rotate around the direction of the relative motion velocity v1 to ensure that the side wall of the deep cavity forming roller 4 is in contact with the side wall of the outer flange 7-4 of the part. 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 flange 7-4 of the part. The outer flange 7-4 of the part is formed by progressive rolling in local heating layer by layer.

[0058] It is worth noting that the inclination angle α2 of the outer flange 7-4 sidewall of the part gradually increases from 0° to 90°, and the radial movement d2 of the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 of each forming layer in the radial direction also changes accordingly.

[0059] Step 12: The robotic arm 5 drives the deep cavity forming roller 4 and the electromagnetic induction heating coil 6 away from the large thin-walled ribbed deep cavity component 7, removes the upper mold 9, and takes out the large thin-walled ribbed deep cavity component 7.

[0060] The beneficial effects of this embodiment: Refer to Figure 1 , 3 5. By integrating local electromagnetic induction heating and progressive rolling, the integral forming of large, thin-walled, ribbed, deep-cavity, and difficult-to-deform 2219 aluminum alloy components using local electromagnetic induction heating and simultaneous progressive rolling was achieved; (Refer to...) Figure 1 , 3 This invention provides a method for adjusting the distance between the roller and the electromagnetic induction heating coil according to the forming temperature and process parameters to adapt to the forming requirements of different geometric configurations of large thin-walled ribbed deep cavity 2219 aluminum alloy components. This embodiment achieves flexible, labor-saving, and low-cost manufacturing of large thin-walled ribbed deep cavity 2219 aluminum alloy components with high shape accuracy and stable microstructure by using a local heating and layer-by-layer progressive forming method.

Claims

1. A method for integral forming of large, thin-walled, ribbed, deep-cavity components by local heating and progressive rolling, characterized in that, Includes the following steps: Step 1: Install the deep cavity forming roller (4) and connect the deep cavity forming roller (4) to the robotic arm (5); Step 2, clamp the billet (1). The billet (1) is fixed by the upper pressure plate (2) and the lower mold (3) to ensure that the central axis of the billet (1) coincides with the central axis of the lower mold (3); Step 3: Determine the distance between the electromagnetic induction heating coil (6) and the deep cavity forming roller (4). L 1. Determine the frequency of the electromagnetic induction heating current. f 1. Magnetic permeability of billet (1) and resistivity Afterwards, through Determine the depth of current penetration When using imperial units, It is 3160; however, when using national standard units, The value is 5030; then, simulation or experimental methods are used to determine the temperature at which the billet (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 motion speeds of the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) with the billet (1). v 1; The temperature of the extrusion zone between the deep cavity forming roller (4) and the billet (1) is T 2. The billet (1) is affected by temperature. T 1. Temperature dropped to T 2. The required time is t 2, therefore through Determine the distance between the deep cavity forming roller (4) and the electromagnetic induction heating coil (6). L 1; Step 4: Local electromagnetic induction heating synchronously and progressively roll forming the deep cavity (7-1) of the part; according to the geometry of the deep cavity (7-1), the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) move synchronously at a relative speed. v 1. While locally heating and rolling the blank (1) along the circumferential direction, it moves downward along the axial direction and inward along the radial direction; the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) locally heat and roll the blank one revolution along the circumferential direction, and simultaneously press down along the axial direction by a certain amount. Z 1; The inclination angle of the sidewall of the deep cavity (7-1) of the part is ,pass The radial inward movement of each layer of the progressively rolled blank (1) by the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) was calculated. d 1; The deep cavity forming roller (4) 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 deep cavity forming roller (4) fits the sidewall of the deep cavity (7-1) of the part, while the plane of the electromagnetic induction heating coil (6) is as parallel as possible to the sidewall of the deep cavity (7-1) of the part; the deep cavity (7-1) of the part is formed by progressive local heating and rolling. Step 5, based on the material forming properties of the blank (1) and the forming depth and sidewall inclination angle of the deep cavity (7-1) of the part. Determine the number of forming runs for the deep cavity (7-1) of the part. n 1; Repeat steps 3-4 until the complete shape of the deep cavity (7-1) of the part is formed; Step 6: Replace the reinforcing rib forming roller (8); disassemble the deep cavity forming roller (4) and install the reinforcing rib forming roller (8); connect the reinforcing rib forming roller (8) to the robotic arm (5); realize the free rotation of the reinforcing rib forming roller (8) along its axis; Step 7: Determine the distance between the reinforcing rib forming roller (8) and the electromagnetic induction heating coil (6). L 2. Determine the frequency of the electromagnetic induction heating current. f 2. Through Determine the depth of current penetration Then, simulation or experimental methods are used to determine the temperature at which the deep cavity 7-1 of the part is heated. T 3. Required heating time t 3; through Determine the relative motion speed between the reinforcing rib forming roller (8) and the electromagnetic induction heating coil (6) and the deep cavity (7-1) of the part. v 2; The temperature of the extrusion zone between the reinforcing rib forming roller (8) and the deep cavity (7-1) of the part is T 4. The deep cavity of the part (7-1) 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 reinforcing rib forming roller (8) and the electromagnetic induction heating coil (6). L 2; Step 8: Local electromagnetic induction heating synchronously and progressively roll forming the first reinforcing rib (7-2) of the part; according to the geometric shape and size of the first reinforcing rib (7-2), the reinforcing rib forming roller (8) and the electromagnetic induction heating coil (6) move synchronously at a relative speed. v 2. While moving in the circumferential direction, it presses down in the direction perpendicular to the side wall of the deep cavity (7-1) of the part; when the reinforcing rib forming roller (8) and the electromagnetic induction heating coil (6) move relative to the deep cavity (7-1) of the part for one revolution, the amount of downward pressure in the direction perpendicular to the side wall of the deep cavity (7-1) of the part is Z 2; Step 9: Determine the number of forming reinforcing ribs based on the depth of the first reinforcing rib (7-2) of the part. n 2; Repeat step 8 until the shape of the first reinforcing rib (7-2) of the part is formed; Step 10, repeat steps 7-9 to form the part. m One reinforcing rib; Step 11: If the large, thin-walled, ribbed, deep-cavity component (7) does not have the geometry of an outer flange (7-4), proceed to step 12; if it does have the geometry of an outer flange (7-4), perform local electromagnetic induction heating and synchronous progressive rolling to form the outer flange (7-4); remove the upper pressure plate (2), install the upper mold (9), remove the reinforcing rib forming roller (8), and install the deep-cavity forming roller (4); the distance between the deep-cavity forming roller (4) and the electromagnetic induction heating coil (6) is... L 1. Based on the geometric dimensions of the outer flange (7-4) of the part, the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) are connected to the part's first... m The relative motion speed between the reinforcing ribs v 1. While performing circular motion, it simultaneously moves downward along the axial direction and inward along the radial direction; the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) are locally heated and gradually rolled one revolution along the circumferential direction, and the downward pressure along the axial direction is... Z 3; The inclination angle of the side wall of the outer flange (7-4) of the part is ,pass The radial inward movement of the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) during each local heating and progressive rolling revolution was calculated. d 2; The deep cavity forming roller (4) 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 side wall of the deep cavity forming roller (4) fits the side wall of the outer flange (7-4) of the part, while the plane of the electromagnetic induction heating coil (6) is as parallel as possible to the side wall of the outer flange (7-4) of the part; the outer flange (7-4) of the part is formed by progressive local heating and rolling. Step 12: The robotic arm (5) drives the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) away from the large thin-walled ribbed deep cavity component (7), removes the upper mold (9), and takes out the large thin-walled ribbed deep cavity component (7).

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

3. The method according to claim 1, characterized in that: In step 3, based on the requirements of the local heating progressive rolling integral forming process for the real-time temperature and forming rate of the locally heated area, the relative motion speed between the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) and the blank (1) is determined. v There are two control modes: constant and real-time variable. constant v There are two ways to achieve this: one is to use a robotic arm (5) to drive the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) at a constant linear velocity. v 1. Perform circular motion; 2. Use the lower mold (3) with a real-time changing angular velocity. w 1 drives the blank (1) to rotate, so as to ensure the relative speed of the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) with the blank (1). v 1 remains unchanged; v When changes occur in real time, it is necessary to... Determine that the billet (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) 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 (5) drives the deep cavity forming roller (4) 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 upper pressure plate (2) and the lower mold (3) move at a constant angular velocity. w 1 drives the billet (1) to rotate, and the relative speed of the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) with the billet (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 is constant, the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) are positioned at a distance of 1. L 1. Fixed connection; v When the temperature changes in real time, the distance between the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) is flexibly adjusted in real time by the robotic arm (5) and the electromagnetic induction heating coil control arm (10) to ensure that the temperature of the deep cavity forming roller (4) and the extrusion zone of the blank (1) is within a certain range. T 2.

5. The method according to claim 1, characterized in that: The inclination angle of the sidewall of the deep cavity (7-1) of the part in step 4. The range is Therefore, the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) of each forming layer move radially inward synchronously. d 1 also changes accordingly.

6. The method according to claim 1, characterized in that: The relative motion speed between the reinforcing rib forming roller (8) and the electromagnetic induction heating coil (6) and the deep cavity (7-1) of the part in step 7. v The control method for step 2 is the same as that for step 3.

7. The method according to claim 1, characterized in that: The inclination angle of the side wall of the outer flange (7-4) of the part in step 11 Depend on ° gradually increases to °, the deep cavity forming roller (4) and the electromagnetic induction heating coil (6) of each forming layer move radially inward synchronously. d 2 also changes accordingly.

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