An ultrasonic-assisted rolling-joining integrated processing device

Abstract

The application provides a kind of based on ultrasonic auxiliary roll-connection integrated processing device, belongs to the field of composite forming process, it includes ultrasonic welding unit, press and ultrasonic roll unit, wherein: ultrasonic welding unit is used to heat blank under the assistance of ultrasonic vibration to realize the welding of metal and ceramic;The workbench of press is connected with ultrasonic welding unit, its sliding block is connected with ultrasonic roll unit, for providing pressure for ultrasonic roll unit, so that ultrasonic roll unit under the assistance of ultrasonic vibration to roll metal.The application adds ultrasonic auxiliary energy field on the basis of traditional brazing, increases the atomic layer diffusion range, makes the interface solder distribution uniform, and then effectively improves the connection strength, while loading ultrasonic vibration in the rolling process, can effectively improve the material filling rate, greatly improve the flow filling of material, realize high-precision, low-cost micro-channel forming.

Description

Technical Field

[0001] This application belongs to the field of composite forming processes, and more specifically, relates to an ultrasonic-assisted rolling-connecting integrated processing device. Background Technology

[0002] For the connection of metal-ceramic composites, ordinary brazing often results in low interface strength between ceramics and metals due to differences in the coefficient of linear expansion, thermal conductivity, and chemical bonds. Therefore, certain treatments are required to expand the element diffusion distance and ensure uniform distribution of the brazing filler metal.

[0003] Meanwhile, to fabricate metal-ceramic composites with microchannels, ultrasonic vibration needs to be added to traditional roll forming to reduce the material's rheological resistance and friction, increase the material's filler ratio, and achieve microchannel formation. Using other processes to fabricate microchannel structures is very costly, mainly because the processing precision and quality requirements for microchannel structures are high, making it difficult to simultaneously meet the characteristics of low cost, high quality, and short cycle time. More importantly, combining welding and roll forming is extremely difficult and can easily lead to ceramic cracking during the roll forming process. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the purpose of this application is to provide an ultrasonic-assisted rolling-connection integrated processing device, which aims to solve the problem that the existing forming process cannot combine welding and rolling forming processes.

[0005] To achieve the above objectives, this application provides an ultrasonic-assisted rolling-joining integrated processing device, which includes an ultrasonic welding unit, a press, and an ultrasonic rolling unit. The ultrasonic welding unit heats the blank under the assistance of ultrasonic vibration to achieve metal-ceramic welding. The worktable of the press is connected to the ultrasonic welding unit, and the slide of the press is connected to the ultrasonic rolling unit to provide pressure to the ultrasonic rolling unit, enabling the ultrasonic rolling unit to roll the metal under the assistance of ultrasonic vibration, thereby producing a metal-ceramic composite with microchannels.

[0006] As a further preferred embodiment, the ultrasonic welding unit includes a first tool head, a feeding assembly, a welding assembly, and two sets of first ultrasonic assemblies. The top of the first tool head is provided with a groove for placing a blank. The feeding assembly is disposed above the first tool head for pushing the blank forward. The welding assembly is disposed on the outside of the blank and directly above the first tool head. Meanwhile, the first ultrasonic assemblies are symmetrically disposed on both sides of the first tool head in the horizontal direction and connected to it, so as to heat the blank with the assistance of ultrasonic vibration to achieve welding.

[0007] As a further preferred embodiment, the feeding assembly includes a first guide rail, a second guide rail, a push block, a push rod, and a hydraulic cylinder. The first guide rail consists of two elongated plates symmetrically arranged in the horizontal direction, one end of which extends above the first tool head, and the other end of which is connected to the second guide rail. The second guide rail is a columnar structure with a central opening. The push block is disposed inside the second guide rail and located between the blank and the push rod. The rear end of the push rod is connected to the hydraulic cylinder.

[0008] As a further preferred embodiment, the first ultrasonic component includes a first transducer, a first amplitude transformer, and a first fixed plate. One end of the first transducer is connected to a power source, and the other end is connected to a first tool head via the first amplitude transformer to convert electrical energy into horizontal ultrasonic vibrations and transmit them to the first tool head. The first fixed plate is connected to the first amplitude transformer, and its lower end is connected to a worktable, thereby connecting the first ultrasonic component to a press.

[0009] As a further preferred embodiment, the welding assembly includes a resistance welding machine and a temperature sensor. The welding electrode of the resistance welding machine is connected to the first guide rail and is located directly above the first tool head for heating the blank on the first tool head. The temperature sensor is located above the first tool head for monitoring the surface temperature of the second tool head in contact with the blank.

[0010] As a further preferred embodiment, the ultrasonic rolling unit includes a second tool head and two sets of second ultrasonic components. The second tool head is located directly above the first tool head and is a grooved roller. The second ultrasonic components are symmetrically arranged on both sides of the second tool head in the horizontal direction and connected to it, so that the second tool head rolls the blank with the assistance of ultrasonic vibration.

[0011] As a further preferred embodiment, the second ultrasonic component includes a second transducer, a conductive slip ring, a second amplitude transformer, and a second fixed plate. One end of the second transducer is connected to a power source via the conductive slip ring, and the other end is connected to a second tool head via the second amplitude transformer to convert electrical energy into vertical ultrasonic vibration and transmit it to the second tool head. The second fixed plate is connected to the second amplitude transformer via a bearing, and its upper end is connected to a slider, thereby connecting the second ultrasonic component to the press.

[0012] As a further preferred embodiment, the rolling-connecting integrated processing device further includes a lubricating oil brush, which is disposed above the blank and behind the second tool head, for applying lubricating oil to the surface of the blank.

[0013] As a further preferred embodiment, the integrated rolling-connecting processing device further includes a control unit, which is connected to the ultrasonic welding unit, the press and the ultrasonic rolling unit to control their operation.

[0014] In general, the technical solutions conceived in this application have the following advantages compared with the prior art:

[0015] 1. This application adds an ultrasonic-assisted energy field to the traditional brazing process, which increases the atomic layer diffusion range and makes the interface brazing filler metal distribution uniform, thereby effectively improving the connection strength of the metal-ceramic composite. At the same time, the ultrasonic vibration applied during the rolling process can effectively improve the material filling rate, solve the problem of insufficient filling in traditional rolling technology, and also reduce the material rheological resistance and frictional resistance, significantly improving the material flow and filling, and realizing high-precision, low-cost microchannel forming. More importantly, this application combines rolling and connection, which can not only produce metal-ceramic composites with microchannels in one step, greatly improving the forming efficiency, but also reduce the rolling forming force on the metal strip by heating, thereby avoiding the ceramic from breaking during the forming process.

[0016] 2. At the same time, this application optimizes the structure of the ultrasonic welding unit. By setting a groove on the first tool head to place the ceramic strip, the ceramic strip can move along the first tool head. During the movement, the friction between the metal, the brazing filler metal, and the ceramic increases, promoting the movement between atoms and making the brazing filler metal distribution more uniform. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the ultrasonic-assisted rolling-connecting integrated processing device provided in the embodiments of this application;

[0018] Figure 2 This is a cross-sectional view of the ultrasonic-assisted rolling-joining integrated processing device provided in the embodiments of this application;

[0019] Figure 3 This is an assembly diagram of the second fixing plate in an embodiment of this application;

[0020] Figure 4 This is a schematic diagram of the feeding component in the embodiments of this application, wherein (a) is a left view, (b) is a front view, and (c) is an AA view.

[0021] In all the accompanying drawings, the same reference numerals are used to denote the same elements or structures, wherein:

[0022] 1-Press, 2-Slider, 3-Worktable, 4-Conductive slip ring, 5-Second transducer, 6-Second amplitude rod, 7-Second tool head, 8-Second fixed plate, 81-Fixed flange, 82-Bearing, 9-Metal strip, 10-Bracket filler metal, 11-Ceramic strip, 121-First guide rail, 122-Second guide rail, 13-Welding electrode, 14-Temperature sensor, 15-First tool head, 16-First fixed plate, 17-First amplitude rod, 18-First transducer, 19-Control unit, 20-Push block, 21-Push rod, 22-Hydraulic cylinder, 23-Lubricating oil brush. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0024] like Figure 1 , 2 As shown in the figure, this application provides an ultrasonic-assisted rolling-joining integrated processing device, which includes an ultrasonic welding unit, a press 1, and an ultrasonic rolling unit. The ultrasonic welding unit heats the blank with the assistance of ultrasonic vibration to achieve metal-ceramic welding. The blank includes a metal strip 9, a brazing filler metal 10, and a ceramic strip 11 arranged sequentially from top to bottom. The worktable 3 of the press 1 is connected to the ultrasonic welding unit, and the slider 2 of the press 1 is connected to the ultrasonic rolling unit to drive the ultrasonic rolling unit to move up and down. This provides pressure to the ultrasonic rolling unit, allowing it to roll the metal strip with the aid of ultrasonic vibration. Ultrasonic vibration increases the material's filling rate, reduces its flow resistance and friction, and improves the material's filling of the roller tip, thus producing a metal-ceramic composite with microchannels. Simultaneously, the metal strip connects with the ceramic strip during rolling. Heating reduces the rolling force on the metal strip, preventing excessive load during forming and uneven stress distribution that could lead to ceramic strip breakage.

[0025] Furthermore, the ultrasonic welding unit includes a first tool head 15, a feeding assembly, a welding assembly, and two sets of first ultrasonic assemblies. The top of the first tool head 15 is provided with a groove for placing the blank and providing a guide rail for the transport of the blank. During operation, the ceramic strip 11 is placed in the groove of the first tool head 15, with brazing filler metal 10 and metal strip 9 stacked on top. All three strips are located in the first guide rail 121. The metal strip 9 is in contact with the second tool head 7. The ceramic strip 11 can move along the first tool head 15. During the movement, the friction between the metal, brazing filler metal, and ceramic part is increased, promoting the movement between atoms and making the brazing filler metal 10 more evenly distributed. The feeding assembly is located above the first tool head 15 to push the blank forward. The welding assembly is located on the outside of the blank and directly above the first tool head 15. At the same time, the two sets of first ultrasonic assemblies are symmetrically arranged on both sides of the first tool head 15 in the horizontal direction and connected to it, so as to heat the blank with the assistance of ultrasonic vibration to achieve welding.

[0026] Furthermore, such as Figure 4 As shown, the feeding assembly includes a first guide rail 121, a second guide rail 122, a push block 20, a push rod 21, and a hydraulic cylinder 22. The first guide rail 121 consists of two elongated plates symmetrically arranged in the horizontal direction, one end of which extends above the first tool head 15, allowing the first tool head 15 to directly contact the metal strip 9 and form a microchannel through rolling. The other end of the elongated plate is connected to the second guide rail 122 for fixation. The second guide rail 122 is a columnar structure with a central opening. The push block 20 is disposed inside the second guide rail 122 and located between the blank and the push rod 21. The rear end of the push rod 21 is connected to the hydraulic cylinder 22. During operation, the hydraulic cylinder 22 pushes the push rod 21 to move back and forth to realize the reciprocating motion of the push block 20, thereby using the push block 20 to push the blank forward within the second guide rail 122, thus realizing the feeding of the blank.

[0027] Furthermore, the first ultrasonic component includes a first transducer 18, a first amplitude transformer 17, and a first fixing plate 16. One end of the first transducer 18 is connected to a power source, and the other end is connected to the first tool head 15 via the first amplitude transformer 17. Thus, the first transducer 18 converts electrical energy into ultrasonic vibration, and the first amplitude transformer 17 transmits the horizontal ultrasonic vibration to the first tool head 15. During operation, the two first transducers 18 and the two first amplitude transformers 17 vibrate in tandem to make the first tool head 15 vibrate horizontally. The first fixing plate 16 is connected to the first amplitude transformer 17, and its lower end is connected to the worktable 3 of the press 1, thereby connecting the first ultrasonic component to the press 1.

[0028] Furthermore, the welding assembly includes a resistance welding machine and a temperature sensor 14. The welding electrode 13 of the resistance welding machine is connected to the first guide rail 121 and is located directly above the first tool head 15. It is used to heat the blank on the first tool head 15 and then weld it with the assistance of ultrasonic vibration. The temperature sensor 14 is located above the first tool head 15 and is used to monitor the surface temperature of the metal strip in contact with the second tool head 7, so as to ensure that the heating temperature does not exceed the melting point of the metal, but is not lower than the melting point of the brazing filler metal. The temperature sensor 14 is an infrared temperature sensor or a laser temperature sensor. During operation, the resistance welding machine adjusts the electrode voltage and current according to the temperature monitored by the temperature sensor 14 to control the temperature of the metal strip so that it reaches the set temperature.

[0029] Furthermore, the ultrasonic rolling unit includes a second tool head 7 and two sets of second ultrasonic components. The second tool head 7 is positioned directly above the first tool head 15. The second tool head 7 is a grooved roller, and the cross-sectional shape of the groove can be designed according to requirements. In a preferred embodiment of this application, the cross-sectional shape of the second tool head 7 is a groove with a "V" shaped structure. The entire unit is a rotating body, which allows it to rotate with the movement of the workpiece. During operation, the position and pressure of the second tool head 7 are controlled by the stroke of the slider 2, and the workpiece drives the second tool head 7 to rotate. The second ultrasonic components are symmetrically arranged on the left and right sides of the second tool head 7 in the horizontal direction and connected to it, so that the second tool head 7 is subjected to ultrasonic vibration. The billet is rolled with assistance. The second ultrasonic component includes a second transducer 5, a conductive slip ring 4, a second amplitude transformer 6, and a second fixed plate 8. One end of the second transducer 5 is connected to a power source via the conductive slip ring 4 to convert electrical energy into ultrasonic vibration. The conductive slip ring 4 ensures that the wire does not rotate or become entangled when the second transducer 5 rotates. The other end of the second transducer 5 is connected to a second tool head 7 via the second amplitude transformer 6 to achieve vertical vibration and transmit it to the second tool head 7. During operation, the two second transducers 5 and the two second amplitude transformers 6 vibrate in tandem, causing the second tool head 7 to vibrate vertically. The second fixed plate 8 is connected to the second amplitude transformer 6, such as... Figure 3 As shown, the second fixed plate 8 includes a fixed flange 8.1 and a bearing 8.2. The fixed flange 8.1 is connected to the slider 2, thereby connecting the second ultrasonic component to the press 1. The bearing 8.2 is located between the fixed flange 8.1 and the second amplitude rod 6, so that the second tool head 7 can rotate when the billet is fed.

[0030] Furthermore, the rolling-connecting integrated processing device also includes a lubricating oil brush 23, which is disposed above the blank and between the second tool head 7 and the second guide rail 122. The lubricating oil brush 23 is used to apply lubricating oil to the surface of the blank to reduce the frictional resistance between the second tool head 7 and the metal strip and improve the surface finish of the formed part.

[0031] Furthermore, the integrated rolling-connecting processing device also includes a control unit 19, which specifically includes a controller for the first ultrasonic component, a controller for the second ultrasonic component, a controller for the welding component, a controller for the feeding component, and a controller for the press. The controllers for the first and second ultrasonic components are used to control the vibration amplitude of the first tool head 15 and the second tool head 7, respectively. The controller for the welding component is used to regulate the electrode voltage and current. The controller for the feeding component is used to control the speed and displacement of the pusher 20 to control the feed rate of the blank. The controller for the press is used to control the position and pressure of the slider 2, thereby achieving precise control of ultrasonic vibration, resistance welding, and microchannel rolling.

[0032] The workflow of the ultrasonic-assisted rolling-connecting integrated processing device provided in this application will be further described below with reference to specific embodiments.

[0033] 1. Material selection: In this embodiment, metal strip 9 is 1060 aluminum alloy, brazing filler metal 10 is AlMgSi metal foil, and ceramic strip 11 is Al2O3 ceramic. The material is strip-shaped and the surface needs to be polished to remove contaminants and surface oxide layer, and is free of oil and impurities.

[0034] 2. Assemble the materials by stacking metal strip 9, brazing filler metal 10 and ceramic strip 11 in order from top to bottom to obtain a blank. Then, place the blank into the first guide rail 121 and the second guide rail 122. The blank can slide easily in the first guide rail 121 and the second guide rail 122. One end of the blank contacts the push block 20.

[0035] 3. Roll forming - adjust the slider 2 of the press 1 so that the micro-groove of the second tool head 7 presses down into the metal strip 9. Then fix the slider 2 still. Next, control the hydraulic cylinder 22 and set the feed rate of the push block 20. At the same time, adjust the parameters of the resistance welding machine so that the temperature sensor 14 can accurately detect the temperature of the metal strip 9. When the billet enters the second tool head 7, the first ultrasonic component and the second ultrasonic component are activated to keep the billet feed rate constant until the billet is completely formed.

[0036] In summary, this application utilizes ultrasonic vibration during the rolling process to effectively improve material filling rate, solving the problem of insufficient filling in traditional rolling processes. It also reduces material rheological resistance and frictional resistance, significantly improving material flow and filling while achieving high-precision, low-cost microchannel forming. Furthermore, by adding an ultrasonic energy field to traditional brazing, the atomic layer diffusion range is increased, resulting in uniform distribution of the brazing filler metal and improved metal-ceramic interface strength. This application combines these two processes, enabling both microchannel forming and ceramic bonding to the microchannel-formed part. With wide applicability, it fully leverages the advantages of ultrasonic vibration energy field, achieving composite processing and producing metal-ceramic composite parts with microchannels in a single step, greatly improving forming efficiency. More importantly, the integrated rolling-bonding process connects the metal strip to the ceramic strip simultaneously during rolling. Due to the large load and uneven stress distribution during forming, the ceramic is prone to breakage. Therefore, heating during forming reduces the rolling force on the metal material.

[0037] It should be understood that expressions such as "comprising" and "may include" as used in this application indicate the existence of the disclosed functions, operations, or constituent elements, and do not limit one or more additional functions, operations, and constituent elements. In this application, terms such as "comprising" and / or "having" may be interpreted as indicating a specific characteristic, number, operation, constituent element, component, or combination thereof, but should not be interpreted as excluding the existence or possibility of adding one or more other characteristics, numbers, operations, constituent elements, components, or combinations thereof.

[0038] It should be understood that the terms “center,” “upper,” “lower,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “inner,” “outer,” “clockwise,” “counterclockwise,” “axial,” “radial,” and “circumferential” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0039] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0040] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0041] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. An integrated processing device for ultrasonic-assisted rolling and joining, characterized in that, The integrated rolling-connecting processing device includes an ultrasonic welding unit, a press (1), an ultrasonic rolling unit, and a lubricating brush (23), wherein: The ultrasonic welding unit is used to heat the blank with the assistance of ultrasonic vibration to achieve metal-ceramic welding. The ultrasonic welding unit includes a first tool head (15), a feeding assembly, a welding assembly, and two sets of first ultrasonic assemblies. The top of the first tool head (15) is provided with a groove for placing the blank. The feeding assembly is located above the first tool head (15) to push the blank forward. The welding assembly is located outside the blank and directly above the first tool head (15). At the same time, the first ultrasonic assemblies are symmetrically arranged on both sides of the first tool head (15) in the horizontal direction and connected to it. The blank is heated with the aid of ultrasonic vibration to achieve welding. The first ultrasonic component includes a first transducer (18), a first amplitude transformer (17), and a first fixed plate (16). One end of the first transducer (18) is connected to a power source, and the other end is connected to a first tool head (15) through the first amplitude transformer (17) to convert electrical energy into horizontal ultrasonic vibration and transmit it to the first tool head (15). The first fixed plate (16) is connected to the first amplitude transformer (17), and its lower end is connected to the worktable (3), thereby connecting the first ultrasonic component to the press (1). The worktable (3) of the press (1) is connected to the ultrasonic welding unit, and the slider (2) of the press (1) is connected to the ultrasonic rolling unit to provide pressure to the ultrasonic rolling unit, so that the ultrasonic rolling unit rolls the metal with the assistance of ultrasonic vibration, thereby producing a metal-ceramic composite with microchannels. The ultrasonic rolling unit includes a second tool head (7) and two sets of second ultrasonic components. The second tool head (7) is located directly above the first tool head (15). The second tool head (7) is a grooved roller. The second ultrasonic components are symmetrically arranged on both sides of the second tool head (7) in the horizontal direction and connected to it, so that the second tool head (7) rolls the blank with the assistance of ultrasonic vibration. The second ultrasonic component includes a second transducer (5), a conductive slip ring (4), a second amplitude transformer (6), and a second fixed plate (8). One end of the second transducer (5) is connected to the power supply through the conductive slip ring (4), and the other end is connected to the second tool head (7) through the second amplitude transformer (6) to convert electrical energy into vertical ultrasonic vibration and transmit it to the second tool head (7). The second fixed plate (8) is connected to the second amplitude transformer (6) through a bearing, and its upper end is connected to the slider (2), thereby connecting the second ultrasonic component to the press (1). The lubricating oil brush (23) is positioned above the blank and behind the second tool head (7) for applying lubricating oil to the surface of the blank.

2. The ultrasonic-assisted rolling-joining integrated processing device as described in claim 1, characterized in that, The feeding assembly includes a first guide rail (121), a second guide rail (122), a push block (20), a push rod (21), and a hydraulic cylinder (22). The first guide rail (121) consists of two long strip plates symmetrically arranged in the horizontal direction, one end of which extends above the first tool head (15), and the other end of which is connected to the second guide rail (122). The second guide rail (122) is a columnar structure with a hole in the middle. The push block (20) is located inside the second guide rail (122) and between the blank and the push rod (21). The rear end of the push rod (21) is connected to the hydraulic cylinder (22).

3. The ultrasonic-assisted rolling-joining integrated processing device as described in claim 1, characterized in that, The welding assembly includes a resistance welding machine and a temperature sensor (14). The welding electrode (13) of the resistance welding machine is connected to the first guide rail (121) and is located directly above the first tool head (15) for heating the blank on the first tool head (15). The temperature sensor (14) is located above the first tool head (15) for monitoring the surface temperature of the second tool head (7) in contact with the blank.

4. The ultrasonic-assisted rolling-joining integrated processing device as described in any one of claims 1 to 3, characterized in that, The integrated rolling-connecting processing device also includes a control unit (19), which is connected to the ultrasonic welding unit, the press (1) and the ultrasonic rolling unit to control their operation.

Images