Two-step envelope extrusion forming method for laser copper high rib shell

Abstract

The application relates to a two-step envelope extrusion forming method for a laser copper high-finned shell, which comprises the following steps: S1, envelope extrusion preforming is carried out by adopting a preforming envelope die and a preforming concave die; under the synergistic multi-pass extrusion action of the preforming envelope die and the preforming concave die, a rectangular blank is incrementally plastically deformed and gradually thinned at room temperature, metal flows in multiple directions and in an orderly manner from a bottom plate area to a high-finned area, an inner profile surface of the high fin, an outer profile surface of the high fin and an inner surface of the bottom plate are formed at the same time, a groove of the outer profile surface of the high fin and an annular boss on the back surface of the bottom plate are formed at the same time, and a flash at the top end of the high fin is formed to obtain a preformed piece; S2, the flash of the preformed piece is cut off along the outer profile surface contour of the top end of the high fin of the preformed piece; and S3, envelope extrusion preforming is carried out by adopting a final forming envelope die and a final forming concave die. The application proposes a two-step envelope extrusion forming new process for the laser copper high-finned shell, and plastic forming manufacturing of the laser copper high-finned shell is realized through an incremental deformation mode.

Description

Technical Field

[0001] This invention relates to the field of laser forming and manufacturing, and more specifically, to a two-step enveloping extrusion forming method for a high-ribbed copper shell for lasers. Background Technology

[0002] Copper high-ribbed shells are structurally complex components characterized by high ribs, thin walls, and excellent thermal conductivity and wear resistance. They are widely used in various laser devices and other fields. Currently, copper high-ribbed shells are manufactured using machining methods, which involve milling to remove a large amount of metal. This method is not only inefficient and costly due to low material utilization, but also fails to produce fine, uniform grain structures and continuous conformal metal flow lines, making it difficult to meet the high-performance, high-efficiency, and low-cost manufacturing requirements of copper high-ribbed shells. Integral die forging, on the other hand, can achieve fine, uniform grain structures and continuous conformal metal flow lines while offering high manufacturing efficiency and low cost. It represents a significant development direction for high-performance, high-efficiency, and low-cost manufacturing technologies for metal structures and has wide applications in aerospace, shipbuilding, rail transportation, and automotive industries. However, integral die forging is an integral deformation mode. If integral die forging is used to form the copper high-rib shell of the laser, due to the thin shell structure, a deformation dead zone will inevitably be generated during the integral die forging loading process. Not only is the forming force large, but the metal cannot flow plastically, which ultimately leads to the inability to plastically form the copper high-rib shell of the laser. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a two-step enveloping extrusion forming method for a high-ribbed copper shell for lasers, which can respectively ensure the full filling of the high ribs and the forming accuracy of the high-ribbed copper shell for lasers, thereby realizing the plastic forming manufacturing of the high-ribbed copper shell for lasers.

[0004] The technical solution adopted by this invention to solve its technical problem is: a two-step enveloping extrusion forming method for a copper high-rib shell for lasers. The copper high-rib shell includes a base plate and high ribs. The outer surface of the high ribs is provided with multiple blind hole grooves, and the inner cavity of the base plate is provided with multiple micro-stepped boss structures. The method includes the following steps:

[0005] S1. Enveloping extrusion preforming is performed using a preforming enveloping die and a preforming die. A rectangular billet is placed into the cavity of the preforming die, with the bottom surface of the rectangular billet in contact with the bottom of the cavity. The preforming enveloping die is moved above the rectangular billet, and the preforming enveloping die is deflected at any angle in any direction using the cone point of the preforming enveloping die as a reference point. The preforming enveloping die is driven to move in multiple directions, while the preforming die is driven to move vertically upward in a straight feed motion. Under the combined multi-pass extrusion action of the preforming enveloping die and the preforming die, the rectangular billet undergoes incremental plastic deformation and gradually thins at room temperature. The metal flows in a coordinated and orderly manner from the bottom plate area to the high rib area, first forming the inner surface of the high rib, the outer surface of the high rib, and the inner surface of the bottom plate. At the same time, the groove of the outer surface of the high rib and the annular boss on the back of the bottom plate are formed, and then the flash at the top of the high rib is formed, finally obtaining the pre-forged part. After that, the ejector rod in the preforming die is driven to move upward to eject the pre-forged part from the preforming die.

[0006] S2. Cut off the flash of the pre-forging part along the outer contour of the top of the high rib of the pre-forging part;

[0007] S3. Enveloping extrusion preforming is performed using a final forming envelope die and a final forming die. The pre-forged part, after trimming the flash, is rotated so that the back of the base plate faces upwards and placed inside the final forming die cavity. The inner surface of the pre-forged part's base plate contacts the final forming die cavity, and the top of the high rib of the pre-forged part contacts the bottom of the die cavity. The final forming envelope die is moved above the pre-forged part, and the final forming envelope die is deflected at any angle in any direction, using the cone point of the final forming envelope die as a reference point. The final forming envelope die is driven to move in multiple directions, while the final forming die is driven to move vertically upwards in a straight line. The motion is initiated; under the coordinated multi-pass rolling action of the final forming envelope die and the final forming die, the metal in the annular boss area on the back of the pre-forged part's base plate flows in a multi-directional, coordinated and orderly manner towards the high-rib outer surface area. The height of the high rib remains unchanged, but its thickness gradually increases until the high-rib outer surface fits into the cavity of the final forming die, simultaneously forming a blind hole groove on the high-rib outer surface. Subsequently, excess metal flows outward from the back of the base plate to form a slanted flash, ultimately obtaining the final forging. The elliptical ejector rod inside the final forming die is driven to move upward, ejecting the final forging from the final forming die.

[0008] According to the above scheme, the design method of the final forging of the copper high-rib shell includes:

[0009] With the back of the copper high-rib shell base plate facing upwards, draft angles are added to the inner and outer surfaces of the high ribs. To maintain the thickness of the high rib tops, the inner surface of the high ribs is tilted inwards into the cavity, and the outer surface of the high ribs is tilted outwards. The blind hole grooves on the outer surface of the high ribs are connected to the base plate using a conical surface. Slanted flash is set around the base plate, with the upper surface of the slanted flash connected to the back of the base plate and the lower surface of the slanted flash connected to the outer surface of the high ribs. The angle between the upper surface of the slanted flash and the outer surface of the high ribs is greater than the angle between the lower surface of the slanted flash and the outer surface of the high ribs, ensuring that the thickness of the slanted flash gradually increases from the periphery of the base plate outwards.

[0010] According to the above scheme, the design method of the copper high-rib shell pre-forging part includes:

[0011] Remove the flash from the final forging, then flip the final forging so that the back of the base plate faces down. Open up the bottom plate at the bottom of the blind hole groove on the high-rib outer surface to form a through-hole groove. Simultaneously, add a 2-3mm thick connecting layer to the top of the through-hole groove. Set a slanted flash at the top of the high rib, with the upper surface of the slanted flash connected to the top surface of the high rib, and the lower surface of the slanted flash connected to the outer surface of the high rib. The angle between the upper surface of the slanted flash and the outer surface of the high rib is greater than the angle between the lower surface of the slanted flash and the outer surface of the high rib, ensuring that the thickness of the slanted flash gradually increases outward from the outer surface of the high rib. The pre-forging high... The draft angle of the inner surface of the rib is consistent with the draft angle of the inner surface of the high rib in the final forging. The draft angle of the outer surface of the high rib in the pre-forging is to tilt the outer surface of the high rib inward while keeping the thickness of the top of the high rib unchanged. Part of the metal of the outer surface of the high rib will be removed. The metal removed by the outer surface of the high rib due to the draft angle is compensated to the back of the bottom plate in the form of an annular boss with equal volume. The outline of the annular boss is consistent with the outline of the top of the high rib in the pre-forging. In order to ensure smooth metal flow, each stepped boss in the inner cavity of the bottom plate is transitioned with a slope.

[0012] According to the above scheme, the preforming die is used to form the high-rib outer surface and the back of the base plate of the pre-forged part. The shape of its cavity surface is consistent with the shape of the high-rib outer surface and the back of the base plate of the pre-forged part. Two elliptical ejector holes are provided on the bottom surface of the cavity of the preforming die. The ejector holes are symmetrically distributed along the geometric center of the bottom surface of the inner cavity and are arranged parallel to each other along the length of the bottom surface of the inner cavity. The preforming envelope die is used to form the high-rib inner surface and the inner surface of the base plate of the pre-forged part. The cavity surface design method of the preforming envelope die is as follows: the high-rib inner surface and the inner surface of the base plate of the pre-forged part are discretized into a point cloud. The geometric center of the inner surface of the base plate is used to determine the cone point of the preforming envelope die. The distance from each point in the point cloud to the cone point of the preforming envelope die remains unchanged. The vertical axis passing through the cone point of the preforming envelope die and the plane formed by the point are deflected upward by an angle. γ , obtain the point cloud of the preformed envelope model cavity, and then fit the point cloud of the preformed envelope model cavity into a curved surface to obtain the surface of the preformed envelope model cavity; the specific multi-directional motion determined by the preformed envelope mold (1) ensures that each point in the point cloud of the preformed envelope model cavity coincides with each point in the point cloud of the corresponding pre-forging part once in one motion cycle, that is, the preformed envelope mold and the pre-forging part form an envelope geometric motion relationship to avoid interference between the two, thereby ensuring the preformed part envelope extrusion preforming accuracy; both preformed ejector pins are elliptical long rods, which are fitted with the elliptical ejector pin hole with clearance;

[0013] (1)

[0014] In formula (1) It is the coordinate of a point on the axis of the preformed envelope mold. h It is the distance from a point on the envelope axis to its cone point. It is the cone angle of the preformed envelope mold; It is the rotational angular velocity of the preformed envelope mold.

[0015] According to the above scheme, the final forming die is used to form the high-rib outer surface and the inner surface of the base plate of the final forging. The shape of its cavity surface is consistent with the shape of the high-rib outer surface and the inner surface of the base plate of the final forging. Four elliptical ejector holes are provided on the bottom surface of the cavity of the final forming die, and the ejector holes are symmetrically distributed along the geometric center of the bottom surface of the cavity. The final forming envelope die is used to form the back side of the base plate of the final forging. The cavity surface design method of the final forming envelope die is as follows:

[0016] The back surface of the final forging base plate is discretized into a point cloud. The final forming envelope die cone point is determined by the geometric center of the back surface of the base plate. Keeping the distance from each point in the point cloud to the final forming envelope die cone point constant, each point in the point cloud is deflected upwards by an angle on the plane formed by the vertical axis passing through the final forming envelope die cone point and that point. γ , obtain the point cloud of the final forming envelope model cavity, and then fit the point cloud of the final forming envelope model cavity into a curved surface to obtain the surface of the final forming envelope model cavity; the specific multi-directional motion determined by the final forming envelope model operation formula (1) ensures that each point in the point cloud of the final forming envelope model cavity coincides with each point in the point cloud of the corresponding final forging once in one motion cycle, that is, the final forming envelope model and the final forging form an envelope geometric motion relationship to avoid interference between the two, thereby ensuring the accuracy of the final forging envelope extrusion preforming; the four final forming push rods are all elliptical long rods, which are clearance fit with the elliptical push rod holes.

[0017] According to the above scheme, the geometry of the top of the final forming ejector pin is consistent with the stepped boss on the bottom surface of the cavity of the final forming die, and the tops of the four ejector pins contact the inner surface of the bottom plate of the final forging simultaneously during the ejection process of the final forging.

[0018] According to the above scheme, the blank used for enveloping extrusion forming of copper high-rib shell is a rectangular slab. The length and width of the rectangular slab are equal to the length and width of the minimum inscribed rectangle of the preformed concave cavity. The thickness of the rectangular slab is obtained by converting the volume of the pre-forged part.

[0019] The two-step enveloping extrusion forming method for high-ribbed copper laser housing according to the present invention has the following beneficial effects:

[0020] 1. The two-step enveloping extrusion forming process of the present invention can respectively ensure the full filling of the high ribs of the copper high rib shell of the laser and the forming accuracy, thereby realizing the plastic forming manufacturing of the copper high rib shell of the laser and breaking through the technical taboo that the copper high rib shell of the laser cannot be plastically formed.

[0021] 2. This invention uses a two-step enveloping extrusion molding process to form a copper high-rib shell for lasers, which has high manufacturing efficiency, high material utilization rate and low production cost.

[0022] 3. The laser copper high-rib shell manufactured by the two-step enveloping extrusion molding process of this invention has a fine and uniform grain structure and continuous conformal metal flow lines, which has the advantages of good thermal conductivity and strong wear resistance, and greatly improves the service performance and service life of the laser copper high-rib shell.

[0023] 4. This invention proposes a new two-step enveloping extrusion forming process for high-rigidity copper shells for lasers and proposes a process design method. Through incremental deformation mode, the plastic forming manufacturing of high-rigidity copper shells for lasers is realized, solving the problem of high-performance, high-efficiency, and low-cost manufacturing of high-rigidity copper shells for lasers. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings:

[0025] Figure 1 A schematic diagram of the structure of a copper high-ribbed housing component for a laser;

[0026] Figure 2 A schematic diagram of the final forging structure of a copper high-ribbed housing for a laser.

[0027] Figure 4 A schematic diagram of the final forging section of the copper high-ribbed housing for a laser;

[0028] Figure 3 Schematic diagram of a pre-forged copper high-ribbed housing for laser;

[0029] Figure 5 A schematic diagram of the cross-section of a pre-forged copper high-ribbed housing for a laser;

[0030] Figure 6 A schematic diagram showing the cross-sectional changes between the final forging and the pre-forging of the copper high-ribbed shell for a laser.

[0031] Figure 7 Schematic diagram of the preformed envelope mold for a copper high-ribbed laser housing;

[0032] Figure 8 Schematic diagram of a pre-forming die for a copper high-ribbed laser housing;

[0033] Figure 9 Schematic diagram of the final forming envelope mold for a copper high-ribbed laser housing;

[0034] Figure 10 Schematic diagram of the final forming die for a copper high-ribbed laser housing;

[0035] Figure 11 A schematic diagram of the enveloping extrusion preformed metal flow in a copper high-ribbed housing for a laser.

[0036] Figure 12 A schematic diagram of the metal flow during the enveloping extrusion final forming of a copper high-ribbed laser housing.

[0037] Figure 13 Schematic diagram of enveloping extrusion preforming of a copper high-ribbed shell for a laser;

[0038] Figure 14 This is a schematic diagram of the final forming of a high-ribbed copper shell for a laser through enveloping extrusion. Detailed Implementation

[0039] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0040] Example 1

[0041] The copper high-rib shell consists of a base plate and high ribs. Multiple blind holes and grooves are present on the outer surface of the high ribs, while multiple micro-stepped bosses are present in the inner cavity of the base plate. The two-step enveloping extrusion forming process for the laser copper high-rib shell includes three steps: enveloping extrusion pre-forming, edge trimming, and enveloping extrusion final forming. Its process design method includes the following steps:

[0042] S1. Design of the final forging of the copper high-rib shell: With the back side of the bottom plate of the copper high-rib shell facing upwards, draft angles are added to the inner and outer surfaces of the high ribs. The characteristics are: keeping the thickness of the top of the high rib unchanged, tilting the inner surface of the high rib inwards into the cavity, and tilting the outer surface of the high rib outwards; connecting the blind hole groove of the outer surface of the high rib to the bottom plate with a conical surface; setting oblique flash around the bottom plate, with the upper surface of the oblique flash connected to the back of the bottom plate and the lower surface of the oblique flash connected to the outer surface of the high rib, and the angle between the upper surface of the oblique flash and the outer surface of the high rib being greater than the angle between the lower surface of the oblique flash and the outer surface of the high rib, ensuring that the thickness of the oblique flash gradually increases from the periphery of the bottom plate outwards.

[0043] S2. Design of Copper High-Rib Shell Pre-Forging: Based on the final forging, remove the flash and reverse the final forging so that the back of the base plate faces down. Open up the bottom plate at the bottom of the blind hole groove on the high-rib outer surface to form a through-hole groove. Simultaneously, add a 2-3mm thick connecting layer to the top of the through-hole groove. Set a slanted flash on the top of the high rib, with the upper surface of the slanted flash connected to the top surface of the high rib, and the lower surface of the slanted flash connected to the outer surface of the high rib. The angle between the upper surface of the slanted flash and the outer surface of the high rib is greater than the angle between the lower surface of the slanted flash and the outer surface of the high rib, ensuring that the thickness of the slanted flash gradually increases outwards from the outer surface of the high rib. Thickening; the draft angle of the inner surface of the high rib of the pre-forged part is consistent with the draft angle of the inner surface of the high rib of the final forging. The draft angle of the outer surface of the high rib of the pre-forged part is to tilt the outer surface of the high rib inward while keeping the thickness of the top of the high rib unchanged. Part of the metal of the outer surface of the high rib will be removed. The metal removed by the outer surface of the high rib due to the draft angle is compensated to the back of the bottom plate in the form of an annular boss with equal volume. The outline of the annular boss is consistent with the outline of the top of the high rib of the pre-forged part. In order to ensure smooth metal flow, each stepped boss in the inner cavity of the bottom plate is transitioned by a slope.

[0044] S3. Design of enveloping extrusion forming die for copper high-rib shell: The enveloping extrusion forming die for copper high-rib shell includes an enveloping extrusion pre-forming die and an enveloping extrusion final forming die.

[0045] S31. Enveloping Extrusion Preforming Die Design: The preforming die includes a preforming enveloping die, a preforming die cavity, and preforming ejector pins. The preforming die cavity is used to form the high-rib outer surface and the back of the base plate of the pre-forged part. Its cavity surface is consistent with the shape of the high-rib outer surface and the back of the base plate of the pre-forged part. Two elliptical ejector pin holes are set on the bottom surface of the cavity cavity of the preforming die cavity. The ejector pin holes are symmetrically distributed along the geometric center of the bottom surface of the inner cavity and are arranged parallel to each other along the length of the bottom surface of the inner cavity. The preforming enveloping die is used to form the high-rib inner surface and the inner surface of the base plate of the pre-forged part. Its cavity surface design method is as follows: Discretize the high-rib inner surface and the inner surface of the base plate of the pre-forged part into a point cloud. Determine the cone point of the preforming enveloping die with the geometric center of the inner surface of the base plate. Keep the distance from each point in the point cloud to the cone point of the preforming enveloping die unchanged. Rotate each point in the point cloud upwards at an angle to the plane formed by the vertical axis passing through the cone point of the preforming enveloping die and the point. γ , obtain the point cloud of the preformed envelope model cavity, and then fit the point cloud of the preformed envelope model cavity into a curved surface to obtain the surface of the preformed envelope model cavity; the specific multi-directional motion determined by the preformed envelope mold (1) ensures that each point in the point cloud of the preformed envelope model cavity coincides with each point in the point cloud of the corresponding pre-forging part once in one motion cycle, that is, the preformed envelope mold and the pre-forging part form an envelope geometric motion relationship to avoid interference between the two, thereby ensuring the preformed part envelope extrusion preforming accuracy; both preformed ejector pins are elliptical long rods, which are fitted with the elliptical ejector pin hole with clearance;

[0046] (1)

[0047] In formula (1) It is the coordinate of a point on the axis of the preformed envelope mold. h It is the distance from a point on the envelope axis to its cone point. γ It is the cone angle of the preformed envelope mold; It is the rotational angular velocity of the preformed envelope mold.

[0048] S32. Enveloping Extrusion Final Forming Die Design: The final forming die includes a final forming envelope die, a final forming die cavity, and final forming ejector pins. The final forming die cavity is used to form the high-rib outer surface and the inner surface of the base plate of the final forging. Its cavity profile is consistent with the shape of the high-rib outer surface and the inner surface of the base plate of the final forging. Four elliptical ejector pin holes are set on the bottom surface of the cavity of the final forming die cavity, and the ejector pin holes are symmetrically distributed along the geometric center of the bottom surface of the inner cavity. The final forming envelope die is used to form the back side of the base plate of the final forging. Its cavity profile design method is as follows: Discretize the back side of the base plate of the final forging into a point cloud. Determine the cone point of the final forming envelope die with the geometric center of the back side of the base plate. Keep the distance from each point in the point cloud to the cone point of the final forming envelope die unchanged. Rotate each point in the point cloud upwards at an angle on the plane formed by the vertical axis passing through the cone point of the final forming envelope die and the point. γ , obtain the point cloud of the final forming envelope model cavity, and then fit the point cloud of the final forming envelope model cavity into a curved surface to obtain the surface of the final forming envelope model cavity; the specific multi-directional motion determined by the final forming envelope model operation formula (1) ensures that each point in the point cloud of the final forming envelope model cavity coincides with each point in the point cloud of the corresponding final forging once in one motion cycle, that is, the final forming envelope model and the final forging form an envelope geometric motion relationship to avoid interference between the two, thereby ensuring the accuracy of the final forging envelope extrusion preforming; the four final forming push rods are all elliptical long rods, which are clearance fit with the elliptical push rod holes.

[0049] S4. Design of copper high-rib shell enveloping extrusion forming billet: The billet used for enveloping extrusion forming of copper high-rib shell is a simple rectangular slab. The length and width of the rectangular slab are equal to the length and width of the minimum inscribed rectangle of the preformed concave cavity. The thickness of the rectangular slab is obtained by converting the volume of the pre-forged part.

[0050] S5. Design of the enveloping extrusion forming process for copper high-rib shells: The enveloping extrusion forming process for copper high-rib shells includes the following steps:

[0051] S51. Enveloping Extrusion Preforming: To improve metal flowability and ensure full filling of the pre-forged part, the complex high-rib inner surface and complex base plate inner surface of the pre-forged part are formed by a preforming enveloping die with complex multi-directional movement, while the simple high-rib outer surface and simple base plate back surface of the pre-forged part are formed by a preforming die with linear movement. A rectangular blank is placed into the preforming die cavity, with the bottom surface of the rectangular blank in contact with the bottom of the preforming die cavity. The preforming enveloping die is moved above the rectangular blank, and the preforming enveloping die is deflected by an angle in any direction, using the cone point of the preforming enveloping die as a reference point. γ The preforming enveloping die is driven to perform a specific multi-directional motion as determined by formula (1), while simultaneously driving the preforming die to perform a linear feed motion vertically upward. Under the combined multi-pass extrusion action of the preforming enveloping die and the preforming die, the rectangular billet undergoes incremental plastic deformation and gradually thins at room temperature. The metal flows in a multi-directional, coordinated and orderly manner from the bottom plate area to the high rib area, first forming the high rib inner surface, the high rib outer surface and the bottom plate inner surface, while simultaneously forming the groove of the high rib outer surface and the annular boss on the back of the bottom plate, and then forming the flash at the top of the high rib, finally obtaining a pre-forged part with qualified dimensions and precision. After that, the elliptical ejector rod in the preforming die is driven to move upward, ejecting the pre-forged part from the preforming die.

[0052] S52, Trimming: Cut off the flash of the pre-forged part along the outer contour of the top of the high rib of the pre-forged part.

[0053] S53. Enveloping Extrusion Final Forming: To improve production efficiency and the hardness of the copper high-rib shell, the pre-forged part obtained in S52 after trimming the flash does not require softening annealing heat treatment and is directly subjected to enveloping extrusion final forming at room temperature. To improve the forming accuracy of the final forging, the high-rib outer surface and the inner surface of the base plate of the final forging are formed by a final forming die with linear motion, while the back of the base plate of the final forging is formed by a final forming enveloping die with complex multi-directional motion. The pre-forging part obtained in S52 after trimming the flash is rotated so that the back of the base plate faces upward and placed in the cavity of the final forming die, with the inner surface of the base plate of the pre-forging in contact with the cavity of the final forming die and the top of the high rib of the pre-forging in contact with the bottom of the cavity. The final forming enveloping die is moved above the pre-forging part, and the final forming enveloping die is deflected by an angle in any direction using the cone point of the final forming enveloping die as a reference point. γ The final forming envelope mold is driven to perform a specific multi-directional motion as determined by formula (1), and at the same time, the final forming die is driven to make a linear feed motion vertically upward. Under the combined multi-pass rolling action of the final forming envelope mold and the final forming die, the metal in the annular boss area on the back of the pre-forged part base plate flows in a multi-directional coordinated and orderly manner to the high rib outer surface area. The height of the high rib remains unchanged, but the thickness gradually increases until the high rib outer surface fits into the cavity of the final forming die, and at the same time, the blind hole groove of the high rib outer surface is formed. After that, the excess metal flows outward from the back of the base plate to form a slanted flash, and finally the final forging with qualified dimensions, accuracy and hardness is obtained. The elliptical ejector rod in the final forming die is driven to move upward, and the final forging is ejected from the final forming die.

[0054] Furthermore, in step S32, the geometry of the top of the final forming ejector pin is consistent with the stepped boss on the bottom surface of the cavity of the final forming die, ensuring the accuracy of the bottom surface of the cavity of the final forming die; during the ejection process of the final forging, the tops of the four ejector pins contact the inner surface of the bottom plate of the final forging simultaneously, ensuring that the final forging does not deflect during the ejection process, thereby achieving smooth demolding.

[0055] Example 2

[0056] The two-step enveloping extrusion forming method for a high-ribbed copper laser housing of the present invention includes the following steps:

[0057] S1. Final Forging Design: The back side of the base plate of the copper high-rib shell faces upward; a 1° draft angle is added to the inner and outer surfaces of the high rib, characterized by maintaining the thickness of the high rib tops unchanged, tilting the inner surface of the high rib towards the inner cavity of the copper high-rib shell, and tilting the outer surface of the high rib towards the outer surface of the copper high-rib shell; the blind hole groove on the outer surface of the high rib is connected to the base plate using a conical surface; oblique flash is provided around the base plate, the upper surface of the oblique flash is connected to the back side of the base plate, and the lower surface of the oblique flash is connected to the outer surface of the high rib, with an angle of 135° between the upper surface of the oblique flash and the outer surface of the high rib, and an angle of 120° between the lower surface of the oblique flash and the outer surface of the high rib. Figure 2 and Figure 3 As shown.

[0058] S2. Pre-forging design: Based on the final forging, remove the flash and reverse the final forging so that the back of the base plate faces down; open up the bottom plate at the bottom of the blind hole groove on the high rib outer surface to form a through hole groove, and add a 2mm thick connecting skin to the top of the through hole groove; set a slanted flash on the top of the high rib, with the upper surface of the slanted flash connected to the top surface of the high rib, and the lower surface of the slanted flash connected to the outer surface of the high rib. The angle between the upper surface of the slanted flash and the outer surface of the high rib is 135°, and the angle between the lower surface of the slanted flash and the outer surface of the high rib is 120°. Figure 4 and Figure 5 As shown; the draft angle of the inner surface of the high rib of the pre-forged part is consistent with the draft angle of the inner surface of the high rib of the final forging. The draft angle of the outer surface of the high rib of the pre-forged part is to tilt the outer surface of the high rib inward while keeping the thickness of the top of the high rib unchanged, and part of the metal of the outer surface of the high rib will be removed. The metal removed from the outer surface of the high rib due to the draft angle is compensated to the back of the bottom plate in the form of an annular boss with equal volume. The outline of the annular boss is consistent with the outline of the top of the high rib of the pre-forged part, such as... Figure 6 As shown, the stepped bosses of the inner cavity are transitioned by bevels.

[0059] S3. Enveloping Extrusion Molding Die Design: Enveloping extrusion molding dies for copper high-ribbed shells include pre-forming dies and final forming dies; specifically, they include:

[0060] S31. Preforming Die Design: The preforming die includes a preforming envelope die, a preforming cavity die, and preforming ejector pins. The preforming cavity die is used to form the high-rib outer surface and the back of the base plate of the pre-forged part. Its cavity profile is consistent with the shape of the high-rib outer surface and the back of the base plate of the pre-forged part. Two elliptical ejector pin holes are provided on the bottom surface of the cavity within the preforming cavity. These ejector pin holes are symmetrically distributed along the geometric center of the bottom surface of the inner cavity and are aligned parallel to each other along the length of the bottom surface of the inner cavity. Figure 8 As shown; the preforming envelope mold is used to form the high-rib inner surface of the pre-forged part and the inner surface of the base plate of the pre-forged part. The cavity surface design method is as follows: Discretize the high-rib inner surface of the pre-forged part and the inner surface of the base plate into point clouds. Determine the cone point of the preforming envelope mold with the geometric center of the inner surface of the base plate. Keep the distance from each point in the point cloud to the cone point of the preforming envelope mold constant. Rotate all points in the point cloud upwards by an angle of 2° to obtain the point cloud of the preforming envelope model cavity. Then, fit the point cloud of the preforming envelope model cavity into a curved surface to obtain the surface of the preforming envelope model cavity, as shown. Figure 7 As shown; the preforming envelope mold performs specific multi-directional motion to ensure that each point in the preforming envelope model cavity point cloud coincides with each point in the corresponding pre-forging part point cloud once within one motion cycle, that is, an envelope geometric motion relationship is formed between the preforming envelope mold and the pre-forging part to avoid interference between the two, thereby ensuring the preforming accuracy of the preforming envelope extrusion; both preforming ejector pins are elliptical long rods, which are clearance-fitted with the elliptical ejector pin holes.

[0061] S32. Final Forming Die Design: The final forming die includes a final forming envelope die, a final forming cavity die, and final forming ejector pins. The final forming cavity die is used to form the high-rib outer surface and the inner surface of the base plate of the final forging. Its cavity profile is consistent with the shape of the high-rib outer surface and the inner surface of the base plate of the final forging. Four elliptical ejector pin holes are provided on the bottom surface of the cavity of the final forming die. The ejector pin holes are symmetrically distributed along the geometric center of the bottom surface of the inner cavity. Figure 10 As shown; the final forming envelope mold is used to form the back side of the final forging base plate. Its cavity surface design method is as follows: Discretize the back side of the final forging base plate into a point cloud. Determine the cone point of the final forming envelope mold using the geometric center of the back side of the base plate. Keep the distance from each point in the point cloud to the cone point of the final forming envelope mold constant. Rotate all points in the point cloud upwards by an angle of 2° to obtain the point cloud of the final forming envelope model cavity. Then, fit the point cloud of the final forming envelope model cavity into a curved surface to obtain the surface of the final forming envelope model cavity, as shown. Figure 9 As shown; the final forming envelope mold performs specific multi-directional motion to ensure that each point in the point cloud of the final forming envelope model cavity coincides with each point in the point cloud of the corresponding final forging once within one motion cycle. That is, an envelope geometric motion relationship is formed between the final forming envelope mold and the final forging to avoid interference between the two, thereby ensuring the envelope extrusion preforming accuracy of the final forging; all four final forming ejector pins are elliptical long rods, which are clearance-fitted with the elliptical ejector pin holes.

[0062] S4. Blank Design: The blank used to form the copper high-rib shell is a rectangular slab. The length and width of the rectangular slab are 192mm and 60mm respectively, which are equal to the length and width of the minimum inscribed rectangle of the preformed concave cavity. The thickness of the rectangular slab is 20mm, which is obtained by converting the pre-forged part into an equal volume.

[0063] S5. Enveloping Extrusion Molding Process Route Design: The enveloping extrusion molding of copper high-ribbed shells includes the following steps:

[0064] S51, Enveloping Extrusion Preforming: Place the rectangular blank 2 into the cavity of the preforming die 3, with the bottom surface of the rectangular blank in contact with the bottom of the preforming die cavity; move the preforming enveloping die 1 above the rectangular blank, and deflect the preforming enveloping die by an angle of 2° in any direction, using the cone point of the preforming enveloping die as the reference point; drive the preforming enveloping die to perform a specific multi-directional movement determined by formula (1), and simultaneously drive the preforming die to perform a vertical upward feed movement, such as Figure 13 As shown; under the combined action of the preforming envelope die and the preforming cavity die, the rectangular blank gradually thins, and the metal flows from the bottom plate area to the high rib area, first forming the inner surface of the high rib, the outer surface of the high rib, and the inner surface of the bottom plate, while simultaneously forming the groove of the outer surface of the high rib and the annular boss on the back of the bottom plate, and then forming the flash at the top of the high rib, finally obtaining a pre-forged part with qualified dimensions; thereafter, the ejector rod 4 in the preforming cavity die is driven to move upward, ejecting the pre-forged part from the preforming cavity die, as shown. Figure 11 As shown.

[0065] S52, Trimming: Cut off the flash of the pre-forged part along the outer contour of the top of the high rib of the pre-forged part.

[0066] S53, Enveloping Extrusion Final Forming: Rotate the pre-forged part 6 obtained in S52 after removing the flash so that the back of the bottom plate faces upward, and place it in the cavity of the final forming die 7. The inner surface of the bottom plate of the pre-forged part contacts the cavity of the final forming die, and the top of the high rib contacts the bottom of the cavity. Move the final forming enveloping die 5 above the pre-forged part, and deflect the final forming enveloping die by an angle of 2° in any direction with the cone point of the final forming enveloping die as the reference point. Drive the final forming enveloping die to perform a specific multi-directional movement determined by formula (1), and at the same time drive the final forming die to perform a vertical upward feed movement, such as... Figure 14 As shown; under the combined action of the final forming envelope die and the final forming die, the metal in the annular boss area on the back of the base plate flows towards the high-rib outer surface area. The height of the high rib remains unchanged, but its thickness gradually increases until the high-rib outer surface fits into the cavity of the final forming die, simultaneously forming a blind hole groove on the high-rib outer surface; thereafter, excess metal flows outward from the back of the base plate to form a slanted flash, ultimately obtaining a final forging with acceptable dimensions; subsequently, the ejector pin 8 inside the final forming die is driven to move upward, ejecting the final forging from the final forming die, as shown. Figure 12 As shown.

[0067] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.

Claims

1. A two-step enveloping extrusion forming method for a copper high-ribbed shell for a laser, the copper high-ribbed shell comprising a base plate and high ribs, wherein the outer surface of the high ribs is provided with multiple blind hole grooves, and the inner cavity of the base plate is provided with multiple micro-stepped boss structures, characterized in that, The forming method includes the following steps: S1. Enveloping extrusion preforming is performed using a preforming enveloping die and a preforming die. A rectangular billet is placed into the cavity of the preforming die, with the bottom surface of the rectangular billet in contact with the bottom of the cavity. The preforming enveloping die is moved above the rectangular billet, and the preforming enveloping die is deflected at any angle in any direction using the cone point of the preforming enveloping die as a reference point. The preforming enveloping die is driven to move in multiple directions, while the preforming die is driven to move vertically upward in a straight feed motion. Under the combined multi-pass extrusion action of the preforming enveloping die and the preforming die, the rectangular billet undergoes incremental plastic deformation and gradually thins at room temperature. The metal flows in a coordinated and orderly manner from the bottom plate area to the high rib area, first forming the inner surface of the high rib, the outer surface of the high rib, and the inner surface of the bottom plate. At the same time, the groove of the outer surface of the high rib and the annular boss on the back of the bottom plate are formed, and then the flash at the top of the high rib is formed, finally obtaining the pre-forged part. After that, the ejector rod in the preforming die is driven to move upward to eject the pre-forged part from the preforming die. S2. Cut off the flash of the pre-forging part along the outer contour of the top of the high rib of the pre-forging part; S3. Enveloping extrusion forming is performed using a final forming envelope die and a final forming die. The pre-forged part, after the flash has been removed, is rotated so that the back of the base plate faces upwards and placed inside the final forming die cavity. The inner surface of the pre-forged part's base plate contacts the final forming die cavity, and the top of the high rib of the pre-forged part contacts the bottom of the die cavity. The final forming envelope die is moved above the pre-forged part, and the final forming envelope die is deflected at any angle in any direction, using the cone point of the final forming envelope die as a reference point. The final forming envelope die is driven to perform multi-directional movement, while the final forming die is driven to move vertically upwards in a straight line. The process involves multiple passes of rolling and extrusion in coordination between the final forming envelope die and the final forming die. Metal from the annular boss area on the back of the pre-forged part's base plate flows in a multi-directional, coordinated, and orderly manner towards the high-rib outer surface area. The height of the high rib remains constant, but its thickness gradually increases until the high-rib outer surface fits into the cavity of the final forming die, simultaneously forming blind hole grooves on the high-rib outer surface. Subsequently, excess metal flows outward from the back of the base plate, forming oblique flash, ultimately yielding the final forging. The elliptical ejector rod inside the final forming die is then driven upward to eject the final forging from the final forming die. The preforming envelope die is used to form the inner surface of the high-ribbed pre-forged part and the inner surface of the base plate of the pre-forged part. The cavity surface design method of the preforming envelope die is as follows: Discretize the inner surface of the high-ribbed pre-forged part and the inner surface of the base plate into a point cloud. Determine the cone point of the preforming envelope die with the geometric center of the inner surface of the base plate. Keep the distance from each point in the point cloud to the cone point of the preforming envelope die constant. Rotate each point in the point cloud upwards at an angle on the plane formed by the vertical axis passing through the cone point of the preforming envelope die and the point itself. γ , obtain the point cloud of the preformed envelope model cavity, and then fit the point cloud of the preformed envelope model cavity into a curved surface to obtain the surface of the preformed envelope model cavity; the specific multi-directional motion determined by the preformed envelope mold (1) ensures that each point in the point cloud of the preformed envelope model cavity coincides with each point in the point cloud of the corresponding pre-forging part once in one motion cycle, that is, the preformed envelope mold and the pre-forging part form an envelope geometric motion relationship to avoid interference between the two, thereby ensuring the preformed part envelope extrusion preforming accuracy; both preformed ejector pins are elliptical long rods, which are fitted with the elliptical ejector pin hole with clearance; （1） In formula (1) It is the coordinate of a point on the axis of the preformed envelope mold. h It is the distance from a point on the envelope axis to its cone point. It is the cone angle of the preformed envelope mold; It is the rotational angular velocity of the preformed envelope mold; The final forming envelope die is used to form the back side of the final forging base plate. The cavity and surface design method of the final forming envelope die is as follows: The back surface of the final forging base plate is discretized into a point cloud. The final forming envelope die cone point is determined by the geometric center of the back surface of the base plate. Keeping the distance from each point in the point cloud to the final forming envelope die cone point constant, each point in the point cloud is deflected upwards by an angle on the plane formed by the vertical axis passing through the final forming envelope die cone point and that point. γ , obtain the point cloud of the final forming envelope model cavity, and then fit the point cloud of the final forming envelope model cavity into a curved surface to obtain the surface of the final forming envelope model cavity; the specific multi-directional motion determined by the final forming envelope model operation formula (1) ensures that each point in the point cloud of the final forming envelope model cavity coincides with each point in the point cloud of the corresponding final forging once in one motion cycle, that is, the final forming envelope model and the final forging form an envelope geometric motion relationship to avoid interference between the two, thereby ensuring the accuracy of the final forging envelope extrusion preforming; the four final forming push rods are all elliptical long rods, which are clearance fit with the elliptical push rod holes.

2. The two-step enveloping extrusion forming method for a high-ribbed copper laser housing according to claim 1, characterized in that, The design method for the final forging of the copper high-rib shell includes: With the back of the copper high-rib shell base plate facing upwards, draft angles are added to the inner and outer surfaces of the high ribs. To maintain the thickness of the high rib tops, the inner surface of the high ribs is tilted inwards into the cavity, and the outer surface of the high ribs is tilted outwards. The blind hole grooves on the outer surface of the high ribs are connected to the base plate using a conical surface. Slanted flash is set around the base plate, with the upper surface of the slanted flash connected to the back of the base plate and the lower surface of the slanted flash connected to the outer surface of the high ribs. The angle between the upper surface of the slanted flash and the outer surface of the high ribs is greater than the angle between the lower surface of the slanted flash and the outer surface of the high ribs, ensuring that the thickness of the slanted flash gradually increases from the periphery of the base plate outwards.

3. The two-step enveloping extrusion forming method for a high-ribbed copper laser housing according to claim 2, characterized in that, The design method for the copper high-rib shell pre-forging includes: Remove the flash from the final forging, then flip the final forging so that the back of the base plate faces down. Open up the bottom plate at the bottom of the blind hole groove on the high-rib outer surface to form a through-hole groove. Simultaneously, add a 2-3mm thick connecting layer to the top of the through-hole groove. Set a slanted flash at the top of the high rib, with the upper surface of the slanted flash connected to the top surface of the high rib, and the lower surface of the slanted flash connected to the outer surface of the high rib. The angle between the upper surface of the slanted flash and the outer surface of the high rib is greater than the angle between the lower surface of the slanted flash and the outer surface of the high rib, ensuring that the thickness of the slanted flash gradually increases outward from the outer surface of the high rib. The pre-forging high... The draft angle of the inner surface of the rib is consistent with the draft angle of the inner surface of the high rib in the final forging. The draft angle of the outer surface of the high rib in the pre-forging is to tilt the outer surface of the high rib inward while keeping the thickness of the top of the high rib unchanged. Part of the metal of the outer surface of the high rib will be removed. The metal removed by the outer surface of the high rib due to the draft angle is compensated to the back of the bottom plate in the form of an annular boss with equal volume. The outline of the annular boss is consistent with the outline of the top of the high rib in the pre-forging. In order to ensure smooth metal flow, each stepped boss in the inner cavity of the bottom plate is transitioned with a slope.

4. The two-step enveloping extrusion forming method for a high-ribbed copper laser housing according to claim 1, characterized in that, The preforming die is used to form the high-rib outer surface and the back of the bottom plate of the pre-forged part. Its cavity surface is consistent with the shape of the high-rib outer surface and the back of the bottom plate of the pre-forged part. Two elliptical ejector holes are provided on the bottom surface of the cavity of the preforming die. The ejector holes are symmetrically distributed along the geometric center of the bottom surface of the inner cavity and are arranged in parallel along the length direction of the bottom surface of the inner cavity.

5. The two-step enveloping extrusion forming method for a high-ribbed copper laser housing according to claim 4, characterized in that, The final forming die is used to form the outer surface of the high ribs and the inner surface of the base plate of the final forging. The shape of its cavity surface is consistent with the shape of the outer surface of the high ribs and the inner surface of the base plate of the final forging. Four elliptical ejector holes are provided on the bottom surface of the inner cavity of the final forming die. The ejector holes are symmetrically distributed along the geometric center of the bottom surface of the inner cavity.

6. The two-step enveloping extrusion forming method for a high-ribbed copper laser housing according to claim 5, characterized in that, The geometry of the top of the final forming ejector pin is consistent with the stepped boss on the bottom surface of the cavity of the final forming die. During the ejection process of the final forging, the tops of the four ejector pins contact the inner surface of the bottom plate of the final forging simultaneously.

7. The two-step enveloping extrusion forming method for a high-ribbed copper laser housing according to claim 1, characterized in that, The blank used for enveloping extrusion forming of copper high-rib shells is a rectangular slab. The length and width of the rectangular slab are equal to the length and width of the minimum inscribed rectangle of the preformed concave cavity. The thickness of the rectangular slab is obtained by converting the volume of the pre-forged part.

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