A super large thin-walled component forming device and heat treatment composite manufacturing method

Abstract

The application provides a super-large thin-wall component forming device and heat treatment composite manufacturing method, and relates to the field of sheet metal processing technology.The device comprises an auxiliary machine tool, specifically a base, a hydraulic lifting platform arranged at one end of the base away from the ground, a movable end of the hydraulic lifting platform moving along a vertical direction, a rotating table arranged at the movable end of the hydraulic lifting platform and rotating relative to the vertical direction, a guide rail unit fixedly arranged at the movable end of the rotating table, a supporting unit embedded in the guide rail unit, the supporting unit moving linearly along the extension direction of the guide rail unit, the supporting unit rotating relative to the vertical direction, tool heads arranged at one end of the supporting unit away from the guide rail unit and a movable end of an incremental forming machine tool, a clamp for limiting the position of a sheet metal to be processed, and a control unit for generating a motion track, the tool head assisting in forming the sheet metal to be processed along the motion track.

Description

Technical Field

[0001] This invention relates to the field of sheet metal processing technology, and in particular to a forming device for ultra-large thin-walled components and a heat treatment composite manufacturing method. Background Technology

[0002] Traditional sheet metal forming primarily involves deep drawing, using stamping dies under cold and hot forming conditions. Its drawbacks include the need for specialized dies tailored to the original part shape, long manufacturing cycles, high costs, and wear and tear from prolonged use. Incremental forming mitigates these drawbacks. It involves localized dynamic loading, layer by layer, causing uneven deformation of the sheet metal. The trajectory of the incremental forming equipment is designed and input into the machine tool to achieve the desired shape—a die-free processing technology. This process shortens product development cycles, reduces energy consumption, and offers advantages such as speed, flexibility, environmental friendliness, and low cost, making it suitable for small-batch production. However, due to its die-free nature, it suffers from lower shape accuracy, uneven processing, and significant springback at bent or deformed areas. In actual production, heat treatment is required after sheet metal forming, further amplifying the issue of low forming accuracy. Post-forming straightening is necessary to improve precision, further increasing forming costs and extending the processing cycle.

[0003] Therefore, it is essential to provide a forming device and a heat treatment composite manufacturing method for ultra-large thin-walled components, which can provide support points for the sheet metal during the forming process, achieve auxiliary forming, reduce the springback of the sheet metal, and effectively reduce the heat treatment time of the sheet metal by rationally planning the process content, while ensuring the plasticity and strength required for the sheet metal during processing. Summary of the Invention

[0004] In view of this, the present invention proposes an ultra-large thin-walled component forming device that can assist in the forming of sheet metal, reduce springback and improve forming accuracy, and further proposes a heat treatment composite manufacturing method to improve the forming performance and mechanical properties of sheet metal.

[0005] The technical solution of this invention is implemented as follows:

[0006] On one hand, the present invention provides a forming apparatus for ultra-large thin-walled components, including an auxiliary machine tool, the auxiliary machine tool specifically comprising:

[0007] The base is fixed relative to the ground.

[0008] The hydraulic lifting platform is located at the end of the base away from the ground, and the movable end of the hydraulic lifting platform moves along the vertical direction.

[0009] A rotary table is located at the movable end of the hydraulic lifting platform, and the movable end of the rotary table rotates relative to the vertical direction.

[0010] The guide rail unit is fixedly installed on the surface away from the ground at the movable end of the rotary table and extends horizontally along the diameter direction of the movable end of the rotary table.

[0011] A support unit is embedded in the guide rail unit; the support unit moves linearly along the extension direction of the guide rail unit; several support units also rotate relative to the vertical direction; a tool head is provided at the end of several support units away from the guide rail unit and the movable end of the incremental forming machine tool, and the tool head abuts against different positions on the surface of the sheet material to be processed.

[0012] A clamp is arranged around the hydraulic lifting platform. One end of the clamp is fixedly connected to the base, and the other end of the clamp extends vertically along the vertical direction and is fixedly connected to the sheet material to be processed, which is used to limit the position of the sheet material to be processed.

[0013] The control unit is used to generate the motion trajectory of the auxiliary machine tool, or the incremental forming machine tool and the auxiliary machine tool, and the tool head assists in forming the sheet material to be processed along the motion trajectory.

[0014] Based on the above technical solutions, preferably, the guide rail unit includes a guide rail body and a first linear motion mechanism; one end of the guide rail body is fixedly connected to the movable end of the rotary table, and the other end of the guide rail body extends outward in a direction away from the rotary table. The guide rail body is hollow inside and communicates with the interior of the rotary table. The first linear motion mechanism is disposed inside the rotary table, and the movable end of the first linear motion mechanism is embedded in the guide rail and slidably connected to the inner surface of the guide rail. The first linear motion mechanism drives its movable end to reciprocate along the horizontal extension direction of the guide rail. A support unit is also fixedly disposed on the movable end of the first linear motion mechanism.

[0015] Preferably, the support unit includes a base and a first rotating mechanism; the base is hollow inside, one end of the base is fixedly disposed at the movable end of the first linear motion mechanism, the end of the base away from the guide rail unit is provided with a through hole, the first rotating mechanism is fixedly disposed inside the base, and the output shaft of the first rotating mechanism is disposed inside the through hole; the output shaft of the first rotating mechanism is also detachably connected to the tool head.

[0016] More preferably, the tool head is a hemispherical tool head; the tool head includes a rod and a positioning flange, the positioning flange being located at a non-end position of the rod; the rod extends vertically along the axial direction of the hydraulic lifting platform, one end of the rod extends into a through hole and is fixedly connected to the output shaft of the first rotating mechanism, the positioning flange abuts against the end face of the base, and the other end of the rod is provided with a hemispherical working part, the hemispherical working part abutting against the surface of the sheet metal to be processed.

[0017] More preferably, the tool head is a lubrication tool head; the lubrication tool head includes a rod body, a positioning flange, ball bearings, an oil seal, and a constant force spring, with the positioning flange located at a non-end position of the rod body; the rod body extends vertically along the axial direction of the hydraulic lifting platform, with one end of the rod body extending into a through hole and fixedly connected to the output shaft of the first rotating mechanism; the rod body has a hollow first cavity and a lubrication channel inside, and a spherical limiting part is provided at the other end of the rod body, with the lubrication channel communicating with the spherical limiting part and the first cavity respectively; an oil seal is provided in the first cavity, and the oil seal is slidably connected to the inner wall of the first cavity, with a constant force spring provided on the side of the oil seal away from the lubrication channel, with both ends of the constant force spring fixedly connected to the inner wall of the first cavity and the oil seal respectively, and the first cavity on the other side of the oil seal is filled with lubricating fluid; the ball bearings are embedded in the spherical limiting part, and the ball bearings partially pass through the spherical limiting part and roll in connection with the surface of the sheet material to be processed.

[0018] More preferably, the forming trajectory of the tool head disposed on the support unit envelops the forming trajectory of the incremental forming machine tool; the surface of the tool head on the support unit or the tool head of the incremental forming machine tool is tangent to the surface of the sheet metal to be processed.

[0019] Based on the above technical solutions, preferably, the fixture includes a columnar body and a pressure plate; one end of the columnar body is detachably connected to the base, and the columnar body extends outward along the central axis of the hydraulic lifting platform, and the columnar body is arranged around the rotating platform; the other end of the columnar body is provided with a detachable pressure plate, the pressure plate is annular and matches the end face contour of the columnar body; the pressure plate and the end face of the columnar body together abut and limit the position of the sheet material to be processed.

[0020] Preferably, a second cavity is formed inside the columnar body; the side surface of the columnar body is provided with a number of through windows, and the windows are interconnected with the second cavity.

[0021] Based on the above technical solutions, preferably, a position sensor is also included. The position sensor acquires the real-time position of the tool head on the motion trajectory of the incremental forming machine tool or the auxiliary machine tool and feeds it back to the control unit. When the incremental forming machine tool and the auxiliary machine tool are used simultaneously to form the sheet material to be processed, the springback compensation of the tool head on the auxiliary machine tool is later than the action time of the tool head on the incremental forming machine tool.

[0022] On the other hand, the present invention provides a method for heat treatment composite manufacturing of ultra-large thin-walled components, comprising the following steps:

[0023] S1: Solution treatment, water quenching, and pre-aging strengthening treatment are performed on the sheet material to be processed;

[0024] S2: Configure the above-mentioned ultra-large thin-walled component forming device, arrange the incremental forming machine tool, and make the control unit communicate with the incremental forming machine tool;

[0025] S3: And equip the auxiliary machine tool or incremental forming machine tool with a tool head;

[0026] S4: Fix the sheet material to be processed onto the fixture;

[0027] S5: The control unit inputs the set process parameters to the auxiliary machine tool, or the auxiliary machine tool and the incremental forming machine tool, and adjusts the position of the tool head;

[0028] S6: Start the auxiliary machine tool and incremental forming machine tool, and perform incremental forming processing according to the trajectory set by the control unit.

[0029] The present invention provides a forming device and a heat treatment composite manufacturing method for ultra-large thin-walled components, which have the following advantages compared with the prior art:

[0030] (1) This application provides an auxiliary forming device that can assist forming machine tools in processing. It mainly plays a supporting role, reduces the impact of sheet springback and thinning on the unformed area, and suppresses the pillow effect. When the auxiliary machine tool is used alone as a basic forming machine tool, it can also use its own structure to perform corresponding forming work on the surface of the sheet, meet the quality requirements of sheet forming, improve the surface quality of the forming area, improve the dimensional accuracy and positional accuracy of the first processing, reduce the number of secondary processing, and improve processing efficiency.

[0031] (2) The overall heat treatment and processing procedures of the sheet material to be processed have been improved. The solution treatment, water quenching and pre-aging strengthening treatment before forming are beneficial to improving the strength and plasticity of the sheet material, shortening the overall heat treatment time of the sheet material processing, and making it easier to suppress springback and improve forming accuracy.

[0032] (3) Different tool heads with different structures are designed so that different tool heads have different functional combinations, such as forming and supporting functions, forming and lubrication functions, etc., which are suitable for various working conditions such as incremental forming, deep drawing forming, and needing to ensure the surface quality of the sheet or control the surface temperature of the sheet. One set of equipment can meet different processing needs. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 This is a perspective view of an auxiliary machine tool for a forming device for ultra-large thin-walled components and a heat treatment composite manufacturing method according to the present invention.

[0035] Figure 2 This is a front view of an auxiliary machine tool for a forming device and heat treatment composite manufacturing method for ultra-large thin-walled components according to the present invention.

[0036] Figure 3 This is an exploded perspective view of the auxiliary machine tool used in the forming device for ultra-large thin-walled components and the heat treatment composite manufacturing method of the present invention.

[0037] Figure 4 This is a front view of a tool head structure of a forming device and heat treatment composite manufacturing method for ultra-large thin-walled components according to the present invention;

[0038] Figure 5 This is a partial cross-sectional front view of another tool head structure of the ultra-large thin-walled component forming device and heat treatment composite manufacturing method of the present invention;

[0039] Figure 6 This is a flowchart illustrating the steps of a forming device and heat treatment composite manufacturing method for ultra-large thin-walled components according to the present invention.

[0040] Figure 7 This is a time relationship chart for each step of a forming device and heat treatment composite manufacturing method for ultra-large thin-walled components.

[0041] Figure 8 This is a schematic diagram showing the positions of the tool head and the sheet material to be processed in the first and second embodiments of the forming device and heat treatment composite manufacturing method for ultra-large thin-walled components of the present invention.

[0042] Figure 9 This is a schematic diagram showing the positions of the tool head and the sheet material to be processed in the third embodiment of the ultra-large thin-walled component forming device and heat treatment composite manufacturing method of the present invention.

[0043] Figure 10 This is a schematic diagram showing the positions of the tool head and the sheet material to be processed in the fourth embodiment of the ultra-large thin-walled component forming device and heat treatment composite manufacturing method of the present invention.

[0044] Figure 11 This is a schematic diagram of the incremental forming defects of the ultra-large thin-walled component forming device and heat treatment composite manufacturing method of the present invention.

[0045] Reference numerals: 1. Base; 2. Hydraulic lifting platform; 3. Rotary table; 4. Guide rail unit; 5. Support unit; 50. Tool head; 6. Fixture; 7. Control unit; 8. Sheet material to be processed; 51. Base; 52. First rotating mechanism; 100. Through hole; 501. Rod; 502. Positioning flange; 503. Ball bearing; 504. Oil seal; 505. Constant force spring; 506. First cavity; 507. Lubrication channel; 508. Spherical limiting part; 61. Columnar body; 62. Pressure plate; 200. Second cavity; 300. Window. Detailed Implementation

[0046] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0047] like Figure 1-5 As shown, in one aspect, the present invention provides a forming apparatus for ultra-large thin-walled components, including an auxiliary machine tool, which specifically includes:

[0048] The base 1 is fixed relative to the ground. When the auxiliary machine tool is used in conjunction with the incremental forming machine tool, the base needs to be aligned with the incremental forming machine tool. When the auxiliary machine tool is used alone, this requirement does not apply.

[0049] The hydraulic lifting platform 2 is located at the end of the base 1 away from the ground, and the movable end of the hydraulic lifting platform 2 moves along the vertical direction. The hydraulic lifting platform 2 can adjust the relative height of the rotating platform 3, the guide rail unit 4 and the support unit 5 in the vertical direction, so as to better adapt to the shape of the sheet material surface.

[0050] The rotary table 3 is located at the movable end of the hydraulic lifting platform 2. The movable end of the rotary table 3 rotates relative to the vertical direction. The rotary table 3 can drive the guide rail unit 4 and the support unit 5 to rotate to a suitable position, such as making the extension direction of the guide rail unit 4 parallel or coincident with the set auxiliary machine tool processing trajectory.

[0051] The guide rail unit 4 is fixedly installed on the surface away from the ground at the movable end of the rotary table 3 and extends horizontally along the diameter direction of the movable end of the rotary table 3; the guide rail unit 4 can drive the support unit 5 to move horizontally along the preset processing trajectory.

[0052] Support unit 5 is embedded in guide rail unit 4; support unit 5 moves linearly along the extension direction of guide rail unit 4; several support units 5 also rotate relative to the vertical direction; tool head 50 is provided at the end of several support units 5 away from guide rail unit 4 and the movable end of incremental forming machine tool, and tool head 50 is held against different positions on the surface of the sheet to be processed; support unit 5 is used to clamp tool head 50 and drive tool head 50 to rotate, so as to realize the forming requirements of sheet to be processed in specific situations, such as forming and support function, or forming and lubrication function, etc.

[0053] The fixture 6 is arranged around the hydraulic lifting platform 2. One end of the fixture 6 is fixedly connected to the base 1, and the other end of the fixture 6 extends vertically along the vertical direction and is fixedly connected to the sheet material to be processed, which is used to limit the position of the sheet material to be processed. The fixture 6 can limit the position of the sheet material to be processed relative to the auxiliary machine tool or the externally set incremental forming machine tool, and ensure that the position of the sheet material to be processed remains unchanged during the forming process.

[0054] The base 1, hydraulic lifting platform 2, rotary table 3, guide rail unit 4, and support unit 5 together constitute the structure of a multi-degree-of-freedom auxiliary machine tool.

[0055] The control unit 7 is used to generate the motion trajectory of the auxiliary machine tool, or the incremental forming machine tool and the auxiliary machine tool, and the tool head 50 performs auxiliary forming of the sheet metal to be processed along the motion trajectory. Specifically, this is divided into the following two categories:

[0056] When using both an incremental forming machine and an auxiliary machine, the line connecting the cross-sections of the tool head on the auxiliary machine and the tool head on the incremental forming machine should be the thickness of the sheet metal to be processed. The thickness variation should follow the cosine theorem of sheet metal thinning. Therefore, with the tool head vertex as the origin of the coordinate system, the coordinates of the tool head on the auxiliary machine should be higher than those on the incremental forming machine. This means that during the forming process, the forming trajectory of the tool head on the auxiliary machine can completely enclose the forming trajectory of the incremental forming machine, and the forming process is completed later than that of the incremental forming machine. When the sheet metal springs back, the incremental forming machine achieves the following two aspects: First, it uses the control unit 7 to set the trajectory for incremental forming, enabling the tool head on the auxiliary machine to track this trajectory, continuously providing support, suppressing springback, and improving component accuracy. Second, it uses sensors to acquire the coordinate position information of the tool head, processes this information in the control unit 7, optimizes the springback compensation trajectory based on the actual position, feeds the real-time position information back to the control system, calculates springback compensation based on the position information, and adjusts the trajectories of the incremental forming machine and the auxiliary machine in a timely manner to further improve forming accuracy. When the auxiliary machine tool is used alone, the tool head on the auxiliary machine tool simultaneously undertakes the forming and support functions of the sheet material to be processed.

[0057] The guide rail unit 4 includes a guide rail body and a first linear motion mechanism. One end of the guide rail body is fixedly connected to the movable end of the rotary table 3, and the other end of the guide rail body extends outward in a direction away from the rotary table 3. The guide rail body is hollow inside and communicates with the interior of the rotary table 3. The first linear motion mechanism is located inside the rotary table 3. The movable end of the first linear motion mechanism is embedded in the guide rail and slidably connected to the inner surface of the guide rail. The first linear motion mechanism drives its movable end to reciprocate along the horizontal extension direction of the guide rail. A support unit 5 is also fixedly installed on the movable end of the first linear motion mechanism. Specifically, in this case, the first linear motion mechanism can be a first drive motor and a lead screw mechanism. The output shaft of the first drive motor is connected to the end of the lead screw mechanism. The lead screw mechanism is provided with a linearly movable slide table, which is embedded in the inner surface of the guide rail body and slidably connected to the guide rail body. The cross-sectional profile of the guide rail body is a rounded rectangle. The profile of the slide table and the profile of the support unit 5 do not exceed the profile of the movable end of the first linear motion mechanism. Figure 3 The guide rail unit 4 shown is arranged in three rows, and the number of guide rail unit 4 can be increased or decreased according to actual needs.

[0058] like Figure 1-3 As shown, the support unit 5 includes a base 51 and a first rotating mechanism 52. The base 51 is hollow inside, with one end fixedly disposed at the movable end of the first linear motion mechanism. A through hole 100 is provided at the end of the base 51 away from the guide rail unit 4. The first rotating mechanism 52 is fixedly disposed inside the base 51, and its output shaft is disposed inside the through hole 100. The output shaft of the first rotating mechanism 52 is also detachably connected to the tool head 50. The base 51 is used to accommodate the first rotating mechanism 52 and facilitates the positioning and installation of the tool head 50.

[0059] like Figure 4 As shown in the figure, a specific structure of the tool head is illustrated. The tool head 50 is a hemispherical tool head; the tool head 50 includes a rod body 501 and a positioning flange 502, the positioning flange 502 being located at a non-end position of the rod body 501; the rod body 501 extends vertically along the axial direction of the hydraulic lifting platform 2, one end of the rod body 501 extends into the through hole 100 and is fixedly connected to the output shaft of the first rotating mechanism 52, the positioning flange 502 abuts against the end face of the base 51, and the other end of the rod body 501 is provided with a hemispherical working part, which abuts against the surface of the sheet metal to be processed. In this embodiment, the end profile of the rod body 501 is hemispherical, which is more conducive to processing irregularly shaped sheets. Of course, it can also be further customized into different shapes as needed, which will not be elaborated here.

[0060] like Figure 5As shown in the figure, another specific structure of the tool head is illustrated. Tool head 50 is a lubrication tool head; the lubrication tool head includes a rod body 501, a positioning flange 502, a ball bearing 503, an oil seal 504, and a constant force spring 505. The positioning flange 502 is located at a non-end position of the rod body 501. The rod body 501 extends vertically along the axial direction of the hydraulic lifting platform 2. One end of the rod body 501 extends into the through hole 100 and is fixedly connected to the output shaft of the first rotating mechanism 52. The rod body 501 has a hollow first cavity 506 and a lubrication channel 507 inside. The other end of the rod body 501 is provided with a spherical limiting part 508, and the lubrication channel 507 is respectively connected to the spherical limiting part 508. The positioning part 508 and the first cavity 506 are connected. An oil seal 504 is provided inside the first cavity 506, and the oil seal 504 is slidably connected to the inner wall of the first cavity 506. A constant force spring 505 is provided on the side of the oil seal 504 away from the lubrication channel 507. The two ends of the constant force spring 505 are fixedly connected to the inner wall of the first cavity 506 and the oil seal 504, respectively. The first cavity 506 on the other side of the oil seal 504 is filled with lubricating fluid. A ball bearing 503 is embedded in the spherical limiting part 508, and the spherical crown of the ball bearing 503 passes through the spherical limiting part 508 and rolls with the surface of the sheet metal 8 to be processed. In order to facilitate the replenishment of lubricating fluid, a sealable injection hole can be opened on the side surface of the rod 501 near the ball bearing to replenish the lubricating fluid into the first cavity 506 periodically.

[0061] The hemispherical tool head and the lubrication tool head correspond to different working conditions. As a preferred embodiment, when these two tool heads are used, the surface of the tool head 50 on the support unit 5 or the tool head 50 of the incremental forming machine tool is tangent to the surface of the sheet metal 8 to be processed.

[0062] The hemispherical tool head is mainly used for support and auxiliary processing. The lubrication tool head is suitable for incremental forming situations where it is necessary to ensure the surface quality of the sheet metal or control the surface temperature of the sheet metal. When using the lubrication tool head, the ball bearing 503 contacts the surface of the sheet metal 8 to be processed. As the lubrication tool head moves along a preset trajectory, the ball bearing drives the lubricant to flow out from the lubrication channel 507, thereby coating the surface of the sheet metal 8 to be processed and continuously providing lubricant to the ball bearing 503. When the lubricant is insufficient, lubricant can be injected into the first cavity 506 before the forming operation. Regardless of the type of tool head used, they are all interchangeable due to their similar size, which can meet the needs of different applications.

[0063] The following are several different embodiments demonstrating the use of tool heads alone or in combination in different incremental forming scenarios:

[0064] Example 1: Refer to Appendix Figure 8This is an example of assisted incremental forming. A hemispherical tool head 50 is positioned above the sheet metal 8 on an incremental forming machine tool, and the pre-treated sheet metal 8 is placed on a fixture 6. During the forming process, the hemispherical tool head 50 above the sheet metal 8 moves first, while the tool head 50 below the sheet metal 8, also a hemispherical tool head, moves later than the hemispherical tool head on the incremental forming machine tool. The movement trajectories of the auxiliary machine tool and the hemispherical tool head are set by the control unit 7. In this embodiment, the hemispherical tool head on the support unit 5 primarily serves a supporting function during the forming process, further enhancing the strength of the finished sheet metal through friction between the tool head and the sheet metal.

[0065] Example 2: Refer to Appendix Figure 8 This is a combined application of auxiliary incremental forming and surface quality control. A hemispherical tool head 50 is positioned above the sheet metal 8 to be processed on the incremental forming machine. The pre-treated sheet metal 8 is placed on the fixture 6. During the forming process, the hemispherical tool head 50 above the sheet metal 8 moves first, while the tool head 50 below the sheet metal 8 is a lubricated tool head, and its movement is later than that of the hemispherical tool head 50 on the incremental forming machine. The forming process is similar to that in Example 1. The lubricated tool head on the support unit 5 mainly functions as an incremental forming and auxiliary lubricant during the forming process. This improves the strength of the finished sheet metal and also improves the surface quality or controls the surface temperature of the sheet metal by applying lubricant to its surface. The pre-treatment process of the sheet metal 8 is the same as in Example 1.

[0066] Example 3: Refer to Appendix Figure 9 This is a schematic diagram of symmetrical sheet metal incremental forming. In this method, there are two guide rail units 4, each independently configured with a support unit 5 and a tool head 50. The difference from Embodiment 2 is that, after the hemispherical tool head 50 above the sheet metal 8 to be processed moves first, the tool heads 50 located below the sheet metal 8 to be processed are both lubricated tool heads, and the two lubricated tool heads perform incremental forming processing along the symmetry axis of the sheet metal; the pretreatment process before forming is the same as in Embodiment 1, and the role of the two lubricated tool heads in the forming process is the same as in Embodiment 2.

[0067] Example 4: Refer to Appendix Figure 10 In this case, no incremental forming machine tool was used; only an auxiliary machine tool was used for incremental forming. The pre-treated sheet metal 8 was placed on the fixture 6, and a lubrication tool head was configured on the support unit 5. Incremental forming was performed from bottom to top. Due to the influence of gravity, the lubrication tool head could simultaneously undertake the functions of forming, lubrication, and support, thereby reducing the springback of the sheet metal. The pre-treatment process of the sheet metal 8 before forming was the same as in Example 1, and the working process of the lubrication tool head achieved the same effect as in Example 2.

[0068] Figures 8-10 The solid line in the diagram represents the current position of the sheet material 8 to be processed, and the dashed line represents the set target position.

[0069] The trajectory accuracy of this invention is optimized through the support and machining process between the tool heads. Incremental forming accuracy defects include... Figure 11 As shown, the springback occurring during the initial bending of the sheet metal and at the tool head retraction position at the end of processing are the most significant. Sometimes, defects caused by the bottom of the component protruding vertically upwards may also occur; this is known as the pincushion effect. Taking Examples 1-3 as examples, the tool head on the incremental forming machine mainly plays the role of processing and forming, while the tool head on the auxiliary machine mainly plays the role of support and assisting in forming. Due to the change in position, taking the apex of each tool head as its respective coordinate point, the height of the tool head on the auxiliary machine is higher than that of the tool head on the incremental forming machine. That is, the trajectory of the tool head on the auxiliary machine has a certain lag, and the springback can be further adjusted by the trajectory of the auxiliary forming tool head.

[0070] Step 1): When the position sensor continuously samples, if at least three consecutive sampled values ​​of the initial sheet bending area or the actual forming trajectory deviate from the set trajectory position, the control unit 7 determines that the springback occurs at the current sheet position. At this time, the tool head on the incremental forming machine above the sheet 8 to be processed first performs incremental forming. The control unit 7 monitors the springback position of the sheet in real time. The tool head on the auxiliary machine below the sheet 8 to be processed moves towards the set forming trajectory position through step adjustment until the continuous sampled values ​​of the sensor do not deviate from the set trajectory position.

[0071] Step 2): When the position sensor continuously samples, and at least three consecutive sample values ​​in the tool head retraction position area deviate from the set trajectory position, or the actual forming trajectory is embedded in the set forming trajectory, the control unit 7 determines that springback occurs at the current sheet position. The tool head on the auxiliary machine tool below the sheet stops approaching the set forming trajectory. The actual forming trajectory is corrected through step adjustment. The limit position of the step adjustment is the position where the tool head on the auxiliary machine tool separates from the sheet, until the continuous sample values ​​of the sensor do not deviate from the set trajectory position. The deviation from the set trajectory position in Step 1) and Step 2) is at least 20% of the sheet thickness beyond the set trajectory position. The step adjustment range of the tool head on the auxiliary machine tool does not exceed 1%-5% of the sheet thickness each time.

[0072] Step 3): When the relative error between the set forming trajectory and the actual forming trajectory is less than the set maximum error value, the sheet metal is processed normally according to the set forming trajectory. When the relative error is about to exceed the set maximum error value, the control unit 7 performs either step 1) or step 2) based on the relative error. The set maximum error value is 1.2 times the thickness of the sheet metal.

[0073] like Figure 3 As shown, to better define the position of the sheet metal 8 to be processed, the fixture 6 includes a cylindrical body 61 and a pressure plate 62. One end of the cylindrical body 61 is detachably connected to the base 1, and the cylindrical body 61 also extends outward along the central axis of the hydraulic lifting platform 2, surrounding the rotating platform 3. The other end of the cylindrical body 61 is detachably fitted with the pressure plate 62, which is annular and matches the end face contour of the cylindrical body 61. The pressure plate 62 and the end face of the cylindrical body 61 together abut and define the position of the sheet metal to be processed. The pressure plate 62 in the figure defines the position of the sheet metal 8 to be processed through multiple bolts.

[0074] To facilitate observation of the forming process, a second cavity 200 is formed inside the columnar body 61. Several through windows 300 are provided on the side surface of the columnar body 61, and these windows 300 are interconnected with the second cavity 200. Through the windows 300, the working status of the hydraulic lifting platform 2, the rotary table 3, the guide rail unit 4, or the support unit 5 can be observed, and the surface quality of the sheet metal 8 to be processed inside the columnar body 61 can also be observed.

[0075] To better achieve incremental control of the auxiliary machine tool, this application also configures a position sensor. The position sensor acquires the real-time position of the tool head 50 on the motion trajectory of the incremental forming machine tool or the auxiliary machine tool and feeds it back to the control unit 7. The control unit 7 processes the coordinate point position information, optimizes the springback compensation trajectory based on the actual position, feeds back the real-time position information to the control system, and calculates the springback compensation based on the position information to adjust the trajectory of the incremental forming machine tool and the auxiliary machine tool in a timely manner. When the incremental forming machine tool and the auxiliary machine tool are used simultaneously to form the sheet material to be processed, the springback compensation of the tool head 50 on the auxiliary machine tool is later than the action time of the tool head 50 on the incremental forming machine tool.

[0076] like Figure 6 As shown, on the other hand, the present invention provides a method for heat treatment composite manufacturing of ultra-large thin-walled components, comprising the following steps:

[0077] S1: Solution treatment, water quenching, and pre-aging strengthening treatment are performed on the sheet material to be processed;

[0078] Reference Figure 7Based on the required forming properties and component strength of the sheet material 8 to be processed, an appropriate heat treatment process is selected for the sheet material.

[0079] The heat treatment process consists of three steps. The first step is solution treatment, which involves heat preservation based on the type of sheet material and the heat preservation time based on the thickness of the sheet material. The second step is water quenching, which requires the sheet material to be completely immersed in cooling water from the heating furnace within 20 seconds for quenching. The third step is artificial aging treatment, which involves artificially aging the sheet material according to the requirements of the processed components to change its strength and plasticity. When the sheet material is a 2-series aluminum alloy, the solution treatment temperature is 490-540℃, the holding time is 10-60 minutes, the artificial aging temperature is 100-200℃, and the holding time is 4-24 hours. Compared with the T6 state sheet material, the strength is increased by more than 2%, and the plasticity is increased by more than 5%. When the sheet material is a 6-series aluminum alloy, the solution treatment temperature is 510-575℃, the holding time is 10-60 minutes, the artificial aging temperature is 60-180℃, and the holding time is 3-16 hours. When the sheet material is a 7-series aluminum alloy, the solution treatment temperature is 460-495℃, the holding time is 10-60 minutes, the artificial aging temperature is 80-175℃, and the holding time is 3-20 hours. Compared with the T6 state sheet material, the strength can be increased by more than 3%, and the plasticity can be increased by more than 6%. The heat-treated sheet material is formed according to the incremental forming method selected in Examples 1-4 above.

[0080] Taking 7055 aluminum alloy sheet as an example, the solution treatment time is selected according to the sheet thickness, the solution temperature is 480℃, and the holding time is 10-60 minutes. After quenching, pre-aging treatment is performed at 80-120℃ for 3-7 hours. After treatment, the strength can reach 620MPa, and the elongation can reach 14%. Compared with T6 state sheet, the strength is increased by more than 3.4%, and the elongation is increased by more than 7.7%. After treatment, the sheet is formed according to the incremental forming method selected in Examples 1-4.

[0081] S2: Configure the above-mentioned ultra-large thin-walled component forming device, and if necessary, further arrange an incremental forming machine tool and make the control unit 7 communicate with the incremental forming machine tool.

[0082] S3: Configure tool head 50 on auxiliary machine tools or incremental forming machine tools;

[0083] S4: Fix the sheet material to be processed onto the fixture 6;

[0084] S5: Control unit 7 inputs the set process parameters to the auxiliary machine tool, or the auxiliary machine tool and the incremental forming machine tool, and adjusts the position of the tool head 50;

[0085] S6: Start the auxiliary machine tool and incremental forming machine tool, and perform incremental forming processing according to the trajectory set by the control unit 7.

[0086] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A forming device for ultra-large thin-walled components, characterized in that, This includes auxiliary machine tools, which specifically include: The base (1) is fixed relative to the ground; The hydraulic lifting platform (2) is located at the end of the base (1) away from the ground, and the movable end of the hydraulic lifting platform (2) moves along the vertical direction. A rotating platform (3) is set at the movable end of the hydraulic lifting platform (2), and the movable end of the rotating platform (3) rotates relative to the vertical direction. The guide rail unit (4) is fixedly installed on the surface away from the ground at the movable end of the rotary table (3) and extends horizontally along the diameter direction of the movable end of the rotary table (3). Support unit (5) is embedded in guide rail unit (4); the support unit (5) moves linearly along the extension direction of guide rail unit (4); several support units (5) also rotate relative to the vertical direction; tool head (50) is provided at the end of several support units (5) away from guide rail unit (4) and the movable end of incremental forming machine tool, and the tool head (50) abuts against different positions on the surface of the sheet material to be processed; A clamp (6) is arranged around the hydraulic lifting platform (2). One end of the clamp (6) is fixedly connected to the base (1), and the other end of the clamp (6) extends vertically along the vertical direction and is fixedly connected to the plate to be processed, which is used to limit the position of the plate to be processed. The control unit (7) is used to generate the motion trajectory of the auxiliary machine tool, or the incremental forming machine tool and the auxiliary machine tool, and the tool head (50) performs auxiliary forming of the sheet material to be processed along the motion trajectory.

2. The apparatus according to claim 1, wherein The guide rail unit (4) includes a guide rail body and a first linear motion mechanism; one end of the guide rail body is fixedly connected to the movable end of the rotary table (3), and the other end of the guide rail body extends outward in a direction away from the rotary table (3). The guide rail body is hollow inside and communicates with the interior of the rotary table (3). The first linear motion mechanism is set inside the rotary table (3). The movable end of the first linear motion mechanism is embedded in the guide rail and slidably connected to the inner surface of the guide rail. The first linear motion mechanism drives its movable end to reciprocate along the horizontal extension direction of the guide rail. A support unit (5) is also fixedly set on the movable end of the first linear motion mechanism.

3. The apparatus according to claim 2, wherein The support unit (5) includes a base (51) and a first rotating mechanism (52); the base (51) is hollow inside, one end of the base (51) is fixedly set at the movable end of the first linear motion mechanism, and a through hole (100) is provided at the end of the base (51) away from the guide rail unit (4); the first rotating mechanism (52) is fixedly set inside the base (51), and the output shaft of the first rotating mechanism (52) is set inside the through hole (100); the output shaft of the first rotating mechanism (52) is also detachably connected to the tool head (50).

4. The apparatus according to claim 3, wherein The tool head (50) is a hemispherical tool head; the tool head (50) includes a rod (501) and a positioning flange (502), the positioning flange (502) is located at the non-end position of the rod (501); the rod (501) extends vertically along the axial direction of the hydraulic lifting platform (2), one end of the rod (501) extends into the through hole (100) and is fixedly connected to the output shaft of the first rotating mechanism (52), the positioning flange (502) abuts against the end face of the base (51), and the other end of the rod (501) is provided with a hemispherical working part, the hemispherical working part abuts against the surface of the plate to be processed.

5. The apparatus according to claim 3, wherein The tool head (50) is a lubrication tool head; the lubrication tool head includes a rod body (501), a positioning flange (502), a ball bearing (503), an oil seal (504), and a constant force spring (505). The positioning flange (502) is located at a non-end position of the rod body (501). The rod body (501) extends vertically along the axial direction of the hydraulic lifting platform (2). One end of the rod body (501) extends into the through hole (100) and is fixedly connected to the output shaft of the first rotating mechanism (52). The rod body (501) has a hollow first cavity (506) and a lubrication channel (507) inside. The other end of the rod body (501) is provided with a spherical limiting part (508). The lubrication channel (507) is respectively... It communicates with the spherical limiting part (508) and the first cavity (506); an oil seal (504) is provided in the first cavity (506), the oil seal (504) is slidably connected to the inner wall of the first cavity (506), a constant force spring (505) is provided on the side of the oil seal (504) away from the lubrication channel (507), the two ends of the constant force spring (505) are fixedly connected to the inner wall of the first cavity (506) and the oil seal (504) respectively, and the first cavity (506) on the other side of the oil seal (504) is filled with lubricating fluid; a ball (503) is embedded in the spherical limiting part (508), and part of the ball (503) passes through the spherical limiting part (508) and rolls with the surface of the sheet material to be processed.

6. An apparatus for forming a super-large thin-walled member according to claim 4 or 5, wherein The forming trajectory of the tool head (50) set on the support unit (5) envelops the forming trajectory of the incremental forming machine tool; the surface of the tool head (50) on the support unit (5) or the tool head (50) of the incremental forming machine tool is tangent to the surface of the sheet material to be processed.

7. The apparatus according to claim 1, wherein The fixture (6) includes a columnar body (61) and a pressure plate (62); one end of the columnar body (61) is detachably connected to the base (1), and the columnar body (61) extends outward along the central axis of the hydraulic lifting platform (2), and the columnar body (61) is arranged around the rotating platform (3); the other end of the columnar body (61) is provided with a detachable pressure plate (62), the pressure plate (62) is annular and matches the end face contour of the columnar body (61); the end faces of the pressure plate (62) and the columnar body (61) together abut and limit the position of the sheet material to be processed.

8. The apparatus according to claim 6, wherein The columnar body (61) forms a second cavity (200) inside; the side surface of the columnar body (61) is provided with several through windows (300), and the windows (300) are interconnected with the second cavity (200).

9. The apparatus according to claim 1, wherein It also includes a position sensor, which acquires the real-time position of the tool head (50) on the motion trajectory of the incremental forming machine tool or the auxiliary machine tool and feeds it back to the control unit (7); when the incremental forming machine tool and the auxiliary machine tool are used to form the sheet material to be processed at the same time, the springback compensation of the tool head (50) on the auxiliary machine tool is later than the action time of the tool head (50) on the incremental forming machine tool.

10. A method of heat treatment hybrid manufacturing of an ultra-large thin-walled component, characterized in that, Includes the following steps: S1: Solution treatment, water quenching, and pre-aging strengthening treatment are performed on the sheet material to be processed; S2: Configure the ultra-large thin-walled component forming device as described in any one of claims 1-9, arrange the incremental forming machine tool, and make the control unit (7) communicate with the incremental forming machine tool; S3: Configure a tool head (50) on an auxiliary machine tool or an incremental forming machine tool; S4: Fix the sheet material to be processed onto the fixture (6); S5: The control unit (7) inputs the set process parameters to the auxiliary machine tool, or the auxiliary machine tool and the incremental forming machine tool, and adjusts the position of the tool head (50); S6: Start the auxiliary machine tool and the incremental forming machine tool, and perform incremental forming processing according to the trajectory set by the control unit (7).

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