Plate flanging forming method with constant flanging transition radius

Abstract

A plate flanging forming method with a constant flanging transition radius is disclosed. The method defines the initial position of the flanging forming roller by setting a horizontal spacing between the left end of the flanging forming roller and the transition radius of the pressing die. A local rectangular coordinate system is established with the end of the flanging forming roller's busbar as the flanging reference point. The method quickly determines the real-time position and working condition of the flanging forming roller during the plate flanging forming process based on the flanging angle and translation speed. The method allows the forming roller to rotate along the flanging reference point while moving longitudinally to ensure that the flanging reference point is always in contact with the plate, thereby controlling the transition radius to be constant. The method can quickly determine the real-time position of the flanging forming roller during the plate flanging forming process. The method allows the forming roller to rotate along the flanging reference point while moving longitudinally to ensure that the flanging reference point is always in contact with the plate, thereby ensuring that the transition radius of the part remains unchanged during the flanging forming process, significantly improving the flanging forming quality.

Description

Technical Field

[0001] The present invention relates to a technology in the field of flanging forming, in particular to a plate flanging forming method with a constant flanging transition radius. Background Art

[0002] Sheet metal flanging components are widely used in aerospace, automotive, and other manufacturing applications. However, manual hammering is noisy and inefficient. Furthermore, robotically guided rollers rotate within their initial plane to form the flanging. This results in inconsistent flanging forces applied by the rollers, increasing the radius of the flanging transition and making it difficult to ensure quality and consistency. Therefore, new sheet metal flanging methods are urgently needed to address the current challenges in manufacturing sheet metal flanging components. Summary of the Invention

[0003] The present invention aims to address the problem that the forming force applied by the forming roller during the forming process of the existing plate flanging forming technology is uneven, so that the flanging transition radius gradually increases as the flanging proceeds, and the flanging forming force gradually decreases, resulting in a larger transition fillet radius and springback of the final part. The present invention proposes a plate flanging forming method with a constant flanging transition radius, which can quickly determine the real-time position of the flanging forming roller during the plate flanging forming process, so that the forming roller rotates along the flanging reference point and moves longitudinally to ensure that the flanging reference point is always in contact with the plate, thereby ensuring that the transition fillet radius of the part remains unchanged during the flanging forming process, significantly improving the flanging forming quality, and having important engineering application value and obvious economic benefits in engineering fields such as aviation, aerospace, and automobile manufacturing.

[0004] The present invention is achieved through the following technical solutions:

[0005] The present invention relates to a plate flanging forming method with a constant flanging transition radius. After the initial position of the flanging forming roller is limited by setting the horizontal spacing between the left end of the flanging forming roller and the transition radius of the pressing die, a local rectangular coordinate system is established with the end of the flanging forming roller busbar as the flanging reference point. The real-time position and working condition of the flanging forming roller during the plate flanging forming process are quickly determined according to the flanging angle and the rotation speed, so that the forming roller rotates along the flanging reference point and moves longitudinally at the same time to ensure that the flanging reference point is always in contact with the plate, thereby controlling the transition radius to be constant.

[0006] The initial position means that the generatrix of the horizontally placed flanging forming roller is located on the lower plane of the plate on the flanging workbench, and the left end of the flanging forming roller and the transition radius of the pressing mold meet the preset horizontal spacing.

[0007] The rapid determination means: the height of the flanging forming roller is calculated according to the flanging angle at any time, and the translation speed of the flanging forming roller is calculated according to the rotation speed of the flanging forming roller. Specifically, the horizontal distance from the intersection of the extension line to the transition fillet of the pressing die is: , horizontal distance from the intersection of the extension lines to the flanging reference point , the height of the flanging roller at any moment i ; The longitudinal translation speed of the flanging forming roller , where: t is the target flanging thickness, r is the inner radius of the flanging transition zone, L is the horizontal distance between the left end of the flanging forming roller generatrix and the transition fillet of the pressing die, ,φ i is the flanging angle, , is the rotation speed of the forming roller.

[0008] The translation speed v along the Y axis at any time i t It is based on the movement height h of the flanging forming roller i and the rotation speed v of the flanging forming roller r Calculated.

[0009] The control of the transition fillet radius to be constant means: when the flanging forming roller is at a speed v r When the self-rotation gradually forms the flange angle, the longitudinal translation speed v is calculated according to the flange angle and the longitudinal movement height of the forming roller. t , the forming roller continuously moves in the longitudinal direction, so that the flanging reference point is always in contact with the sheet during the entire forming process, thereby controlling the transition fillet radius to be constant.

[0010] Technical Effects

[0011] The present invention optimizes the motion trajectory of the forming roller during the flanging process by adding calculations to the longitudinal translation of the forming roller as it rotates to form the flanging angle. Compared to existing technologies, the present invention can quickly determine the real-time position of the flanging roller during sheet flanging. This allows the forming roller to simultaneously rotate along the flanging reference point and move longitudinally to ensure that the flanging reference point remains in contact with the sheet. This ensures that the transition radius of the part remains constant during the flanging process, significantly improving the quality of the flanging. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 Flowchart of the present invention;

[0013] Figure 2 Schematic diagram of the embodiment position;

[0014] Figure 3 This is a diagram showing the height variation of the flanging forming roller during the forming process of the embodiment;

[0015] Figure 4 This is a graph showing the change in longitudinal translation speed during the forming process of the embodiment;

[0016] Figure 5 This is a comparison diagram of the transition fillet radius of the embodiment;

[0017] Figure 6 This is a comparison chart of the rebound angles of the embodiments.

[0018] In the figure: 1-1 the pressing part of the pressing die, 1-2 the transition radius part of the pressing die, 2 the flanging workbench, 3 the plate, 4-1 the flanging forming roller at the initial position, 4-i the flanging forming roller at any time i. DETAILED DESCRIPTION

[0019] like Figure 2 As shown in FIG, the target flanged part of this embodiment is made of 5A06 aluminum alloy, with a thickness t of 2 mm, an inner radius r of the transition zone of the flanged part of 6 mm, and a flange opening angle φ of 60°. Figure 2 As shown, the rightmost end of the transition radius part 1-2 of the pressing die is aligned with the flanging workbench 2, the flanging forming roller 4 is placed horizontally, its busbar is located on the lower plane of the plate 3 placed on the flanging workbench 2, and the horizontal distance L between its left end and the transition radius of the pressing die 1 is 7 mm.

[0020] like Figure 1 As shown, this embodiment relates to a plate flanging forming method with a constant flanging transition radius, comprising:

[0021] 1) The left endpoint of the generatrix where the flange forming roller 4 contacts the sheet 3 is used as the flange reference point. A Cartesian coordinate system is established at this point, with the X-axis oriented along the generatrix of the flange forming roller 4 and the Y-axis oriented radially along the left end of the flange forming roller. During the subsequent flange forming process, the flange forming roller 4 rotates around the flange reference point to form the flange angle.

[0022] 2) Determine the horizontal distance from the intersection of the extension lines at any time i to the transition fillet of the pressing die 1 ; Determine the horizontal distance from the intersection of the extension lines to the flange reference point at any time i ; The height of the flanging roller at any moment i is .

[0023] 3) Set the rotation speed v of the flanging forming roller 4 r If it is 1° / s, the longitudinal translation speed of the flanging forming roller is , the height change of the forming roller along the longitudinal translation motion during the flanging forming process is calculated as follows Figure 3 shown.

[0024] 4) When the flanging forming roller rotation speed v r When set to 1° / s, the longitudinal translation speed v of the forming roller during the flanging forming process is obtained. t ,like Figure 4 As shown; according to v r and v t , the motion trajectory of the target flanging part with a flanging angle of 60° can be generated, the process parameters at this time can be saved, and the actual flexible flanging forming can be performed.

[0025] like Figure 5 and Figure 6 The figure shows the comparison between the transition fillet radius and springback angle obtained using this method and the springback angle of the prior art. The maximum error in the transition fillet radius of the flanging obtained using this method is 1 mm, and the maximum springback angle is 0.4°. Compared with the maximum error in the transition fillet radius of 4.5 mm and the maximum springback angle of 2.4° obtained with the prior art, the present invention significantly improves the forming quality of the flanging.

[0026] Compared with the prior art, this method adds the longitudinal translation movement of the forming roller during the process of the forming roller rotating to form the flanging angle, thereby optimizing the movement trajectory of the forming roller during the flanging forming process; and the present invention is simple and feasible, and can quickly determine the real-time position of the flanging forming roller during the flanging forming process of the plate, so that the forming roller rotates along the flanging reference point and moves longitudinally at the same time to ensure that the flanging reference point is always in contact with the plate, and ensure that the area where the flanging forming roller applies the forming force remains consistent, thereby forming a flanging part with a constant transition fillet radius, significantly improving the flanging forming quality.

[0027] The above-mentioned specific implementation can be partially adjusted in different ways by those skilled in the art without departing from the principles and purpose of the present invention. The scope of protection of the present invention shall be based on the claims and shall not be limited by the above-mentioned specific implementation. All implementation schemes within its scope shall be subject to the constraints of the present invention.

Claims

1. A method for forming a plate flange with a constant flange transition radius, characterized in that: By setting the horizontal distance between the left end of the flanging forming roller and the transition fillet of the pressing die, the initial position of the flanging forming roller is defined. Then, a local rectangular coordinate system is established with the end of the flanging forming roller generatrix as the flanging reference point. The real-time position and working condition of the flanging forming roller during the sheet flanging forming process are quickly determined according to the flanging angle and translation speed. The forming roller rotates along the flanging reference point and moves longitudinally to ensure that the flanging reference point is always in contact with the sheet, thereby controlling the transition fillet radius to be constant. The rapid determination means: calculating the movement height of the flanging forming roller according to the flanging angle at any moment and calculating the translation speed of the flanging forming roller according to the rotation speed of the flanging forming roller; The quick determination is specifically: the horizontal distance from the intersection of the extension line to the transition fillet of the pressing die , horizontal distance from the intersection of the extension lines to the flanging reference point , the height of the flanging roller at any moment i ; The longitudinal translation speed of the flanging forming roller , where: t is the target flanging thickness, r is the inner radius of the flanging transition zone, L is the horizontal distance between the left end of the flanging forming roller generatrix and the transition fillet of the pressing die, ,φ i is the flanging angle, , is the rotation speed of the forming roller.

2. The plate flanging forming method with a constant flanging transition radius according to claim 1, characterized in that: The initial position means that the generatrix of the horizontally placed flanging forming roller is located on the lower plane of the plate on the flanging workbench, and the left end of the flanging forming roller and the transition radius of the pressing mold meet the preset horizontal spacing.

3. The plate flanging forming method with a constant flanging transition radius according to claim 1, characterized in that: The control of the transition fillet radius to be constant means that: when the flanging forming roller is at a speed v r When the self-rotation gradually forms the flange angle, the longitudinal translation speed v is calculated according to the flange angle and the longitudinal movement height of the forming roller. t , the forming roller continuously moves in the longitudinal direction, so that the flanging reference point is always in contact with the sheet during the entire forming process, thereby controlling the transition fillet radius to be constant.

4. The plate flanging forming method with a constant flanging transition radius according to any one of claims 1 to 3, wherein include: 1) The left end point of the generatrix where the flanging forming roller contacts the sheet is used as the flanging reference point. A Cartesian coordinate system is established at this point, with the X-axis direction being the generatrix direction of the flanging forming roller and the Y-axis direction being the radial direction of the left end of the flanging forming roller. In the subsequent flanging forming process, the flanging forming roller rotates around the flanging reference point to form the flanging angle. 2) When r is 6 mm and t is 2 mm, determine the horizontal distance from the intersection of the extension lines to the transition radius of the pressing die at any time i. ; When L is 7mm, determine the horizontal distance from the intersection of the extension lines to the flange reference point at any time i ; The height of the flanging roller at any moment i is ; 3) Set the flanging roller rotation speed v r If it is 1° / s, the longitudinal translation speed of the flanging forming roller is , calculate the longitudinal translation height of the forming roller during the flanging forming process; 4) When the flanging forming roller rotation speed v r When set to 1° / s, the longitudinal translation speed v of the forming roller during the flanging forming process is obtained. t , according to v r and v t , the motion trajectory of the target flanging part with a flanging angle of 60° can be generated, the process parameters at this time can be saved, and the actual flexible flanging forming can be performed.

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