Electromagnetic back pressure coupled ultrasonic assisted forming method and mold for new energy vehicle scroll disk
By adopting electromagnetic backpressure coupled ultrasonic assisted forming method in the manufacturing of vortex discs of new energy vehicles, combined with ultrasonic vibration and magnetic levitation technology, the problems of difficult forming, poor mechanical performance and high energy consumption are solved, and a high efficiency and low energy consumption are achieved. Rotary molding and mold life are extended.
Patent Information
- Application Number
- CN202411365939.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-29
- Publication Date
- 2024-12-31
- Estimated Expiration
- 2044-09-29
AI Technical Summary
The existing scroll forming methods have problems such as difficult forming, poor mechanical properties, high energy consumption, low mold life and unstable backpressure systems, especially in the manufacturing of scrolls of new energy vehicles with complex shapes and high requirements.
Electromagnetic backpressure coupled ultrasonic assisted forming methods and molds, including ultrasonic assisted systems and magnetic levitation backpressure systems, material forming is realized through ultrasonic vibration and magnetic levitation technology, reducing heating temperature and energy consumption, and improving molding accuracy and mold life.
It realizes high-efficiency and low-energy consumption scroll forming, improves molding quality and mold service life, simplifies the backpressure system structure, and is suitable for the production needs of complex shapes.
Smart Images
Figure CN118875119B_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of manufacturing aluminum alloy scroll disks for compressors of new energy vehicles, and in particular discloses an electromagnetic back pressure coupled ultrasonic assisted forming method and a mold for scroll disks of new energy vehicles. Background Art
[0002] The scroll disk is the core component of the scroll refrigeration compressor of new energy vehicles. Its performance is directly related to whether the compressor can operate smoothly, and its shape and structure are complex and difficult to form. At present, the manufacture of scroll disks generally adopts metal mold casting, low-pressure casting or forging and other process methods. If it is prepared by metal mold casting or low-pressure casting process, the casting is difficult to form, resulting in a fuzzy involute profile and poor mechanical properties. The tensile strength is only about 220MPa, which usually cannot meet the needs of harsh working environments. Therefore, this type of product is more used in the spare parts market. On the other hand, although traditional hot die forging technology can ensure excellent mechanical properties, it is powerless in the face of complex-shaped holes and protrusions. The forming requires additional processing steps. In addition, the hot die forging process has high energy consumption and strict requirements on the mold material. In short, the above methods cannot change the fluidity of the blank, resulting in defects such as excessively high die forging temperature, low die life, high energy consumption, and poor mechanical properties.
[0003] In addition, the existing back pressure forming molds on the market have many shortcomings. For example, when using hydraulic back pressure (ZL201120265635.6), since the liquid directly acts on the workpiece, sealing is difficult, and there are problems such as unstable hydraulic system and easy oil leakage. The operation process is much more complicated than general molds; when using springs to provide back pressure (ZL200320100429.5), the back pressure is difficult to adjust and is not suitable for multi-variety production; when using nitrogen cylinders, the life of the sealing ring is low in a hot forming environment.
[0004] Therefore, the above-mentioned deficiencies existing in the existing scroll disk forming method are technical problems that need to be solved urgently. Summary of the invention
[0005] The present invention provides an electromagnetic back pressure coupled ultrasound assisted forming method and a mold for a vortex disk of a new energy vehicle, aiming to solve the above-mentioned deficiencies existing in the existing vortex disk forming method.
[0006] One aspect of the present invention relates to an electromagnetic back pressure coupled ultrasonic assisted forming die for a scroll disk of a new energy vehicle, comprising an ultrasonic assisted system, a forming die system and a magnetic levitation back pressure system, wherein:
[0007] The forming die system comprises a blank, an upper forming die and a lower forming die, wherein the blank is arranged between the upper forming die and the lower forming die;
[0008] The ultrasonic auxiliary system includes an ultrasonic vibration mechanism connected to the blank and used to transmit ultrasonic vibration to the blank;
[0009] The magnetic levitation back pressure system includes a push-down magnetic levitation back pressure device, which is arranged under the blank and is used to rise and suspend at a set speed to achieve back pressure and complete product forming.
[0010] Furthermore, the ultrasonic vibration mechanism includes an ultrasonic generator, an ultrasonic transducer, an ultrasonic horn and an ultrasonic tool punch. The ultrasonic horn is arranged between the ultrasonic transducer and the ultrasonic tool punch. The ultrasonic generator is electrically connected to the ultrasonic transducer. The ultrasonic generator drives the ultrasonic transducer to operate. The ultrasonic transducer converts the electrical signal into mechanical vibration and then transmits the vibration to the ultrasonic horn. The ultrasonic horn transmits the amplified ultrasonic vibration to the ultrasonic tool punch, and the ultrasonic tool punch then transmits the ultrasonic vibration to the blank.
[0011] Furthermore, the ultrasonic horn is formed by combining a cylindrical horn and a sinusoidal horn.
[0012] Furthermore, the magnetic levitation back pressure system also includes a back pressure plate, a controller and a driver. The back pressure plate is arranged above the push-down magnetic levitation back pressure device, and the driver is arranged below the push-down magnetic levitation back pressure device. The controller is respectively connected to the driver and the push-down magnetic levitation back pressure device.
[0013] Furthermore, the push-down magnetic levitation back pressure device includes a strong magnet, an electromagnetic coil, a float magnet and a Hall element. The float magnet is arranged below the back pressure plate, the float magnet is arranged directly above the Hall element, and the two electromagnetic coils are respectively arranged on both sides of the Hall element; the two strong magnets are respectively located on both sides of the electromagnetic coil.
[0014] Further, the float magnet is installed and embedded in the bottom of the back pressure plate.
[0015] Furthermore, the number of the Hall elements is three, and the three Hall elements are all located below the float magnet.
[0016] Another aspect of the present invention relates to a method for electromagnetic back pressure coupling and ultrasonic assisted forming of a scroll disk for a new energy vehicle, which is applied to the electromagnetic back pressure coupling and ultrasonic assisted forming mold for the scroll disk for a new energy vehicle as described above. The method for electromagnetic back pressure coupling and ultrasonic assisted forming of a scroll disk for a new energy vehicle comprises the following steps:
[0017] Setting parameters: According to the material, geometric complexity, size and temperature parameters required for forming of the workpiece, determine the appropriate ultrasonic vibration frequency to adjust the amplitude of the ultrasonic wave, and obtain the required ultrasonic vibration mode by replacing the gear shifter or adjusting the ultrasonic horn;
[0018] Process preparation, pre-forging and die closing: prepare the blank according to the design requirements, then put the blank into the forming lower die, then the forming upper die extrude the blank into the forming lower die at a preset speed, and start die closing;
[0019] Vibration pressing: After the upper and lower molds are closed, they are locked, and the ultrasonic vibration mechanism performs the action at the same time. The ultrasonic transducer converts the electrical signal into mechanical vibration, and then transmits the vibration to the ultrasonic horn. The ultrasonic horn transmits the amplified ultrasonic vibration to the ultrasonic tool punch, and the ultrasonic tool punch transmits the ultrasonic vibration to the blank;
[0020] Final forging and back pressure forming: The ultrasonic vibration mechanism continues to work, and the upper forming die moves upward and further vibrates and presses downward with the ultrasonic tool punch. The push-down magnetic suspension back pressure device is started, and the back pressure plate is controlled to rise and suspend at a set speed to achieve back pressure, and paired products are formed;
[0021] Mold separation: The ultrasonic vibration mechanism is closed, and the upper mold moves upward to separate the upper mold from the lower mold, and the back pressure plate is controlled to float upward to eject the finished product.
[0022] Furthermore, in the step of vibrating and pressing, the length of the ultrasonic tool punch is:
[0023] in, is the length of the ultrasonic tool punch, is the propagation wavelength of ultrasonic wave in the punch material, is the propagation speed of ultrasonic wave in the punch material, is the ultrasonic frequency.
[0024] Furthermore, in the step of vibrating and pressing down, the acoustic vibration frequency of the ultrasonic vibration mechanism is 15-80 kHz, and the amplitude range is 5-80 μm.
[0025] The beneficial effects achieved by the present invention are:
[0026] The present invention provides an electromagnetic back-pressure-coupled ultrasonic-assisted forming method and mold for a vortex disk of a new energy vehicle. The mold adopts an ultrasonic-assisted system, a molding mold system and a magnetic suspension back-pressure system. The molding mold system includes a blank, a molding upper mold and a molding lower mold. The blank is arranged between the molding upper mold and the molding lower mold; the ultrasonic-assisted system includes an ultrasonic vibration mechanism, which is connected to the blank and is used to transmit ultrasonic vibration to the blank; the magnetic suspension back-pressure system includes a push-down magnetic suspension back-pressure device, which rises and suspends at a set speed to achieve back pressure and complete the molding of the product. The electromagnetic back-pressure-coupled ultrasonic-assisted forming method and mold for a vortex disk of a new energy vehicle provided by the present invention have beneficial effects as follows:
[0027] 1. Use a push-down magnetic levitation device to provide back thrust. Magnetic levitation uses the principle of like-pole repulsion and opposite-pole attraction between magnetic fields to give objects an upward force, so that the object can overcome gravity and stably suspend in a certain position without contact, friction or resistance. Compared with the existing back-pressure forming molds that use clamping cylinders to provide back thrust, the back-pressure forming molds that use a push-down magnetic levitation device to provide back thrust have a simple structure, are easy to replace and have a longer service life.
[0028] 2. Use ultrasonic vibration to assist blank forming. Ultrasonic vibration assisted plastic forming is a typical energy field assisted plastic forming process. Compared with traditional plastic forming, it has the advantages of small flow stress, high material forming ability, small interface friction, and good forming quality. The use of ultrasonic vibration auxiliary system can reduce the blank heating temperature, save energy, and is more economical and environmentally friendly.
[0029] 3. The ultrasonic horn adopts a sinusoidal cylindrical composite horn, which has a simple structure, is easy to process, easy to excite, has high power and is easy to form. Its amplification factor and load capacity are also significantly improved. Under the selected horn area coefficient, the appropriate sinusoidal segment busbar initial phase and length can obtain amplification speed and shape factor that are better than the traditional stepped horn. BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Figure 1 It is a structural schematic diagram of an embodiment of an electromagnetic back pressure coupled ultrasonic assisted forming die for a scroll disk of a new energy vehicle according to the present invention;
[0031] Figure 2 for Figure 1 An enlarged cross-sectional structural schematic diagram of a push-down magnetic levitation device shown in ;
[0032] Figure 3 for Figure 1 Conceptual diagram of the push-down magnetic levitation device shown in;
[0033] Figure 4 for Figure 1 The push-down magnetic levitation stabilization field working principle diagram of the push-down magnetic levitation device shown in FIG.
[0034] Description of Figure Numbers:
[0035] 10. Ultrasonic auxiliary system; 20. Forming die system; 30. Magnetic levitation back pressure system; 21. Blank; 22. Forming upper die; 23. Forming lower die; 11. Ultrasonic transducer; 12. Ultrasonic amplitude transformer; 13. Ultrasonic tool punch; 31. Back pressure plate; 32. Driver; 33. Push-down magnetic levitation back pressure device; 331. Strong magnet; 332. Electromagnetic coil; 333. Float magnet; 334. Hall element. DETAILED DESCRIPTION
[0036] In order to better understand the above technical solution, the above technical solution will be described in detail below in conjunction with the accompanying drawings and specific implementation methods.
[0037] like Figure 1 and Figure 2 As shown, the first embodiment of the present invention proposes an electromagnetic back pressure coupled ultrasonic assisted forming mold for a vortex disk of a new energy vehicle, including an ultrasonic assisted system 10, a forming mold system 20 and a magnetic suspension back pressure system 30, wherein the forming mold system 20 includes a blank 21, a forming upper mold 22 and a forming lower mold 23, and the blank 21 is arranged between the forming upper mold 22 and the forming lower mold 23; the ultrasonic assisted system 10 includes an ultrasonic vibration mechanism, which is connected to the blank 21 and is used to transmit ultrasonic vibration to the blank 21; the magnetic suspension back pressure system 30 includes a push-down magnetic suspension back pressure device 33, which rises and suspends at a set speed to realize back pressure and complete the forming of the product. In this embodiment, the ultrasonic vibration mechanism and the push-down magnetic suspension back pressure device 33 can use existing equipment.
[0038] Further, see Figures 1 to 4 The electromagnetic back pressure coupled ultrasonic assisted forming die for the vortex disk of new energy vehicles provided in this embodiment, the ultrasonic vibration mechanism includes an ultrasonic generator, an ultrasonic transducer 11, an ultrasonic horn 12 and an ultrasonic tool punch 13, the ultrasonic horn 12 is arranged between the ultrasonic transducer 11 and the ultrasonic tool punch 13, the ultrasonic generator is electrically connected to the ultrasonic transducer 11, the ultrasonic generator drives the ultrasonic transducer 11 to move, the ultrasonic transducer 11 converts the electrical signal into mechanical vibration, and then transmits the vibration to the ultrasonic horn 12, the ultrasonic horn 12 transmits the amplified ultrasonic vibration to the ultrasonic tool punch 13, and the ultrasonic tool punch 13 transmits the ultrasonic vibration to the blank 21. Preferably, the ultrasonic horn 12 is composed of a cylindrical horn and a sine function horn. The electromagnetic back pressure coupled ultrasonic assisted forming mold for the vortex disk of new energy vehicles provided in this embodiment adopts acoustic assisted forming technology. Due to the mechanical and thermal effects generated by ultrasonic vibration, the dynamic deformation resistance of the material is reduced, so that the molding can be carried out at a lower temperature, and the heating temperature can be reduced by 50°C to 100°C, which helps to reduce energy consumption and improve production efficiency. Secondly, ultrasonic vibration can promote more uniform flow of materials, reduce stress concentration, and thus reduce the incidence of defects and other advantages.
[0039] Specifically, see Figures 1 to 4The electromagnetic back pressure coupled ultrasonic assisted forming mold for the vortex disk of new energy vehicles provided in this embodiment, the magnetic suspension back pressure system 30 also includes a back pressure plate 31, a controller and a driver 32, the back pressure plate 31 is arranged above the push-down magnetic suspension back pressure device 33, the driver 32 is arranged below the push-down magnetic suspension back pressure device 33, and the controller is connected to the driver 32 and the push-down magnetic suspension back pressure device 33 respectively. The push-down magnetic suspension back pressure device 33 includes a strong magnet 331, an electromagnetic coil 332, a float magnet 333 and a Hall element 334, the float magnet 333 is arranged below the back pressure plate 31, the float magnet 333 is arranged directly above the Hall element 334, and the two electromagnetic coils 332 are respectively arranged on both sides of the Hall element 334; the two strong magnets 331 are respectively located on both sides of the electromagnetic coil 332. The float magnet 333 is installed and embedded in the bottom of the back pressure plate 31. The number of Hall elements 334 is three, and the three Hall elements 334 are all located below the float magnet 333. The electromagnetic back pressure coupled ultrasonic assisted forming mold for the vortex disk of new energy vehicles provided in this embodiment adopts the push-down electromagnetic suspension back pressure technology, which can control the application of back pressure through the electromagnetic field, and can accurately adjust the size and distribution of back pressure, thereby achieving fine control of the material deformation process and improving the forming accuracy; adopting the non-contact method, significantly reducing the friction and wear between the mold and the material, and extending the service life of the mold; being able to control the internal flow of the material more evenly; compared with the traditional mechanical back pressure device, the electromagnetic suspension back pressure is more efficient in energy conversion and control, so the overall energy consumption is lower.
[0040] Another aspect of the present invention relates to a method for electromagnetic back pressure coupling and ultrasonic assisted forming of a scroll disk for a new energy vehicle, which is applied to the electromagnetic back pressure coupling and ultrasonic assisted forming mold for the scroll disk for a new energy vehicle as described above. The method for electromagnetic back pressure coupling and ultrasonic assisted forming of a scroll disk for a new energy vehicle comprises the following steps:
[0041] Step S100, setting parameters: according to the material, geometric structure complexity, size and temperature parameters required for forming of the workpiece, determine the appropriate ultrasonic vibration frequency to adjust the amplitude of the ultrasonic wave, and obtain the required ultrasonic vibration mode by replacing the gear shifter or adjusting the ultrasonic amplitude rod.
[0042] First, according to the material, geometric complexity, size and temperature of the workpiece, the appropriate ultrasonic vibration frequency is selected and the amplitude of the ultrasonic wave is adjusted. The desired ultrasonic vibration mode can be obtained by replacing the gear shifter or adjusting the ultrasonic horn 12. Further, through simulation calculation, the ultrasonic tool punch 13 is designed so that its length L is equal to the wavelength of the ultrasonic wave, and at the same time, the natural frequency of the ultrasonic tool punch 13 is synchronized with the ultrasonic vibration frequency.
[0043] Step S200, process preparation, pre-forging and die closing: prepare the blank according to the design requirements, then put the blank into the forming lower die, then the forming upper die extrude the blank into the forming lower die at a preset speed, and start die closing.
[0044] According to the processing drawing requirements, a round cake-shaped blank is prepared, cleaned, machined, and preheated, and then placed on the molding lower mold 23. Then, the molding upper mold 22 extrude the blank 21 into the molding lower mold 23 at a preset speed, and the mold is closed.
[0045] Step S300, vibration pressing: after the upper forming mold and the lower forming mold are closed, the upper forming mold and the lower forming mold are locked, and the ultrasonic vibration mechanism performs the action at the same time. The ultrasonic transducer converts the electrical signal into mechanical vibration, and then transmits the vibration to the ultrasonic amplitude transformer. The ultrasonic amplitude transformer transmits the amplified ultrasonic vibration to the ultrasonic tool punch, and the ultrasonic tool punch then transmits the ultrasonic vibration to the blank.
[0046] After the upper forming mold 22 and the lower forming mold 23 are closed and locked, the ultrasonic vibration mechanism simultaneously executes the program (the ultrasonic vibration frequency and amplitude range are 15KHz-80KHz, 5μm-80μm respectively): the ultrasonic transducer 11 converts the electrical signal into mechanical vibration, and then transmits the vibration to the ultrasonic horn 12, the ultrasonic horn 12 transmits the amplified ultrasonic vibration to the ultrasonic tool punch 13, and the ultrasonic tool punch 13 then transmits the ultrasonic vibration to the blank 21.
[0047] Step S400, final forging and back pressure forming: the ultrasonic vibration mechanism continues to work, and the upper forming die moves upward and further vibrates downward with the ultrasonic tool punch, and the push-down magnetic suspension back pressure device is started, and the back pressure plate is controlled to rise and suspend at a set speed to achieve back pressure, and paired products are formed.
[0048] The ultrasonic vibration mechanism continues to work, and the upper forming die 22 moves upward and further vibrates downward with the ultrasonic tool punch 13, and the push-down magnetic suspension back pressure device 33 is started: according to the preset program, the back pressure plate 31 rises and suspends at a speed to achieve back pressure, and the product is formed.
[0049] Step S500, mold separation: the ultrasonic vibration mechanism is closed, the upper molding die moves upward, the upper molding die and the lower molding die are separated, and the back pressure plate is controlled to float upward to eject the finished product.
[0050] The ultrasonic vibration mechanism is closed, the upper molding die 22 moves upward, the die is separated, and the back pressure plate 31 is suspended upward to eject the finished product.
[0051] like Figures 1 to 4 As shown, the electromagnetic back pressure coupled ultrasonic assisted forming method and mold for the new energy vehicle scroll disk provided in this embodiment have the following working principles:
[0052] 1. Component composition and working principle
[0053] An ultrasonic vibration mechanism is arranged on the forming die, and the ultrasonic vibration mechanism is connected to the ultrasonic tool punch 13 through the through slot in the middle of the forming upper die 22. The ultrasonic transducer 1 converts the electrical signal into mechanical vibration, and then transmits the vibration to the ultrasonic horn 12. The ultrasonic horn 12 transmits the amplified ultrasonic vibration to the ultrasonic tool punch 13, and the ultrasonic tool punch 13 transmits the ultrasonic vibration to the blank 21, so that the resonant ultrasonic tool punch 13 transmits the ultrasonic vibration to the blank 21. The ultrasonic vibration frequency, amplitude, vibration mode and the shape and size of the punch are changed to be suitable for different products.
[0054] The electromagnetic back pressure final forging method mainly includes a controller and a driver 32, a strong magnet 331, an electromagnetic coil 332, a float magnet 333, a Hall element 334, a back pressure plate 31, etc. In addition, the float magnet is installed and embedded at the bottom of the back pressure plate 31, and the up and down movement of the back pressure plate 31 is indirectly controlled by controlling the suspension of the float magnet 333.
[0055] The final forging adopts push-down magnetic suspension to realize back pressure forming. The concept of push-down magnetic suspension magnetic source is as follows Figure 4 As shown. Since the strong magnet 331 can generate a specific valley-shaped magnetic field, this causes the float magnet 6 to be subjected to a repulsive force in the vertical direction opposite to the direction of gravity. Therefore, the suspension height of the back pressure plate 31 is mainly controlled by the magnetic force of the strong magnet 331 and the mass of the float magnet 333.
[0056] In the horizontal plane, the float magnet 333 will be affected by the random disturbances in the magnetic field, which causes the repulsive force generated by the magnetic field to show an asymmetric trend. Specifically, the side with stronger attraction will continue to increase, while the side with weaker attraction will gradually decrease. This imbalance will cause the float magnet 333 to tend to deviate from its center position. In addition, the float magnet 333 will also be subjected to the rotational torque in the magnetic field, causing it to produce rotational motion. In order to ensure that the float magnet 333 can maintain horizontal stability in the magnetic field, the system must introduce additional magnetic fields for adjustment, such as Figure 4 As shown, an electromagnetic coil is used to fine-tune the position of the float magnet at high frequency, and the three Hall elements 334 generate voltage when the magnetic lines of force pass through them, and the ratio is positively correlated. Specifically, the stronger the magnetic induction passing through the plane of the Hall element 334, the higher the Hall output voltage. When the float magnet 333 tends to move, the magnetic lines of force passing through the corresponding plane of the Hall element 334 will be enhanced, and its output voltage will also be enhanced. After the output voltage is detected by the controller, it will control the corresponding electromagnetic coil 332 to perform repulsive force and attractive force on the opposite side, so as to overcome its original movement trend, and then achieve the purpose of stable control of the float magnet 333.
[0057] 2. Ultrasonic vibration frequency and amplitude
[0058] The ultrasonic generator used in the present invention has a wide frequency adjustment capability, between 15KHz-80KHz. The amplitude adjustment range is also quite wide, 5μm-80μm. During the forging process, the ultrasonic vibration modes are diverse, including but not limited to radial vibration, axial vibration, bending vibration, composite longitudinal and torsional vibration, longitudinal and bending vibration, and composite vibration of bending and torsional vibration. In this way, it can adapt to products of different shapes and sizes.
[0059] The softening effect of ultrasonic vibration is divided into two parts: stress superposition and acoustic softening. The stress drop caused by the stress superposition part increases linearly with the increase of amplitude, and the frequency has little effect on it. At the same time, ultrasonic vibration also produces acoustic softening, which greatly reduces the forming force of the material. When the frequency is between 15 and 28 kHz and the amplitude is between 3.34 and 4.81 μm, the total stress drop of aluminum alloy is between 23.5 and 47.5 MPa, the stress superposition part is between 3.22 and 4.73 MPa, and the acoustic softening part is between 20.3 and 42.8 MPa. Especially when the frequency is 28 kHz and the amplitude is 4.81 μm, the stress drop caused by acoustic softening is 61.74% compared with the yield strength of aluminum alloy material under non-vibration conditions.
[0060] 3. Ultrasonic tool punch length
[0061] (1)
[0062] In formula (1), is the length of the ultrasonic tool punch, is the propagation wavelength of ultrasonic wave in the punch material, is the propagation speed of ultrasonic wave in the punch material, is the ultrasonic frequency.
[0063] The electromagnetic back-pressure coupled ultrasonic assisted forming method and mold for the vortex disk of new energy vehicles provided in this embodiment, compared with the prior art, the mold adopts an ultrasonic assisted system, a molding mold system and a magnetic levitation back pressure system, the molding mold system includes a blank, a molding upper mold and a molding lower mold, and the blank is arranged between the molding upper mold and the molding lower mold; the ultrasonic assisted system includes an ultrasonic vibration mechanism, which is connected to the blank and is used to transmit ultrasonic vibration to the blank; the magnetic levitation back pressure system includes a push-down magnetic levitation back pressure device, which rises and suspends at a set speed to achieve back pressure and complete the molding of the product. The electromagnetic back-pressure coupled ultrasonic assisted forming method and mold for the vortex disk of new energy vehicles provided by the present invention have beneficial effects as follows:
[0064] 1. Use a push-down magnetic levitation device to provide back thrust. Magnetic levitation uses the principle of like-pole repulsion and opposite-pole attraction between magnetic fields to give objects an upward force, so that the object can overcome gravity and stably suspend in a certain position without contact, friction or resistance. Compared with the existing back-pressure forming molds that use clamping cylinders to provide back thrust, the back-pressure forming molds that use a push-down magnetic levitation device to provide back thrust have a simple structure, are easy to replace and have a longer service life.
[0065] 2. Use ultrasonic vibration to assist blank forming. Ultrasonic vibration assisted plastic forming is a typical energy field assisted plastic forming process. Compared with traditional plastic forming, it has the advantages of small flow stress, high material forming ability, small interface friction, and good forming quality. The use of ultrasonic vibration auxiliary system can reduce the blank heating temperature, save energy, and is more economical and environmentally friendly.
[0066] 3. The ultrasonic horn adopts a sinusoidal cylindrical composite horn, which has a simple structure, is easy to process, easy to excite, has high power and is easy to form. Its amplification factor and load capacity are also significantly improved. Under the selected horn area coefficient, the appropriate sinusoidal segment busbar initial phase and length can obtain amplification speed and shape factor that are better than the traditional stepped horn.
[0067] Although preferred embodiments of the present invention have been described, additional changes and modifications may be made to these embodiments by those skilled in the art once the basic inventive concepts are known. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention. Obviously, those skilled in the art may make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.
Claims
1. A new energy vehicle scroll disk electromagnetic back pressure coupling ultrasound assisted forming die, characterized in that: It comprises an ultrasonic auxiliary system (10), a molding die system (20) and a magnetic suspension back pressure system (30), wherein: The forming die system (20) comprises a blank (21), a forming upper die (22) and a forming lower die (23), wherein the blank (21) is arranged between the forming upper die (22) and the forming lower die (23); The ultrasonic auxiliary system (10) comprises an ultrasonic vibration mechanism, which is connected to the blank (21) and is used to transmit ultrasonic vibration to the blank (21); The magnetic suspension back pressure system (30) comprises a push-down magnetic suspension back pressure device (33), wherein the push-down magnetic suspension back pressure device (33) is arranged below the blank (21) and is used to rise and suspend at a set speed to realize back pressure and complete product forming; The ultrasonic vibration mechanism comprises an ultrasonic generator, an ultrasonic transducer (11), an ultrasonic horn (12) and an ultrasonic tool punch (13); the ultrasonic horn (12) is arranged between the ultrasonic transducer (11) and the ultrasonic tool punch (13); the ultrasonic generator is electrically connected to the ultrasonic transducer (11); the ultrasonic generator drives the ultrasonic transducer (11) to operate; the ultrasonic transducer (11) converts an electrical signal into a mechanical vibration and then transmits the vibration to the ultrasonic horn (12); the ultrasonic horn (12) transmits the amplified ultrasonic vibration to the ultrasonic tool punch (13); and the ultrasonic tool punch (13) transmits the ultrasonic vibration to the blank (21); The magnetic suspension back pressure system (30) further comprises a back pressure plate (31), a controller and a driver (32); the back pressure plate (31) is arranged above the push-down magnetic suspension back pressure device (33); the driver (32) is arranged below the push-down magnetic suspension back pressure device (33); and the controller is connected to the driver (32) and the push-down magnetic suspension back pressure device (33), respectively. The push-down magnetic suspension back pressure device (33) comprises a strong magnet (331), an electromagnetic coil (332), a float magnet (333) and a Hall element (334); the float magnet (333) is arranged below the back pressure plate (31); the float magnet (333) is arranged directly above the Hall element (334); the two electromagnetic coils (332) are respectively arranged on both sides of the Hall element (334); and the two strong magnets (331) are respectively located on both sides of the electromagnetic coil (332).
2. The electromagnetic back pressure coupled ultrasonic assisted forming die for the scroll disk of the new energy vehicle according to claim 1, characterized in that: The ultrasonic horn (12) is formed by combining a cylindrical horn and a sinusoidal function horn.
3. The electromagnetic back pressure coupled ultrasonic assisted forming die for the scroll disk of the new energy vehicle according to claim 1, characterized in that: The float magnet (333) is installed and embedded in the bottom of the back pressure plate (31).
4. The electromagnetic back pressure coupled ultrasonic assisted forming die for the scroll disk of the new energy vehicle according to claim 1, characterized in that: The number of the Hall elements (334) is three, and the three Hall elements (334) are all located below the float magnet (333).
5. A method for electromagnetic back pressure coupling and ultrasonic assisted forming of a scroll disk for a new energy vehicle, applied to the electromagnetic back pressure coupling and ultrasonic assisted forming mold for a scroll disk for a new energy vehicle as claimed in any one of claims 1 to 4, characterized in that: The electromagnetic back pressure coupled ultrasonic assisted forming method for the scroll disk of the new energy vehicle comprises the following steps: Setting parameters: According to the material, geometric complexity, size and temperature parameters required for forming of the workpiece, determine the appropriate ultrasonic vibration frequency to adjust the amplitude of the ultrasonic wave, and obtain the required ultrasonic vibration mode by replacing the gear shifter or adjusting the ultrasonic horn; Process preparation, pre-forging and die closing: prepare the blank according to the design requirements, then put the blank into the forming lower die, then the forming upper die extrude the blank into the forming lower die at a preset speed, and start die closing; Vibration pressing: After the upper forming die and the lower forming die are closed, the upper forming die and the lower forming die are locked, and the ultrasonic vibration mechanism performs the action at the same time, the ultrasonic transducer converts the electrical signal into mechanical vibration, and then transmits the vibration to the ultrasonic horn, the ultrasonic horn transmits the amplified ultrasonic vibration to the ultrasonic tool punch, and the ultrasonic tool punch transmits the ultrasonic vibration to the blank; Final forging and back pressure forming: The ultrasonic vibration mechanism continues to work, and the upper forming die moves upward and further vibrates and presses downward with the ultrasonic tool punch. The push-down magnetic suspension back pressure device is started, and the back pressure plate is controlled to rise and suspend at a set speed to achieve back pressure, completing the product forming; Mold separation: the ultrasonic vibration mechanism is closed, and the upper molding mold moves upward to separate the upper molding mold from the lower molding mold, and the back pressure plate is controlled to float upward to eject the finished product.
6. The electromagnetic back pressure coupled ultrasonic assisted forming method for a new energy vehicle scroll disk according to claim 5, characterized in that: In the vibration pressing step, the length of the ultrasonic tool punch is: in, is the length of the ultrasonic tool punch, is the propagation wavelength of ultrasonic wave in the punch material, is the propagation speed of ultrasonic wave in the punch material, is the ultrasonic frequency.
7. The electromagnetic back pressure coupled ultrasonic assisted forming method for a new energy vehicle scroll disk according to claim 5, characterized in that: In the vibration pressing step, the acoustic vibration frequency of the ultrasonic vibration mechanism is 15-80 kHz, and the amplitude range is 5-80 μm.