Double-curved-surface foam processing method and double-curved-surface foam thereof

Abstract

The invention discloses a double-curved-surface foam processing method, and belongs to the technical field of double-curved-surface foam. Comprising the following steps that a to-be-machined foam blank is placed on a machining plane, the foam blank is fixed through a pressing plate, and a preset area of the foam blank is milled to be flat through a milling machine to form a fixed face; the foam blank is installed on a machining jig with the fixing face facing downwards, a fixing frame, a water gap and a foam part body are built for machining of the foam blank, the foam part body is connected with the fixing frame through the water gap, the foam part body is machined to form a first curved face, and a foam product is obtained after machining of the first curved face is completed; and the fixing frame is installed on the sacrifice plate, under the cooperation of the sacrifice plate and the fixing frame, the first curved surface faces downwards, after the foam product is machined to form a second curved surface, the water gap is removed, the foam part body is separated from the fixing frame, and the machined foam part is obtained. According to the invention, the foam pieces with different curvatures, sizes and thicknesses can be processed without using a special tool.

Description

Technical Field

[0001] The invention belongs to the technical field of hyperbolic foams, and in particular relates to a hyperbolic foam processing method and the hyperbolic foam. Background Art

[0002] With the progress of the times, the requirements for weight of aerospace equipment are getting higher and higher. They need to fly faster and consume as little energy as possible for the same range. Compared with metal materials, composite materials have high specific strength, high specific modulus, low density, good shock resistance, fatigue resistance, and designability. Composite materials have been widely used in aerospace and automotive fields.

[0003] Polymethacrylimide foam is a common sandwich component in aircraft. Some sandwich components have curved surfaces on both sides. After the first curved surface is processed, it needs to be turned over for processing. When clamping the part, it is necessary to use a special tooling that fits the first curved surface for support and fixation. If the part has different profiles, multiple sets of special tooling are required for support, which not only increases the purchase cost of the tooling, but also requires a larger site for placement. Summary of the invention

[0004] Purpose of the invention: To provide a method for processing hyperbolic foam, which solves the above-mentioned problems existing in the prior art.

[0005] Technical solution: A method for processing a hyperbolic foam, comprising the following steps: The foam material to be processed is placed on a processing plane, and the foam material is fixed by a clamp, and a predetermined area of ​​the foam material is milled flat by a milling machine to form a fixed surface, that is, the foam material forms a fixed surface and a surface to be processed, and the surface to be processed and the fixed surface are opposite to each other; The fixed surface is placed on the processing jig with the fixed surface facing downward, and the fixed surface is adsorbed and limited by the processing jig. After the fixed surface is adsorbed and limited, the surface to be processed is processed to form a fixed frame, a nozzle and a foam part body. The foam part body is connected to the fixed frame through the nozzle, and the surface to be processed in the foam part body is processed to form a first curved surface. After the first curved surface is processed, a foam product is obtained; The fixing frame is installed on the sacrificial plate. With the cooperation of the sacrificial plate and the fixing frame, the foam product is turned over so that the first curved surface is placed downward on the processing jig. After the fixed surface in the foam part body is processed to form the second curved surface, the sprue is removed using a cutting tool, and the foam part body is separated from the fixing frame to obtain a processed foam part.

[0006] Preferably, the fixed surface milling process is as follows: Place the foam material on the processing plane and between the clamps, and use the clamps to abut the edge of the foam material so that the edge of the foam material is in contact with the processing plane; When the foam material is fixed, the predetermined surface of the foam material is processed by a milling machine until the lowest point of the warping of the predetermined surface of the foam material is reached, and the fixed surface of the foam material is milled flat to form a fixed surface.

[0007] Preferably, the first curved surface processing step is as follows: placing the fixed surface on a processing jig, and adsorbing the foam wool material through the processing jig, so that the fixed surface of the foam wool material is attached to the processing jig; The surface to be processed of the foam raw material is processed by a milling machine, and during the processing, the outer ring of the foam raw material does not need to be processed to form a fixed frame, the foam part body is formed in the fixed frame, and the foam part body is connected to the fixed frame through a nozzle; A milling machine is used to process the surface to be processed in the foam part body, and a first curved surface is formed after the processing of the surface to be processed is completed. After the processing of the first curved surface is completed, a foam product is obtained. The foam product is connected to a fixed frame through a nozzle, and at least two groups of first limiting holes are opened on the fixed frame. The first limiting holes are located at the top corners of the fixed frame. After the first limiting holes are opened, a vacuum cleaner is used to remove surface dust on the foam product, the fixed frame and the nozzle.

[0008] Preferably, the installation process of the fixing frame to the sacrificial plate is as follows: The sacrificial plate is placed on the processing jig, the fixing frame is placed on the sacrificial plate, and second limiting holes are opened at corresponding positions of the sacrificial plate according to the positions of the first limiting holes opened in the fixing frame, the number of the second limiting holes is the same as the number of the first limiting holes, and each of the second limiting holes corresponds to each of the first limiting holes; After the second limiting hole is opened, the foam product is turned over and placed on the sacrificial plate, and the fixing frame is connected to the sacrificial plate through the cooperation between the first limiting hole and the second limiting hole. At this time, the first curved surface is in contact with the sacrificial plate surface; With the cooperation of the first limiting hole and the second limiting hole, the processing coordinates of the foam product after flipping are kept consistent with the processing coordinates of the foam part body before flipping.

[0009] Preferably, the second curved surface processing steps are as follows: The foam product is turned over and placed on the sacrificial plate. At this time, the second limiting hole on the sacrificial plate corresponds to the first limiting hole on the fixed frame, and the first curved surface contacts the sacrificial plate surface. After the sacrificial plate and the fixed frame are connected by a connecting piece to form a fixed part, the sacrificial plate is placed on a processing jig, and the fixed surface is away from the processing jig. The fixed part is limited and fixed by the processing jig. At this time, the processing coordinate system remains consistent, and the fixed surface can be processed by a milling machine. During the processing, the water outlet is retained and the fixed surface is processed into the second curved surface to obtain a foam part.

[0010] Preferably, the steps of removing the nozzle are as follows: The sacrificial plate is removed, and the end of the sprue close to the fixed frame is cut off with a cutting tool to separate the fixed frame and the sprue from each other. After the fixed frame is separated, the edge of the sprue is cut with a cutting tool to bring the edge of the sprue closer to the edge of the hyperbolic part until the sprue is completely separated from the hyperbolic part to obtain a hyperbolic foam.

[0011] A hyperbolic foam comprises a foam material, which is mounted on a processing plane by a clamp, and a predetermined surface of the foam material is milled flat to form a fixed surface. The fixed surface of the foam material is placed in a processing jig and cut into a fixed frame, a nozzle and a foam part body by a milling machine. The foam part body is connected to the fixed frame through the nozzle, and at least two groups of first limiting holes are opened on the fixed frame. A first curved surface is processed on the plane of the foam part body. The foam part body is mounted on a sacrificial plate through the first limiting holes and a connecting piece, and a second curved surface is processed on the fixed surface of the foam part. The nozzle is cut by a cutting tool, and the foam part body is separated from the fixed frame.

[0012] Beneficial effects: The present invention relates to a method for processing hyperbolic foam, which can process foam parts with different curvatures, sizes and thicknesses without using special tooling, and can be widely used in the processing of various types of sandwich parts; By opening the first limiting hole and the second limiting hole on the fixed frame, the foam part body to be processed is positioned, that is, the second curved surface can be processed without deleting the coordinate system, saving a lot of special tooling, simplifying the processing procedures, and improving the processing efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a diagram showing the installation state of the foam wool material of the present invention; Figure 2 This is a first curved surface processing state diagram of the present invention; Figure 3 It is a second curved surface processing state diagram of the present invention; Figure 4 It is a schematic diagram of the foam part body of the present invention; Figure 5 It is the processing jig of the present invention.

[0014] Figures 1 to 5 The figures are marked as follows: 1. processing plane; 2. fixture; 3. foam material; 4. fixing frame; 5. water inlet; 6. foam part body; 7. support frame; 8. air inlet pipe; 9. suction plate. DETAILED DESCRIPTION

[0015] like Figures 1 to 4 As shown, the present invention provides a technical solution: a method for processing a hyperbolic foam, comprising the following steps: First, place the foam material 3 to be processed on the processing plane 1, as shown in FIG. Figure 1 As shown, the foam material 3 is fixed by the clamp 2, wherein the fixing process is as follows: the foam material 3 is placed between the clamps 2, and the edge of the foam material 3 is abutted by the clamp 2 so that the edge of the foam material 3 is in contact with the processing plane 1; after the foam material 3 is fixed, a predetermined area of ​​the foam material 3 is milled flat by a milling machine to form a fixed surface, that is, the foam material 3 forms a fixed surface and a surface to be processed, and the surface to be processed and the fixed surface are opposite to each other, and the fixed surface is placed face down on the processing jig, and the fixed surface is adsorbed and limited by the processing jig. After the fixed surface completes the adsorption and limitation, the surface to be processed is processed, so that the foam material 3 is processed to form a fixed frame 4, a sprue 5 and a foam part body 6, and the foam part body 6 is connected to the fixed frame 4 through the sprue 5, and the surface to be processed in the foam part body 6 is processed to form a first curved surface, after the first curved surface is processed, a foam product is obtained; the fixing frame 4 is installed on the sacrificial plate, and with the cooperation of the sacrificial plate and the fixing frame 4, the foam product is turned over so that the first curved surface is placed downward on the processing jig, and after the fixed surface in the foam part body 6 is processed to form the second curved surface, the sprue 5 is removed by a cutting tool, and the foam part body 6 is separated from the fixing frame 4 to obtain a processed foam part. Foam parts with different curvatures, sizes and thicknesses can be processed without using special tooling, and can be widely used in the processing of various different types of sandwich parts. By opening a first limiting hole and a second limiting hole on the fixing frame 4, the foam part body 6 to be processed is positioned, that is, the second curved surface can be processed without deleting the coordinate system, thereby saving a large amount of special tooling, simplifying the processing procedure, and improving the processing efficiency.

[0016] Wherein, the processing jig is as follows Figure 5 As shown, the processing jig includes a support frame 7, a suction plate 9 is installed on the top surface of the support frame 7, an air intake pipe 8 is installed on one side of the support frame 7, the air intake pipe 8 is connected to the suction plate 9, and the air intake pipe 8 is connected to the five-axis vacuum pump through a hose. The hose cooperates with the five-axis vacuum pump to enable the suction plate 9 to perform suction processing on the foam wool 3.

[0017] In a further embodiment, the first curved surface processing step is as follows: The fixed surface is placed on a processing jig, and the foam material 3 is adsorbed by the processing jig so that the fixed surface of the foam material 3 is attached to the processing jig; The surface to be processed of the foam material 3 is processed by a milling machine, and during the processing, the outer ring of the foam material 3 does not need to be processed to form a fixing frame 4, and a foam part body 6 is formed inside the fixing frame 4, and the foam part body 6 is connected to the fixing frame 4 through a nozzle 5; A milling machine is used to process the surface to be processed in the foam part body 6, and the surface to be processed is processed to form a first curved surface. After the first curved surface is processed, a foam product is obtained, the foam product is connected to the fixed frame 4 through the nozzle 5, and at least two groups of first limiting holes are opened on the fixed frame 4, and the first limiting holes are located at the top corners of the fixed frame 4. After the first limiting holes are opened, a vacuum cleaner is used to remove surface dust of the foam product, the fixed frame 4 and the nozzle 5. The sacrificial plate is placed on the processing jig, and the fixed frame 4 is placed on the sacrificial plate. According to the positions of the first limiting holes opened in the fixed frame, second limiting holes are opened at corresponding positions of the sacrificial plate. The number of the second limiting holes is the same as the number of the first limiting holes, and each of the second limiting holes corresponds to each of the first limiting holes. After the second limiting hole is opened, the foam product is turned over and placed on the sacrificial plate, and the fixing frame is connected to the sacrificial plate through the cooperation between the first limiting hole and the second limiting hole. At this time, the first curved surface is in contact with the sacrificial plate surface; With the cooperation of the first limiting hole and the second limiting hole, the processing coordinates of the foam product after flipping are kept consistent with the processing coordinates of the foam part body 6 before flipping, that is, the foam product can be flipped, and the fixed surface can be processed into the second curved surface without adjusting the processing coordinates, which saves a lot of special tooling, simplifies the processing procedures, and improves the processing efficiency.

[0018] In a further embodiment, the second curved surface processing steps are as follows: The foam product is turned over and placed on the sacrificial plate. At this time, the second limiting hole on the sacrificial plate corresponds to the first limiting hole on the fixed frame 4, and the first curved surface contacts the sacrificial plate surface. After the sacrificial plate and the fixed frame are connected by a connecting member to form a fixed part, wherein the connecting member can be a positioning pin, but is not limited to a positioning pin. The sacrificial plate is placed on a processing jig, and the fixed surface is away from the processing jig. The fixed part is limited and fixed by the processing jig. At this time, the processing coordinate system remains consistent, and the fixed surface can be processed by a milling machine without adjusting the processing coordinates. During the processing, the sprue 5 is retained, and the fixed surface is processed into a second curved surface to obtain a foam part. This can not only simplify the processing procedure and improve the processing efficiency, but also save a large amount of special tooling.

[0019] In a further embodiment, the steps of removing the nozzle 5 are as follows: Remove the sacrificial plate and use a cutting tool to cut off the end of the sprue 5 close to the fixed frame 4 to separate the fixed frame 4 and the sprue 5 from each other. After the fixed frame 4 is separated, use a cutting tool to cut the edge of the sprue 5. In this embodiment, a utility knife is used to cut the sprue 5. First, cut the sprue 5 from the fixed frame 4 and make a small amount of cut along the cut end of the sprue 5 to slowly approach the edge of the hyperbolic part until the sprue 5 is completely separated from the hyperbolic part. Hyperbolic foam can be obtained. The sprue 5 can be quickly separated from the hyperbolic part without the need for additional processing tools.

[0020] A hyperbolic foam, comprising a foam wool 3 and a sacrificial plate, such as Figure 1 As shown, the foam material 3 is installed on the processing plane 1 through the clamp 2, wherein the edge of the foam material 3 abuts against the edge of the clamp 2, so that the edge of the foam material 3 is in contact with the processing plane 1, that is, the foam material 3 is in an arc state with both ends facing downward and a convex middle. The predetermined area of ​​the foam material 3 is processed by a milling machine. After the predetermined surface of the foam material 3 is milled flat to form a fixed surface, the fixed surface of the foam material 3 is placed in a processing fixture. The foam material 3 is cut into a fixed frame 4, a sprue 5 and a foam part body 6 by the milling machine. The foam part body 6 is connected to the fixed frame 4 through the sprue 5, and the fixed frame 4 is opened. At least two groups of first limiting holes are provided, and a first curved surface is processed on the plane of the foam part body 6. The first limiting holes cooperate with the connecting parts to install the foam part body 6 on the sacrificial plate. At least two groups of second limiting holes are opened at predetermined positions of the sacrificial plate. With the cooperation of the sacrificial plate and the foam part, the foam part is turned over, and the foam product is installed on the processing plane 1 through the second limiting holes. The second curved surface can be processed at the same coordinate while adjusting the coordinates. After the second curved surface is processed, the water outlet 5 is cut by a cutting tool, that is, the foam part body 6 is separated from the fixed frame 4, and the processing of the hyperbolic foam part is completed.

[0021] The preferred embodiments of the present invention are described in detail above; however, the present invention is not limited to the specific details in the above embodiments. Within the technical concept of the present invention, various equivalent transformations can be made to the technical solutions of the present invention, and these equivalent transformations all belong to the protection scope of the present invention.

Claims

1. A method for processing a hyperbolic foam, characterized in that: The following steps are involved: Placing a foam material (3) to be processed on a processing plane (1), fixing the foam material (3) by a clamp (2), and milling a predetermined area of ​​the foam material (3) by a milling machine to form a fixed surface, that is, the foam material (3) forms a fixed surface and a surface to be processed, and the surface to be processed and the fixed surface are opposite to each other; The fixed surface is placed on a processing jig with the fixed surface facing downwards, and the fixed surface is adsorbed and limited by the processing jig. After the fixed surface is adsorbed and limited, the surface to be processed is processed, so that the foam raw material (3) is processed to form a fixed frame (4), a nozzle (5) and a foam part body (6). The foam part body (6) is connected to the fixed frame (4) through the nozzle (5), and the surface to be processed in the foam part body (6) is processed to form a first curved surface. After the first curved surface is processed, a foam product is obtained; The fixing frame (4) is mounted on the sacrificial plate. With the cooperation of the sacrificial plate and the fixing frame (4), the foam product is turned over so that the first curved surface is placed on a processing jig with the first curved surface facing downward. After the fixing surface in the foam part body (6) is processed to form a second curved surface, the water outlet (5) is removed using a cutting tool, and the foam part body (6) is separated from the fixing frame (4) to obtain a processed foam part.

2. A method for processing a hyperbolic foam according to claim 1, characterized in that: The fixed surface milling process is as follows: The foam material (3) is placed on the processing plane and located between the clamps (2), and the edge of the foam material (3) is abutted by the clamps (2) so that the edge of the foam material (3) is in surface contact with the processing plane (1); When the foam material (3) is fixed, the predetermined surface of the foam material (3) is processed by a milling machine until the predetermined surface is processed to the lowest point of the warping, thereby completing the milling of the predetermined surface of the foam material (3) to form a fixed surface.

3. A method for processing a hyperbolic foam according to claim 1, characterized in that: The first surface processing steps are as follows: Placing the fixed surface on a processing jig, and allowing the processing jig to adsorb the foam wool (3) so that the fixed surface of the foam wool (3) is attached to the processing jig; The surface to be processed of the foam raw material (3) is processed by a milling machine, and during the processing, the outer ring of the foam raw material (3) does not need to be processed to form a fixed frame (4), a foam part body (6) is formed inside the fixed frame (4), and the foam part body (6) is connected to the fixed frame (4) via a nozzle (5); A milling machine is used to machine the surface to be machined in the foam part body (6), and the surface to be machined is machined to form a first curved surface. After the first curved surface is machined, a foam product is obtained. The foam product is connected to the fixed frame (4) via a nozzle (5). At least two groups of first limiting holes are opened on the fixed frame (4), and the first limiting holes are located at the top corners of the fixed frame (4). After the first limiting holes are opened, a vacuum cleaner is used to remove dust from the surface of the foam product, the fixed frame (4) and the nozzle (5).

4. A method for processing a hyperbolic foam according to claim 3, characterized in that: The installation process of the fixing frame to the sacrificial plate is as follows: The sacrificial plate is placed on the processing jig, the fixing frame is placed on the sacrificial plate, and second limiting holes are opened at corresponding positions of the sacrificial plate according to the positions of the first limiting holes opened in the fixing frame, the number of the second limiting holes is the same as the number of the first limiting holes, and each of the second limiting holes corresponds to each of the first limiting holes; After the second limiting hole is opened, the foam product is turned over and placed on the sacrificial plate, and the fixing frame is connected to the sacrificial plate through the cooperation between the first limiting hole and the second limiting hole. At this time, the first curved surface is in contact with the sacrificial plate surface; With the cooperation of the first limiting hole and the second limiting hole, the processing coordinates of the foam product after flipping are kept consistent with the processing coordinates of the foam component body (6) before flipping.

5. A method for processing a hyperbolic foam according to claim 4, characterized in that: The second surface processing steps are as follows: The foam product is turned over and placed on a sacrificial plate. At this time, the second limiting hole on the sacrificial plate corresponds to the first limiting hole on the fixed frame (4), and the first curved surface contacts the surface of the sacrificial plate. After the sacrificial plate and the fixed frame are connected by a connecting piece to form a fixed part, the sacrificial plate is placed on a processing jig, and the fixed surface is away from the processing jig. The fixed part is limited and fixed by the processing jig. At this time, the processing coordinate system remains consistent, and the fixed surface can be processed by a milling machine. During the processing, the water outlet (5) is retained, and the fixed surface is processed into a second curved surface to obtain a foam part.

6. A method for processing a hyperbolic foam according to claim 1, characterized in that: The steps to remove the nozzle (5) are as follows: The sacrificial plate is removed, and the end of the sprue (5) close to the fixed frame (4) is cut off using a cutting tool, so that the fixed frame (4) and the sprue (5) are separated from each other. After the fixed frame (4) is separated, the edge of the sprue (5) is cut using a cutting tool, so that the edge of the sprue (5) is close to the edge of the hyperbolic part, until the sprue (5) and the hyperbolic part are completely separated, thereby obtaining a foam part.

7. A hyperbolic foam, produced by a hyperbolic foam processing method according to any one of claims 1 to 6, characterized in that: The foam material (3) comprises a foam material (3), wherein the foam material (3) is mounted on a processing plane (1) through a clamp (2), a predetermined surface of the foam material (3) is milled flat to form a fixed surface, the fixed surface of the foam material (3) is placed in a processing jig and cut by a milling machine into a fixed frame (4), a nozzle (5) and a foam part body (6), the foam part body (6) is connected to the fixed frame (4) through the nozzle (5), the fixed frame (4) is provided with at least two groups of first limiting holes, a first curved surface is machined on the plane of the foam part body (6), the foam part body (6) is mounted on a sacrificial plate through the first limiting holes in cooperation with a connecting piece, a second curved surface is machined on the fixed surface of the foam part, the nozzle (5) is cut by a cutting tool, and the foam part body (6) is separated from the fixed frame (4).

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