A hyperboloid foam processing method and hyperboloid foam thereof

Abstract

The application discloses a hyperboloid foam processing method and belongs to the technical field of hyperboloid foams. The method comprises the following steps: placing foam raw material to be processed on a processing plane, fixing the foam raw material through a pressing plate, and using a milling machine to mill a predetermined area of the foam raw material to form a fixed surface; installing the fixed surface downward on a processing jig, processing the foam raw material to establish a fixed frame, a water gap and a foam part body, connecting the foam part body and the fixed frame through the water gap, processing the foam part body to form a first curved surface, and obtaining a foam product after the processing of the first curved surface; installing the fixed frame on a sacrifice plate, making the first curved surface downward under the cooperation of the sacrifice plate and the fixed frame, processing the foam product to form a second curved surface, removing the water gap, separating the foam part body from the fixed frame, and obtaining a processed foam part. The application can process foam parts with different curvatures, sizes and thicknesses without using special tooling.

Description

Technical Field

[0001] This invention belongs to the field of hyperboloid foam technology, specifically relating to a hyperboloid foam processing method and the hyperboloid foam thereof. Background Technology

[0002] With the advancement of technology, aerospace devices face increasingly stringent requirements for weight reduction, faster flight speeds, and lower energy consumption for the same range. Compared to metallic materials, composite materials possess high specific strength, high specific modulus, low density, better shock resistance, fatigue resistance, and designability. As a result, composite materials have been widely used in aerospace, automotive, and other 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 machined, when it needs to be flipped for machining, special tooling that fits the first curved surface is required for support and fixation when clamping the parts. If the parts have different shapes, multiple sets of special tooling are required for support, which not only increases the cost of purchasing tooling but also requires a large space for placement. Summary of the Invention

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

[0005] Technical solution: A method for processing hyperboloid foam, comprising the following steps: The foam material to be processed is placed on the processing plane and fixed by a fixture. A milling machine is used to mill a predetermined area of ​​the foam material 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. Place the fixed surface downwards on the processing fixture. The processing fixture adsorbs and limits the fixed surface. After the fixed surface is adsorbed and limited, the surface to be processed is processed to form a fixed frame, a sprue and a foam part body. The foam part body is connected to the fixed frame through the sprue. 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 flipped over so that the first curved surface is placed on the processing fixture. After the fixing surface in the foam part body is processed to form the second curved surface, the sprue is removed using a cutting tool. The foam part body is separated from the fixing frame to obtain the 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. The clamps abut against the edges of the foam material to make the edges of the foam material contact the processing plane. After the foam material is fixed, the predetermined surface of the foam material is machined by a milling machine until the lowest point of the warp of the predetermined surface of the foam material is reached, thus completing the milling of the fixed surface of the foam material to form the fixed surface.

[0007] Preferably, the first curved surface processing step is as follows: the fixed surface is placed on the processing fixture, and the foam material is adsorbed by the processing fixture so that the fixed surface of the foam material is attached to the processing fixture; The foam material is machined on the surface to be processed by a milling machine. During the processing, the outer ring of the foam material does not need to be machined to form a fixed frame. The foam part body is formed inside the fixed frame. The foam part body is connected to the fixed frame through a sprue. The surface to be machined in the body of the foam part is machined using a milling machine. After the surface to be machined is completed, a first curved surface is formed. After the first curved surface is machined, a foam product is obtained. The foam product is connected to a fixed frame through a sprue. At least two sets of first limiting holes are opened on the fixed frame. The first limiting holes are located at the top corner of the fixed frame. After the first limiting holes are opened, a vacuum cleaner is used to remove the surface dust of the foam product, the fixed frame and the sprue.

[0008] Preferably, the installation process of the fixing frame to the sacrificial plate is as follows: The sacrificial plate is placed on the processing fixture, and the fixing frame is placed on the sacrificial plate. According to the position of the first limiting hole opened in the fixing frame, a second limiting hole is opened at the corresponding position on 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 flipped over and placed on the sacrificial plate. The fixing frame is connected to the sacrificial plate by the cooperation of the first and second limiting holes. At this time, the first curved surface is in contact with the surface of the sacrificial plate. With the cooperation of the first limiting hole and the second limiting hole, the processing coordinates of the flipped foam product are kept consistent with the processing coordinates of the foam part body before flipping.

[0009] Preferably, the second surface processing steps are as follows: After the foam product is flipped over and placed on the sacrificial plate, 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 surface of the sacrificial plate. After the sacrificial plate and the fixed frame are connected by the connector to form a fixed part, the sacrificial plate is placed on the processing fixture, and the fixed surface is away from the processing fixture. The fixed part is limited and fixed by the processing fixture. At this time, the processing coordinate system is kept consistent, and the fixed surface can be processed by the milling machine. During the processing, the sprue is retained, and the fixed surface is processed into the second curved surface to obtain the foam part.

[0010] Preferably, the steps for removing the sprue are as follows: Remove the sacrificial plate, and use a cutting tool to cut off the sprue end near the fixed frame, so that the fixed frame and the sprue are separated. After the fixed frame is separated, use a cutting tool to cut the edge of the sprue, so that the edge of the sprue moves closer to the edge of the hyperboloid part, until the sprue and the hyperboloid part are completely separated, and hyperboloid foam is obtained.

[0011] A hyperboloid foam includes foam blanks. The foam blanks are mounted on a processing plane by a fixture. A predetermined surface of the foam blanks is milled flat to form a fixed surface. The fixed surface of the foam blanks is placed in a processing fixture and cut by a milling machine into a fixed frame, a sprue, and a foam part body. The foam part body is connected to the fixed frame through the sprue. The fixed frame has at least two sets of first limiting holes. A first curved surface is machined 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. A second curved surface is machined on the fixed surface of the foam part. The sprue is cut by a cutting tool, thus separating the foam part body from the fixed frame.

[0012] Beneficial effects: This invention relates to a hyperboloid foam processing method, which can process foam parts with different curvatures, sizes and thicknesses without the need for special tooling, and can be widely used in the processing of various types of sandwich parts; By opening the first and second limiting holes on the fixed frame, the body of the foam part 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 steps and improving processing efficiency. Attached Figure Description

[0013] Figure 1 This is a diagram showing the installation state of the foam material according to the present invention; Figure 2 This is a diagram showing the first surface processing state of the present invention; Figure 3 This is a diagram showing the second surface machining state of the present invention; Figure 4 This is a schematic diagram of the foam part body of the present invention; Figure 5 This is the processing fixture of the present invention.

[0014] Figures 1 to 5 The reference numerals in the attached diagram are as follows: 1. Machining plane; 2. Fixture; 3. Foam material; 4. Fixing frame; 5. Sprue; 6. Foam part body; 7. Support frame; 8. Air inlet pipe; 9. Adsorption plate. Detailed Implementation

[0015] like Figures 1 to 4 As shown, the present invention provides a technical solution: a hyperboloid foam processing method, comprising the following steps: First, place the foam material 3 to be processed on the processing surface 1, as follows: Figure 1 As shown, the foam material 3 is fixed by the clamp 2. The fixing process is as follows: the foam material 3 is placed between the clamps 2, and the clamps 2 abut against the edge of the foam material 3, so that the edge of the foam material 3 contacts the processing plane 1. After the foam material 3 is fixed, a milling machine is used to mill a predetermined area of ​​the foam material 3 to form a fixing surface. That is, the foam material 3 forms a fixing surface and a surface to be processed. The surface to be processed and the fixing surface are opposite to each other. The fixing surface is placed face down on the processing fixture. The processing fixture adsorbs and limits the fixing surface. After the fixing surface is adsorbed and limited, the surface to be processed is processed, so that the foam material 3 is processed to form a fixing frame 4, a sprue 5 and a foam part body 6. The foam part body 6 is connected to the fixing frame 4 through the sprue 5. The surface to be processed in the foam part body 6 is processed to form the first... After the first curved surface is processed, a foam product is obtained. The fixing frame 4 is installed on the sacrificial plate. With the cooperation of the sacrificial plate and the fixing frame 4, the foam product is flipped so that the first curved surface is placed on the processing fixture. After the fixing surface in the foam part body 6 is processed to form the second curved surface, the sprue 5 is removed using a cutting tool. The foam part body 6 is separated from the fixing frame 4 to obtain the processed foam part. Foam parts with different curvatures, sizes and thicknesses can be processed without the use of special tooling. It 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 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, saving a lot of special tooling, simplifying the processing steps and improving processing efficiency.

[0016] Wherein, the processing fixture is as follows Figure 5 As shown, the processing fixture includes a support frame 7, an adsorption plate 9 is installed on the top surface of the support frame 7, an air inlet pipe 8 is installed on one side of the support frame 7, the air inlet pipe 8 is connected to the adsorption plate 9, and the air inlet pipe 8 is connected to a five-axis vacuum pump through a hose. The adsorption plate 9 adsorbs and processes the foam material 3 through the cooperation of the hose and the five-axis vacuum pump.

[0017] In a further embodiment, the first surface processing steps are as follows: The fixed surface is placed on the processing fixture, and the foam material 3 is adsorbed by the processing fixture, so that the fixed surface of the foam material 3 is attached to the processing fixture. The surface to be processed of the foam material 3 is processed by a milling machine. During the processing, the outer ring of the foam material 3 does not need to be processed to form a fixed frame 4. The foam part body 6 is formed inside the fixed frame 4. The foam part body 6 is connected to the fixed frame 4 through a sprue 5. The surface to be machined in the foam part body 6 is machined using a milling machine. After the surface to be machined is completed, a first curved surface is formed. After the first curved surface is machined, a foam product is obtained. The foam product is connected to the fixed frame 4 through the sprue 5. At least two sets of first limiting holes are opened on the fixed frame 4. The first limiting holes are located at the top corner of the fixed frame 4. After the first limiting holes are opened, the surface dust of the foam product, the fixed frame 4 and the sprue 5 is removed using a vacuum cleaner. The sacrificial plate is placed on the machining fixture, and the fixed frame 4 is placed on the sacrificial plate. According to the position of the first limiting hole opened in the fixed frame, a second limiting hole is opened at the corresponding position on the sacrificial plate. The number of the second limiting holes is the same as the number of the first limiting holes, and each second limiting hole corresponds to each first limiting hole. After the second limiting hole is opened, the foam product is flipped over and placed on the sacrificial plate. The fixing frame is connected to the sacrificial plate by the cooperation of the first and second limiting holes. At this time, the first curved surface is in contact with the surface of the sacrificial plate. 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. This allows the foam product to be flipped without adjusting the processing coordinates, and the fixed surface can be processed into a second curved surface, saving a lot of special tooling, simplifying the processing steps and improving processing efficiency.

[0018] In a further embodiment, the second surface processing steps are as follows: After the foam product is flipped over and placed on the sacrificial plate, 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 connector to form a fixed part, the connector can be a positioning pin, but is not limited to a positioning pin. The sacrificial plate is placed on the processing fixture, and the fixed surface is away from the processing fixture. The fixed part is limited and fixed by the processing fixture. At this time, the processing coordinate system is kept consistent, and there is no need to adjust the processing coordinate. The fixed surface can be processed by a milling machine. During the processing, the sprue 5 is retained, and the fixed surface is processed into the second curved surface to obtain the foam part. This simplifies the processing procedure, improves the processing efficiency, and also saves a lot of special tooling.

[0019] In a further embodiment, the step of removing the sprue 5 is as follows: Remove the sacrificial plate and use a cutting tool to cut off the end of the sprue 5 near the fixed frame 4, so that the fixed frame 4 and the sprue 5 are separated 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 off the sprue 5. First, cut the sprue 5 away from the fixed frame 4, and make a small cut along the cut end of the sprue 5, so that the cut end of the sprue 5 slowly approaches the edge of the hyperboloid part until the sprue 5 is completely separated from the hyperboloid part, and the hyperboloid foam can be obtained. No additional processing tools are needed to quickly separate the sprue 5 from the hyperboloid part.

[0020] A hyperboloid foam, comprising foam blank 3 and a sacrificial board, such as Figure 1 As shown, the foam material 3 is mounted on the processing plane 1 by a fixture 2, wherein the edge of the foam material 3 abuts against the edge of the fixture 2, so that the edge of the foam material 3 contacts the surface of the processing plane 1, that is, the foam material 3 is in an arc shape with both ends pointing downwards and the middle convex. After the predetermined area of ​​the foam material 3 is processed by a milling machine 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 by the milling machine into a fixed frame 4, a sprue 5 and a foam part body 6. The foam part body 6 is connected to the fixed frame 4 through the sprue 5. The fixed frame 4 has an opening on it. At least two sets of first limiting holes are provided to process a first curved surface on the plane of the foam part body 6. The first limiting holes cooperate with the connector to install the foam part body 6 on the sacrificial plate. At least two sets of second limiting holes are opened at predetermined positions on the sacrificial plate. With the cooperation of the sacrificial plate and the foam part, the foam part is flipped over and the foam product is installed on the processing plane 1 through the second limiting holes. When the coordinates are adjusted, the second curved surface can be processed in the same coordinate. After the second curved surface is processed, the sprue 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 hyperboloid foam part is completed.

[0021] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the scope of 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 fall within the protection scope of the present invention.

Claims

1. A method for processing hyperboloid foam, characterized in that, Includes the following steps: The foam material (3) to be processed is placed on the processing plane (1) and fixed by the clamp (2). The predetermined area of ​​the foam material (3) is milled flat by the 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. Place the fixed surface downwards on the processing fixture. The processing fixture adsorbs and limits the fixed surface. After the fixed surface is adsorbed and limited, 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). The foam part body (6) is connected to the fixed frame (4) through the sprue (5). 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, the foam product is obtained. Install the fixing frame (4) onto the sacrificial plate. With the cooperation of the sacrificial plate and the fixing frame (4), flip the foam product so that the first curved surface is placed on the processing fixture. After processing the fixing surface in the foam part body (6) to form the second curved surface, use a cutting tool to remove the sprue (5). The foam part body (6) is separated from the fixing frame (4) to obtain the processed foam part.

2. The hyperboloid foam processing method according to claim 1, characterized in that, The process of milling a fixed surface is as follows: Place the foam material (3) on the processing plane and between the clamps (2). The clamps (2) abut against the edge of the foam material (3) so that the edge of the foam material (3) is in contact with the processing plane (1). After the foam material (3) is fixed, the predetermined surface of the foam material (3) is machined by a milling machine until the lowest point of the warp of the predetermined surface is reached, thus completing the milling of the predetermined surface of the foam material (3) to form a fixed surface.

3. The hyperboloid foam processing method according to claim 1, characterized in that, The first surface machining steps are as follows: The fixed surface is placed on the processing fixture, and the foam material (3) is adsorbed by the processing fixture, so that the fixed surface of the foam material (3) is attached to the processing fixture; The surface to be processed of the foam material (3) is processed by a milling machine. During the processing, the outer ring of the foam material (3) does not need to be processed to form a fixed frame (4). The foam part body (6) is formed inside the fixed frame (4). The foam part body (6) is connected to the fixed frame (4) through a sprue (5). The surface to be processed in the foam part body (6) is processed by a milling machine. After the surface to be processed is completed, a first curved surface is formed. After the first curved surface is processed, a foam product is obtained. The foam product is connected to the fixed frame (4) through the sprue (5). At least two sets of first limiting holes are opened on the fixed frame (4). The first limiting holes are located at the top corner of the fixed frame (4). After the opening of the first limiting holes is completed, the surface dust of the foam product, the fixed frame (4) and the sprue (5) is removed by a vacuum cleaner.

4. The hyperboloid foam processing method 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 fixture, and the fixing frame is placed on the sacrificial plate. According to the position of the first limiting hole opened in the fixing frame, a second limiting hole is opened at the corresponding position on 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 flipped over and placed on the sacrificial plate. The fixing frame is connected to the sacrificial plate by the cooperation of the first and second limiting holes. At this time, the first curved surface is in contact with the surface of the sacrificial plate. With the cooperation of the first limiting hole and the second limiting hole, the processing coordinates of the flipped foam product are kept consistent with the processing coordinates of the foam part body (6) before flipping.

5. The hyperboloid foam processing method according to claim 4, characterized in that, The machining steps for the second curved surface are as follows: After the foam product is flipped over and placed on the sacrificial plate, 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 the connector to form a fixed part, the sacrificial plate is placed on the processing fixture, and the fixed surface is far away from the processing fixture. The fixed part is fixed by the processing fixture. At this time, the processing coordinate system is kept consistent, and the fixed surface can be processed by the milling machine. During the processing, the sprue (5) is retained, and the fixed surface is processed into the second curved surface to obtain the foam part.

6. The hyperboloid foam processing method according to claim 1, characterized in that, The steps for removing the sprue (5) are as follows: Remove the sacrificial plate and use a cutting tool to cut off the end of the sprue (5) near the fixed frame (4) so ​​that the fixed frame (4) and the sprue (5) are separated from each other. After the fixed frame (4) is separated, use a cutting tool to cut the edge of the sprue (5) so that the edge of the sprue (5) moves closer to the edge of the hyperboloid part until the sprue (5) is completely separated from the hyperboloid part, and the foam part is obtained.

7. A hyperboloid foam, processed by the hyperboloid foam processing method according to any one of claims 1-6, characterized in that, The process includes foam material (3), which is mounted on the processing plane (1) by a fixture (2). 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 the processing fixture and cut by a milling machine into a fixed frame (4), a sprue (5) and a foam part body (6). The foam part body (6) is connected to the fixed frame (4) through the sprue (5). At least two sets of first limiting holes are provided on the fixed frame (4). The first curved surface is processed on the plane of the foam part body (6). The foam part body (6) is mounted on the sacrificial plate through the first limiting hole and the connecting piece. The second curved surface is processed on the fixed surface of the foam part. The sprue (5) is cut by a cutting tool, that is, the foam part body (6) is separated from the fixed frame (4).

Images