A round steel bending die and bending method

Abstract

This invention provides a round steel bending die and bending method. The round steel bending die includes an upper die and a lower die. The round steel to be bent is placed between the upper and lower dies, with the two lower dies positioned on either side of a single upper die along the length of the round steel. When the hydraulic press acts on the upper surface of the upper die's top seat, the roller can rotate around its own axis. As the round steel is bent under pressure, it maintains surface contact with the lower die's radius adjustment guide sleeve, uniformly transmitting pressure and making the entire bending process more stable and reliable. Simultaneously, the radius adjustment guide sleeve is detachable and can be flexibly replaced according to the round steel size, ensuring a good fit with the round steel surface. Furthermore, the insertion hole design of the base plate allows for flexible movement of the lower die's position, enabling different opening distances to be flexibly adopted according to the different lengths of the round steel. This invention effectively improves the bending efficiency of round steel, can adjust the processing of round steel of different types and lengths, and achieves rapid forming of round steel.

Description

Technical Field

[0001] This invention relates to the field of machining technology, and in particular to a round steel bending die and bending method. Background Technology

[0002] In the shipbuilding industry, the midship section, where the stern section outer plating meets the port and starboard sides, is linear and is mostly made of round steel, which needs to be machined into a curved shape. The diameter of the round steel varies from 80 to 200 mm, and how to machine it quickly, efficiently, and accurately is a technical challenge.

[0003] Due to the unique properties of round steel, traditional processing methods include heating or roll forming. Heating involves heating the round steel to a high temperature and then manually bending it. Disadvantages include high cost, long processing time, high energy and labor consumption, altered product properties after heating, unsafe construction, and products with hammer marks and poor quality. Roll forming involves forcefully bending the round steel using roller presses. Disadvantages include roller marks on the surface, deformation, poor product quality, and impact on ship streamline performance. Currently, there is no efficient, high-quality, and safe method for bending and shaping round steel.

[0004] In view of this technical challenge, the purpose of this invention is to provide a new bending die and a new method for bending round steel bars, so as to improve the efficiency, quality and safety of bending round steel bars. Summary of the Invention

[0005] In view of the shortcomings of the prior art described above, the present invention provides a round steel bending die, the round steel bending die including an upper die and a lower die;

[0006] The upper mold includes an upper mold top seat, an upper mold guide sleeve, and an upper mold radius adjusting guide sleeve connected sequentially from top to bottom; the upper surface of the upper mold top seat is a plane, serving as the downward pressing surface of the hydraulic press; both the upper mold guide sleeve and the upper mold radius adjusting guide sleeve are upwardly arched semi-cylindrical shapes, and the upper mold radius adjusting guide sleeve is detachably stacked on the lower surface of the upper mold guide sleeve; the lower surface of the upper mold top seat forms a concave first arc-shaped groove, and the upper surface of the upper mold guide sleeve is fitted and fixed within the first arc-shaped groove;

[0007] The lower mold includes a roller, a connecting block, a lower mold top seat, a lower mold guide sleeve, and a lower mold radius adjusting guide sleeve connected sequentially from bottom to top; both the lower mold guide sleeve and the lower mold radius adjusting guide sleeve are downwardly recessed semi-cylindrical shapes, the lower mold radius adjusting guide sleeve is detachably stacked on the upper surface of the lower mold guide sleeve, the upper surface of the lower mold top seat has an inwardly recessed second arc-shaped groove, and the lower surface of the lower mold guide sleeve is fitted and fixed in the second arc-shaped groove;

[0008] In the vertical direction, the round steel to be bent is placed between the upper mold radius adjustment guide sleeve and the lower mold radius adjustment guide sleeve; along the length of the round steel, two lower molds are arranged on both sides of a single upper mold.

[0009] Optionally, the axis of the roller is perpendicular to the length direction of the round steel, and the roller can rotate about its own axis.

[0010] Optionally, the lower mold is located between two parallel vertical baffles, and the two ends of the roller are mounted to the vertical baffles.

[0011] Optionally, a baffle reinforcement is fixed to the surface of the vertical baffle away from the lower mold, and the baffle reinforcement is perpendicular to the vertical baffle.

[0012] Optionally, the round steel bending die further includes a base plate, the vertical baffle is placed on the base plate, and the bottom of the vertical baffle and the bottom of the baffle reinforcement are in contact with the upper surface of the base plate.

[0013] Optionally, the base plate is provided with a plurality of sockets arranged in an array, the sockets being used to insert pins, and the periphery of the vertical baffle and the baffle reinforcement is closely attached to a plurality of pins to limit the vertical baffle.

[0014] The present invention also provides a bending method for the aforementioned round steel bending die, comprising the following steps:

[0015] S1: Information verification, verifying the material, diameter, length, and part information of the incoming materials;

[0016] S2: Die radius adjustment. Based on the diameter of the part to be bent, adjust the matching radius of the upper and lower dies through the radius adjustment guide sleeves of the upper and lower dies.

[0017] S3: Lower die opening adjustment. Adjust the opening distance L between the two lower dies according to the diameter D and material of the part to be bent.

[0018] S4: Scribing, scribing the part to be processed, drawing out the pressing line, which is a surface center line of the round steel.

[0019] S5: Segmented linear pressing, first pressing both ends of the round steel, then pressing the middle, with each pressing segment being 1m long;

[0020] S6: Segmented line shape inspection, inspection while pressing. During inspection, a 1m long short template is placed on the upper surface of the round steel to check whether the short template fits the curvature of the round steel.

[0021] S7: Overall linear pressing. After pressing each segment, the entire part is pressed as a whole.

[0022] S8: Overall line shape inspection. Use the long template corresponding to the part to inspect the overall line shape of the entire part, check whether the long template and the curvature of the round steel fit together, and make fine repairs to the places where the line shape matches the tolerance.

[0023] S9: Information transfer, placing the machined parts on a horizontal platform and transferring relevant information.

[0024] Optionally, in step S3, L = k * D; for ordinary steel with a yield strength of 200 MPa to 350 MPa, k is 2.5 to 5; for high-strength steel with a yield strength of 350 MPa to 1000 MPa, k is 5 to 8.

[0025] As described above, this invention provides a round steel bending die and bending method. The round steel bending die includes an upper die and a lower die. The upper die includes an upper die top seat, an upper die guide sleeve, and an upper die radius adjusting guide sleeve. The lower die includes a roller, a connecting block, a lower die top seat, a lower die guide sleeve, and a lower die radius adjusting guide sleeve. The round steel to be bent is placed between the upper die radius adjusting guide sleeve and the lower die radius adjusting guide sleeve, and the two lower dies are arranged on both sides of a single upper die along the length of the round steel. When the hydraulic press acts on the upper surface of the upper die top seat, the roller can rotate around its own axis. Even after the round steel is bent under pressure, it can still maintain surface contact with the lower die radius adjusting guide sleeve, uniformly transmitting pressure, making the entire bending process more stable and reliable. At the same time, the radius adjusting guide sleeve is detachable and can be flexibly replaced according to the size of the round steel, ensuring the fit with the surface of the round steel. In addition, the insertion hole design of the base plate allows for flexible movement of the lower die position, so as to flexibly adopt different opening distances according to different round steel lengths.

[0026] Compared with conventional processes, this invention can simply and effectively improve the bending efficiency and quality of round steel, significantly saving labor costs and energy consumption. This mold system features simple and efficient operation, adjustability for processing round steel of different models and lengths, and high product quality. Compared with conventional processing methods, this mold system not only improves operational safety and processing accuracy but also enables rapid forming of round steel, significantly saving processing time and rework time. Attached Figure Description

[0027] Figure 1 The diagram shown is a three-dimensional structural schematic of the round steel bending mold in Embodiment 1 of the present invention.

[0028] Figure 2 The diagram shown is a side view of the round steel bending die in Embodiment 1 of the present invention.

[0029] Figure 3 The diagram shows the connection between the lower mold and the vertical baffle in Embodiment 1 of the present invention.

[0030] Figure 4 The diagram shown is a three-dimensional structural schematic of the lower mold in Embodiment 1 of the present invention.

[0031] Figure 5 The diagram shows the steps of the bending method in Embodiment 2 of the present invention.

[0032] Component designation explanation

[0033] Upper mold top seat 151; upper mold guide sleeve 152; upper mold radius adjusting guide sleeve 153; roller 141; connecting block 142; lower mold top seat 143; lower mold guide sleeve 144; lower mold radius adjusting guide sleeve 145; round steel 100; vertical baffle 131; baffle reinforcement 132; base plate 11; pin 12. Detailed Implementation

[0034] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention.

[0035] In the detailed description of embodiments of the present invention, for ease of explanation, the cross-sectional views illustrating the device structure may be partially enlarged and not to scale. Furthermore, the schematic diagrams are merely examples and should not limit the scope of protection of the present invention. In actual fabrication, the three-dimensional spatial dimensions of length, width, and depth should be included.

[0036] For ease of description, spatial relation terms such as “below,” “under,” “lower than,” “below,” “above,” and “upper” may be used herein to describe the relationship between one element or feature shown in the accompanying drawings and other elements or features. It will be understood that these spatial relation terms are intended to include directions other than those depicted in the drawings for the device in use or operation. Furthermore, when a layer is referred to as being “between” two layers, it can be the only layer between the two layers, or there may be one or more layers in between. The phrase “between” as used herein includes both endpoint values.

[0037] In the context of this application, the structure described above the first feature may include embodiments in which the first and second features are formed in direct contact, or embodiments in which additional features are formed between the first and second features, such that the first and second features may not be in direct contact.

[0038] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of the present invention. Therefore, the illustrations only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0039] Example 1

[0040] like Figures 1 to 4 As shown, this embodiment provides a round steel bending die, which includes an upper die and a lower die:

[0041] The upper mold includes an upper mold top seat 151, an upper mold guide sleeve 152, and an upper mold radius adjustment guide sleeve 153 connected sequentially from top to bottom; the upper surface of the upper mold top seat 151 is a plane, which serves as the downward pressing surface of the hydraulic press.

[0042] The upper mold guide sleeve 152 and the upper mold radius adjusting guide sleeve 153 are both upwardly arched semi-cylindrical shapes. The upper mold radius adjusting guide sleeve 153 is detachably stacked on the lower surface of the upper mold guide sleeve 152. The lower surface of the upper mold top seat 151 has a concave first arc groove. The upper surface of the upper mold guide sleeve 152 is fitted and fixed in the first arc groove.

[0043] The lower mold includes a roller 141, a connecting block 142, a lower mold top seat 143, a lower mold guide sleeve 144, and a lower mold radius adjusting guide sleeve 145 connected sequentially from bottom to top. The lower mold guide sleeve 144 and the lower mold radius adjusting guide sleeve 145 are both downwardly recessed semi-cylindrical shapes. The lower mold radius adjusting guide sleeve 145 is detachably stacked on the upper surface of the lower mold guide sleeve 144. The upper surface of the lower mold top seat 143 forms an inwardly recessed second arc-shaped groove, and the lower surface of the lower mold guide sleeve 144 is fitted and fixed in the second arc-shaped groove.

[0044] In the vertical direction, the round steel 100 to be bent is placed between the upper mold radius adjustment guide sleeve 153 and the lower mold radius adjustment guide sleeve 145; along the length of the round steel, the two lower molds are arranged on both sides of a single upper mold.

[0045] Furthermore, the axis of the roller 141 is perpendicular to the length direction of the round steel 100, and the roller 141 is able to rotate around its own axis.

[0046] The lower mold is located between two parallel vertical baffles 131. The two ends of the roller 141 are installed on the vertical baffles 131, thereby realizing the rotation of the roller. The rotation of the roller is conducive to the bending deformation of the round steel under pressure. After the round steel is bent under pressure, it can still maintain surface contact with the lower mold radius adjustment guide sleeve 145 of the lower mold, increasing the force-bearing surface and transmitting pressure evenly. The whole bending process is more stable and reliable.

[0047] The upper mold top seat 151 and the upper mold guide sleeve 152 are connected by welding or other fixing methods. The upper mold guide sleeve 152 and the upper mold radius adjusting guide sleeve 153 are detachable, for example, by bolting, so that the corresponding upper mold radius adjusting guide sleeve can be flexibly replaced according to the size of the round steel to ensure the fit with the surface of the round steel. Similarly, the roller 141, connecting block 142, lower mold top seat 143, and lower mold guide sleeve 144 are connected by welding or other fixing methods. The lower mold guide sleeve 144 and the lower mold radius adjusting guide sleeve 145 are detachable, for example, by bolting. The connecting block 142 is mainly used to connect the roller 141 and the lower mold top seat 143. It is welded and has an arch bridge shape. Its lower surface has an arc groove that fits with the surface of the roller, and its upper surface is flat to fix the lower mold top seat.

[0048] Furthermore, a baffle reinforcement 132 is fixed to the surface of the vertical baffle 131 away from the lower mold, and the baffle reinforcement 132 is perpendicular to the vertical baffle 131. The round steel bending mold also includes a base plate 11, which has a plurality of insertion holes arranged in an array. The vertical baffle 131 is placed on the base plate 11, and the bottom of the vertical baffle 131 and the bottom of the baffle reinforcement 132 are in contact with the upper surface of the base plate 11.

[0049] The insertion hole is used to insert the pin 12. The vertical baffle 131 and the baffle reinforcement 132 are closely attached to the periphery of multiple pins 12 to limit the vertical baffle. The design of the insertion hole can flexibly move the position of the vertical baffle, thereby changing the position of the lower mold, so as to flexibly adopt different opening distances according to the different lengths of the round steel, that is, the distance between the two lower molds.

[0050] As an example, the dimensions of each component are described in detail below.

[0051] The upper mold top seat is a cuboid. The pressure of the hydraulic press is directly applied to the upper surface of the upper mold top seat. The upper mold guide sleeve is a semi-circular tube with an inner diameter of 200mm and a thickness of 10mm. The upper mold top seat and the upper mold guide sleeve are connected by welding. The upper mold radius adjustment guide sleeve is a semi-circular tube, and the radius value can be made by the user according to their own needs. The upper mold guide sleeve and the upper mold radius adjustment guide sleeve are connected by a flexible connection for easy replacement.

[0052] The base plate is 2000mm long, 700mm wide, and 20mm thick, with a 31mm diameter opening for easy movement and fixation of the vertical baffle and lower mold. A 30mm diameter pin is used to secure the various components. The vertical baffle and its reinforcement are welded together. The vertical baffle measures 400mm x 400mm and is 20mm thick. The reinforcement is a triangular plate, 150mm wide, 250mm high, and 20mm thick. The roller is a 130mm diameter round steel bar that directly contacts the vertical baffle without welding, facilitating rotation during machining. A protective sleeve can be installed on the outside to prevent slippage. The connecting block is welded to the roller, the connecting block to the lower mold top seat, and the lower mold top seat to the lower mold guide sleeve. The lower mold radius adjustment guide sleeve does not need to be welded to the lower mold guide sleeve for easy replacement. This example mold is suitable for machining round steel bars with diameters from 80mm to 200mm. The machined lines are inspected using relevant templates.

[0053] Example 2

[0054] Based on the round steel bending die in Embodiment 1, this embodiment provides a bending method using the round steel bending die, such as... Figure 5 As shown, it includes the following steps:

[0055] S1: Information Verification. Verify the material, diameter, length, and part information of the incoming materials to ensure consistency with the parts, drawings, and samples. For example, Q235 steel with a diameter of 180mm and a length of 4m.

[0056] S2: Die Radius Adjustment. Based on the diameter of the part to be bent, adjust the fitting radius of the upper and lower dies using the radius adjustment guide sleeves. The inner diameter of the radius adjustment guide sleeve is 180mm, and the thickness is 10mm, ensuring a close fit with the surface of the round steel.

[0057] S3: Adjusting the opening distance of the lower die. Based on the diameter D and material of the part to be bent, adjust the opening distance L between the two lower dies. L = k * D, where k is a coefficient. For ordinary steel round bars (yield strength 200MPa~350MPa), k is 2.5~5; for high-strength steel round bars (yield strength 350MPa~1000MPa), k is 5~8. Here, k is set to 3, and the opening distance L = 3 * 180 = 540mm.

[0058] S4: Marking. Mark the lines on the part to be processed, drawing out the pressing lines (usually the center line of a round steel bar) for pressing and inspection.

[0059] S5: Segmented linear pressing. First press both ends of the round steel, generally pressing 1m on each end first, then pressing the middle.

[0060] S6: Segmented Linearity Inspection. During pressing, the steel is pressed segment by segment, and inspection is carried out simultaneously. During inspection, a short template of about 1m in length is placed on the upper surface of the round steel to check whether the short template fits the curvature of the round steel.

[0061] Taking the pressing of the left end of the round steel as an example, a surface center line is drawn 0.5m away from the left end. The upper mold is pressed down under the drive of the hydraulic cylinder. After each pressing, a short template is used to check the curvature. If the curvature does not meet the short template, pressing is performed again. The operation is repeated several times until the segmented line shape meets the curvature of the short template.

[0062] S7: Overall Line Pressing. After pressing each segment, the entire part needs to be pressed as a whole to ensure the smoothness of the overall line.

[0063] S8: Overall Linearity Inspection. Use the corresponding long template to inspect the overall linearity of the entire part, checking whether the long template and the curvature of the round steel fit together, and perform fine-tuning on any areas where the linearity mismatch exceeds the tolerance.

[0064] S9: Information Transfer. Place the machined parts on a horizontal platform and transfer the relevant information.

[0065] In summary, this invention provides a round steel bending die and bending method. The round steel bending die includes an upper die and a lower die. The upper die includes an upper die top seat, an upper die guide sleeve, and an upper die radius adjusting guide sleeve. The lower die includes a roller, a connecting block, a lower die top seat, a lower die guide sleeve, and a lower die radius adjusting guide sleeve. The round steel to be bent is placed between the upper and lower die radius adjusting guide sleeves, with the two lower dies positioned on either side of a single upper die along the length of the round steel. When the hydraulic press acts on the upper surface of the upper die top seat, the roller can rotate around its own axis. Even after the round steel is bent under pressure, it can still maintain surface contact with the lower die radius adjusting guide sleeve, uniformly transmitting pressure and making the entire bending process more stable and reliable. Furthermore, the radius adjusting guide sleeve is detachable and can be flexibly replaced according to the size of the round steel, ensuring a good fit with the surface of the round steel. In addition, the insertion hole design of the base plate allows for flexible movement of the lower die position, enabling different opening distances to be flexibly adopted according to the different lengths of the round steel.

[0066] Compared with conventional processes, this invention can simply and effectively improve the bending efficiency and quality of round steel, significantly saving labor costs and energy consumption. This mold system features simple and efficient operation, adjustability for processing round steel of different models and lengths, and high product quality. Compared with conventional processing methods, this mold system not only improves operational safety and processing accuracy but also enables rapid forming of round steel, significantly saving processing time and rework time.

[0067] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A round steel bending die, characterized in that, The round steel bending die includes an upper die and a lower die; The upper mold includes an upper mold top seat, an upper mold guide sleeve, and an upper mold radius adjusting guide sleeve connected sequentially from top to bottom; the upper surface of the upper mold top seat is a plane, serving as the downward pressing surface of the hydraulic press; both the upper mold guide sleeve and the upper mold radius adjusting guide sleeve are upwardly arched semi-cylindrical shapes, and the upper mold radius adjusting guide sleeve is detachably stacked on the lower surface of the upper mold guide sleeve; the lower surface of the upper mold top seat forms a concave first arc-shaped groove, and the upper surface of the upper mold guide sleeve is fitted and fixed within the first arc-shaped groove; The lower mold includes a roller, a connecting block, a lower mold top seat, a lower mold guide sleeve, and a lower mold radius adjusting guide sleeve connected sequentially from bottom to top; both the lower mold guide sleeve and the lower mold radius adjusting guide sleeve are downwardly recessed semi-cylindrical shapes, the lower mold radius adjusting guide sleeve is detachably stacked on the upper surface of the lower mold guide sleeve, the upper surface of the lower mold top seat has an inwardly recessed second arc-shaped groove, and the lower surface of the lower mold guide sleeve is fitted and fixed in the second arc-shaped groove; Vertically, the round steel to be bent is placed between the upper mold radius adjusting guide sleeve and the lower mold radius adjusting guide sleeve; along the length of the round steel, two lower molds are arranged on both sides of a single upper mold; the opening distance between the two lower molds is L = k * D; for ordinary steel with a yield strength of 200MPa to 350MPa, k is 2.5 to 5; for high-strength steel with a yield strength of 350MPa to 1000MPa, k is 5 to 8; D is the diameter of the round steel.

2. The round steel bending die according to claim 1, characterized in that: The axis of the roller is perpendicular to the length of the round steel, and the roller can rotate around its own axis.

3. The round steel bending die according to claim 2, characterized in that: The lower mold is located between two parallel vertical baffles, and the two ends of the roller are installed to the vertical baffles.

4. The round steel bending die according to claim 3, characterized in that: A baffle reinforcement is fixed to the surface of the vertical baffle away from the lower mold, and the baffle reinforcement is perpendicular to the vertical baffle.

5. The round steel bending die according to claim 4, characterized in that: The round steel bending die also includes a base plate, and the vertical baffle is placed on the base plate. The bottom of the vertical baffle and the bottom of the baffle reinforcement are in contact with the upper surface of the base plate.

6. The round steel bending die according to claim 5, characterized in that: The base plate is provided with multiple insertion holes arranged in an array. The insertion holes are used to insert pins. Multiple pins are closely attached to the periphery of the vertical baffle and the baffle reinforcement to limit the vertical baffle.

7. A bending method for a round steel bending die as described in claim 6, characterized in that, Includes the following steps: S1: Information verification, verifying the material, diameter, length, and part information of the incoming materials; S2: Die radius adjustment. Based on the diameter of the part to be bent, adjust the matching radius of the upper and lower dies through the radius adjustment guide sleeves of the upper and lower dies. S3: Adjust the opening distance of the lower die. According to the diameter D and material of the part to be bent, adjust the opening distance L of the two lower dies; L = k * D; for ordinary steel with a yield strength of 200MPa to 350MPa, k is 2.5 to 5; for high-strength steel with a yield strength of 350MPa to 1000MPa, k is 5 to 8. S4: Scribing, scribing the part to be processed, drawing out the pressing line, which is a surface center line of the round steel. S5: Segmented linear pressing, first pressing both ends of the round steel, then pressing the middle, with each pressing segment being 1m long; S6: Segmented line shape inspection, inspection while pressing. During inspection, a 1m long short template is placed on the upper surface of the round steel to check whether the short template fits the curvature of the round steel. S7: Overall linear pressing. After pressing each segment, the entire part is pressed as a whole. S8: Overall line shape inspection. Use the long template corresponding to the part to inspect the overall line shape of the entire part, check whether the long template and the curvature of the round steel fit together, and make fine repairs to the places where the line shape matches the tolerance. S9: Information transfer, placing the machined parts on a horizontal platform and transferring relevant information.

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