Integrated Manufacturing Apparatus and Method for Electro-Auxiliary Forming and Electro-Pulse Solution Aging of Aluminum Alloys

Abstract

An aluminum alloy electric auxiliary forming and electric pulse solid solution aging integrated manufacturing device and method, comprising: a stretch bending die, a pulse power supply, a temperature monitoring device and a cooling device, wherein: the two ends of the aluminum alloy profile are connected with the stretch bending die respectively and the middle part is in contact with the stretch bending die, the pulse power supply outputs multiple groups of parallel electrode pairs and is symmetrically arranged on the two sides of the aluminum alloy profile in turn, the temperature monitoring device collects temperature signals of several positions on the aluminum alloy profile, and the cooling device is arranged on the stretch bending die and cools by spraying. The present application combines electric auxiliary stretch bending forming with solid solution aging treatment, improves the comprehensive performance of the aluminum alloy stretch bending part, so that the parts with forming precision and performance meeting the requirements are obtained, the complexity of the heat treatment process of the stretch bending part is simplified, and the manufacturing cycle is shortened.

Description

Technical Field

[0001] This invention relates to a technology in the field of alloy manufacturing, specifically an integrated manufacturing apparatus and method for aluminum alloy electro-assisted forming and electro-pulse solution aging. Background Technology

[0002] Aluminum alloys possess many excellent properties, making them widely used in structural components for automobiles, aerospace, and other industries. Structural components made of aluminum alloys can meet the requirements of strength and stiffness while significantly reducing overall weight. However, due to the high strength and hardness but poor elongation of aluminum alloys, significant springback and errors occur during forming and processing. For aluminum alloy stretch-bending structural components, improving plasticity and reducing forming errors are key factors affecting processing quality. Summary of the Invention

[0003] This invention addresses the shortcomings of existing methods that improve forming accuracy by modifying mold structures or pre-treating aluminum alloys. These methods involve complex processes, long processing cycles, and require extensive springback compensation after bending, making it impossible to achieve precise processing of aluminum alloy profiles in a single operation. The invention proposes an integrated manufacturing device and method for aluminum alloy electric-assisted forming and electric pulse solution aging. This method combines electric-assisted bending forming with solution aging treatment to improve the overall performance of bent aluminum alloy parts, thereby obtaining parts with satisfactory forming accuracy and performance. Furthermore, it simplifies the complexity of the heat treatment process for bent parts and shortens the manufacturing cycle.

[0004] This invention is achieved through the following technical solution:

[0005] This invention relates to an integrated manufacturing apparatus for electro-assisted forming and electro-pulse solution aging of aluminum alloys, comprising: a bending die, a pulse power supply, a temperature monitoring device, and a cooling device, wherein: both ends of the aluminum alloy profile are connected to the bending die and the middle part is in contact with the bending die; the pulse power supply outputs multiple sets of parallel electrode pairs and is symmetrically arranged on both sides of the aluminum alloy profile; the temperature monitoring device collects temperature signals at several locations on the aluminum alloy profile; and the cooling device is arranged on the bending die and cools the profile by spraying.

[0006] The bending die includes a forming die and a pair of bending machine arms rotatably mounted thereon. The bending machine arms are respectively connected to both ends of the aluminum alloy profile. The forming die is in contact with the middle of the aluminum alloy profile. The bending of the aluminum alloy profile by the forming die is achieved by the relative rotation of the bending machine arms.

[0007] This invention relates to a method for the integrated manufacturing of aluminum alloy electro-assisted forming and electro-pulse solution aging based on the above-mentioned device, comprising:

[0008] Step 1) Electrically assisted stretch bending: Load the aluminum alloy profile onto the clamps at both ends of the stretch bending machine, and clamp the input / output electrodes and temperature sensor wires onto the aluminum alloy profile in sequence. Set up the liquid nitrogen cooling equipment, set the initial current density and forming temperature, start the pulse power supply to heat up, and start the stretch bending machine to begin stretch bending after the overall temperature of the profile has stabilized near the forming temperature. After forming is completed, turn off the stretch bending machine.

[0009] Step 2) Electrical pulse solution treatment: Keep the bent part in the same position on the mold, set the solution treatment temperature, and continue to heat the bent part with electricity. After the bent part reaches the solution temperature, the pulse power supply will automatically reduce the input current to keep the bent part within the solution temperature range. Then, the bent part will undergo solution treatment for a certain period of time.

[0010] Step 3) Cooling and quenching: After the solution treatment is completed, set the quenching temperature and turn on the liquid nitrogen cooling equipment to spray liquid nitrogen onto the surface of the bent part to cool it rapidly to the quenching temperature range for cooling and quenching.

[0011] Step 4) Electrical Pulse Aging Treatment: After the quenching treatment is completed, the aging treatment temperature is set, and the pulse power supply automatically increases the current density to heat the bent part. Once the bent part reaches the quenching temperature, the power supply system automatically adjusts the current density to keep the temperature of the bent part within the aging temperature range. Then, an aging treatment is performed for a certain period of time. After the aging treatment is completed, the pulse power supply is turned off, and the bent part is unloaded and removed after it has cooled naturally.

[0012] Technical effect

[0013] This invention allows for the completion of multiple processing steps, including bending and solution aging of aluminum alloy profiles, on a single device. It reduces flow stress and improves material plasticity by using the electroplasticity of pulsed current, thereby reducing springback after forming. The Joule heating effect of the pulsed current rapidly heats the profile, promoting the solution aging process of the bent parts. Precise temperature control of the profile is achieved through multi-zone energized temperature control technology. Compared to existing technologies, this invention eliminates the need for multiple loading and unloading of profiles, allowing the bending and heat treatment processes to be completed on the same set of equipment, thus simplifying the processing flow. Current heating significantly reduces heating time and improves the efficiency of hot processing. During operation, only the temperature for each processing step needs to be set; the control system automatically adjusts the input current based on the profile's temperature changes, ensuring the bent part's temperature quickly reaches and stabilizes within the processing temperature range. Multi-zone energized temperature control technology allows for real-time monitoring of the temperature in different areas of the bent part during processing, precisely adjusting the heating rate of different areas based on temperature changes. This achieves accurate temperature control, preventing localized overheating or temperature concentration, and ensuring the bent part maintains a uniform overall temperature during processing. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the integrated manufacturing apparatus for aluminum alloy electro-assisted forming and electro-pulse solution aging according to the present invention.

[0015] In the diagram: 1 Bending machine arm, 2 Input / output electrodes, 3 Forming mold, 4 Aluminum alloy profile, 5 Temperature sensor, 6 Liquid nitrogen nozzle, 7 Bending machine fixture, 8 Pulse power supply, 9 Temperature monitoring device, 10 Liquid nitrogen cooling device;

[0016] Figure 2 This is a schematic diagram illustrating the operation of an example. Detailed Implementation

[0017] like Figure 1 As shown, this embodiment relates to an integrated manufacturing apparatus for aluminum alloy electro-assisted forming and electro-pulse solution aging, comprising: a bending die, a pulse power supply 8, a temperature monitoring device, and a cooling device. The aluminum alloy profile 4 is connected to the bending die at both ends and is in contact with the bending die at the middle. The pulse power supply 8 outputs multiple sets of parallel electrodes 2 pairs, which are symmetrically arranged on both sides of the aluminum alloy profile 4. The temperature monitoring device collects temperature signals at several locations on the aluminum alloy profile 4. The cooling device is installed on the bending die and cools the material by spraying.

[0018] The bending die includes a forming die 3 and a pair of bending machine arms 1 rotatably mounted thereon. The bending machine arms 1 are respectively connected to both ends of the aluminum alloy profile 4. The forming die 3 is in contact with the middle of the aluminum alloy profile 4. The forming die 3 bends the aluminum alloy profile 4 at 30° by the relative rotation of the bending machine arms 1.

[0019] Insulating gaskets are provided between the bending machine arm 1 and the aluminum alloy profile 4, and between the forming mold 3 and the bending machine arm 1.

[0020] There are five pairs of electrodes 2.

[0021] The temperature monitoring device includes four sets of temperature sensors 6 and a temperature monitor 9 connected to them.

[0022] The 7075 aluminum alloys involved in this embodiment are all industrial-grade profiles.

[0023] Step 1) Profile Pretreatment: The selected 7075 aluminum alloy profile is 1m long, 10mm thick, and has a T-shaped cross-section. The surface of the profile, especially the two ends that come into contact with the bending machine clamp and power chuck, is sanded with sandpaper to remove surface impurities and obtain a clean and flat surface.

[0024] Step 2) Electrically Assisted Bending Forming: The aluminum alloy profile is mounted on the bending machine. Input / output electrodes and temperature sensors are clamped at different parts of the profile. The forming temperature and initial output current are set. The forming temperature is 180℃, and the initial output current for each pair of electrodes is 200A. The pulse power supply and temperature monitoring device are activated to begin heating. During the heating process, the central area of ​​the profile heats up at a higher rate, so the control system automatically reduces the input current to the outer edges of the profile to maintain a consistent overall temperature. Once the overall profile temperature stabilizes at approximately the forming temperature, the bending machine is started to begin bending. After forming is complete, the bending machine and pulse power supply are turned off.

[0025] Step 3) Electrical pulse solution treatment: After the bending is completed, set the solution treatment temperature to 450℃ and restart the pulse power supply to heat the bent part. After the temperature of the bent part reaches 450℃, the control system automatically adjusts the input current of each area to stabilize the overall temperature of the bent part within the solution treatment temperature range. Then, maintain the bent part at this temperature for 40 minutes of solution treatment. After the solution treatment is completed, turn off the pulse power supply.

[0026] Step 4) Cooling and quenching: After the solution treatment is completed, open the liquid nitrogen nozzle and spray liquid nitrogen evenly on each area of ​​the bent part to quickly reduce its temperature to about 25°C, thus completing the cooling and quenching.

[0027] Step 5) Electrical pulse aging treatment: After quenching, set the aging temperature to 180℃ and start the pulse power supply to continue heating the bent part. When the overall temperature of the bent part stabilizes at around 180℃, perform aging treatment on the bent part at this temperature for 3 hours. After the treatment is completed, turn off the pulse power supply and remove the bent part after it has cooled naturally.

[0028] Comparative Example 1

[0029] In contrast, when bending and solution aging aluminum alloy profiles, a heat treatment furnace is used to heat the bent parts to the corresponding processing temperature (the average heating rate will not exceed 30℃ / min) before processing.

[0030] Compared with Comparative Example 1, the springback angle of the bent part formed by the method of the present invention is only about 5°, while the springback angle of the bent part heated by the heat treatment furnace reaches 10°. The heating time to reach the solution temperature range of the present invention is reduced by 1 hour compared with the heating time of the heat treatment furnace, and the heating time to reach the aging temperature range is reduced by 30 minutes compared with the heating time of the heat treatment furnace. Under the same mechanical performance requirements, the solution treatment time in the present invention is reduced by 2 hours compared with Comparative Example 1, the aging treatment time is reduced by 4 hours compared with Comparative Example 1, and the total heat treatment time is shortened by 6 to 7 hours, which greatly improves the processing efficiency.

[0031] Compared with existing technologies, this invention improves the plasticity of aluminum alloys through electric assisted processing, significantly reduces the springback of bent parts, and controls the springback angle after forming to within 5°; pulsed current directly heats the billet, resulting in high energy utilization efficiency; current heating improves the heating rate and promotes the solution aging process; after each process is completed, only the processing temperature of the next process needs to be set, and the system will automatically adjust the current to ensure that the profile temperature reaches the processing temperature range, greatly simplifying the user's operation process.

[0032] The above-described specific implementations can be partially adjusted by those skilled in the art in different ways without departing from the principles and purpose of the present invention. The scope of protection of the present invention is defined by the claims and is not limited to the above-described specific implementations. All implementation schemes within the scope of the claims are bound by the present invention.

Claims

1. An aluminum alloy electro-assisted forming and electro-impulse solution and aging integrated manufacturing method based on aging integrated manufacturing device, characterized in that, The manufacturing device comprises a stretch bending die, a pulse power supply, a temperature monitoring device and a cooling device, wherein: two ends of the aluminum alloy profile are connected with the stretch bending die respectively and the middle part is in contact with the stretch bending die, the pulse power supply outputs multiple groups of parallel electrode pairs and is symmetrically arranged on both sides of the aluminum alloy profile in sequence, the temperature monitoring device collects temperature signals of multiple positions on the aluminum alloy profile, and the cooling device is arranged on the stretch bending die and cools by spraying. The manufacturing method comprises: Step 1) electric auxiliary stretch bending forming: loading the aluminum alloy profile on the two end clamps of the stretch bending machine, clamping the input / output electrodes and temperature sensor wires on the aluminum alloy profile in sequence, erecting the liquid nitrogen cooling equipment, setting the initial current density and forming temperature, starting the pulse power supply to heat, starting the stretch bending machine to begin stretch bending forming after the overall temperature of the profile is stabilized near the forming temperature, and closing the stretch bending machine after forming; Step 2) electric pulse solid solution treatment: keeping the position of the stretch bending part on the die unchanged, setting the solid solution treatment temperature, continuing to heat the stretch bending part, reducing the input current size of the pulse power supply when the temperature of the stretch bending part reaches the solid solution temperature, so that the stretch bending part is always kept in the solid solution temperature range, and then performing solid solution treatment on the stretch bending part for a certain time; Step 3) cooling and quenching: setting the quenching temperature after the solid solution treatment is completed, opening the liquid nitrogen cooling equipment at the same time, spraying liquid nitrogen on the surface of the stretch bending part to cool it quickly to the quenching temperature range, and performing cooling and quenching; During the operation, the temperature of each processing step is set, and the control system automatically adjusts the input current size according to the temperature change of the profile, so that the temperature of the stretch bending part quickly reaches and stabilizes in the processing temperature range; Step 4) electric pulse aging treatment: setting the aging treatment temperature after the quenching treatment is completed, automatically increasing the current density of the pulse power supply to heat the stretch bending part, automatically adjusting the current density of the power supply system when the stretch bending part rises to the quenching temperature, so that the temperature of the stretch bending part is kept in the aging temperature range, then performing aging treatment for a certain time, and closing the pulse power supply after the aging treatment is completed, and then naturally cooling and unloading the stretch bending part.

2. The aluminum alloy electro-assisted forming and electro-impulse solution and aging integrated manufacturing method according to claim 1, characterized in that, The stretch bending die comprises a forming die and a pair of stretch bending machine rotating arms rotatably arranged thereon, the stretch bending machine rotating arms are connected with the two ends of the aluminum alloy profile respectively, the forming die is in contact with the middle part of the aluminum alloy profile, and the bending forming of the aluminum alloy profile by the forming die is realized through the relative rotation of the stretch bending machine rotating arms.

3. The aluminum alloy electro-assisted forming and electro-impulse solution and aging integrated manufacturing method according to claim 1, characterized in that, Insulating gaskets are arranged between the stretch bending machine rotating arms and the aluminum alloy profile and between the forming die and the stretch bending machine rotating arms.

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