A cold bending and profiling process for the arc of the section steel of the car body of a rail vehicle

Abstract

The present invention relates to a cold bending and profiling process for the car body of a rail vehicle, which solves the problems that the springback amount and burr of the shearing surface do not meet the requirements. The process includes confirming the size of the profiled steel material; specifying the slitting specifications according to the drawing; selecting the die and installing the cutting tool, placing the laser scanner, setting the parameters of the profiled steel. When the profiled steel enters the shearing mechanism, it passes through the front die, the front pre-tightening mechanism, the front fixing mechanism, the cutting tool, the rear fixing mechanism, the rear pre-tightening mechanism, and the rear die. When the profiled steel enters the shearing mechanism, the front pre-tightening mechanism and the rear pre-tightening mechanism are inflated to wrap the profiled steel tightly, the front fixing mechanism and the rear fixing mechanism fix the profiled steel, and the profiled steel is preheated for a short time. The cutting tool shears the profiled steel hydraulically, and grinds and cools the shearing surface of the profiled steel. After the processing of the profiled steel is completed, the present invention fixes and locks the profiled steel through the front fixing mechanism and the rear fixing mechanism, preheats the shearing surface range during shearing, grinds the shearing surface while shearing, and cools the profiled steel at the same time, meeting the standard requirements.

Description

Technical Field

[0001] The present invention relates to the technical field of shearing and processing of vehicle body profile steels, and particularly to a cold bending and profiling process for arc-shaped cold bending profiled steels of a railway vehicle body. Background Art

[0002] For the roof side beam and roof side top plate of the 160km power-concentrated electric vehicle body of the drum-shaped vehicle, a small and complex cross-section high-precision roll forming technology is adopted. The body of the drum-shaped vehicle is made by roll forming cold bending profiled steels of the roof side beam and roof side top plate of the vehicle body. The main technological steps are: steel strip feeding - leveling - pre-punching - steel strip introduction - roll forming - welding - shearing.

[0003] The technical index requirements for the roof side beam and roof side top plate are that the overall product is straight, without wrinkles, hard bends, bulges, twists, and burrs. The length direction completeness is less than 8mm. The twist requirement for the roof side beam product is less than 5mm, and the twist requirement for the roof side top plate is less than 8mm. The dimensional tolerance requirement is within 0.4mm. When cutting, sharp waves are not allowed in the length direction, and obvious unilateral waviness is not allowed. The flatness of the shear surface ≤ 1mm / 2m.

[0004] In the entire forming process, the quality control of the product is reflected in each link. The main research direction of the present invention is the possible impact on the product during shearing. During shearing, it is generally divided into flying saw shearing and hydraulic shearing. The advantage of flying saw shearing is that the blade does not need to be replaced and can adapt to different shaped profiled steels. The disadvantages are slow shearing speed, long cutting stroke, regular maintenance of grinding teeth or replacement is required, the maintenance cycle is short, and the wear is relatively large. The advantage of hydraulic shearing is fast shearing speed. The present invention mainly studies hydraulic shearing. Hydraulic shearing is further divided into longitudinal shearing and inclined shearing. In order to reduce the deformation and bending of the profiled steel during shearing, the shapes of the cutting blades for longitudinal shearing and inclined shearing match the shape of the product. However, longitudinal shearing is mostly non-wrapping type, and inclined shearing is mostly wrapping type. Wrapping shearing compared with non-wrapping shearing is to minimize the bending range of the profiled steel as much as possible.

[0005] During the hydraulic shearing process, the profiled steel will be extruded, resulting in complete deformation of the profiled steel. The greater the thickness of the profiled steel, the greater the springback. As a result, at the moment of cutting, the springback amount of the profiled steel around the cut is relatively large, and there is a deviation in flatness during cutting, and burrs exist. In order to avoid this situation, the process has been changed from the original "cut first and then punch" to the current "punch first and then cut", and the product quality has been significantly improved, but the above situation still occurs.

[0006] After multiple process improvements, the quality of section steel processing has been greatly improved. However, for the processing product standards of the car body roof side beam and roof side top plate, problems such as cutting surface burrs and large material springback range still occur. Based on the long-term experience and experiments of the R & D personnel, after analysis, it is found that during shearing, due to the large variety of section steel processing shapes, different-shaped section steels require different molds and cutting tools. Therefore, in order to improve processing efficiency, during current processing, the molds and cutting tools will adopt a wide range. For example, Figure 2 As shown, one kind of mold can adapt to multiple shapes of the same type. Then, during the moment of shearing, the section steel is subjected to shearing extrusion and bending. Due to the relatively thick thickness of the section steel and large springback amount, the two sides of the section steel are not firmly fixed during shearing, and the space between the mold and the cutting tool is larger than the size of the section steel itself. Therefore, the springback amount, flatness, and burrs of the product do not meet the standard requirements.

[0007] On this basis, the present invention provides a cold bending and forming process for the section steel of the track vehicle car body to solve the above problems. Summary of the Invention

[0008] In view of the above situation, in order to overcome the defects of the prior art, the present invention provides a cold bending and forming process for the section steel of the track vehicle car body. The present invention effectively solves the technical problems that the springback amount, flatness, and burrs of the shearing surface of the roof side beam and roof side top plate do not meet the standard requirements.

[0009] A cold bending and forming process for the section steel of the track vehicle car body is characterized by including the following steps:

[0010] S1. Conduct pre-operation inspection on the process equipment and molds;

[0011] Confirm the size of the section steel raw material used;

[0012] Confirm that the drawings used are correct and the process documents are valid;

[0013] S2. Specify the slitting specifications according to the drawings in S1;

[0014] S3. Select the mold, install the wrapped cutting tool, place a laser scanner at the front end of the whole machine, and set the parameters of section steels with different sizes and shapes in the host computer of the whole machine in advance. The laser scanner matches the corresponding parameters in the host computer according to the scanned section steel or manually selects the corresponding parameters;

[0015] S4. The section steel passes through the uncoiling mechanism, leveling mechanism, stamping mechanism, rolling mechanism, welding mechanism, and shearing mechanism in sequence;

[0016] S5. When the section steel enters the shearing mechanism, it passes through the front mold, front pre-tightening mechanism, front fixing mechanism, cutting tool, rear fixing mechanism, rear pre-tightening mechanism, and rear mold in sequence;

[0017] S6. When the profiled steel enters the shearing mechanism and reaches the set length, the front pre-tightening mechanism and the rear pre-tightening mechanism are inflated to wrap the profiled steel tightly, the front fixing mechanism and the rear fixing mechanism fix the profiled steel, and preheat the profiled steel briefly. The cutter shears the profiled steel hydraulically, and grinds and cools the shearing surface of the profiled steel;

[0018] S7. Complete the processing of the profiled steel.

[0019] Preferably, mold holes are provided on the front mold, the front pre-tightening mechanism, the front fixing mechanism, the cutter, the rear fixing mechanism, the rear pre-tightening mechanism, and the rear mold in the step S5 or S6.

[0020] Preferably, a plurality of single-acting or double-acting hydraulic telescopic rods are installed inside the front fixing mechanism and the rear fixing mechanism in the step S5 or S6. The hydraulic telescopic rods are connected to the mold holes. The hydraulic telescopic rods expand and contract according to the parameters set in the step S3. After the corresponding parameters are matched, when the profiled steel moves to the set length of the shearing mechanism and stops, the hydraulic telescopic rods corresponding to the parameters extend into the mold holes to extrude and fix the profiled steel.

[0021] Preferably, a PTC heating sheet is fixed to the end of the hydraulic telescopic rod.

[0022] Preferably, the front pre-tightening mechanism and the rear pre-tightening mechanism in the step S5 or S6 are provided with air inlet pipes. After the profiled steel moves to the set length of the shearing mechanism and stops, an external air pump inflates the air inlet pipes through the solenoid valves on the air inlet pipes, causing the front pre-tightening mechanism and the rear pre-tightening mechanism to expand, thereby reducing the space of the mold holes for extruding and fixing the profiled steel, so as to achieve pre-compression. After shearing, the air is released through the solenoid valves at the other end of the air inlet pipes to return to the original state.

[0023] Preferably, a grinding strip and cold air holes are installed on one side of the cutter in the step S5 or S6. When the profiled steel is sheared, it is cooled by the cold air from the cold air holes and ground by the grinding strip.

[0024] Preferably, the front mold, the front pre-tightening mechanism, the front fixing mechanism, the cutter, the rear fixing mechanism, the rear pre-tightening mechanism, and the rear mold are installed in a shearing bin. A replacement hole is provided at the upper end of the shearing bin. A double-acting cylinder is installed at the upper end of the shearing bin in an inclined and rotatable manner. The double-acting cylinder is connected to a worm gear through a rotating shaft. The worm gear meshes with a worm, and the worm is connected to an adjustment motor;

[0025] The double-acting cylinder is fixed with a cutter seat, the cutter is installed in the cutter seat, and a guide hole is provided at the lower end of the cutter seat;

[0026] An adjusting cylinder is installed obliquely in the shearing bin. The adjusting cylinder fixes a guide rod corresponding to the guide hole through an adjusting bracket. The end of the guide rod is fixed with a hydraulic buffer rod, and the end of the hydraulic buffer rod is sleeved with a buffer spring. An infrared emitter is installed on the adjusting bracket, and a corresponding infrared receiver is installed at the lower end of the tool holder.

[0027] Preferably, adjusting lead screws with opposite threads are rotatably installed at the bottom of the shearing bin. Two adjusting sliders with matching threads are installed on the adjusting lead screws. Both sides of the adjusting sliders are connected to both sides of the front fixing mechanism and the rear fixing mechanism through connecting rods. Positioning rods fixed in the shearing bin penetrate through the front pre-tightening mechanism, the rear pre-tightening mechanism, the front fixing mechanism, and the rear fixing mechanism.

[0028] Preferably, adjusting bases are fixed at both ends of the shearing bin. The adjusting lead screws are rotatably installed on the adjusting bases. Adjusting guide rods are fixed at both ends of the adjusting bases, and the adjusting sliders slide on the adjusting guide rods.

[0029] Preferably, shearing plates are detachably installed at both ends of the shearing bin. The front die and the rear die are installed on the shearing plates. The positioning rods are fixed on the front die and the rear die. The front pre-tightening mechanism and the rear pre-tightening mechanism are sleeved on the positioning rods, and the front fixing mechanism and the rear fixing mechanism slide on the positioning rods.

[0030] The present invention has the following technical effects.

[0031] 1. The process improvement of the present invention mainly involves shearing. The original section steel passes through the die and is sheared by the tool. However, since the section steel is in a movable state during shearing, the size of the section steel is smaller than the die hole, and in addition, the section steel is relatively thick, resulting in large bending deformation and large springback during shearing of the section steel. The present invention pre-tightens the section steel in advance through the addition of a front pre-tightening mechanism and a rear pre-tightening mechanism, fixes and locks the section steel through the front fixing mechanism and the rear fixing mechanism, preheats the shearing surface range during shearing, realizes rapid shearing, reduces the yield strength, grinds the shearing surface during shearing, reduces flash and burrs, and cools the section steel at the same time to meet the standard requirements.

[0032] 2. The present invention improves the existing fully manual tool replacement to automatic tool replacement, improves the tool replacement efficiency. At the same time, when replacing the tool, it does not affect the normal use of the tool, maintains the stability of the tool during operation, and reduces the vibration of the tool during shearing.

[0033] 3. The present invention realizes the position adjustment of the front fixing mechanism and the fixing mechanism through the adjusting lead screw with double threads, can meet the requirements of different section steels, can control the springback amount during shearing of the section steel, and at the same time, can also realize not affecting the tool replacement. Description of the Drawings

[0034] The accompanying drawings are used to provide a further understanding of the present invention and form a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation to the present invention. In the accompanying drawings:

[0035] Figure 1 is the overall process flow chart of the present invention.

[0036] Figure 2 is the schematic diagram of the main corresponding equipment of the process of the present invention.

[0037] Figure 3 is the schematic diagram of the die hole type in the process of the present invention.

[0038] Figure 4 is the three-dimensional schematic diagram of the shearing mechanism of the present invention.

[0039] Figure 5 is the sectional schematic diagram of the shearing mechanism of the present invention.

[0040] Figure 6 is the sectional three-dimensional schematic diagram of the shearing mechanism of the present invention.

[0041] Figure 7 is the three-dimensional schematic diagram of the partial enlargement of the present invention Figure 1 。

[0042] Figure 8 is the three-dimensional schematic diagram of the partial enlargement of the present invention Figure 2 。

[0043] Figure 9 is the three-dimensional schematic diagram of the partial enlargement of the present invention Figure 3 。

[0044] Figure 10 is the sectional schematic diagram of the front pre-tightening mechanism or the rear pre-tightening mechanism of the present invention.

[0045] Figure 11 is the sectional schematic diagram of the front fixing mechanism or the rear pre-tightening mechanism of the present invention.

[0046] Reference numerals:

[0047] 1 - Roller pressing mechanism; 2 - Shearing mechanism; 3 - Front die; 4 - Front pre - tightening mechanism; 5 - Front fixing mechanism; 6 - Cutting tool; 7 - Rear fixing mechanism; 8 - Rear pre - tightening mechanism; 9 - Rear die; 10 - Die hole; 11 - Hydraulic telescopic rod; 12 - PTC heating sheet; 13 - Intake pipeline; 14 - Frosted strip; 15 - Cold air hole; 16 - Shearing bin; 17 - Replacement hole; 18 - Double - stroke cylinder; 19 - Worm gear; 20 - Worm; 21 - Adjusting motor; 22 - Tool holder; 23 - Adjusting cylinder; 24 - Adjusting bracket; 25 - Guide rod; 26 - Hydraulic buffer rod; 27 - Buffer spring; 28 - Infrared emitter; 29 - Adjusting screw rod; 30 - Adjusting slider; 31 - Connecting rod; 32 - Positioning rod; 33 - Adjusting base; 34 - Adjusting guide rod; 35 - Shearing plate. Detailed implementation mode

[0048] Regarding the foregoing and other technical contents, features and effects of the present invention, they will be clearly presented in the following detailed description of the embodiments in conjunction with the attached Figures 1 to 11 drawings. The content mentioned in the following embodiments is all referenced to the drawings of the specification.

[0049] The following will describe the exemplary embodiments of the present invention with reference to the drawings.

[0050] The research direction of the present invention is to improve from the "cut first and then punch" of the existing process to "punch first and then cut", the cutting tool is improved from a flying saw to a hydraulic shear, and the hydraulic cutting tool is improved from not being wrapped to a wrapped cutting tool. This is a relatively advanced process in the current market, all in order to improve the quality of profiled steel products, reduce burrs, bending degree, tolerance and flatness as much as possible. Since the present invention researches the profiled steel products of the roof side beam and the roof side top plate, and its standard requirements are relatively high, the above - mentioned problems still exist in the production. Therefore, it is necessary to further improve the current process to achieve high - efficiency product quality.

[0051] More detailed requirements for the profiled steel products of the roof side beam and the roof side top plate are:

[0052] 1. Good surface quality and high dimensional accuracy.

[0053] 2. Better flatness of the shearing surface without waviness.

[0054] 3. The shearing surface is not allowed to have an opening phenomenon.

[0055] 4. The arc fillet is not allowed to have cracks after PT (penetration) detection.

[0056] 5. The qualified rate of the notch quality reaches more than 98% without burrs.

[0057] The present invention is a cold - bending profiled steel arc - processing and forming process for a railway vehicle body, including the following steps:

[0058] S1. Conduct pre-operation inspections on the process equipment and molds to ensure they are in effective use condition, ensure that the whole machine is clean and tidy, select appropriate molds according to the shape of the processed section steel, and the subsequent installation position is on the shearing mechanism 2 of the whole machine. The operating environment temperature is -40°C to +40°C, and the maximum relative humidity is ≤95%.

[0059] Confirm the dimensions of the raw section steel materials used, and ensure that the surface quality meets the technical requirements. Select the dimensions of the processed materials. If the material dimensions do not match, pre-shearing is required.

[0060] Confirm that the used drawings are correct, the process documents are valid, and the materials are complete. Be familiar with the operation requirements, familiarize yourself with the drawings of the processed section steel products in advance, confirm the dimensions of the processed products, be familiar with the operation specifications of the whole machine, and set and select the parameters of the processed products in advance on the main machine of the whole machine.

[0061] S2. According to the specified slitting specifications in the drawings in S1, conduct appearance inspections for scratches, bumps, etc., and check whether the slitting dimensions are qualified.

[0062] Select molds and wrapping cutters that match the dimensions and shapes of the processed section steel for installation. Place a laser scanner at the front end of the whole machine to scan the dimensions and shapes of the section steel. Set the parameters of section steel with different dimensions and shapes in advance in the main machine of the whole machine. The laser scanner matches the corresponding parameters in the main machine according to the scanned section steel or manually selects the corresponding parameters.

[0063] Install the selected molds and wrapping cutters on the shearing mechanism 2. The molds are used for the processed section steel to pass through during processing according to its dimensions and shapes. After the section steel passes through the cutter 6, it is subsequently sheared by the wrapping cutter. The whole machine refers to the collective name of all the mechanisms passed through during cold bending forming. Install a laser scanner at the very front end of the whole, or it can also be other sensors with scanning and recognition functions. Its purpose is to identify the dimensions and shapes of the processed section steel and send signals to the main machine of the whole machine. The main machine is equivalent to the control system for operation. Different corresponding parameters of section steel with different specifications, dimensions, and shapes are pre-compiled in the control system. After the laser scanner finishes scanning, it sends signals to the main machine, and the main machine identifies the corresponding set parameters, which are the working basis for the subsequent mechanism operations.

[0064] S4. The section steel passes through the uncoiling mechanism, leveling mechanism, stamping mechanism, rolling mechanism 1, welding mechanism, and shearing mechanism 2 in sequence; these mechanisms are branches of the whole machine, and the present invention mainly focuses on the shearing mechanism 2.

[0065] When the H-shaped steel enters the shearing mechanism 2, it sequentially passes through the front die 3, the front pre-tightening mechanism 4, the front fixing mechanism 5, the cutter 6, the rear fixing mechanism 7, the rear pre-tightening mechanism 8, and the rear die 9. Here, the "front" and "rear" refer to the front being the part that the H-shaped steel contacts first and the rear being the part that it contacts later. Inside the shearing mechanism 2, the front die 3, the front pre-tightening mechanism 4, the front fixing mechanism 5, the cutter 6, the rear fixing mechanism 7, the rear pre-tightening mechanism 8, and the rear die 9 are installed in sequence from front to rear. Among them, the front die 3 and the rear die 9 have the same structure, the front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 have the same structure, and the front fixing mechanism 5 and the rear fixing mechanism 7 have the same structure. All of them are provided with die holes 10 for the H-shaped steel to pass through.

[0066] S6. When the H-shaped steel enters the shearing mechanism 2 and reaches the set length, the front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 are inflated to wrap the H-shaped steel tightly, the front fixing mechanism 5 and the rear fixing mechanism 7 fix the H-shaped steel, and at the same time, the H-shaped steel is preheated briefly. The cutter 6 shears the H-shaped steel hydraulically, and grinds and cools the shearing surface of the H-shaped steel. The front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 are made of silica gel material and can withstand a temperature of 250 °C. They are used to wrap the H-shaped steel tightly to prevent large deformation of the H-shaped steel during shearing. The front fixing mechanism 5 and the rear fixing mechanism 7 are used to fix the H-shaped steel during shearing. Since the width and size of the die hole 10 are larger than the size and shape of the H-shaped steel, it can prevent the H-shaped steel from shaking and having a large degree of bending during shearing, and is used to fix the H-shaped steel. At the same time, a preheating device is arranged inside the front fixing mechanism 5 and the rear fixing mechanism 7, and the preheating temperature is 150 °C. The H-shaped steel is locally preheated to 150 °C to reduce the yield strength of the H-shaped steel and accelerate shearing. The cutter 6 shears the H-shaped steel. The cutter 6 is a wrapped cutter. After shearing, the shearing surface of the H-shaped steel is ground immediately to reduce burrs, and at the same time, cold air is sprayed into the H-shaped steel immediately to cool it down and suppress springback.

[0067] S7. After the processing of the H-shaped steel is completed, the product is inspected after processing.

[0068] As an embodiment, during processing, die holes 10 are provided on the front die 3, the front pre-tightening mechanism 4, the front fixing mechanism 5, the cutter 6, the rear fixing mechanism 7, the rear pre-tightening mechanism 8, and the rear die 9 in the above step S5 or S6. The die holes 10 are used for the H-shaped steel to pass through, but the size of the die holes 10 is larger than the size of the H-shaped steel.

[0069] As an embodiment, a plurality of unidirectional or bidirectional hydraulic telescopic rods 11 are installed inside the front fixing mechanism 5 and the rear fixing mechanism 7 in step S5 or S6. The hydraulic telescopic rods 11 are controlled to expand and contract pneumatically, hydraulically or electrically. For example, Enerpac SMC-50 micro hydraulic cylinders or Huali HL-MHG20 are used. Since at this time, it is mainly to fix the profiled steel in the die hole 10, a required stroke of ≤5 cm is sufficient. The hydraulic telescopic rods 11 are installed inside the front fixing mechanism 5 and the rear fixing mechanism 7 and are communicated with the die hole 10, so that the hydraulic telescopic rods 11 can extend into the die hole 10 to extrude the profiled steel. After the laser scanner scans the size and shape of the profiled steel, a signal is sent to the parameters preset in the host computer, and a signal is sent to the hydraulic telescopic rods 11. The hydraulic telescopic rods 11 expand and contract according to the parameters set in step S3. After the corresponding parameters are matched, after the profiled steel moves to the set length of the shearing mechanism 2 and stops (this is the prior art), the hydraulic telescopic rods 11 corresponding to the parameters extend into the die hole 10 to extrude and fix the profiled steel.

[0070] As an embodiment, a PTC heating sheet 12 is fixed at the end of the hydraulic telescopic rod 11. The PTC heating sheet 12 is controlled by electric heating. For example, the model Heraeus PTC HTF-200X can be instantaneously heated to 150 °C within 0.5 seconds. Since the profiled steel is fixed and heated at multiple positions simultaneously, and the profiled steel has good heat transfer performance, and the front fixing mechanism 5 and the rear fixing mechanism 7 are adjacent to the cutter 6 but do not touch, the heat can be conducted in a short time to reduce the yield strength of the profiled steel and speed up shearing. After the profiled steel is preheated for a short time, it is cooled in time, which does not affect the strength of the profiled steel itself.

[0071] As an embodiment, an air inlet pipe 13 is built in the front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 in step S5 or S6. The front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 are made of hard silicone material and can withstand high temperature of 250 °C. A pressure gauge, an air inlet pipe and a solenoid valve are installed on the air inlet pipe 13. The solenoid valve is used for air intake and air release. After the profiled steel moves to the set length of the shearing mechanism 2 and stops, through the set parameters, an external air pump inflates the air inlet pipe 13 through the solenoid valve on the air inlet pipe 13. When the set pressure value is reached, it stops, so that the front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 expand, thereby reducing the space of the die hole 10 for extruding and fixing the profiled steel, so as to achieve pre-tightening. When the shearing is over, the air is released through the solenoid valve at the other end of the air inlet pipe 13, and when the pressure value returns to the initial pressure, it stops. It should be noted that at the initial pressure, the front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 are not in a shriveled state, but in a semi-full state, which satisfies the passage of the profiled steel through the die hole 10. Since the processing speed of the profiled steel itself is relatively slow, the front pre-tightening mechanism 4, the rear pre-tightening mechanism 8, the front fixing mechanism 5 and the rear fixing mechanism 7 all operate synchronously with the shearing of the cutter 6. Therefore, it does not affect the production efficiency of the profiled steel processing.

[0072] It should be noted that the air pump, pressure gauge, and solenoid valve are connected to the main machine.

[0073] As an embodiment, two abrasive strips 14 and cold air holes 15 are installed on one side of the cutter 6 in step S5 or S6. The cold air holes 15 are placed between the two abrasive strips 14. One abrasive strip 14 is placed between the die holes 10, and one abrasive strip 14 is placed outside the die holes 10. The abrasive strips 14 are embedded in the cutter 6. When the profiled steel is sheared, it is cooled by the cold air from the cold air holes 15 and ground by the abrasive strips 14.

[0074] It should be noted that the cutter 6 is a wrapped cutter. The cutting edge of the wrapped cutter is at the edge of the die hole 10. The cutting edge at the die hole 10 mainly plays a shearing role. The area of the entire cutter 6 is relatively large. Therefore, the cold air holes 15 and the abrasive strips 14 will not affect the wrapped cutter. When shearing, at the moment when the cutter 6 shears the profiled steel, the abrasive strip 14 grinds the cut surface of the profiled steel to reduce burrs. At the same time, the cold air holes 15 are connected to an external pumping power and cooling gas, such as nitrogen, through a hose. In this way, the other abrasive strip 14 grinds the shearing surface again to reduce the existence of burrs and flash.

[0075] As an embodiment, the shearing mechanism 2 includes a shearing chamber 16. The front die 3, front pre-tightening mechanism 4, front fixing mechanism 5, cutter 6, rear fixing mechanism 7, rear pre-tightening mechanism 8, and rear die 9 are installed in the shearing chamber 16 in sequence from front to back. A replacement hole 17 is opened at the upper end of the shearing chamber 16. A double-acting cylinder 18 is installed at the upper end of the shearing chamber 16 in an inclined and rotatable manner. The double-acting cylinder 18 is connected to a gas source. Specifically, a support plate is fixed on the inclined surface of the shearing chamber 16 through a pillar. The double-acting cylinder 18 is placed between the two support plates. Rotating shafts are fixed on both sides in the middle of the double-acting cylinder 18 through base plates. The rotating shafts are rotatably installed on the support plates. One of the rotating shafts penetrates through the support plate and is fixedly sleeved with a worm gear 19. The worm gear 19 meshes with a worm 20. The worm 20 is connected to an adjustment motor 21. The adjustment motor 21 is connected to a power source. A tool holder 22 is fixed on the double-acting cylinder 18. The cutter 6 is installed in the tool holder 22. Two guide holes are opened at the lower end of the inclined surface of the tool holder 22. An adjustment cylinder 23 is installed at the bottom of the shearing chamber 16 in an inclined manner. The adjustment cylinder 23 is connected to a gas source. The adjustment cylinder 23 is fixed with a guide rod 25 corresponding to the guide hole through an adjustment bracket 24. The guide rod 25 can enter the guide hole for positioning. A hydraulic buffer rod 26 is fixed at the end of the guide rod 25. A buffer spring 27 is sleeved at the end of the hydraulic buffer rod 26. An infrared emitter 28 is installed on the adjustment bracket 24. The infrared emitter 28 is connected to a controller and a power source. An installation hole is opened at the lower end of the tool holder 22, and a corresponding infrared receiver is installed in the installation hole.

[0076] As the tool 6 continuously shears, the tool 6 needs to be replaced regularly. Currently, all the tools 6 need to be replaced manually. Different from the round head tool of a lathe, the section steel tool 6 can be replaced through an intermittent mechanism. When shearing and replacing the tool 6 in the present invention, the tool holder 22 and the tool 6 can be installed in advance at the other end of the double-stroke cylinder 18 before replacement. When the tool 6 needs to be replaced, first stop the machine, adjust the cylinder 23 to pull out the hydraulic buffer rod 26 and the guide rod 25 from the guide hole, start the adjustment motor 21, the adjustment motor 21 drives the worm 20 to rotate, the worm 20 drives the worm wheel 19 to rotate, the worm wheel 19 drives the double-stroke cylinder 18 to rotate, and the internal tool holder 22 and the tool 6 are rotated out from the replacement hole 17. The newly installed tool holder 22 and the tool 6 enter the shearing bin 16 from the replacement hole 17 on the other side. When the infrared emitter 28 and the infrared receiver are matched, the adjustment motor 21 stops, and at this time, the replacement of the tool 6 is completed. Start the adjustment cylinder 23, and the adjustment cylinder 23 drives the guide rod 25, the hydraulic buffer rod 26, and the buffer spring 27 to enter the guide hole to ensure the stability of the tool 6 during shearing and reduce the unevenness of the shearing surface caused by vibration.

[0077] As an embodiment, an adjustment screw rod 29 with opposite threads on both sides is rotatably installed at the bottom of the shearing bin 16. Specifically, adjustment bases 33 are fixed at both ends of the bottom of the shearing bin 16, and the adjustment screw rod 29 is rotatably installed on the adjustment bases 33. The adjustment screw rod 29 does not affect the normal operation of the tool 6. Adjustment guide rods 34 are fixed at both ends of the adjustment base 33. Two adjustment sliders 30 are threadedly matched with the adjustment screw rod 29, and the adjustment sliders 30 slide on the adjustment guide rods 34. Both sides of the adjustment sliders 30 are connected to both sides of the front fixing mechanism 5 and the rear fixing mechanism 7 through connecting rods 31. One end of the adjustment screw rod 29 penetrates through the shearing bin 16 and is rotated manually or connected to a motor. Positioning rods 32 fixed on the shearing bin 16 penetrate through the front pre-tightening mechanism 4, the rear pre-tightening mechanism 8, the front fixing mechanism 5, and the rear fixing mechanism 7.

[0078] As an embodiment, the inside of the shearing bin 16 is a cavity, and shearing plates 35 are detachably installed at both ends. Installation holes are provided on the shearing plates 35, and a front die 3 and a rear die 9 are installed in the installation holes. The adjustment guide rods 34 are detachably installed on the front die 3 and the rear die 9. The front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 are sleeved on the adjustment guide rods 34, and the front fixing mechanism 5 and the rear fixing mechanism 7 slide on the adjustment guide rods 34.

[0079] Overall process flow:

[0080] S1. Conduct pre-operation inspection on the process equipment and molds to ensure they are in an effective use state;

[0081] Confirm that the size and surface quality of the used section steel raw materials meet the technical requirements;

[0082] Confirm that the drawings used are correct, the process documents are valid, the data is complete, and be familiar with the operation requirements.

[0083] S2. Specify the slitting specifications according to the drawings in S1.

[0084] S3. Select the dies that match the size and shape of the processed section steel, install the wrapping tool, place a laser scanner at the front end of the whole machine to scan the size and shape of the section steel, set the parameters of section steel with different sizes and shapes in the main machine of the whole machine in advance, and the laser scanner matches the corresponding parameters in the main machine according to the scanned section steel or manually selects the corresponding parameters.

[0085] S4. The section steel passes through the uncoiling mechanism, leveling mechanism, stamping mechanism, rolling mechanism 1, welding mechanism, and shearing mechanism 2 in sequence.

[0086] S5. When the section steel enters the shearing mechanism 2, it passes through the front die 3, front pre-tightening mechanism 4, front fixing mechanism 5, tool 6, rear fixing mechanism 7, rear pre-tightening mechanism 8, and rear die 9 in sequence.

[0087] S6. When the section steel enters the shearing mechanism 2 and reaches the set length, the whole machine stops running.

[0088] The front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 inflate the air inlet pipes 13 in the front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 quickly according to the pressure values corresponding to the matching parameters through the air inlet pipes and solenoid valves, so that the front pre-tightening mechanism 4 and the rear pre-tightening mechanism 8 expand rapidly to wrap and pre-tighten the section steel.

[0089] At the same time, the hydraulic telescopic rods 11 in the front fixing mechanism 5 and the rear fixing mechanism 7 only extend and retract the set hydraulic telescopic rods 11 according to the matching parameters. The hydraulic telescopic rods 11 fix multiple local positions of the section steel and lock and fix both sides of the section steel cut surface.

[0090] Meanwhile, the PTC heating sheets 12 preheat multiple positions of the section steel to facilitate the tool 6 to quickly cut the section steel.

[0091] The double-acting cylinder 18 drives the tool holder 22 and the wrapping tool to quickly cut the section steel. While cutting, the abrasive strip 14 grinds the cutting surface to reduce burrs and flash, and the cooling holes 15 quickly cool the section steel.

[0092] When the tool holder 22 moves, it is limited by the guide holes and guide rods 25 to ensure the stability of the tool holder 22 during shearing. At the same time, it is shock-absorbed by the buffer springs 27 and hydraulic buffer rods 26 to reduce the vibration of the tool holder 22 during cutting.

[0093] S7. Complete the processing of the section steel.

[0094] S8. During shearing, the closer the front fixing mechanism 5 and the rear fixing mechanism 7 of the section steel are to the shearing surface of the section steel, the smaller the springback will be. However, different section steel sizes have different requirements. At the same time, in order to ensure that the front fixing mechanism 5 and the rear fixing mechanism 7 do not affect the rotation of the tool holder 22 when replacing the tool 6, the front fixing mechanism 5 and the rear fixing mechanism 7 need to be adjusted.

[0095] During adjustment, the adjusting screw rod 29 is rotated manually or by an electric motor. The adjusting screw rod 29 drives the adjusting slider 30 to move away from or close to each other on the adjusting screw rod 29. The adjusting screw rod 29 drives the front fixing mechanism 5 and the rear fixing mechanism 7 to move away from or close to each other on the adjusting guide rod 34 through the connecting rod 31, thereby realizing the adjustment of the front fixing mechanism 5 and the rear fixing mechanism 7.

[0096] S9. When the tool 6 needs to be replaced, the tool holder 22 and the wrapped tool are installed outside the double-acting cylinder 18 in advance. Then, after the machine stops, the adjusting motor 21 drives the worm 20 to rotate. The worm 20 drives the worm wheel 19 to rotate. The worm wheel 19 drives the double-acting cylinder 18 to rotate. The double-acting cylinder 18 drives the tool holder 22 to rotate out from the replacement hole 17. At the same time, the newly replaced tool 6 enters the shearing chamber 16 through the replacement hole 17. When the infrared emitter 28 and the infrared receiver are matched, the replacement of the tool 6 is completed.

[0097] The present invention has the following technical effects.

[0098] 1. The process improvement of the present invention mainly relates to shearing. The original section steel passes through the mold and is sheared by the tool. However, since the section steel is in a movable state during shearing, the size of the section steel is smaller than the mold hole, and the section steel is relatively thick, resulting in large bending deformation and large springback during shearing of the section steel. The present invention pre-tightens the section steel in advance by adding a front pre-tightening mechanism and a rear pre-tightening mechanism, fixes and locks the section steel by the front fixing mechanism and the rear fixing mechanism, preheats the shearing surface range during shearing, realizes rapid shearing, reduces the yield strength, grinds the shearing surface while shearing, reduces flash and burrs, and cools the section steel at the same time to meet the standard requirements.

[0099] 2. The present invention improves the existing fully manual tool replacement to automatic tool replacement, improves the tool replacement efficiency. At the same time, when replacing the tool, it does not affect the normal use of the tool, maintains the stability of the tool during operation, and reduces the vibration of the tool during shearing.

[0100] 3. The present invention realizes the position adjustment of the front fixing mechanism and the fixing mechanism through the adjusting screw rod with a double-thread, which can meet the requirements of different section steels, can control the springback amount during shearing of the section steel, and can also realize not affecting the tool replacement.

[0101] Although the content of the present invention has been described in detail through the above preferred embodiments, it should be recognized that the above description should not be construed as a limitation of the present invention. After those skilled in the art have read the above content, various modifications and alternatives to the present invention will be obvious. Therefore, the protection scope of the present invention should be defined by the appended claims.

Claims

1. A cold bending and forming process for the arc of the section steel of the car body of an orbital vehicle, characterized in that The following steps are involved: S1. Check the process equipment and molds before starting work; Confirm the size of the steel raw materials used; Confirm that the drawings used are correct and the process documents are valid; S2. Specify the striping specifications according to the drawings in S1; S3. Select the mold, package the tool and install it, place the laser scanner at the front end of the whole machine, set the parameters of steel sections of different sizes and shapes in the main machine in advance, and the laser scanner matches the corresponding parameters in the main machine according to the scanned steel section or manually selects the corresponding parameters; S4. The steel section passes through the unwinding mechanism, the leveling mechanism, the stamping mechanism, the rolling mechanism (1), the welding mechanism, and the shearing mechanism (2) in sequence; S5. When the steel section enters the shearing mechanism (2), it passes through the front mold (3), the front pre-tightening mechanism (4), the front fixing mechanism (5), the cutter (6), the rear fixing mechanism (7), the rear pre-tightening mechanism (8), and the rear mold (9) in sequence; S6. When the steel section enters the shearing mechanism (2) and reaches the set length, the front pre-tightening mechanism (4) and the rear pre-tightening mechanism (8) are inflated to tighten the steel section, the front fixing mechanism (5) and the rear fixing mechanism (7) fix the steel section and preheat the steel section for a short time, the cutter (6) hydraulically shears the steel section, and grinds and cools the sheared surface of the steel section; The front pre-tightening mechanism (4) and the rear pre-tightening mechanism (8) in step S5 or S6 are built in an air intake pipe (13). After the steel section moves to the set length of the shearing mechanism (2) and stops, the air intake pipe (13) is inflated through the solenoid valve on the air intake pipe (13) by an external air pump, so that the front pre-tightening mechanism (4) and the rear pre-tightening mechanism (8) expand, thereby reducing the space of the die hole (10) for extruding and fixing the steel section, thereby achieving pre-tightening. When the shearing is completed, the air is released through the solenoid valve at the other end of the air intake pipe (13) to restore to the original state; S7. Complete the processing of steel sections.

2. The cold bending and profiling process for the arc of the section steel of the car body of a rail vehicle according to claim 1, characterized in that, In the step S5 or S6, the front mold (3), the front pre-tightening mechanism (4), the front fixing mechanism (5), the tool (6), the rear fixing mechanism (7), the rear pre-tightening mechanism (8), and the rear mold (9) are all provided with mold holes (10).

3. A cold bending and profiling process for the arc of the section steel of the car body of a rail vehicle according to claim 2, characterized in that, The front fixing mechanism (5) and the rear fixing mechanism (7) in step S5 or S6 are internally installed with a plurality of unidirectional or bidirectional hydraulic telescopic rods (11), the hydraulic telescopic rods (11) being connected to the die hole (10), the hydraulic telescopic rods (11) being telescoped according to the parameters set in step S3, and when the corresponding parameters are matched, after the steel section moves to the set length of the shearing mechanism (2) and stops, the hydraulic telescopic rods (11) corresponding to the parameters are extended into the die hole (10) to extrude and fix the steel section.

4. A cold bending and profiling process for the arc of the section steel of the car body of a rail vehicle according to claim 3, characterized in that, A PTC heating plate (12) is fixed to the end of the hydraulic telescopic rod (11).

5. A cold bending and profiling process for the arc of the section steel of an orbital vehicle car body according to claim 1, characterized in that, In step S5 or S6, a side surface of the cutter (6) is provided with a grinding strip (14) and a cooling air hole (15), and when the steel section is sheared, it is cooled by the cooling air from the cooling air hole (15) and ground by the grinding strip (14).

6. A cold bending and profiling process for the arc of the section steel of the car body of a rail vehicle according to claim 1, characterized in that, The front die (3), front pre-tightening mechanism (4), front fixing mechanism (5), cutting tool (6), rear fixing mechanism (7), rear pre-tightening mechanism (8), and rear die (9) are installed in the shearing bin (16). A replacement hole (17) is provided at the upper end of the shearing bin (16). A double-acting cylinder (18) is installed at the upper end of the shearing bin (16) in an inclined and rotatable manner. The double-acting cylinder (18) is connected to a worm gear (19) through a rotating shaft. The worm gear (19) meshes with a worm (20), and the worm (20) is connected to an adjusting motor (21). A tool holder (22) is fixed to the double-acting cylinder (18). The cutting tool (6) is installed in the tool holder (22). A guiding hole is provided at the lower end of the tool holder (22). An adjusting cylinder (23) is installed in the shearing bin (16) in an inclined manner. A guiding rod (25) corresponding to the guiding hole is fixed to the adjusting cylinder (23) through an adjusting bracket (24). A hydraulic buffer rod (26) is fixed to the end of the guiding rod (25). A buffer spring (27) is sleeved on the end of the hydraulic buffer rod (26). An infrared emitter (28) is installed on the adjusting bracket (24), and a corresponding infrared receiver is installed at the lower end of the tool holder (22).

7. A cold bending and forming process for the arc of the section steel of the car body of a rail vehicle according to claim 6, characterized in that, Adjusting lead screws (29) with opposite threads are rotatably installed at the bottom of the shearing bin (16). Two adjusting sliders (30) that are thread-matched to the adjusting lead screws (29) are connected to both sides of the front fixing mechanism (5) and the rear fixing mechanism (7) through connecting rods (31). Positioning rods (32) fixed in the shearing bin (16) penetrate through the front pre-tightening mechanism (4), rear pre-tightening mechanism (8), front fixing mechanism (5), and rear fixing mechanism (7).

8. A cold bending and profiling process for the arc of the section steel of the car body of a rail vehicle according to claim 7, characterized in that, Adjusting bases (33) are fixed to both ends of the shearing bin (16). The adjusting lead screws (29) are rotatably installed on the adjusting bases (33). Adjusting guiding rods (34) are fixed to both ends of the adjusting bases (33). The adjusting sliders (30) slide on the adjusting guiding rods (34).

9. The cold bending and profiling process for the arc of the section steel of the car body of a rail vehicle according to claim 8, characterized in that, Shearing plates (35) are detachably installed at both ends of the shearing bin (16). The front die (3) and the rear die (9) are installed on the shearing plates (35). The positioning rods (32) are fixed to the front die (3) and the rear die (9). The front pre-tightening mechanism (4) and the rear pre-tightening mechanism (8) are sleeved on the positioning rods (32). The front fixing mechanism (5) and the rear fixing mechanism (7) slide on the positioning rods (32).

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