Aluminum alloy profile roll bending forming device and roll bending forming method using same

Abstract

The invention discloses a roll bending forming device for an aluminum alloy profile. The roll bending forming device comprises a crankshaft, a rotating shaft, a roll bending die, a clamping structure and a sliding plate structure. One end of the crankshaft is fixed with roll bending equipment, and the other end is coaxially fixed with the rotating shaft; a roll bending die and a clamping structure which are adjacent to each other are arranged below the rotating shaft; the roll bending die comprises a die core, outer side die baffles and inner side die baffles, the upper end of the die core is fixed to the rotating shaft, an arc face is arranged at the bottom of the front end of the die core, the outer side die baffles are fixed to the two sides of the die core, and the two opposite inner side die baffles are fixed in the two outer side die baffles and located below the die core. A to-be-bent profile is inserted into a gap below the die core and is clamped from two sides by the clamping structure, so that the to-be-bent profile, the roll bending die and the clamping structure form a whole; the sliding plate structure is located below the whole and fixed to the roll bending equipment, and the sliding plate structure makes sliding contact with the lower surface of the whole. The invention further discloses a roll bending forming method using the aluminum alloy profile roll bending forming device.

Description

Technical Field

[0001] The present invention belongs to the field of forming technology, and is mainly used for the forming of aluminum alloy profiles. Specifically, it relates to an aluminum alloy profile roll bending forming device and a roll bending forming method using the same. Background Art

[0002] In rail transit vehicles, the application of bent formed parts is becoming more and more extensive. Bent formed parts can not only meet the structural strength of the rail transit vehicle body, but also ensure that the vehicle can maintain good performance and appearance in various environments.

[0003] In subway vehicles, bent formed parts are widely used in the manufacture of vehicle bodies, including the manufacture of components such as underframes, side walls, and car roofs. These components not only have high strength and stability, but also can meet the requirements of subway vehicles for lightweight, environmental protection, and energy conservation. Through precise bending and forming processes, components with a streamlined appearance and high strength can be produced, thereby improving the running speed and safety of the train.

[0004] Therefore, the manufacturing process design (device and method) of bent formed parts is particularly crucial in the manufacture of rail transit vehicles. It not only relates to the quality and performance of products, but also directly affects production efficiency and costs. A reasonable manufacturing device and method can not only reduce cost investment, but also make the product quality more stable.

[0005] For traditional three-roll roll bending forming, its roll bending forming requires three circular rolls to cooperate and go through multiple repeated rollings to achieve forming, as Figure 1 shown. Summary of the Invention

[0006] In order to solve the problems of roll bending forming, the purpose of the present invention is to provide an aluminum alloy profile roll bending forming device and a roll bending forming method using the same, which can not only ensure product quality but also achieve rapid forming. The present invention significantly shortens the production cycle, reduces manual intervention and waiting time on the production line, thereby reducing labor costs and time costs.

[0007] To achieve the above purpose, the technical solution provided by the present invention is as follows: An aluminum alloy profile roll bending forming device includes a crankshaft, a rotating shaft, a roll bending die, a clamping structure, and a sliding plate structure; one end of the crankshaft is fixedly connected to the hydraulic push rod of the roll bending equipment, and the other end of the crankshaft is coaxially fixed to the rotating shaft; a roll bending die and a clamping structure are arranged adjacent to each other below the rotating shaft; The roll bending die includes a die core, an outer die baffle, and an inner die baffle. The upper end of the die core is fixed to a rotating shaft. The bottom of the front end of the die core is provided with an arc surface. Outer die baffles are fixed on both sides of the die core. Two opposite inner die baffles are fixed below the die core and inside the two outer die baffles. The profile to be bent is inserted into the gap below the die core and clamped from both sides by a clamping structure, so that the profile to be bent, the roll bending die, and the clamping structure form an integral body. The skateboard structure is located below the integral body and fixed to the roll bending equipment. The skateboard structure is in sliding contact with the lower surface of the integral body.

[0008] Furthermore, the roll bending die and the clamping structure are replaceable. The upper end of the die core is fixedly connected to the rotating shaft through bolts.

[0009] Furthermore, the inner arc radius of the die core is 0.9 - 0.97 times the inner arc radius of the profile after final roll bending.

[0010] Furthermore, the clamping structure is set in a concave shape and includes an outer baffle, an inner baffle, and a lower fixing plate. Two inner baffles that cooperate with each other are provided on the lower fixing plate. An outer baffle is provided outside the inner baffle. Bolt holes are provided in both the upper and lower parts of the outer baffle. The upper part of the outer baffle is pre-fixed or fixed to the outside of the die core using a tightening bolt. The lower part of the outer baffle clamps and fixes the lower part of the profile to be bent between the two inner baffles using a tightening bolt. The bottom end of the outer baffle and the lower fixing plate are fixedly connected by tightening bolts.

[0011] Furthermore, the rotating shaft is set in a "Ω" - shaped structure. The upper hole of the "Ω" - shaped structure and the other end of the crankshaft are both penetrated on the protruding shaft of the roll bending equipment. The movement of the hydraulic push rod drives the crankshaft and the rotating shaft to rotate around the protruding shaft.

[0012] Furthermore, side holes are provided on the outside of both the die core and the inner die baffle. The die core and the inner die baffle are assembled and fixed to the outer die baffle through the side holes using bolts.

[0013] A roll bending method using the roll bending forming device for aluminum alloy profiles according to any one of the above, characterized in that the method includes: (1) Assembling the roll bending forming device for aluminum alloy profiles to the roll bending equipment; (2) Inserting the profile to be bent from the side of the clamping structure into the side of the roll bending die, and confirming the length of the profile to be bent extending from the side of the roll bending die; (3) Fixing the clamping structure to the die core by tightening the tightening bolts through the bolt holes; (4)Set the rotation angle, which is the angle of the profile after bending. Start the roll bending equipment, and the hydraulic push rod moves downward to drive the crankshaft and the rotating shaft to rotate around the protruding shaft; control the bending arc angle and arc length of the profile to be bent through the roll bending die: during roll bending forming, after the die core and the profile to be bent rotate, the arc surface of the die core fits with the arc of the profile to be bent to realize the roll bending forming of the profile. (5)Loosen the tightening bolt of the clamping structure, and then the roll-bent profile can be taken out.

[0014] Furthermore, the assembly process of the aluminum alloy profile roll bending forming device on the roll bending equipment is as follows: First, fix the crankshaft and the rotating shaft together and assemble them through the protruding shaft of the roll bending equipment. One end of the crankshaft is fixed to the telescopic end of the hydraulic push rod. Then, fix the upper end of the die core to the bottom of the rotating shaft, and fix the inner die baffle and the outer die baffle respectively below and outside the die core. A gap for inserting the profile to be bent is left below the die core. Then, pre-fix the clamping structure to the die core through the bolt holes using the tightening bolts. Finally, fix the lower fixing plate of the slide plate structure on the roll bending equipment.

[0015] Furthermore, the roll bending die and the clamping structure are replaceable.

[0016] Furthermore, the inner arc radius of the die core is 0.9 - 0.97 times the inner arc radius of the profile after final roll bending forming.

[0017] The advantages of the present invention are mainly manifested in: (1)Compared with the traditional three-roll roll bending forming, there are significant differences in both the structure and the forming principle between the two. The traditional roll bending forming requires the cooperation of three round rolls and multiple repeated rollings to achieve forming, while the roll bending forming method of the present invention can achieve forming through one-time roll bending.

[0018] (2)The roll bending forming device of the present invention can achieve a large torsional force through the cooperation of the hydraulic push rod and the rotating shaft, and can also achieve roll bending for profiles with a large cross-section and high rigidity, while the traditional three-roll roll bending forming cannot achieve this.

[0019] (3)The roll bending forming device of the present invention is easy to operate, and the final forming state can be observed during the operation process, while the forming quality of the traditional roll bending forming can only be measured and confirmed after it is completely finished.

[0020] (4)The roll bending forming device of the present invention can achieve the roll bending forming of different profiles by replacing the roll bending die and the clamping structure according to profiles with different structures.

[0021] (5) In traditional roll bending forming, each batch of materials will affect the final forming quality. After roll bending, manual adjustment and repair are required, which is time-consuming and laborious. However, the present invention can avoid this problem, has low requirements for the stability of materials, high roll bending forming efficiency, and stable product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of traditional three-roll roll bending forming; Figure 2 It is a schematic diagram of the roll bending forming device for aluminum alloy profiles of the present invention; Figure 3 It is a schematic diagram of a crankshaft; Figure 4 It is a schematic diagram of a rotating shaft; Figure 5 It is a schematic diagram of a roll bending die; Figure 6 It is a schematic diagram of a die core; Figure 7 It is a schematic diagram of a clamping structure; Figure 8 It is a schematic diagram of a slide plate; Figure 9 It is a schematic diagram of the roll bending forming device for aluminum alloy profiles of the present invention during the operation of the roll bending equipment; Figure 10 It is a three-dimensional view of the roll bending forming device for aluminum alloy profiles of the present invention in the roll bending equipment Figure 1 ; Figure 11 It is a three-dimensional view of the roll bending forming device for aluminum alloy profiles of the present invention in the roll bending equipment Figure 2 ; Figure 12 It is the profile after roll bending forming in this embodiment; Figure 13 It is the relative movement process of the upper slide plate g, the lower fixing plate h, the roll bending die 3, the clamping structure 4, and the die core a; Figure 14 It is a schematic diagram of the clamping structure from another perspective; Figure 15 In this embodiment, a straight profile is roll bent into a profile with a certain curvature (the profile after roll bending forming) through the device of the present invention.

[0023] Among them, 1 - crankshaft; 2 - rotating shaft; 3 - roll bending die; a - die core, b - outer die baffle, c - inner die baffle; 4 - clamping structure; d - outer baffle, e - inner baffle, f - lower fixing plate; 5 - slide plate structure; g - upper slide plate, h - lower fixing plate. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0024] In order to make the technical means, creative features, achieved purposes and effects realized by the present invention easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the specification.

[0025] Embodiment 1: The roll bending forming device for aluminum alloy profiles in this embodiment is used for the forming of bent parts. The roll winding forming is realized through the cooperation of the crankshaft 1 and the rotating shaft 2 with the roll bending equipment, and the bending arc angle and arc length of the profile to be bent are controlled through the roll bending die 3. When the die core a rotates a certain angle with the profile to be bent during roll bending, after the roll bending die 3 fits with the profile to be bent, the required finished part can be obtained. The operation is simple, and the forming state can be observed intuitively. For profiles to be bent with different structures, the roll bending of profiles with different structures can be realized by replacing the illustrated roll bending die 3 and the clamping structure 4 (the structures of the roll bending die 3 and the clamping structure do not need to be changed. Roll bending dies 3 of different sizes are used according to the size of the profile, and the clamping structure 4 also needs to be replaced to adapt to different profiles according to different profiles, but clamping structures 4 of different sizes are also used. The purpose is to clamp and fix the profile to be roll bent on the die core a, so that the clamping structure 4, the roll bending die 3, and the profile to be roll bent form a whole).

[0026] Refer to Figures 2 to 8 As shown, the roll bending forming device for aluminum alloy profiles in this embodiment includes a crankshaft 1, a rotating shaft 2, a roll bending die 3, a clamping structure 4 and a slide plate structure 5; Among them, the crankshaft 1 includes a big end and a small end. The small end is connected to the telescopic end of the hydraulic push rod of the roll bending equipment (such as Figure 11 The part on the left side of the red arrow is the roll bending equipment, which belongs to the prior art), and the big end is assembled through-penetration on the protruding shaft of the roll bending equipment; when the hydraulic push rod moves downward, it drives the crankshaft 1 to rotate around the protruding shaft of the roll bending equipment. Preferably, a plurality of screw holes are arranged around the center of the big end.

[0027] Among them, the rotating shaft 2 is set in a structure similar to the shape of "Ω". The upper hole of it is assembled through-penetration on the protruding shaft of the roll bending equipment. The rotating shaft 2 is fixedly connected to the big end of the crankshaft 1 (preferably, a plurality of holes are arranged around the upper hole of the rotating shaft 2, and these holes correspond one by one to the screw holes on the big end of the crankshaft 1. The rotating shaft 2 can be fixedly connected to the big end of the crankshaft 1 by inserting bolts into the holes and the screw holes). When the hydraulic push rod moves downward, it drives the crankshaft 1 and correspondingly drives the rotating shaft 2 to rotate around the protruding shaft of the roll bending equipment.

[0028] Among them, as Figure 5 shown, the roll bending die 3 includes a die core a, an outer die baffle b and an inner die baffle c: The die core a is set as a block structure with a continuous arc at the front end and the bottom, as Figure 6As shown, during roll bending, the arc surface at the bottom of the front end is made to fit the arc of the profile to be bent, thereby achieving roll bending. The top of the die core a is provided with an upper hole, and the die core a is fixedly connected to the bottom of the rotating shaft 2 through the upper hole using bolts.

[0029] On both sides of the die core a, outer die baffle plates b are fixed (side holes are provided on both sides of the die core a, and the die core a is assembled and fixed to the outer die baffle plates b through the side holes using bolts); Inside both outer die baffle plates b and below the die core a, two inner die baffle plates c that cooperate with each other are provided. The two inner die baffle plates c are respectively fixed on their respective outer die baffle plates b (side holes are provided on the outer sides of the inner die baffle plates c, and the inner die baffle plates c are assembled and fixed to their respective outer die baffle plates b through the side holes using bolts).

[0030] Above, the roll bending die 3 forms a fixed whole, and the profile to be bent can be inserted from below the die core a. Among them, the lower part of the profile to be bent is located between the two inner die baffle plates c.

[0031] Among them, as Figure 7 shown, the clamping structure 4 includes an outer baffle plate d, an inner baffle plate e, and a lower fixing plate f; on the lower fixing plate f, two inner baffle plates e that cooperate with each other are provided, and the lower part of the profile to be bent can be inserted between the two inner baffle plates e; on the outer sides of the two inner baffle plates e, there is an outer baffle plate d. Bolt holes are provided in both the upper and lower parts of the outer baffle plate d. The upper part of the outer baffle plate d can be pre-fixed and subsequently fixed to the outside of the die core 3 through the bolt holes using tightening bolts. The lower part of the outer baffle plate d can clamp and fix the lower part of the profile to be bent between the two inner baffle plates e through the bolt holes using tightening bolts; the bottom end of the outer baffle plate d is also located above the lower fixing plate f, and the bottom end of the outer baffle plate d and the lower fixing plate f are fixedly connected by tightening bolts, as Figure 14 shown.

[0032] Among them, as Figure 8 shown, the slide plate structure 5 includes an upper slide plate g and a lower fixing plate h. The lower fixing plate h is fixed on the roll bending equipment, and the upper slide plate g is fixedly arranged on the lower fixing plate h; the upper slide plate g is in sliding contact with the lower surface of the roll bending die 3 and the lower surface of the clamping structure 4.

[0033] Specifically, the upper slide plate g and the lower fixing plate h are fixed together with bolts and then placed on the Figure 9 roll bending equipment shown. During the roll bending process, it serves as a support surface and does not move at all. The roll bending die 3 (outer die baffle plates b, inner die baffle plates c) and the clamping structure 4 are fixed to the die core a. As an overall structure, during the roll bending process, it rotates as a whole in the direction shown in Figure 13 shown.

[0034] Embodiment 2: The assembly process of the roll bending forming device for aluminum alloy profiles in Example 1 on the roll bending equipment is as follows: First, the crankshaft 1 and the rotating shaft 2 are fixed together and assembled through the extended shaft of the roll bending equipment. The small head end of the crankshaft 1 is fixedly connected to the telescopic end of the hydraulic push rod; Then, the die core a is fixed to the bottom of the rotating shaft 2 through the upper hole using bolts; the outer die baffle b and the inner die baffle c are assembled and fixed to the die core a through the side holes using bolts. A gap for inserting the profile to be bent is left between the die core a and the inner die baffle c; Then, the clamping structure 4 is pre-fixed to the die core a through the bolt holes using bolts (the bolts do not need to be tightened, only pre-fixed); Finally, the lower fixing plate h of the sliding plate structure 5 is fixed on the roll bending equipment. The assembled state is as shown in Figure 9 and Figure 10 shown.

[0035] Example 3: Using the roll bending forming device for aluminum alloy profiles assembled on the roll bending equipment in Example 2 to perform roll bending forming, the method process is as follows: First, insert the profile to be bent from the side of the clamping structure 4 of the above roll bending forming device for aluminum alloy profiles to the side of the roll bending die 3; Confirm the length of the profile extending from the side of the roll bending die 3, and determine it according to the position of the arc of the profile roll bending confirmed by measurement; After confirming the correct position, tighten and fix the top bolt on the upper part of the outer baffle d of the clamping structure 4 and the bolts of the lower fixing plate f (here refers to the tightening bolts at the bottom end of the outer baffle d and the lower fixing plate f, as shown in Figure 14 shown).

[0036] Start the roll bending equipment, set the rotation angle, and the rotation angle is the profile bending angle (the bending angle can be reduced or increased according to the actual forming effect). The rotating shaft 2 and the hydraulic push rod move according to the movement trajectory mode shown in Figure 9 shown, and the forming of the profile can be realized; After the forming is completed, loosen the bolts of the clamping structure 4 (it does not need to be completely loosened, as long as the profile can be taken out), take out the roll bent profile, and the entire roll bending forming process ends.

[0037] Figure 15 To roll a straight profile (the profile to be bent) into a profile with a certain curvature (the roll bent profile) through the present invention.

[0038] Figure 12 Shown in

[0039] The contact surfaces between the mold core a and the profile also have a certain curvature. When roll bending, after the roll bending equipment rotates a certain angle, the arc surface of the roll bending die 3 fits with the arc of the profile to achieve forming. When designing the roll bending die 3, usually according to the deformation amount of the material, the radius of the inner arc of the roll bending die 3 is appropriately reduced, usually 0.9 - 0.97 times the inner arc radius of the profile after roll bending.

[0040] The above are only the preferred embodiments of the present invention and do not constitute a limitation on the protection scope of the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the claims of the present invention.

Claims

1. A roll-bending device for aluminum alloy profiles, characterized in that: The device comprises a crankshaft, a rotating shaft, a rolling and bending die, a clamping structure and a slide plate structure; one end of the crankshaft is fixed to a hydraulic push rod of the rolling and bending device, and the other end of the crankshaft is coaxially fixed to the rotating shaft; an adjacent rolling and bending die and a clamping structure are arranged below the rotating shaft; The rolling die includes a die core, an outer die baffle plate and an inner die baffle plate. The upper end of the die core is fixed to the rotating shaft. The front end bottom of the die core is provided with an arc surface. The outer die baffle plates are fixed on both sides of the die core. Two opposite inner die baffle plates are fixed inside the two outer die baffle plates and below the die core. The profile to be bent is inserted into the gap below the die core and clamped from both sides by the clamping structure, so that the profile to be bent, the rolling die and the clamping structure form a whole. The slide plate structure is located below the whole body and is fixed on the rolling device, and the slide plate structure is in sliding contact with the lower surface of the whole body.

2. The aluminum alloy profile roll forming device according to claim 1, characterized in that: The rolling and bending mold and the clamping structure are replaceable, and the upper end of the mold core is fixedly connected to the rotating shaft by bolts.

3. An aluminum alloy profile roll forming device as claimed in claim 1 or 2, characterized in that: The inner arc radius of the mold core is 0.9-0.97 times the inner arc radius of the profile after final roll bending.

4. The aluminum alloy profile roll forming device according to claim 1 or 2, characterized in that: The clamping structure is set to a concave shape, including an outer baffle, an inner baffle and a lower fixed plate. The lower fixed plate is provided with two inner baffles that match each other. The outer side of the inner baffle is provided with an outer baffle. Bolt holes are provided on the upper and lower parts of the outer baffle. The upper part of the outer baffle is pre-fixed or fixed to the outer side of the mold core with a tightening bolt. The lower part of the outer baffle is clamped and fixed with a tightening bolt between the two inner baffles. The bottom end of the outer baffle and the lower fixed plate are tightened and fixed by bolts.

5. The aluminum alloy profile roll forming device according to claim 1 or 2, characterized in that: The rotating shaft is set as an "Ω"-shaped structure, and the upper hole of the "Ω"-shaped structure and the other end of the crankshaft are penetrated together on the extended shaft of the rolling bending equipment, and the movement of the hydraulic push rod drives the crankshaft and the rotating shaft to rotate around the extended shaft.

6. The aluminum alloy profile roll forming device according to claim 1 or 2, characterized in that: The outer sides of the mold core and the inner mold baffle are both provided with side holes, and the mold core and the inner mold baffle are assembled and fixed with the outer mold baffle by bolts through the side holes.

7. A roll forming method using the aluminum alloy profile roll forming device according to any one of claims 1 to 6, characterized in that: The method comprises: (1) The aluminum alloy profile rolling and forming device is assembled onto the rolling and bending equipment; (2) Inserting the profile to be bent from the clamping structure side into the rolling die side, and confirming the length of the profile to be bent extending from the rolling die side; (3) Tighten the clamping structure onto the mold core using the tightening bolts through the bolt holes; (4) Setting the rotation angle, i.e., the angle after the profile is bent, starting the rolling equipment, and the hydraulic push rod moving downward drives the crankshaft and the rotating shaft to rotate around the extension shaft; the bending arc angle and arc length of the profile to be bent are controlled by the rolling die: during the rolling forming, after the mold core and the profile to be bent are rotated, the arc surface of the mold core fits the arc of the profile to be bent to realize the rolling forming of the profile; (5) Loosen the tightening bolts of the clamping structure to take out the rolled profile.

8. The roll forming method according to claim 7, characterized in that: The assembly process of the aluminum alloy profile roll-bending device on the roll-bending equipment is as follows: First, fix the crankshaft and the rotating shaft together and assemble them to the extended shaft of the rolling bending equipment. One end of the crankshaft is fixed to the telescopic end of the hydraulic push rod. Then fix the upper end of the mold core to the bottom of the rotating shaft, fix the inner mold baffle plate and the outer mold baffle plate below and outside the mold core respectively, and leave a gap below the mold core for inserting the profile to be bent; Then the clamping structure is pre-fixed to the mold core using jacking bolts through the bolt holes; Finally, the lower fixing plate of the slide plate structure is fixed on the rolling bending equipment.

9. The roll forming method according to claim 7 or 8, characterized in that: The rolling and bending mould and the clamping structure are replaceable.

10. The roll forming method according to claim 7 or 8, characterized in that: The inner arc radius of the mold core is 0.9-0.97 times the inner arc radius of the profile after final roll bending.

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