Manufacturing method of mold for shaping surrounding flanging of outer plate of aluminum alloy automobile top cover

Abstract

The invention discloses a manufacturing method of a mold for surrounding flanging and shaping of an outer plate of an aluminum alloy automobile top cover. The manufacturing method comprises the following steps: step 1, layout of a difficult point guiding mold structure; 2, a multi-loose-block application scheme is provided; 3.1, moving the parting line backwards; 3.2, left-right time sequence forming is carried out; 3.3, window time sequence forming is carried out; step 3.4, shaping the rear end; 4, over-shaping and forced-pressing shaping are carried out; step 5, rotating and retreating; 6, ridge protection is reserved; and 7, difficult point guiding debugging. According to the top cover outer plate flanging and shaping die, one working procedure integrates the working content of original multiple working procedures, meanwhile, the influences of the positioning problem, the surface product problem and the working procedure superposition interference problem caused by the working procedure arrangement problem are eliminated, and top cover outer plate flanging and shaping die manufacturing which is few in working procedure, high in quality and high in debugging efficiency is achieved; a new process arrangement and design architecture thought is created for difficult parts, and the mold development cost and the later part manufacturing cost are greatly reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile panel dies, and particularly to a die manufacturing method for the surrounding flanging and shaping of the outer panel of an aluminum alloy automobile roof. Background Art

[0002] The outer panel of the automobile roof is a core part of the automobile appearance and an important component for ensuring the overall performance and streamline of the automobile. It has always been in an important position in automobile manufacturing and is a core Class A component. At the same time, it is also one of the components with the highest difficulty coefficient among automobile panels. It has high surface quality requirements, complex forming processes, and high requirements for lap joint performance.

[0003] With the continuous improvement of the quality requirements and the increasing requirements for lightweight of new energy vehicles, the application of lightweight materials has become an important direction. Aluminum alloy has become an important lightweight material for the outer panel of the automobile roof. However, during the forming process of the aluminum alloy automobile roof outer panel, due to the small number of forming control points of the roof outer panel, high appearance requirements, and the requirements for strength and other mechanical properties, the forming is extremely difficult. During its forming process, after the drawing process is completed, negative angle side shaping is required at the front end, positive shaping and side shaping are required at the rear end and the periphery, positive shaping is required around the skylight opening, and the flanging of the claws around the part and the flanging of the skylight opening are also required. The process content is complex. Affected by the interference of the forming content and the material forming ability, this flanging and shaping operation is usually completed in two or three processes. Due to the large number of processes, it is interfered by many factors such as positioning and springback between processes, which has a great impact on the product quality and surface quality effect. Moreover, during the flanging process, it is easy to cause force deformation and damage the shaping effect. As a result, many technical problems occur, and craftsmen need to carry out a large number of debugging activities to correct the problems, resulting in high die costs, difficult manufacturing, complex processes, and long cycles.

[0004] Normally, the price of a single set of dies is often over one million, and the cycle is about one year. The labor input of craftsmen is huge, which has become a bottleneck in manufacturing. In the existing manufacturing technologies, the overall product quality is usually continuously trimmed and debugged by using multiple processes to meet the requirements of qualified part accuracy in the final die manufacturing. The resulting cost, quality, and cycle problems seriously plague the development of the roof outer panel forming. How to develop an innovative forming method that can efficiently and qualitatively complete the flanging and shaping work of the overall roof outer panel in one process has become an urgent technical innovation direction in the industry.

[0005] It should be particularly noted that the above technical information is only intended to deepen the understanding of the overall background technology of the present invention, and should not be regarded as an admission or any form of suggestion that the above technical information constitutes the prior art known to those skilled in the art. Summary of the Invention

[0006] In view of the deficiencies in the above-mentioned background art, the present invention proposes a method for manufacturing a mold for the circumferential flanging and shaping of the outer panel of an aluminum alloy automobile roof, and the technical problem to be solved is: how to efficiently and qualitatively complete the flanging and shaping work of the overall outer panel of the aluminum alloy automobile roof in one process.

[0007] The technical solution of the present invention is as follows: A method for manufacturing a mold for the circumferential flanging and shaping of the outer panel of an aluminum alloy automobile roof, comprising the following steps: Step 1: Difficulty-oriented mold structure layout.

[0008] Step 2: Application plan of multiple movable blocks: After completing the mold structure layout, reasonably plan and layout each area of the mold structure, and frame the movable block plan of the mold structure according to the forming difficulties and process requirements.

[0009] Step 3.1: Move the parting line backward. Set the parting line by moving it backward 15 - 20 mm from the position of the conventional parting line at the front end fillet, and change the forming mode of the upper mold from forward shaping to a combination of forward shaping and lateral shaping; Step 3.2: Left and right sequential forming: Left and right sequential forming is a comprehensive design process of the process sequence of the movable block forming, sequential shaping, and flanging operation after shaping on the left and right sides of the outer panel of the roof.

[0010] Step 3.3: Window sequential forming: Window sequential forming is mainly divided into two parts of sequential forming. The first part of sequential forming is that the four corners of the window are formed first and the middle part is formed later; after the shaping module works in place, start the second part of the flanging sequential forming. The mode of the flanging sequential forming is that the flanging inserts first flang the four corners of the window part, and then extend from the inside to the outside to realize the flanging operation of the overall window.

[0011] Step 3.4: Rear-end shaping: Mainly aiming at the problems of collapse and springback in the middle of the rear end, perform sequential forming on the left and right edges of the rear end and perform prior shaping on both sides.

[0012] Step 4: Over-shaping and strong-pressure shaping.

[0013] Step 5: Rotational retraction.

[0014] Step 6: Reserve for rib protection.

[0015] Step 7: Difficulty-oriented debugging.

[0016] The difficult point-oriented die structure layout in Step 1 includes: a front negative angle forming area, which mainly overlaps with the front windshield or the upper crossbeam and the side wall, has a negative angle forming structure, adopts an overall extended layout, and reserves an adjustment space. During the die structure layout process, the die structure in the long direction of this end is lengthened, and at the same time, a design space for the driving device is left in the left-right direction, making this area in a T-shaped structure; considering the front-end negative angle shaping, strong pressing shaping, and overall module block shaping, and leaving space, so it is necessary to design the layout to expand the front end to leave an activity space for the side shaping slider, and expand the left and right sides to increase the placement space for the rotating mechanism, forming a simple T-shaped structure.

[0017] The difficult point-oriented die structure layout in Step 1 also includes: the left and right side forming structure layout: the left and right sides are symmetric about the midline. The main forming content in this area is to shape the left and right side facades and the upper round corners, to flanging the left and right side claws to meet the fitting requirements, expand this area in the left-right direction, and its structure layout should take into account the up-down movement of the flanging block, the lateral movement of the lateral shaping block, and the up-down movement space of the upper positive shaping block; at the same time, it is necessary to reserve a key shaping movable block area at the front and rear ends of the left and right sides to meet the overall forming requirements and the layout structure design.

[0018] The difficult point-oriented die structure layout in Step 1 also includes: the rear-end forming and window structure layout. The window structure layout method is to leave an activity and strong pressing block space at the four corners of the window; after the overall die structure layout is completed, it will present a T-shaped overall structure with a wide front end, an extended middle part, and a normal rear end.

[0019] The operation mode of Step 2 is as follows: The front end adopts a mode mainly of lateral shaping and assisted by positive shaping, changing the traditional lateral shaping mode, setting a lateral shaping movable insert as the main shaping method for lateral negative angle forming; at the same time, leaving a positive shaping space, and adopting positive shaping for the upper part. The two shaping modes cooperate to eliminate the material pulling and surface deformation problems caused by the lateral shaping in the conventional process to the top. To ensure that the part can be smoothly taken out from the negative angle area after forming, it is necessary to convert the overall structure of the front-end lower die into a rotating activity mode; forming a multi-movable block application solution combining the rotation of the lateral shaping insert, the positive shaping insert of the upper die, and the lateral shaping insert.

[0020] Left and right side forming: Due to the concentration of processes in left and right side forming, its manufacturing process is integrated into a mode combining shaping and flanging. The shaping is adjusted to lateral shaping to avoid shaping springback and shaping jamming. The claw flanging performs forward flanging operations, which requires changing the traditional three - process mode of forward shaping, lateral shaping, and forward flanging and concentrating them into one process. Therefore, it is a frequent interference area. To solve the interference problem, this area is adjusted to a combination of rotary shaping and forward flanging. The adjustment method is segmented rollerization, adding a rotating structural member for rotary forming, and setting two or four groups of rotating movable blocks on each of the left and right sides to complete the design of the lower die movable block scheme. For the upper die movable block scheme, a stepped and segmented structure is adopted, with movable modules set at the front and rear ends of the left and right sides to form a pre - shaping module structure, and a pre - shaping blank - holding and a subsequent claw - flanging sequential forming module are set for the remaining part.

[0021] For the left and right sides of the rear end, an active pre - shaping structure is set on the upper die to complete a mode combining pre - shaping and subsequent strong pressing, so as to eliminate the springback problem of corner warping during the forming process. For the window part, based on the traditional insert flanging and shaping, a four - corner active pre - shaping and a four - corner pre - flanging mechanism are set to eliminate problems such as four - corner springback, surface warping, middle collapse, and poor flanging.

[0022] In step 3.1: During the process of setting the parting line to move backward, to reduce the strip deformation problem caused by the negative - angle withdrawal during lateral shaping and the inconvenience of yielding caused by the backward movement of the parting line, it is necessary to create a die structure by combining a sliding - block treatment and a roller treatment for the lower die structure. The implementation method is that the front - end area of the lower die is divided into blocks at an inclined angle of 30 - 45 degrees; when withdrawing, it first withdraws 5 - 10 mm forward and downward, and then rotates to withdraw. For the upper die area, the sequence of the inserts needs to be set. The forward - shaping insert performs pre - shaping first, and then the lateral insert is driven by a sliding block for shaping.

[0023] In step 3.2: During the process of setting the left - right sequential forming, the lower die adopts a roller - mechanism forming mode. The parting line extends 20 - 30 mm inward along the upper rounded corner of the top cover, and two to four groups of active rollers are set in the shaping area of the lower die.

[0024] For the upper die, more timing content needs to be designed. Therefore, the front and rear end areas on the left and right sides of the upper die adopt an auxiliary pressure source construction mode. Floating inserts are set in the front and rear end areas of the upper die, and a pressure nitrogen cylinder is added to complete the priority timing movement. The sequence is to start from the outer endpoints of the front and rear ends on the left and right sides, and according to the calculated springback area, extend 30 to 50 mm forward to set the movable nitrogen cylinder floating inserts. The pre-pressure is 15 - 20 tons, and a fixed cushion block is set below to make it press the material and shape it 10 - 15 mm in advance. The middle part adopts normal forward shaping. After the upper die shaping is in place, the lateral shaping insert shapes, and then the flanging insert descends to perform the flanging operation; the overall structure of the upper die timing is that a movable floating insert is installed on the shaping pressure pad for shaping, and the flanging insert is directly installed on the upper die for the final movement.

[0025] The overall operation timing structure is: the lower die roller movable block arrives first - the floating inserts at the front and rear ends of the upper die arrive for shaping - the shaping block of the upper die arrives for shaping - the lateral shaping block arrives for shaping - the flanging block of the upper die flanges, thus completing the overall left and right timing forming.

[0026] During the setting process of the window timing forming in step 3.3: The window timing forming is mainly divided into two parts of timing forming. The first part of the timing forming is that the four corners of the window are formed first and the middle part is formed later in time sequence; the operation method is that the lower die is designed according to the normal mode, and the upper die part takes the inflection points of the four corners of the window as the center, expands 50 - 60 mm to the left and right and extends about 40 mm inward to set the pre-forming inserts, adopting a floating insert forming structure mode, with a pre-pressure of 10 - 15 tons. The later pressure is distributed according to the overall pressure of the upper die shaping. The middle part shaping is designed according to the conventional shaping mode, and the corner parts are formed first to reduce the defects of the overall surface quality and the collapse angle problem of the forming; after the shaping module works in place, the second part of the flanging timing forming starts. The mode of the flanging timing forming is that the flanging inserts first flange the four corners of the window part, and then extend from the inside to the outside to realize the flanging operation of the overall window. The structure mode is that the cutting-in height of the flanging inserts increases by 4 - 6 mm at the corners and transitions 50 - 70 mm inward to the normal state, so as to spread the stress concentration to the middle through the flanging timing, thereby reducing the occurrence of problems such as the collapse of the middle part of the window, the springback of the four corners, and the stacking and gathering of materials through the reverse movement of the internal stress, and forming a perfect surface quality and flanging effect.

[0027] During the setting process of over-shaping and strong pressing shaping in step 4: The implementation method of over-shaping is: optimize the process and perform reverse shaping and pressing on the severely springback area to eliminate the springback problem through excessive correction. The over-shaped area is the floating insert area designed in the previous step. According to the analysis of the law of the results of multiple repeated tests and the calculation of the maximum over-shaping amount based on the material thickness and springback amount of the material. Let the material thickness of the outer panel of the roof cover be D and the springback amount be H, then the maximum over-shaping amount is: L = H + D * H * 10%.

[0028] The over-integration design sets the over-integration amount with the midline of the floating insert as the center, and makes a gradual transition to both sides, and sets the over-integration gradual transition to 0 at the edge of the insert; for the middle area of ​​the rear end, the over-integration amount also needs to be designed. There is no need to set a floating insert at this position, and only a smooth transition ridge is required. The ridge is 0.3mm centered on the center line of the rear end, and transitions to the left and right by 10% to 15% of the left and right width of the overall top cover outer panel, and the upper and lower molds are set and adjusted accordingly.

[0029] Strong pressure shaping: Strong pressure shaping is a shaping mode that performs strong coloring shaping on other positive shaping areas outside the floating insert. The method is to hard color the positive shaping area and make a uniform transition to other parts.

[0030] In the process of setting the rotation and retreat in step 5: it is mainly realized by the roller mechanism set during the left and right sequential forming in step 3.2. The flange shaping area on the rotating roller needs to be set to the eccentric mode, and the cam movement route is operated in the eccentric mode. During the rotation, the bidirectional movement structure effect of downward and retreat can be achieved at the same time, reducing the deformation of the flange ejection and the deformation of the parts removed caused by the vertical surface and the edge line holding the rounded corners after shaping, so as to achieve a precise noodle forming effect.

[0031] In step 6, during the setting process of edge protection reservation: the edge line of the upper large plane is the contour line, which is expanded inward by 5mm to make a strong pressure shaping area, and the strong pressure transition area is made 20mm inward from the strong pressure shaping area. The strong pressure shaping area is strongly colored, and the transition area is subjected to transitional coloring from strong pressure to normal, and other parts are subjected to normal coloring, so as to make centralized adjustments to noodle quality problems during the later debugging process to achieve excellent noodle quality effects.

[0032] In the difficulty-oriented debugging and setting process in step 7: using a complex movable block structure to implement the overall flanging shaping solution in a centralized manner, the debugging craftsman needs to first determine whether the timing of the overall debugging is appropriate, and then, based on the undesirable problems that occur during the process, concentrate the adjustments in a small area by adjusting the strong pressure area, strong pressure content, floating insert pressure, etc., to achieve an overall fast and accurate debugging effect.

[0033] Compared with the prior art, the mold manufacturing method for aluminum alloy automobile top cover outer panel surrounding flanging shaping provided by the technical solution has the following beneficial effects: 1. The present invention conducts a concentrated design of the flanging and shaping die process for the outer panel of the roof cover through a difficulty-oriented design pattern, realizing that one process integrates the work content of multiple original processes. At the same time, it eliminates the positioning problems, surface quality problems, and interference problems caused by the process layout, and achieves the manufacturing of the flanging and shaping die for the outer panel of the roof cover with fewer processes, high quality, and high debugging efficiency. It has created a new process layout and design architecture idea for difficult parts, greatly reducing the mold development cost and the subsequent part manufacturing cost, and providing excellent technical support for the quality improvement and cost reduction of new energy vehicles and traditional vehicles.

[0034] 2. The multi-movable block application solution provides a good solution for the interference caused by process concentration, and can be used as a general technical design architecture for reference by other difficult parts.

[0035] 3. The intensive application of sequential forming solves many forming defect problems of the traditional outer panel of the roof cover in a sequential manner by the method of mutual cancellation of internal stresses. While enhancing the product strength and product quality, it reduces the debugging difficulty of craftsmen for large automotive body panels. It provides a technical reference for the application of mutual cancellation of internal stresses in large body panels.

[0036] 4. The mode of combining debugging craftsmen and technicians breaks through the process barriers and provides a liaison bridge between technology and craftsmen for the development of high-tech content molds. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the embodiments of the present invention, the drawings required for the description of the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0038] Figure 1 It is a flowchart of a method for manufacturing a die for the circumferential flanging and shaping of an aluminum alloy automotive roof cover outer panel. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0039] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, rather than all embodiments. Based on the core concept of the present invention and the following embodiments, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present invention.

[0040] These embodiments are provided in this application to make the application thorough and complete, and to fully convey the scope of the application to those skilled in the art. It should be noted that: unless otherwise specifically stated, the relative arrangements of components and steps, the compositions of materials, numerical expressions and values set forth in these embodiments should be construed as merely exemplary, rather than as limitations.

[0041] It should be noted that in the description of this application, unless otherwise specified, the meaning of "a number of" is greater than or equal to two; the orientation or positional relationships indicated by terms such as "upper", "lower", "left", "right", "inner", "outer", "axial", "radial", etc. are only for the convenience of describing this application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be construed as a limitation of this application. When the absolute position of the object being described changes, the relative position relationship may also change accordingly.

[0042] In addition, the "first", "second" and similar terms used in this application do not denote any order, quantity or importance, but are only used to distinguish different parts. "Vertical" is not strictly vertical, but within the allowable error range. "Parallel" is not strictly parallel, but within the allowable error range. Words such as "including" or "comprising" mean that the elements before this word cover the elements listed after this word, and do not exclude the possibility of also covering other elements.

[0043] It should also be noted that in the description of this application, unless otherwise clearly defined and limited, the terms "mounted", "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances. When it is described that a specific device is located between a first device and a second device, there may or may not be an intermediate device between the specific device and the first device or the second device.

[0044] All terms used in this application have the same meanings as those understood by those of ordinary skill in the art to which this application belongs, unless otherwise specifically defined. It should also be understood that terms defined in a general dictionary, for example, should be construed as having meanings consistent with their meanings in the context of the relevant art, and should not be interpreted in an idealized or overly formal sense, unless specifically defined as such here.

[0045] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0046] The patent of this invention relates to the field of automobile molds. It is used in the forming process of automobile roof outer panels made of aluminum alloy sheets. It integrates the flanging and shaping processes into an integrated manufacturing method to achieve fewer processes and higher quality.

[0047] In order to solve the problems raised in the background technology, the present invention conducts an in-depth analysis of the causes of top cover outer panel forming defects and a detailed step-by-step decomposition of a large number of top cover outer panel forming schemes, and digitizes the compensation amount, springback amount and problem point correction method in the overall forming process. It uses CAE technology to return to the forming process in multiple ways, and combines the batch summary of the experience of craftsmen with typical characteristics; taking the typical characteristics of the top cover outer panel as the in-depth analysis point, and the forming control method of aluminum alloy materials as the expansion direction, the modular experiment and module superposition method are adopted to continuously integrate the forming results, and develop a manufacturing method and application of an aluminum alloy automobile top cover outer panel surround flanging shaping mold.

[0048] The present invention utilizes the molding difficulties and process interference areas to construct the overall layout of the flanging shaping mold, arranges a multi-active module structure, breaks the traditional way of arranging the mold structure according to the process content, selects a reasonable layout mode based on the problem, and forms a difficulty-oriented mold layout structure; utilizes the mode of rearward movement of the parting line and the front-end molding of the mechanism roller movement to increase the utilization of space, and at the same time, performs negative angle shaping and shape surface accuracy maintenance on the defective area of ​​the front-end product; utilizes the sequential molding mode to perform one-time sequential molding on the shaping areas and flanging areas on both sides to ensure the molding quality and eliminate the positioning and force-related defects of multi-process molding; utilizes over-shaping and high-pressure shaping of the problem area to comprehensively shape the overall rebound area to ensure molding accuracy and product quality; utilizes the edge protection reserved for craftsmen to ensure the quality of the noodle products while reserving operating space for craftsmen to debug and research, thereby reducing the subsequent large-scale debugging workload; utilizes the rotation retreat method to retreat the flanging area to prevent the parts from fitting with the flanging block, and the quality defects such as ejection warping and rebound caused by the ejection of the flanging ejector. In this way, multiple active modules can be used to complete one-time wraparound flanging and shaping, and flanging and shaping can be completed at one time in the same process, eliminating product defects caused by process transfer, maximizing the use of space, saving mold costs, increasing mold manufacturing speed, and accelerating the development and application of new products; providing strong support for the application of lightweight materials in automobile manufacturing, and freeing up space for the large-scale craftsmanship of top cover molding, thereby promoting the development and application of high-quality automobile top covers.

[0049] That is, the present invention refines the forming process through the analysis of the forming process steps of the outer panel of the roof cover and the analysis of batch craftsmanship experience, and constructs a research process method based on the modular combination application; by using the forming difficulties of the outer panel of the roof cover and the forming difficulties of aluminum alloy materials, the overall structure layout of the mold is constructed, and the mode of multi-movable module forming and sequential forming cooperation is used to realize the circumferential flanging and shaping of the outer panel of the automobile roof cover, integrating the flanging and shaping work completed by traditional multi-processes in the same mold. At the same time, the rotational method is used to avoid the ejection deformation defects caused by the shrinkage and inward lodging between the part and the mold. And an empirical data application formula for regional over-shaping and strong pressure shaping is formed; the debugging area is locked by using the ridge line to protect the craftsman's reservation, greatly reducing the craftsman's debugging operation, so as to realize the circumferential flanging and shaping of the outer panel of the automobile roof cover, greatly reducing the mold cost and development cycle, and improving the product quality accuracy, thus realizing a cold stamping forming manufacturing method for the outer panel of the roof cover with low cost, short cycle and high quality. The present invention is applicable to ordinary aluminum plates, 5xxx, 6xxx, 7xxx series aluminum alloys, and the thickness of the test plates used in the present invention is 0.7 - 1.5 mm.

[0050] As Figure 1 shown, the main processes of the present invention are as follows: 1. Difficulty-oriented mold structure layout, which is based on the common process forming difficulties of the outer panel of the roof cover, the forming difficulties of the drawing process, the forming difficulties of the flanging and shaping process, the craftsman debugging difficulties and the overall structure interference difficulties; the overall difficulties are classified according to the structural positions of the outer panel of the back door, and at the same time, the difficulties are classified and summarized by region, thus forming a difficulty set area, and the overall mold structure expansion layout and overall forming method planning are carried out according to the situation of the relative area. According to the comprehensive analysis, the main layout is divided into areas according to the following regions.

[0051] 1) The front negative angle forming area, which is mainly lapped with the front windshield or the upper crossbeam and lapped with the side panel, and has a negative angle forming structure. The drawing depth is relatively deep, and it is a concentrated area of many product problems such as wrinkling, springback, twisting, cracking, etc., and also a concentrated area of difficulties. Therefore, for the layout of this area, an overall expansion layout is adopted, and adjustment space is reserved. During the process of the mold structure layout, the length direction mold structure of this end is lengthened, and at the same time, design space for driving equipment such as driving cylinders is left in the left and right directions, so that this area has a T-shaped structure; considering the front negative angle shaping, strong pressure shaping and overall module block forming, space is left, so it is necessary to design the layout to expand the front end to leave space for the side shaping slider, and expand the left and right sides to increase the placement space for the rotating mechanism, forming a simple T-shaped structure.

[0052] 2) Left and right side forming structure layout: The left and right sides are generally symmetrical, symmetrical along the center line. The main forming content of this area is to shape the left and right side facades and upper fillets, and to flanging the left and right side claws to meet the matching requirements. The main problems in this area are the warping, unevenness, convexity and concaveness of the part surface, as well as the overall front and rear springback and facade springback, drawing shrinkage and clamping of the mold. Therefore, this area is expanded in the left and right directions, and its structural layout must take into account the up and down movement of the flanging block and the lateral movement of the lateral shaping block, as well as the up and down movement space of the upper positive shaping block; at the same time, in order to correct the overall springback problem of the top cover outer panel, it is necessary to reserve key shaping block areas for the front and rear ends of the left and right sides to meet the overall forming requirements and layout structure design.

[0053] 3) Rear-end molding: The main problems at the rear end are collapse in the middle and warping of the corners. Therefore, the layout space of this area can be designed in a normal way, but it is necessary to consider reserving structural space for the middle bulge and key shaping of the corners in the overall layout.

[0054] 4) Window structure layout: The window area is the concentrated area for noodle problems. Problems such as springback at the four corners, warping of noodle products, collapse in the middle, and poor flanging are concentrated here. Therefore, this area should be focused on in the layout. The layout method is to leave space for movable pressure blocks at the four corners of the window.

[0055] After the overall mold structure layout is completed, it will present a T-shaped overall structure with a wide front end, an expanded middle part, and a normal back end.

[0056] 2. Multi-block application solution: This solution mainly plans and lays out the various areas of the mold structure reasonably after completing the mold structure layout, and constructs a block solution for the mold structure according to the molding difficulties and process requirements, so as to provide centralized processing area division for later adjustments. At the same time, it avoids interference to achieve the process concentration of the entire mold, ensure that multiple operations are completed in the same process, establish a compact mold structure, and complete the implementation method of the layout plan. Its operation mode is as follows.

[0057] 1) The front end adopts a mode of mainly forming by lateral shaping and auxiliary by positive shaping, changes the traditional side shaping mode, and sets a side shaping movable insert as the main forming method for lateral negative angle forming; at the same time, leaves space for positive shaping, and adopts positive shaping for the upper part. The two shaping modes are coordinated to eliminate the problems of material pulling and surface deformation caused by lateral forming on the top of the conventional process. In order to ensure that the parts can be smoothly removed from the negative angle area after forming, the overall structure of the front end lower die needs to be converted into a rotating movable mode; a multi-movable block application solution is formed by rotating the side shaping insert, combining the upper die positive shaping insert and the lateral shaping insert.

[0058] 2) Left and right side forming: Due to the concentration of processes, the manufacturing process of left and right side forming is integrated into a mode combining shaping and flanging. Shaping is adjusted to lateral shaping to avoid shaping rebound and shaping locking. For the forward flanging operation of the clamping claw flanging, it is necessary to change the traditional three-process mode of forward shaping, lateral shaping and forward flanging, and concentrate it into one process. Therefore, it is a high-incidence area of ​​interference. In order to solve the interference, this area is adjusted to a combination of rotation shaping and forward flanging. The adjustment method is segmented rollerization, and a rotating structural component is added for rotational forming (the same as the rotating roller mechanism in the prior art, which will not be repeated in this application). Generally, two or four groups of rotating live blocks are set on each side of the left and right to complete the design of the lower mold live block scheme. The live block scheme of the upper mold adopts a hierarchical and block structure, and active modules are set on the front and rear ends of the left and right sides to form a first shaping module structure. The remaining part is set with a sequential forming module of first shaping and pressing, and then clamping claw flanging. In this way, the left and right multi-block shaping structure scheme is completed.

[0059] 3) For the left and right sides of the rear end, an active pre-forming structure is set on the upper die to complete the mode of combining pre-forming and post-strong pressure to eliminate the springback problem of corner warping during the forming process; for the window part, on the basis of traditional insert flanging shaping, four-corner active pre-forming and four-corner pre-flanging mechanisms are set to eliminate the problems of four-corner springback, surface warping, middle collapse, and poor flanging. At this point, the design of the multi-active block application solution is completed.

[0060] 3.1, Rearward movement of the parting line and T-shaped structure. During the traditional forming process, a parting line is usually set on the front end of the outer panel of the roof cover at the forming fillet to complete the overall layout of the parting line and provide an active area for lateral shaping. However, in this mode, during lateral shaping, the upper area formed by drawing is stretched inward, resulting in a series of problems such as deformation and distortion of the overall part, causing difficulties in debugging, poor surface quality, and a decrease in product accuracy, increasing the forming difficulty and debugging workload, and the result is inconvenient for debugging and adjustment. Therefore, the parting line of the front-end area is moved backward, that is, the parting line is set by moving 15 - 20 mm backward from the conventional parting line setting position of the front-end fillet, and the forming mode of the upper die is changed from forward shaping to a combination of forward shaping and lateral shaping to eliminate this problem. During the setting process, to reduce the strip deformation problem caused by the negative angle withdrawal formed by lateral shaping and the inconvenience of withdrawal caused by the backward movement of the parting line, it is necessary to create a die structure by combining the pulley treatment and roller treatment of the lower die structure. The implementation method is that the front-end area of the lower die is divided into blocks with an inclination angle of 30 - 45 degrees; when withdrawing, it first withdraws 5 - 10 mm forward and downward, and then rotates to withdraw. To achieve this function, it is necessary to set a withdrawal drive block at the front end of the die, and install a rotary cylinder in the trapezoidal expansion area previously laid out on the left and right sides so that the overall module can rotate and make a full-range avoidance. The rotation angle should be such that the overall part can be smoothly withdrawn and there is more than 3 mm of space to prevent springback during the debugging process. The specific value is calculated and set according to the depth of the negative angle. The rotary motion is driven by a rotary cylinder or a rotary motor.

[0061] For the sequence of setting inserts in the upper die area, the forward shaping insert is shaped first, and then the lateral insert is shaped by the pulley drive. Pay attention to the timing setting. The forward shaping works first, and the lateral shaping works later to avoid product defect problems caused by poor timing (this type of timing structure design is the same as the die structure form of the prior art, and the mechanism movement description will not be elaborated in detail).

[0062] 3.2, Left and right sequential forming: Left and right sequential forming is a comprehensive design process of the sequence of technological contents such as forming movable blocks, sequential shaping, and flanging operation after shaping on the left and right sides of the outer panel of the roof cover. The main design method of the lower die under this design scheme is as follows: The lower die adopts a roller mechanism forming mode. The parting line extends 20 - 30 mm inward along the upper fillet of the roof cover top. Two to four groups of movable rollers are set in the shaping area of the lower die; note that since the roller lower die area includes the lateral shaping area and the flanging area, an extension of 5 - 10 mm can be added inward in the flanging area to set the parting line to enhance the strength of the flanging area.

[0063] For the upper die, more timing content needs to be designed. Therefore, the front and rear end areas on the left and right sides of the upper die adopt an auxiliary pressure source construction mode. Floating inserts are set in the front and rear end areas of the upper die, and a pressure nitrogen cylinder is added to complete the priority timing movement. The sequence is that starting from the outer end points of the front and rear ends on the left and right sides, according to the calculated springback area, a movable nitrogen cylinder floating insert is set by extending 30 to 50 mm forward. The pre-pressure is 15 - 20 tons, and a fixed pad is set below to make it press and shape the material 10 - 15 mm in advance. The middle part adopts normal forward shaping. After the upper die is shaped in place, the lateral shaping insert is shaped (the lateral shaping insert installed on the lower die), and then the flanging insert descends to achieve the flanging operation. The overall structure of the upper die timing is that a movable floating insert is installed on the shaping and blank-holding core for shaping, and the flanging insert is directly installed on the upper die for the final movement.

[0064] The overall operating timing structure is: the lower die roller movable block arrives first - the floating inserts at the front and rear ends of the upper die arrive for shaping - the shaping block of the upper die arrives for shaping - the lateral shaping block arrives for shaping - the flanging block of the upper die flanges, thus completing the overall left and right timing shaping.

[0065] 3.3, Window timing shaping: Window timing shaping is mainly divided into two parts of timing shaping. The first part of timing shaping is that the four corners of the window are shaped first and the middle part is shaped later. The operation method is that the lower die is designed according to the normal mode. The upper die part takes the inflection points of the four corners of the window as the center, extends 50 - 60 mm to the left and right respectively, and extends about 40 mm inward to set the pre-shaping inserts. The floating insert shaping structure mode is adopted, and the pre-pressure is 10 - 15 tons. The later pressure is distributed according to the overall pressure of the upper die shaping (refer to the floating insert design method in 3.2, not detailed here). The middle part shaping is designed according to the conventional shaping mode, and the corner part is pre-shaped to reduce the defects of the overall surface quality and the collapse angle problem of shaping. After the shaping module works in place, the second part of the flanging timing shaping starts. The mode of the flanging timing shaping is that the flanging insert first flanges the four corners of the window part, and then extends from the inside to the outside to achieve the flanging operation of the overall window. The structure mode is that the cutting-in height of the flanging insert increases by 4 - 6 mm at the corner, and transitions 50 - 70 mm inward to the normal state. By the flanging timing, the stress concentration is diffused to the middle, so as to reduce the occurrence of problems such as the collapse of the middle part of the window, the springback of the four corners, and the stacking and agglomeration of materials through the reverse movement of the internal stress, and form a perfect surface quality and flanging effect.

[0066] 3.4, Rear-end shaping: The rear-end shaping is relatively simple. It mainly aims at the problems of the collapse and springback in the middle of the rear end, and conducts timing shaping on the left and right edges of the rear end. The two sides are pre-shaped first. The area is set according to the calculated springback area and extends 20 to 35 mm forward. The implementation mode is the floating insert mode.

[0067] 4. Over-molding and strong pressure molding: Because this molding manufacturing method is based on molding defects, the molding difficulties have been concentrated and divided in the design of the previous step. Therefore, over-molding is mainly to completely correct the process springback problem of the top cover outer panel. The implementation method is: process optimization and reverse molding and pressing down on the area with severe springback, and eliminating the springback problem through excessive correction. The over-molded area is the floating insert area designed in the previous step. According to the regular analysis of the results of repeated tests, the maximum over-molding amount can be calculated based on the material thickness and the amount of springback. Assuming the material thickness of the top cover outer panel is D and the springback amount is H, the maximum over-molding amount is: L= H+ D*H*10%; The over-integration design sets the over-integration amount with the midline of the floating insert as the center, and makes a gradual transition to both sides, and sets the over-integration gradual transition to 0 at the edge of the insert.

[0068] For the middle area of ​​the rear end, it is also necessary to design the over-molding amount. Tests have verified that there is no need to set a floating insert at this position. Only a smooth transition ridge is required. The ridge is 0.3mm centered on the center line of the rear end, and the transition to the left and right is 10% to 15% of the left and right width of the overall top cover outer panel. The upper and lower molds are set and adjusted accordingly.

[0069] Strong pressure shaping: Strong pressure shaping is a shaping mode that performs strong coloring shaping on other positive shaping areas outside the floating insert. The method is to hard color the positive shaping area and make a uniform transition to other parts (the strong pressure shaping coloring method is an existing technology that has been applied and will not be described in detail).

[0070] 5. Rotational concession: Rotational concession is mainly for the claws and facade shaping areas corresponding to the left and right flange areas. Because the overall structure of the top cover outer panel is large and the control points are few, the flange shaping is easy to hold the mold due to the rebound problem of the material itself. When the flange ejector is used to lift it, the clamping shape is small. The thrust of the flange ejector will cause the claws and the surrounding areas to deform, causing uncertain defect effects on the product, seriously affecting the molding results. Moreover, the result is uncertain and cannot be accurately adjusted. Therefore, rotational concession is required to achieve the overall removal of the parts. The implementation method of rotational concession mainly relies on the roller mechanism set during the left and right sequential molding in step 3.2. The flange shaping area on the rotating roller needs to be set to the eccentric mode, and the cam motion route is run in the eccentric mode. During rotation, the bidirectional motion structural effect of downward and concession can be achieved at the same time, reducing the deformation of the flange ejection and the deformation of the parts removal caused by the vertical surface and the edge line holding the fillet after the shaping, so as to achieve the precise surface molding effect.

[0071] 6. Ridge line protection reservation: The ridge line protection reservation is mainly to eliminate surface quality defects such as the warping and non-connection of the edge surface of the upper large plane of the roof outer panel during the surrounding shaping process. The adjustment reserve made by the craftsman is as follows: The edge line of the upper large plane is used as the contour line, and it is extended inward by 5 mm to form a strong pressing shaping area. The area 20 mm inward from the strong pressing shaping area is used as a strong pressing transition area. Strong coloring is applied to the strong pressing shaping area, strong pressing to normal transition coloring is applied to the transition area, and normal coloring is applied to other parts, so as to centrally adjust the surface quality problems during the later debugging process and achieve an excellent surface quality effect.

[0072] 7. Difficulty-oriented debugging: The process plan of this forming method is oriented by the forming difficulties. The difficulties are divided into regions and blocks for design, and the overall flanging shaping plan is implemented intensively using a complex loose piece structure. The debugging craftsman needs to first determine whether the timing of the overall debugging is appropriate, and then, based on the defective problem points that appear during the process, concentrate on adjusting in a small area by adjusting the strong pressing area, strong pressing content, floating insert pressure, etc., so as to achieve the overall fast and accurate debugging effect. The debugging craftsman needs to have a comprehensive understanding of the design structure of the overall flanging shaping die and the problem-solving functions of the modules, and adopt the mode of combining the debugging craftsman and the design technicians for debugging to achieve the required effect.

[0073] The steps are as follows: Timing motion confirmation - Confirmation of the motion coordination of each region - Confirmation of the product defective information region - Debugging of the movable insert corresponding to the defective region - Debugging of the strong pressing region - Adjustment of the surface quality connection - Completion of the overall difficulty-oriented debugging work.

[0074] 8. When the overall debugging is qualified and the part quality is qualified, the overall die can be subjected to post-treatment and packaging finishing, and then sent to the automobile manufacturer to complete the finished product operation.

[0075] The above content shows and describes the basic principle, main features and beneficial effects of the present invention. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A die manufacturing method for the circumferential flanging and shaping of the outer panel of an aluminum alloy automobile roof cover, characterized in that: It includes the following steps: Step 1: Difficulty-oriented die structure layout; Step 2: Application plan of multiple movable blocks: After completing the die structure layout, reasonably plan and layout each area of the die structure, and frame the movable block plan of the die structure according to the forming difficulties and process requirements; Step 3.1: Move the parting line backward. Set the parting line by moving it backward 15 - 20 mm according to the position of the conventional parting line at the front end fillet, and change the forming mode of the upper die from forward shaping to a combination of forward shaping and lateral shaping; Step 3.2: Left and right sequential forming: Left and right sequential forming is a comprehensive design process of the sequence of technological contents such as forming the left and right sides of the outer panel of the roof cover with movable blocks, sequential shaping, and flanging operation after shaping; Step 3.3: Window sequential forming: Window sequential forming is mainly divided into two parts of sequential forming. The first part of sequential forming is that the four corners of the window are formed first, and the middle part is formed later; after the shaping module works in place, start the second part of flanging sequential forming. The mode of flanging sequential forming is that the flanging inserts first flange the four corners of the window part, and then extend from the inside to the outside to realize the flanging operation of the whole window; Step 3.4: Rear-end shaping: Mainly aiming at the problems of collapse and springback in the middle of the rear end, perform sequential forming on the left and right edges of the rear end, and perform prior shaping on both sides; Step 4: Over-shaping and strong pressure shaping; Step 5: Rotary retraction; Step 6: Reserved ridge line protection; Step 7: Difficulty-oriented debugging.

2. The method for manufacturing a die for the surrounding flanging and shaping of the outer panel of an aluminum alloy automobile roof cover according to claim 1, characterized in that: The difficulty-oriented die structure layout in Step 1 includes: The front negative angle forming area, which mainly laps with the front windshield or the upper crossbeam, and laps with the side wall, has a negative angle forming structure, adopts an overall extended layout, and reserves an adjustment space. During the die structure layout process, lengthen the die structure in the long direction of this end, and at the same time leave a design space for the driving equipment in the left and right directions, so that this area presents a T-shaped structure.

3. The method for manufacturing a mold for the circumferential flanging and shaping of the outer panel of an aluminum alloy automobile roof cover according to claim 2, wherein: The difficulty-oriented die structure layout in Step 1 also includes: Left and right side forming structure layout: The left and right sides are symmetric about the midline. The main forming contents of this area are to shape the left and right side facades and upper fillets, flange the left and right side claws to meet the fitting requirements, expand this area in the left and right directions, and its structure layout should take into account the up and down movement of the flanging block, the lateral movement of the lateral shaping block, and the up and down movement space of the upper positive shaping block; at the same time, it is necessary to reserve key shaping movable block areas at the front and rear ends of the left and right sides to meet the overall forming requirements and layout structure design; It also includes rear-end forming and window structure layout. The window structure layout method is to leave space for movable strong pressure blocks at the four corners of the window; After the overall die structure layout is completed, it will present a T-shaped overall structure with a wide front end, an extended middle part, and a normal rear end.

4. The method for manufacturing a mold for the circumferential flanging and shaping of the outer panel of an aluminum alloy automotive roof cover according to any one of claims 1-3, characterized in that: The operation mode of Step 2 is as follows: The front end adopts a mode of mainly side shaping and auxiliary positive shaping, changing the traditional side shaping mode, setting a side shaping movable insert as the main forming method for side negative angle forming; at the same time, leaving positive shaping space, using positive shaping for the upper part, the two shaping modes are coordinated to eliminate the problems of material pulling and surface deformation caused by the conventional process of side shaping on the top. In order to ensure that the parts can be smoothly removed from the negative angle area after forming, the overall structure of the front end lower die needs to be converted into a rotating movable mode; forming a multi-movable block application solution combining the rotation of the side shaping insert, the upper die positive shaping insert and the side shaping insert; Left and right side forming: Due to the concentrated process of left and right side forming, its manufacturing process is integrated into a combination of shaping and flanging. Shaping is adjusted to lateral shaping to avoid shaping rebound and shaping locking; the adjustment method is segmented roller, adding rotating structural components for rotational forming, and setting two or four groups of rotating live blocks on each side to complete the lower die live block scheme design; the live block scheme of the upper die adopts a hierarchical and block structure, and active modules are set on the front and rear ends of the left and right sides to form a first shaping module structure, and a sequential forming module with first shaping and pressing and rear clamping claw flanging is set for the remaining part; For the left and right sides of the rear end, an active preliminary shaping structure is set on the upper die to complete the mode of combining preliminary shaping and subsequent strong pressure to eliminate the springback problem of corner warping during the forming process; for the window part, on the basis of traditional insert flanging shaping, four-corner active preliminary shaping and four-corner preliminary flanging mechanisms are set to eliminate problems such as four-corner springback, surface warping, middle collapse, and poor flanging.

5. The method for manufacturing a die for the circumferential flanging and shaping of the outer panel of an aluminum alloy automotive roof cover according to claim 4, wherein: In step 3.1: during the process of setting the parting line backward, the mold structure is created by combining the pulley processing and the roller processing mode for the lower mold structure. The implementation method is that the front end area of ​​the lower mold is divided into blocks with an inclination angle of 30 to 45 degrees; when exiting, first exit 5 to 10 mm forward and downward, and then rotate to exit; for the upper mold area, the sequence of the inserts needs to be set, and the forward shaping inserts are shaped first, and then the lateral inserts are shaped by the pulley drive; In the process of setting the left and right sequential molding in step 3.2: the lower mold adopts the roller mechanism molding mode, and the parting line is extended 20 to 30 mm inward along the upper fillet of the top cover, and two to four groups of active rollers are set in the molding area of ​​the lower mold; For the upper die, more timing contents need to be designed. Therefore, the front and rear end areas on the left and right sides of the upper die adopt an auxiliary pressure source construction mode, and floating inserts are set in the front and rear end areas of the upper die. The pressure nitrogen cylinder is increased to complete the priority timing movement. The sequence is to start from the outer end points of the front and rear ends of the left and right sides. According to the calculated rebound area, the floating inserts of the active nitrogen cylinder are extended forward 30 to 50 mm, with a pre-pressure of 15 to 20 tons. The squatting pad is set below to enable it to press and shape the material 10 to 15 mm in advance. The middle part adopts normal forward shaping. After the upper die is shaped in place, the lateral shaping insert is shaped, and then the flanging insert is moved downward to realize the flanging operation. The overall structure of the upper die timing is that the floating insert is installed on the shaping pressing core, and the flanging insert is directly installed on the upper die for the final movement. The overall operation timing structure is as follows: the lower die roller movable block arrives in place first - the upper die front and rear floating inserts arrive for shaping - the upper die shaping block arrives for shaping - the lateral shaping block arrives for shaping - the upper die flanging block flanges, thus completing the overall left - right timing shaping.

6. The method for manufacturing a die for the circumferential flanging and shaping of the outer panel of an aluminum alloy automobile roof cover according to claim 5, wherein: During the window timing shaping setting process in step 3.3: Window timing shaping is mainly divided into two parts of timing shaping. The first part of timing shaping is that the four corners of the window are shaped first and the middle part is shaped later in time sequence. The operation method is that the lower die is designed in the normal mode. For the upper die part, taking the inflection points of the four corners of the window as the center, expand 50 - 60 mm to the left and right and extend about 40 mm inward to set the pre - shaping inserts. The floating insert shaping structure mode is adopted, with a pre - pressure of 10 - 15 tons. The later pressure is distributed according to the overall pressure of the upper die shaping. The middle part shaping is designed according to the conventional shaping mode. By shaping the corners first, it reduces the defects of the overall surface quality and the problem of corner collapse during shaping. After the shaping module works in place, the second part of the flanging timing shaping starts. The mode of the flanging timing shaping is that the flanging inserts first flange the four corners of the window part, and then extend from the inside to the outside to realize the flanging operation of the overall window. The structure mode is that the blade - entering height of the flanging inserts increases by 4 - 6 mm at the corners and transitions 50 - 70 mm inward to the normal state. By the flanging timing sequence, the stress concentration is diffused to the middle, so as to reduce the occurrence of problems such as the middle part of the window sagging, the four - corner springback and material stacking through the way of reverse movement of internal stress, forming a perfect surface quality and flanging effect.

7. The method for manufacturing a die for the surrounding flanging and shaping of the outer panel of an aluminum alloy automobile roof cover according to claim 6, characterized in that: During the over - shaping and strong - pressure shaping setting process in step 4: The implementation method of over - shaping is as follows: optimize the process and perform reverse shaping and downward pressing on the severely springback area. Eliminate the springback problem through excessive correction. The area of over - shaping is the floating insert area designed in the previous step. According to the analysis of the law of the results of multiple repeated tests, calculate the maximum over - shaping amount according to the material thickness and springback amount of the material. Let the material thickness of the top cover outer panel be D and the springback amount be H, then the maximum over - shaping amount is: L = H+D*H*10%; The over - shaping design sets the over - shaping amount centered on the mid - line part of the floating insert and makes a gradual transition to both sides, with the over - shaping gradually transitioning to 0 at the edge of the insert; for the middle area at the rear end, the over - shaping amount also needs to be designed. There is no need to set a floating insert at this position, only a smooth transition bulge is required. The bulge amount is to bulge 0.3 mm centered on the center line of the rear end and transition 10% - 15% of the left - right width of the overall top cover outer panel to the left and right. The upper and lower dies are correspondingly set and adjusted; Strong - pressure shaping: Strong - pressure shaping is a shaping mode that performs strong coloring shaping on other positive - shaping areas outside the floating inserts. The method is to perform hard coloring on the positive - shaping area and make a uniform transition to other parts.

8. The method for manufacturing a mold for the circumferential flanging and shaping of the outer panel of an aluminum alloy automotive roof cover according to claim 7, wherein: In the process of setting the rotation and retreat in step 5: it is mainly realized by the roller mechanism set during the left and right sequential forming in step 3.

2. The flange shaping area on the rotating roller needs to be set to the eccentric mode, and the cam movement route is operated in the eccentric mode. During the rotation, the bidirectional movement structure effect of downward and retreat can be achieved at the same time, reducing the deformation of the flange ejection and the deformation of the parts removed caused by the vertical surface and the edge line holding the rounded corners after shaping, so as to achieve a precise noodle forming effect.

9. The method for manufacturing a die for the surrounding flanging and shaping of the outer panel of an aluminum alloy automobile roof cover according to claim 8, characterized in that: In step 6, during the setting process of edge protection reservation: the edge line of the upper large plane is the contour line, which is expanded inward by 5mm to make a strong pressure shaping area, and the strong pressure transition area is made 20mm inward from the strong pressure shaping area. The strong pressure shaping area is strongly colored, and the transition area is subjected to transitional coloring from strong pressure to normal, and other parts are subjected to normal coloring, so as to make centralized adjustments to noodle quality problems during the later debugging process to achieve excellent noodle quality effects.

10. The method for manufacturing a die for the circumferential flanging and shaping of the outer panel of an aluminum alloy automobile roof cover according to claim 9, characterized in that: In the difficulty-oriented debugging and setting process in step 7: using a complex movable block structure to implement the overall flanging shaping solution in a centralized manner, the debugging craftsman needs to first determine whether the timing of the overall debugging is appropriate, and then, based on the undesirable problems that occur during the process, concentrate the adjustments in a small area by adjusting the strong pressure area, strong pressure content, floating insert pressure, etc., to achieve an overall fast and accurate debugging effect.

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