Rail transit windshield aluminum profile with high bending performance

Abstract

The invention discloses a rail transit windshield aluminum profile with high bending performance. The cross section of the mold is of a rectangular frame structure, and a plurality of oval and hexagonal cavities are arranged in the mold. The oval cavity is of double curvature, the wall thickness is gradually increased from the center to the vertex, the size is gradually reduced from outside to inside, the outer side is large, the inner side is small, smooth transition is achieved, and the bending stress characteristic is matched. The corners of the hexagonal cavity are concave arcs, and cross-shaped reinforcing ribs are arranged in the hexagonal cavity. The cavities are connected through stepped T-shaped connecting parts, arc-shaped stress flow guide grooves are formed in the four corners of the frame, and honeycomb-shaped lightening holes are formed in the walls of the cavities. Wave-shaped flexible connecting belts are arranged between the adjacent cavities and are made of 6005A aluminum alloy materials. And in cooperation with low-temperature preheating, step-by-step bending and rapid water cooling processes, the sectional material effectively disperses bending stress, reduces concentration risks, has the advantages of high strength and light weight, and meets the high-performance requirement of the rail transit windshield component. According to the abstract, the core structure and advantages of the profile are comprehensively extracted.

Description

Technical Field

[0001] The present invention relates to the technical field of rail transit equipment manufacturing, and in particular to a rail transit windshield aluminum profile with high bending performance. Background Art

[0002] In the field of rail transit, windshields, as key components connecting adjacent carriages, need to have good sealing, cushioning, and structural stability to adapt to vibrations, shocks, and changes in air pressure during train operation. Aluminum profiles are widely used in the manufacture of rail transit windshields due to their advantages such as light weight, corrosion resistance, and moderate strength. However, during the bending process, existing windshield aluminum profiles often suffer from problems such as cracks and deformation due to stress concentration, which affects the molding quality and performance of the profiles. At the same time, the structural design of traditional aluminum profiles makes it difficult to achieve efficient bending while ensuring strength and rigidity, which limits their application in windshield structures with complex shapes. Therefore, there is an urgent need to design a rail transit windshield aluminum profile with high bending performance to meet the rail transit industry's demand for high performance and high precision of windshield components. Summary of the Invention

[0003] In order to solve the technical problems existing in the background technology, the present invention proposes a rail transit windshield aluminum profile with high bending performance.

[0004] The present invention proposes a rail transit windshield aluminum profile with high bending performance, the cross-section of the aluminum profile is a rectangular frame structure, and a plurality of elliptical cavities and hexagonal cavities are provided inside the rectangular frame; in the cross-section of the aluminum profile, a plurality of elliptical cavities are provided inside the rectangular frame, and each elliptical cavity is distributed along the length direction of the cross-section, and the line connecting the two vertices of each elliptical cavity is parallel to each other; the hexagonal cavity is provided between the two end vertices of two adjacent elliptical cavities, and the line connecting its two opposite corners is parallel to the line connecting the elliptical vertices; a first T-shaped connecting portion is provided between a vertex of the hexagon and two adjacent elliptical side walls, and a second T-shaped connecting portion is provided between the opposite sides of the two adjacent hexagons and a vertex of the ellipse.

[0005] Preferably, the sizes of the multiple elliptical cavities gradually decrease from the outside to the inside, the larger elliptical cavity is located on the outer wall when the aluminum profile is bent, and the smaller elliptical cavity is located on the inner wall, and the sizes of the elliptical cavities are smoothly transitioned, and the change rate of the long axis length in the transition area does not exceed 15%.

[0006] Preferably, the elliptical cavity is a hyperbolic ellipse, the curvature of the two ends of the long axis of the elliptical cavity is greater than the curvature of the central portion, and the wall thickness of the elliptical cavity gradually increases from the center to the vertex.

[0007] Preferably, the six corners of the hexagonal cavity are concave arc structures, and a cross-shaped slightly convex reinforcement rib is provided inside the hexagonal cavity.

[0008] Preferably, the first T-shaped connecting portion and the second T-shaped connecting portion are both stepped cross-sections, gradually thickening from the connection point to the aluminum profile body, and the edges of the first T-shaped connecting portion and the second T-shaped connecting portion in contact with the cavity are provided with multiple chamfered corners.

[0009] Preferably, the rail transit windshield aluminum profile with high bending performance according to claim 1 is characterized in that arc-shaped stress guide grooves are provided at the four corners of the rectangular frame.

[0010] Preferably, honeycomb-shaped weight-reducing holes are provided on the cavity walls of the elliptical cavity and the hexagonal cavity, and the edges of the weight-reducing holes are provided with flanging structures.

[0011] Preferably, a wavy flexible connecting belt is provided between adjacent elliptical cavities and hexagonal cavities, and the flexible connecting belt is made of 6005A aluminum alloy.

[0012] Preferably, the aluminum profile is preheated to 180°C at a low temperature, bent in 3-4 steps, with the bending angle of each step not exceeding 20°, and quickly water-cooled to finalize the shape after bending.

[0013] The present invention proposes a rail transit windshield aluminum profile with high bending performance, which has the following beneficial effects:

[0014] High Bending Performance: Through a unique oval and hexagonal cavity layout, a hyperbolic oval cavity design, stress guide grooves, and a wavy flexible connecting belt, stress during the bending process is effectively dispersed, reducing stress concentration. This allows the aluminum profile to maintain excellent forming quality during complex bending processes, making it less susceptible to cracking and deformation. In particular, the oval cavity's design, which gradually decreases in size from the outside to the inside, conforms to the stress characteristics of bending, provides a more reasonable deformation space, and further improves bending performance.

[0015] High strength and stability: Structures such as reinforcing ribs and stepped T-shaped connections enhance the overall strength and rigidity of the aluminum profile, ensuring it can withstand external forces such as vibration, impact, and air pressure during rail transit operation, maintaining structural stability.

[0016] Lightweight design: The setting of honeycomb-shaped weight-reducing holes reduces weight without affecting the performance of the profile, which meets the lightweight requirements of rail transit and helps reduce the energy consumption of train operation.

[0017] Good process adaptability: The optimized structural design combined with the specific low-temperature preheating, step-by-step bending and rapid water cooling shaping process improves the feasibility and efficiency of aluminum profile processing and reduces production costs.

[0018] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned by practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic structural diagram of Example 1 of the present invention;

[0020] Figure 2 This is a structural diagram of Example 2 of the present invention.

[0021] Explanation of the reference numerals in the figure: 1, rectangular frame structure; 2, elliptical cavity; 3, hexagonal cavity; 4, first T-shaped connecting portion; 5, second T-shaped connecting portion; DETAILED DESCRIPTION

[0022] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar symbols throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention, and are not to be construed as limiting the present invention.

[0023] Example 1:

[0024] like Figure 1 The present invention provides a rail transit windshield aluminum profile with high bending performance: the cross-section of the aluminum profile is a rectangular frame structure 1, and a plurality of elliptical cavities 2 and hexagonal cavities 3 are provided inside the rectangular frame; in the cross-section of the aluminum profile, a plurality of elliptical cavities 2 are provided inside the rectangular frame, and each elliptical cavity 2 is distributed along the length direction of the cross-section, and the two vertices of each elliptical cavity 2 are parallel to each other; the hexagonal cavity 3 is provided between the two end vertices of two adjacent elliptical cavities 2, and the line connecting its two relative corners is parallel to the line connecting the elliptical vertices; a first T-shaped connecting part 4 is provided between a vertex of the hexagon and two adjacent elliptical side walls, and a second T-shaped connecting part 5 is provided between the opposite sides of the two adjacent hexagons and a vertex of the ellipse.

[0025] Furthermore, the elliptical cavity 2 is a hyperbolic ellipse, with the curvature of its major axis at both ends greater than that at the center, and the wall thickness of the elliptical cavity 2 gradually increases from the center to the apex. This design allows the elliptical cavity 2 to distribute stress more evenly when subjected to force, reducing stress concentration at the apex, improving the cavity's resistance to compression and deformation, and thus enhancing the overall bending performance of the aluminum profile.

[0026] Example 2:

[0027] like Figure 2 The multiple elliptical cavities 2 gradually decrease in size from the outside to the inside. The larger elliptical cavities 2 are located on the outer wall of the aluminum profile when it is bent, while the smaller elliptical cavities 2 are located on the inner wall. The elliptical cavities 2 have a smooth transition in size, and the change in the major axis length in the transition area does not exceed 15%. The outer wall is subject to greater tensile stress, and the larger cavity provides more space for material deformation. The inner wall is subject to greater compressive stress, and the smaller cavity ensures structural stability. The smooth transition helps reduce stress mutations during bending, further improving bending performance.

[0028] Elliptical cavity design: A hyperbolic ellipse is used, with the curvature at both ends of the long axis greater than the curvature at the center, and the wall thickness gradually increases from the center to the apex. This design enables the elliptical cavity to better adapt to deformation when subjected to bending forces, avoiding stress concentration at a certain point, thereby improving the overall bending performance. At the same time, the dimensions of multiple elliptical cavities gradually decrease from the outside to the inside, with the larger elliptical cavity located on the outer wall of the bend and the smaller one on the inner wall. This layout conforms to the force characteristics of the material during the bending process. The outer wall is subject to greater tensile stress, and the larger cavity can provide more space for material deformation; the inner wall is subject to greater compressive stress, and the smaller cavity can ensure the stability of the structure. The dimensions of each elliptical cavity transition smoothly, which helps reduce stress mutations during bending and further improves bending performance.

[0029] The six corners of the hexagonal cavity 3 are concave arc structures, and cross-shaped slightly convex reinforcement ribs are provided inside the hexagonal cavity 3. The concave arc structure avoids stress concentration caused by sharp corners, while the cross-shaped slightly convex reinforcement ribs enhance the structural strength and stability of the hexagonal cavity 3, allowing it to better cooperate with other cavities to withstand external forces during the aluminum profile bending process and prevent cavity deformation.

[0030] Both the first and second T-shaped connecting portions 4 and 5 have stepped cross-sections, gradually increasing in thickness from the connection point toward the main body of the aluminum profile. The edges of the first and second T-shaped connecting portions 4 and 5 that contact the cavity are characterized by multiple rounded corners. This stepped cross-section and rounded corner design effectively reduces stress concentration at the connection, enhances the connection strength between the connection and the cavity, and ensures smooth force transmission at the connection, preventing localized damage caused by weak connections.

[0031] The four corners of the rectangular frame are provided with arc-shaped stress guide grooves. These guide grooves can disperse the stress during the bending process toward the edges of the frame, preventing stress accumulation at the cavity connections, further improving the bending performance and structural reliability of the aluminum profile.

[0032] The walls of the elliptical cavity 2 and the hexagonal cavity 3 are provided with honeycomb-shaped lightening holes, the edges of which are equipped with flanged structures. The honeycomb-shaped lightening holes reduce the weight of the aluminum profile while maintaining the structural strength of the cavity. The flanged structures prevent cracks at the edges of the lightening holes during bending, thus ensuring the integrity of the profile.

[0033] A wavy flexible connecting strip, made of 6005A aluminum alloy, is installed between the adjacent elliptical cavity 2 and hexagonal cavity 3. This strip allows for localized elastic deformation when the aluminum profile is bent, absorbing stress and preventing crack propagation. The excellent flexibility and strength of 6005A aluminum alloy ensures the strip's reliability under various operating conditions.

[0034] The aluminum profile is preheated to 180°C at low temperature, then bent in 3-4 steps, with each bending angle not exceeding 20°. After bending, the profile is quickly water-cooled to finalize the shape. This process reduces the aluminum profile's resistance to deformation, ensuring more uniform deformation during the bending process, minimizing springback and cracking, and ensuring bending accuracy and quality.

[0035] Production process:

[0036] 1. Material Preparation

[0037] We use 6005A aluminum alloy as the raw material for aluminum profiles, and strictly control its chemical composition to ensure that the content of alloying elements such as magnesium and silicon meets standard requirements. The raw materials are pre-treated, including surface cleaning and degreasing, to remove surface oil and impurities in preparation for subsequent processing.

[0038] 2. Mold design and manufacturing

[0039] Based on the structural design of the aluminum profile, an extrusion die is manufactured with a rectangular frame, an elliptical cavity 2, a hexagonal cavity 3, and a T-shaped connection. The die head is designed with a wavy flow channel to form a wavy flexible connecting belt. Corresponding raised or recessed structures are provided in areas such as stress guide grooves and weight-reducing holes. For the elliptical cavity 2, the cavity dimensions are precisely designed, ensuring a smooth, tapering transition from outside to inside. The mold is precisely machined and polished to ensure surface finish and dimensional accuracy, ensuring the quality of the aluminum profile.

[0040] 3. Extrusion molding

[0041] The pretreated 6005A aluminum alloy raw material is heated to 550-580°C to achieve good fluidity. The molten aluminum alloy is then extruded through a die at a pressure of 10-15 MPa. The extrusion speed is controlled to match the pulling speed, allowing the aluminum alloy to form within the die according to the designed shape. During the extrusion process, the profile's temperature, pressure, and dimensional changes are monitored in real time to ensure uniform wall thickness and conformity to the design requirements. In particular, the dimensional gradient of the elliptical cavity 2 meets the design standards.

[0042] 4. Bending

[0043] The extruded aluminum profile is preheated to 180°C to reduce its resistance to deformation. Using specialized bending equipment, the bending operation is performed in 3-4 steps, with each bending angle not exceeding 20°. During the bending process, a mold is used to position and support the aluminum profile to ensure accurate bending angles. Furthermore, the special design of the elliptical cavity 2, with a larger outer cavity and smaller inner cavity, better accommodates bending deformation and reduces stress concentration. After bending is complete, the aluminum profile is immediately subjected to rapid water cooling to quickly cool the profile, reduce springback and deformation, and stabilize the bent shape.

[0044] 5. Post-processing

[0045] The bent aluminum profiles undergo surface treatment, such as anodizing, to form a dense oxide film on the surface, improving the profile's corrosion resistance and aesthetics. Quality inspections are performed on the aluminum profiles, including dimensional measurement, mechanical property testing, and non-destructive testing, to ensure that all performance indicators of the aluminum profiles meet design requirements.

[0046] Through the above implementation methods, a rail transit windshield aluminum profile with high bending performance, high strength and light weight can be manufactured to meet the high performance requirements of the rail transit industry for windshield components.

[0047] It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be understood as limiting the present invention.

[0048] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0049] In the present invention, unless otherwise specified or limited, the terms "installed," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection, or communication; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0050] In the present invention, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it may mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it may mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.

[0051] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A rail transit windshield aluminum profile with high bending performance, characterized in that: The cross section of the aluminum profile is a rectangular frame structure (1), and a plurality of elliptical cavities (2) and hexagonal cavities (3) are provided inside the rectangular frame; in the cross section of the aluminum profile, a plurality of elliptical cavities (2) are provided inside the rectangular frame, and each elliptical cavity (2) is distributed along the length direction of the cross section, and the lines connecting the two vertices of each elliptical cavity (2) are parallel to each other; the hexagonal cavity (3) is provided between the two end vertices of two adjacent elliptical cavities (2), and the line connecting the two opposite corners thereof is parallel to the line connecting the elliptical vertices; a first T-shaped connecting portion (4) is provided between a vertex of the hexagon and two adjacent elliptical side walls, and a second T-shaped connecting portion (5) is provided between the opposite sides of the two adjacent hexagons and a vertex of the ellipse.

2. The rail transit windshield aluminum profile with high bending performance according to claim 1 is characterized in that: The dimensions of the multiple elliptical cavities (2) gradually decrease from the outside to the inside, the larger elliptical cavity (2) is located on the outer wall of the aluminum profile when it is bent, and the smaller elliptical cavity (2) is located on the inner wall, and the dimensions of the elliptical cavities (2) are smoothly transitioned, and the change rate of the major axis length in the transition area does not exceed 15%.

3. The rail transit windshield aluminum profile with high bending performance according to claim 2, characterized in that: The elliptical cavity (2) is a hyperbolic ellipse, the curvatures of the two ends of its major axis are greater than the curvature of the central portion, and the wall thickness of the elliptical cavity (2) gradually increases from the center to the vertex.

4. The rail transit windshield aluminum profile with high bending performance according to claim 1, characterized in that: The six corners of the hexagonal cavity (3) are inwardly concave arc structures, and a cross-shaped slightly convex reinforcing rib is provided inside the hexagonal cavity (3).

5. The rail transit windshield aluminum profile with high bending performance according to claim 1, characterized in that: The first T-shaped connecting portion (4) and the second T-shaped connecting portion (5) both have stepped cross-sections, gradually thickening from the connection point toward the aluminum profile body, and the edges of the first T-shaped connecting portion (4) and the second T-shaped connecting portion (5) contacting the cavity are provided with a plurality of chamfered corners.

6. The rail transit windshield aluminum profile with high bending performance according to claim 1, characterized in that: The rail transit windshield aluminum profile with high bending performance according to claim 1 is characterized in that arc-shaped stress guide grooves are provided at the four corners of the rectangular frame.

7. The rail transit windshield aluminum profile with high bending performance according to claim 1 is characterized in that: Honeycomb-shaped weight-reducing holes are provided on the cavity walls of the elliptical cavity (2) and the hexagonal cavity (3), and the edges of the weight-reducing holes are provided with flanging structures.

8. The rail transit windshield aluminum profile with high bending performance according to claim 1 is characterized in that: A wavy flexible connecting belt is provided between the adjacent elliptical cavities (2) and hexagonal cavities (3), and the flexible connecting belt is made of 6005A aluminum alloy.

9. The rail transit windshield aluminum profile with high bending performance according to claim 1, characterized in that: The aluminum profile is preheated to 180° C. at a low temperature, bent in 3-4 steps, with the bending angle of each step not exceeding 20°, and then quickly water-cooled to finalize the shape.

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