Rail transit windshield aluminum profile with high bending performance

Abstract

The application discloses a rail transit windshield aluminum profile with high bending performance. The cross section of the profile is a rectangular frame structure, and multiple elliptical and hexagonal cavities are arranged in the profile. The elliptical cavity has double curvature, the wall thickness increases from the center to the vertex, the size gradually decreases from the outside to the inside, the outside is large and the inside is small, and the transition is smooth, which is consistent with the bending stress characteristics; the corner of the hexagonal cavity is concave arc, and a cross-shaped reinforcing rib is arranged in the cavity. The cavities are connected through stepped T-shaped connecting parts, arc-shaped stress guide grooves are arranged at the four corners of the frame, and the cavity wall has honeycomb weight-reducing holes. Wave-shaped flexible connecting belts are arranged between adjacent cavities, and the profile is made of 6005A aluminum alloy. The profile effectively disperses the bending stress, reduces the concentration risk, has the advantages of high strength and light weight, and meets the high performance requirements of rail transit windshield components. The above abstract comprehensively extracts the core structure and advantages of the profile.

Description

Technical Field

[0001] This invention relates to the field of rail transit equipment manufacturing technology, and in particular to a rail transit windshield aluminum profile with high bending performance. Background Technology

[0002] In the rail transit sector, windshields, as key components connecting adjacent carriages, require excellent sealing, cushioning, and structural stability to withstand vibrations, impacts, and air pressure changes during train operation. Aluminum profiles, due to their lightweight, corrosion resistance, and moderate strength, are widely used in rail transit windshield manufacturing. However, existing aluminum windshield profiles often suffer from stress concentration during bending, leading to cracks and deformation, affecting the profile's forming quality and performance. Furthermore, the structural design of traditional aluminum profiles makes it difficult to achieve efficient bending while maintaining strength and rigidity, limiting their application in complex windshield structures. 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 demands for high-performance and high-precision windshield components. Summary of the Invention

[0003] To address the technical problems existing in the background art, the present invention proposes an aluminum profile for rail transit windshields with high bending performance.

[0004] This invention proposes a high-bending-performance aluminum profile for rail transit windshields. The aluminum profile has a rectangular frame structure in its cross-section, with multiple elliptical and hexagonal cavities inside the rectangular frame. The elliptical cavities are distributed along the length of the cross-section, and the lines connecting the two vertices of each elliptical cavity are parallel to each other. A hexagonal cavity is located between the two vertices of two adjacent elliptical cavities, and the line connecting the two opposite angles of the two hexagonal cavities between the two vertices of two adjacent elliptical cavities is parallel to the line connecting the two vertices of the elliptical cavity. A first T-shaped connection is provided between one vertex of the hexagon and two adjacent elliptical sidewalls, and a second T-shaped connection is provided between the opposite sides of two adjacent hexagons and one vertex of the ellipse.

[0005] Preferably, the multiple elliptical cavities gradually decrease in size from the outside to the inside, with the larger elliptical cavities located on the outer sidewall when the aluminum profile is bent, and the smaller elliptical cavities located on the inner sidewall. The dimensions of each elliptical cavity have a smooth transition, and the rate of change of the major axis length in the transition region does not exceed 15%.

[0006] Preferably, the elliptical cavity is a hyperbolic ellipse, with the curvature at both ends of its major axis being greater than that at the center, and the wall thickness of the elliptical cavity gradually increases from the center to the apex.

[0007] Preferably, the six corners of the hexagonal cavity are concave arc structures, and the interior of the hexagonal cavity is provided with cross-shaped micro-convex reinforcing ribs.

[0008] Preferably, both the first T-shaped connecting portion and the second T-shaped connecting portion have stepped cross-sections, gradually thickening from the connecting point towards the main body of the aluminum profile, and the edges of the first T-shaped connecting portion and the second T-shaped connecting portion that contact the cavity are provided with multiple rounded corners.

[0009] Preferably, the four corners of the rectangular frame are provided with arc-shaped stress guiding grooves.

[0010] Preferably, the elliptical cavity and the hexagonal cavity have honeycomb-shaped weight-reducing holes on their chamber walls, and the edges of the weight-reducing holes have a flanged structure.

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

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

[0013] The aluminum profile for rail transit windshields with high bending performance proposed in this invention has the following beneficial effects:

[0014] High bending performance: Through unique elliptical and hexagonal cavity layouts, double-curvature elliptical cavity design, stress-guiding grooves, and corrugated flexible connecting strips, stress is effectively dispersed during the bending process, reducing stress concentration. This allows the aluminum profile to maintain good forming quality during complex bending processes, making it less prone to cracking and deformation. In particular, the design of the elliptical cavity gradually decreasing in size from the outside to the inside conforms to the stress characteristics during bending, providing a more reasonable deformation space and further improving bending performance.

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

[0016] Lightweight design: The honeycomb-shaped weight-reducing holes reduce weight without affecting the performance of the profile, meeting the lightweight requirements of rail transit and helping to reduce train operating energy consumption.

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

[0018] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of the present invention;

[0020] Figure 2 This is a schematic diagram of the structure of Embodiment 2 of the present invention.

[0021] Explanation of the labels in the diagram: 1. Rectangular frame structure; 2. Elliptical cavity; 3. Hexagonal cavity; 4. First T-shaped connector; 5. Second T-shaped connector; Detailed Implementation

[0022] Embodiments of the present invention are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar symbols denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0023] Example 1:

[0024] like Figure 1 This invention provides a high-bending-performance aluminum profile for rail transit windshields: the cross-section of the aluminum profile is a rectangular frame structure 1, and the rectangular frame has multiple elliptical cavities 2 and hexagonal cavities 3 inside; in the cross-section of the aluminum profile, the rectangular frame has multiple elliptical cavities 2, each elliptical cavity 2 is distributed along the length 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 located between the two vertices of two adjacent elliptical cavities 2, and the lines connecting its two opposite angles are parallel to the lines connecting the vertices of the ellipse; a first T-shaped connecting part 4 is provided between one vertex of the hexagon and two adjacent elliptical sidewalls, and a second T-shaped connecting part 5 is provided between the opposite sides of two adjacent hexagons and one vertex of the ellipse.

[0025] Furthermore, the elliptical cavity 2 is a hyperbolic ellipse, with the curvature at both ends of its major axis 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 stress in the elliptical cavity 2 to be distributed more evenly when under load, 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. Example 2:

[0026] like Figure 2The multiple elliptical cavities 2 gradually decrease in size from the outside to the inside. The larger elliptical cavities 2 are located on the outer sidewall when the aluminum profile is bent, and the smaller elliptical cavities 2 are located on the inner sidewall. The dimensions of each elliptical cavity 2 have a smooth transition, and the change rate of the major axis length in the transition region does not exceed 15%. The outer sidewall is subjected to greater tensile stress, and the larger cavity can provide more space for material deformation. The inner sidewall is subjected to greater compressive stress, and the smaller cavity can ensure the stability of the structure. The smooth transition also helps to reduce stress abrupt changes during bending, further improving bending performance.

[0027] Elliptical Cavity Design: Employing a hyperbolic ellipse, the curvature at both ends of the major axis is greater than that at the center, and the wall thickness gradually increases from the center to the apex. This design allows the elliptical cavity to better adapt to deformation under bending forces, avoiding stress concentration at a single point and thus improving overall bending performance. Simultaneously, the dimensions of multiple elliptical cavities gradually decrease from the outside to the inside, with larger cavities located on the outer sidewall and smaller ones on the inner sidewall. This layout conforms to the stress characteristics of the material during bending. The outer sidewall experiences higher tensile stress, and the larger cavity provides more space for material deformation; the inner sidewall experiences higher compressive stress, and the smaller cavity ensures structural stability. Furthermore, the smooth transition in size between the elliptical cavities helps reduce stress abrupt changes during bending, further improving bending performance.

[0028] The six corners of the hexagonal cavity 3 are concave arc structures, and the interior of the hexagonal cavity 3 is provided with cross-shaped micro-convex reinforcing ribs. The concave arc structure avoids stress concentration caused by sharp corners, while the cross-shaped micro-convex reinforcing ribs enhance the structural strength and stability of the hexagonal cavity 3, enabling it to better cooperate with other cavities to withstand external forces during the bending process of aluminum profiles and prevent cavity deformation.

[0029] Both the first T-shaped connecting portion 4 and the second T-shaped connecting portion 5 have stepped cross-sections, gradually thickening from the connection point towards the main body of the aluminum profile. Furthermore, the edges of the first T-shaped connecting portion 4 and the second T-shaped connecting portion 5 that contact the cavity have multiple rounded corners. This stepped cross-section and rounded corner design effectively reduces stress concentration at the connection points, enhances the connection strength between the connection points and the cavity, and allows for smooth force transmission at the connection points, preventing localized damage due to weak connections.

[0030] The rectangular frame has arc-shaped stress diversion channels at its four corners. These channels guide stress during bending towards the frame edges, preventing stress accumulation at the cavity connections and further improving the bending performance and structural reliability of the aluminum profile.

[0031] The elliptical cavity 2 and hexagonal cavity 3 have honeycomb-shaped weight-reducing holes on their chamber walls, and the edges of the weight-reducing holes have a flanged structure. The honeycomb-shaped weight-reducing holes reduce the weight of the aluminum profile while maintaining the structural strength of the chamber, and the flanged structure prevents cracks from forming at the edges of the weight-reducing holes during bending, thus ensuring the integrity of the profile.

[0032] A wavy flexible connecting strip is provided between adjacent elliptical cavities 2 and hexagonal cavities 3. The flexible connecting strip is made of 6005A aluminum alloy. The wavy flexible connecting strip can undergo local elastic deformation when the aluminum profile is bent, absorb stress, and prevent crack propagation. At the same time, the 6005A aluminum alloy material has good flexibility and strength, ensuring the reliability of the connecting strip under various working conditions.

[0033] The aluminum profile is preheated to 180°C at a low temperature, then bent in 3-4 steps, with each bending angle not exceeding 20°. After bending, it is rapidly water-cooled for shaping. This process reduces the deformation resistance of the aluminum profile, resulting in more uniform deformation during bending, reducing springback and cracking, and ensuring the bending accuracy and quality of the aluminum profile.

[0034] Production process:

[0035] I. Material Preparation

[0036] 6005A aluminum alloy is selected as the raw material for aluminum profiles, and its chemical composition is strictly controlled to ensure that the content of alloying elements such as magnesium and silicon meets the standard requirements. The raw materials undergo pretreatment, including surface cleaning and degreasing, to remove surface oil and impurities, preparing them for subsequent processing.

[0037] II. Mold Design and Manufacturing

[0038] Based on the structural design of the aluminum profile, extrusion molds are manufactured with shapes such as rectangular frames, elliptical cavities 2, hexagonal cavities 3, and T-shaped connectors. The mold head is designed with a wavy flow channel to form a wavy flexible connecting strip; corresponding protrusions or recesses are set at stress guide grooves, weight reduction holes, and other locations. For the elliptical cavity 2, the mold cavity dimensions are precisely designed according to the requirement of gradually decreasing dimensions from the outside to the inside with a smooth transition. The mold is precisely machined and polished to ensure the surface finish and dimensional accuracy of the mold, thereby ensuring the forming quality of the aluminum profile.

[0039] III. Extrusion Molding

[0040] The pretreated 6005A aluminum alloy raw material is heated to 550-580℃ to achieve good fluidity. The molten aluminum alloy material is extruded through an extruder at a pressure of 10-15MPa into a die. The extrusion speed is controlled to match the traction speed, allowing the aluminum alloy material to be formed into the designed shape within the die. During the extrusion process, the temperature, pressure, and dimensional changes of the profile are monitored in real time to ensure uniform wall thickness and that the shape meets design requirements, especially the gradual dimensional change of the elliptical cavity 2, which conforms to design standards.

[0041] IV. Bending Process

[0042] The extruded aluminum profile is preheated to 180°C at a low temperature to reduce its deformation resistance. 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 die is used to position and support the aluminum profile, ensuring the accuracy of the bending angle. Simultaneously, due to the special design of the elliptical cavity 2, the larger outer cavity and smaller inner cavity better accommodate bending deformation, reducing stress concentration. After bending, the aluminum profile is immediately subjected to rapid water cooling to fix its shape, reducing springback and deformation.

[0043] V. Post-processing

[0044] Surface treatments, such as anodizing, are applied to the bent aluminum profiles to form a dense oxide film on the surface, improving their corrosion resistance and aesthetics. Quality inspections are then performed on the aluminum profiles, including dimensional measurements, mechanical property tests, and non-destructive testing, to ensure that all performance indicators meet design requirements.

[0045] Through the above implementation methods, it is possible to manufacture aluminum profiles for rail transit windshields that have high bending performance, high strength, and lightweight characteristics, thus meeting the high-performance requirements of the rail transit industry for windshield components.

[0046] It should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used 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, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0047] 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 technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0048] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0049] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0050] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-bending-performance aluminum profile for rail transit windshields, characterized in that, The aluminum profile has a rectangular frame structure (1) in its cross section. The rectangular frame has multiple elliptical cavities (2) and hexagonal cavities (3) inside. In the cross section of the aluminum profile, the rectangular frame has multiple elliptical cavities (2) inside. Each elliptical cavity (2) is distributed along the length 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 located between the two vertices of two adjacent elliptical cavities (2). The line connecting the two opposite angles of the two hexagonal cavities (3) between the two vertices of two adjacent elliptical cavities (2) is parallel to the line connecting the two vertices of the elliptical cavity (2). A first T-shaped connection (4) is provided between one vertex of the hexagon and two adjacent elliptical sidewalls. A second T-shaped connection (5) is provided between the opposite sides of two adjacent hexagons and one vertex of the ellipse. The multiple elliptical cavities (2) gradually decrease in size from the outside to the inside. The largest elliptical cavity (2) is located on the outer side wall when the aluminum profile is bent, and the smallest elliptical cavity (2) is located on the inner side wall. The dimensions of each elliptical cavity (2) are smoothly transitioned, and the change rate of the major axis length in the transition area does not exceed 15%.

2. The high bending performance aluminum profile for rail transit windshields according to claim 1, characterized in that, The elliptical cavity (2) is a hyperbolic ellipse, with the curvature at both ends of its major axis being greater than that at the center, and the wall thickness of the elliptical cavity (2) gradually increases from the center to the apex.

3. The high bending performance aluminum profile for rail transit windshields according to claim 1, characterized in that, The six corners of the hexagonal cavity (3) are concave arc structures, and the interior of the hexagonal cavity (3) is provided with cross-shaped micro-convex reinforcing ribs.

4. The high bending performance aluminum profile for rail transit windshields according to claim 1, characterized in that, Both the first T-shaped connecting part (4) and the second T-shaped connecting part (5) have stepped cross sections, which gradually thicken from the connecting point to the main body of the aluminum profile, and the edges of the first T-shaped connecting part (4) and the second T-shaped connecting part (5) that contact the cavity are provided with multiple rounded corners.

5. The high bending performance aluminum profile for rail transit windshields according to claim 1, characterized in that, According to claim 1, the high bending performance of the rail transit windshield aluminum profile is characterized in that the four corners of the rectangular frame are provided with arc-shaped stress guiding grooves.

6. The high-bending-performance aluminum profile for rail transit windshields according to claim 1, characterized in that, The elliptical cavity (2) and the hexagonal cavity (3) have honeycomb-shaped weight-reducing holes on their chamber walls, and the edges of the weight-reducing holes have a flanged structure.

7. The high-bending-performance aluminum profile for rail transit windshields according to claim 1, characterized in that, A wavy flexible connecting strip is provided between adjacent elliptical cavities (2) and hexagonal cavities (3), and the flexible connecting strip is made of 6005A aluminum alloy.

8. The high-bending-performance aluminum profile for rail transit windshields according to claim 1, characterized in that, The aluminum profile is preheated to 180°C at a low temperature, then bent in 3-4 steps, with each bending angle not exceeding 20°, followed by rapid water cooling for shaping.

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