Manual simmering device and method for thin plate type U-shaped beam of grain hopper car

Abstract

A manual simmering device for a thin-plate U-shaped beam of a grain hopper car belongs to the technical field of railway freight manufacturing and comprises a simmering insert and a handle which are detachably connected, one end of the simmering insert protrudes outwards to form an arc working face, and the radius of the arc working face is equal to that of a simmering finished product of the U-shaped beam. An adjusting space is reserved between the upper end of the simmering insert and the arc top of the arc working face, and a clamping groove is formed between the lower end of the simmering insert and the arc working face. A manual simmering method for a thin plate type U-shaped beam of a grain hopper car comprises the steps that a semi-finished U-shaped beam product is prepared, the semi-finished U-shaped beam product is put into an auxiliary tool, a clamping groove of the device is inserted into a U-shaped groove simmering block, and a handle is rotated clockwise; in the rotating process, the U-shaped groove simmering block and 2-3 tangent points of arcs on the two sides of the vertical face of the U-shaped groove are subjected to positioned welding, the device is taken down, and fillet welding seams are subjected to full-length welding. The device is simple in structure, convenient to manufacture, low in cost, high in universality and light in weight; meanwhile, the simmering process is easy to control, and the simmering quality is good.

Description

Technical Field

[0001] The invention belongs to the technical field of railway freight manufacturing, and relates to a shaping device and a shaping method for thin plate U-shaped beams, and in particular to a manual shaping device and method for thin plate U-shaped beams for grain hopper cars. Background Art

[0002] At present, in the railway freight car manufacturing industry, there are more and more hopper cars used to load goods such as coal, ore, slag and grain; and grain hopper cars, which are mainly loaded with food such as corn and flour, have extremely high quality requirements on the sealing of the hopper cars and the materials used in the car body.

[0003] Among the grain hopper car series, hopper cars with bodies made mainly of carbon steel, stainless steel (T4003), aluminum alloy and other materials are the most common. In the side walls, end walls, roofs or chassis structures of these models, there are many U-shaped beams that need to be shaped at one or both ends, such as side cross-belts, end columns, columns, upper end edges, end beams, longitudinal beams and fulcrum beams. Most U-shaped beams are made of medium and thick plates (≤5mm plates). The shapes of these parts are basically similar, and they all need to be shaped using some kind of shaped tooling or molds. The difference lies in the different materials used (carbon steel, stainless steel (T4003), aluminum alloy) and the different thicknesses of the plates (1.5 to 12mm). Commonly used shaped methods are:

[0004] 1. Special mold hydraulic press bending and shaping: Suitable for thick plate parts with a thickness of 7 to 12 mm, made of carbon steel, stainless steel or aluminum alloy, which need to be shaped, such as the inner reinforcement seat of the side column in the ore hopper car series;

[0005] 2. General-purpose forming tooling and mechanical forming: Suitable for forming medium-thick plate parts with a thickness of 3 to 6 mm and made of carbon steel, stainless steel or aluminum alloy, such as the upper end edge, end beam, and side crossband of the coal hopper car series;

[0006] 3. Manual forming with simple tooling and forming device: Suitable for parts with a thickness of 1.5 to 3 mm, made of carbon steel, stainless steel, aluminum alloy and other thin plates that need to be formed; such as the end columns, columns, longitudinal beams, fulcrum beams, etc. in the grain hopper car series;

[0007] 4. Manual flame simmering: This method is only suitable for very small batches (≤5 pieces) and medium and thick plates with a thickness of >3mm.

[0008] However, the existing simmering method mainly has the following shortcomings:

[0009] 1. The production cost of special mold hydraulic press bending and simmering is high and the versatility is poor. In addition, the U-beam bending and simmering surface is prone to quality defects such as oil stains.

[0010] 2. The general-purpose forming tooling mechanical forming requires two forming inserts in each U-beam component, and the forming surface is prone to quality defects such as misaligned teeth and surface scratches;

[0011] 3. Manual flame simmering requires flame heating for simmering carbon steel parts, but stainless steel and aluminum alloys are not allowed to be simmered by artificial flame.

[0012] In order to produce a manual simmering device that does not require too much external force, has low production cost, controllable simmering surface quality, strong versatility, and is easy to promote and apply, the present invention proposes a manual simmering device and method for thin plate U-shaped beams of grain hopper cars. Summary of the Invention

[0013] In view of the shortcomings of the prior art mentioned above, the purpose of the present invention is to provide a manual shaping device and method for thin plate U-shaped beams of grain hopper cars, which is used to solve the technical problems in the prior art of high cost and uncontrollable shaping surface quality of the thin plate U-shaped beam shaping device of aluminum alloy grain hopper cars.

[0014] In order to achieve the above-mentioned purpose and other related purposes, the present invention provides a manual shaping device for thin-plate U-shaped beams of grain hopper cars, comprising a detachably connected shaping insert and a handle, wherein the shaping insert comprises an insert body, wherein one end of the insert body away from the handle protrudes outward to form an arc working surface, and the radius of the arc working surface is equal to the radius of the finished U-shaped beam shaping product, and the upper and lower ends of the insert body are respectively connected to horizontal blocks, and an adjustment space is left between the suspended end of the upper horizontal block and the arc top of the arc working surface, and a slot is formed between the lower horizontal block and the arc working surface.

[0015] Preferably in any of the above schemes, the width of the annealed insert is m2, m2≤a-30mm, wherein a is the maximum inner spacing of the U-shaped groove.

[0016] Preferably, in any of the above schemes, the width of the slot is t1, t1 = t + 0.5 mm, wherein t is the thickness of the U-groove forming block.

[0017] Preferably, in any of the above schemes, the distance of the adjustment space is m3, m3=1.5t, wherein t is the thickness of the U-shaped groove simmering block.

[0018] Preferably in any of the above schemes, the U-beam manual shaping device also includes an auxiliary tooling, and the auxiliary tooling includes a base plate and an L-shaped plate connected to the base plate, and a fixing groove is formed between the L-shaped plate and the base plate.

[0019] A method for manually forming a thin-plate U-shaped beam for a grain hopper car mainly comprises the following steps:

[0020] S1. Preparation of a thin-plate U-shaped semi-finished grain hopper car, the U-shaped semi-finished beam includes a U-shaped beam body and a U-shaped groove simmer block;

[0021] S2. Place the U-shaped groove of the main body of the formed U-shaped beam downward into the auxiliary tooling;

[0022] S3. Insert the U-shaped beam manual simmering device into the slot of the U-shaped groove simmering block, and turn the handle clockwise to make the U-shaped groove simmering block along the U-shaped groove facade on both sides of the arc bend;

[0023] S4. Continue to rotate the handle clockwise to make the U-shaped groove simmering block continue to bend along the arc of the U-shaped groove facade, and position the weld U-shaped groove simmering block and the U-shaped groove facade on both sides of the arc tangent point E2;

[0024] S5. Continue to rotate the handle clockwise to make the U-shaped groove simmering block continue to bend along the arc of the U-shaped groove facade, and position the weld U-shaped groove simmering block and the U-shaped groove facade on both sides of the arc tangent point E3;

[0025] S6. After completing the forming and tack welding, remove the manual forming device for the U-beam;

[0026] S7. After the forming is completed, fully weld the fillet welds between the U-groove forming blocks and the arcs on both sides of the facade.

[0027] Preferably, in any of the above schemes, in step S3, during the bending process of the U-groove forming block along the arcs on both sides of the U-groove vertical surface, the intersection point E1 of the U-groove forming block and the arcs on both sides of the U-groove vertical surface is positioned and welded.

[0028] Preferably in any of the above solutions, the E1 or E2 is located 5 to 10 mm from the middle of the U-shaped groove simmering block.

[0029] Preferably in any of the above schemes, the E3 is located at the extreme corner joint between the U-shaped groove simmering block and the arcs on both sides of the U-shaped groove vertical surface.

[0030] In any of the above solutions, preferably, in step S6, before removing the manual U-beam simmering device, the simmering insert is fine-tuned, specifically:

[0031] When the mouth opening is insufficient and the teeth are misaligned, continue to rotate the handle clockwise to make the U-shaped groove block fit tightly with the vertical surfaces on both sides of the U-shaped groove.

[0032] When the teeth are too far off, rotate the handle counterclockwise to make the U-shaped groove shaping block fit tightly against the vertical surfaces on both sides of the U-shaped groove.

[0033] As described above, the device and method for manually shaping thin-plate U-shaped beams for grain hopper cars of the present invention have the following beneficial effects:

[0034] 1. In the present invention, the device is used for cold bending and forming of thin-plate stainless steel or aluminum alloy U-shaped beams with a thickness of less than 3 mm. It does not require high-cost bending molds or large and medium-sized forming tooling. The entire device has a simple structure, is easy to manufacture, has low cost, is highly versatile, and is light in weight, making it easy to operate manually.

[0035] 2. In the present invention, the shaping process is easy to control, and no surface oil or scratches will be generated during the shaping process. The shaping surface can be adjusted to prevent misalignment between the shaping surface and the vertical surfaces on both sides of the U-shaped groove, thereby effectively ensuring the shaping quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 Shown are three views of the U-shaped manual simmering device of the present invention.

[0037] Figure 2 Shown are three views of the simmering insert in a U-shaped manual simmering device.

[0038] Figure 3 Shown are three views of the handle of a U-shaped hand-simmering device.

[0039] Figure 4 Shown is the expanded view of a U-shaped end column.

[0040] Figure 5 Shown is the expanded view of the simmering area of ​​a U-shaped end column.

[0041] Figure 6 Shown are three views of the finished U-shaped end column component.

[0042] Figure 7 Display as Figure 6 Enlarged schematic diagram of the AA surface in the middle.

[0043] Figure 8 Shown is the expanded view of a U-shaped support beam.

[0044] Figure 9 Shown is the expanded view of the simmering area of ​​a U-shaped pivot beam.

[0045] Figure 10 Three views of the finished component showing the U-shaped pivot beam.

[0046] Figure 11 Shown are the front and cross-sectional views of the U-shaped end column installed in the auxiliary fixture.

[0047] Figure 12 Shown are the front and cross-sectional views of the U-shaped fulcrum beam installed in the auxiliary tooling.

[0048] Figure 13 Shown is the principle of using a U-shaped manual simmering device on a U-shaped end column Figure 1 .

[0049] Figure 14 Shown is the principle of using a U-shaped manual simmering device on a U-shaped end column Figure 2 .

[0050] Figure 15 Shown is the principle of using a U-shaped manual simmering device on a U-shaped end column Figure 3 .

[0051] Figure 16 Shown is the principle of using a U-shaped manual simmering device on a U-shaped end column Figure 4 .

[0052] Component number description

[0053] 1-U-shaped end column U-shaped groove bracing block, 2-U-shaped end column wing surface, 3-U-shaped end column U-shaped groove vertical surface, 4-U-shaped end column U-shaped groove vertical surface, 5-U-shaped fulcrum beam U-shaped groove bracing block, 6-U-shaped fulcrum beam wing surface, 7-U-shaped fulcrum beam U-shaped groove vertical surface, 8-U-shaped fulcrum beam U-shaped groove vertical surface, 9-bracing insert, 91-arc working surface, 92-horizontal block, 93-slot, 94-adjustment space, 95-weight reduction hole, 10-handle, 11-auxiliary tooling, 111-base plate, 112-L-shaped plate. DETAILED DESCRIPTION

[0054] The following describes the implementation of the present invention through specific embodiments. People skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

[0055] See also Figures 1 to 16 . It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions for the implementation of the present invention. Therefore, they have no substantive technical significance. Any modification of the structure, change in the proportional relationship or adjustment of the size should still fall within the scope of the technical content disclosed by the present invention without affecting the efficacy and purpose that can be achieved by the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description, and are not used to limit the scope of the implementation of the present invention. Changes or adjustments in their relative relationships should also be regarded as the scope of the implementation of the present invention without substantially changing the technical content.

[0056] Example 1

[0057] See also Figure 1-3, 11-12, the present invention provides a manual forming device for thin-plate U-shaped beams of grain hopper cars, including a forming insert 9 and a handle 10. The forming insert 9 is formed by laser cutting and processed with an M16 threaded hole; the handle 10 uses ordinary φ20 round steel and is machined with an M16 thread. The forming insert 9 and the handle 10 are detachably connected by being screwed into the threaded hole of the forming insert 9 through the thread on the handle 10, which facilitates the installation and disassembly of the forming insert 9 and the handle 10 of the manual forming device, thereby facilitating the inspection or replacement of the forming insert 9 and / or the handle 10. At the same time, the entire manual forming device is 1.43 kg, which is light in weight, convenient for manual operation by the staff, and reduces the labor intensity of the staff.

[0058] In this embodiment, the simmering insert 9 includes an insert body. The end of the insert body away from the handle 10 protrudes outward to form an arc working surface 91. The radius of the arc working surface 91 is equal to the radius of the U-shaped beam simmering product. The upper and lower ends of the insert body are respectively connected to horizontal blocks 92. The horizontal block 92 and the insert body are formed as one piece. An adjustment space 94 is reserved between the suspended end of the upper horizontal block 92 and the arc top of the arc working surface 91 for adjusting the distance between the U-shaped groove simmering block and the arc space on both sides of the U-shaped groove vertical surface when the angle of the simmering insert 9 is insufficient or the simmering is excessive. A clamping groove 93 for clamping the U-shaped groove simmering block is formed between the lower horizontal block 92 and the bottom of the arc working surface 91. Among them,

[0059] The length of the simmering insert 9 is m1, m1 = m2;

[0060] The width of the simmering insert 9 is m2, m2≤a-30mm, where a is the maximum inner spacing of the U-shaped groove; specifically:

[0061] In the U-shaped end column type U-shaped groove, a1 is the inner side spacing of the U-shaped end column type U-shaped groove, with 60mm and 72mm being the most common.

[0062] In the U-shaped groove of the U-shaped fulcrum beam, a2 is the inner side spacing of the U-shaped groove of the U-shaped fulcrum beam, and 74mm and 80mm are common.

[0063] In this embodiment, in order to ensure a wider range of use of the simmering insert 9, the value of a is calculated based on the maximum inner spacing of the U-shaped groove of 80mm, that is, a=80mm, and the width m2 of the simmering insert 9 is 50mm. At this time, the simmering insert 9 is suitable for U-shaped beams with inner spacings of the U-shaped groove of 50mm, 60mm, 72mm, 74mm, 80mm, etc., and has a wider range of applications; and when the width of the simmering insert 9 is 50mm, the simmering insert 9 can move freely between the two inner vertical surfaces 3 of the U-shaped groove, which can achieve fast and smooth simmering of the simmering surface.

[0064] The height of the simmering insert 9 is n1, n1 = 2m2;

[0065] The width of the slot 93 is t1, t1 = t + 0.5 mm, where t is the thickness of the U-shaped slot block;

[0066] The distance of the adjustment space 94 is m3, m3=1.5t.

[0067] In this embodiment, in order to reduce the weight of the manual simmering device, a weight-reducing hole 95 is further provided in the middle of the simmering insert 9. At the same time, the total weight of the simmering device is ≤1.5Kg.

[0068] In this embodiment, in order to fix the U-shaped beam during the manual shaping process, the U-shaped beam manual shaping device also includes an auxiliary tooling 11, which includes a base plate 111 and an L-shaped plate 112 detachably connected to the base plate 111 by screws, and a fixing groove is formed between the L-shaped plate 112 and the base plate 111.

[0069] Specifically, a number of threaded holes are evenly opened on the bottom plate 111, and a number of threaded holes are opened at the bottom of the vertical end of the L-shaped plate 112. The bottom plate 111 and the L-shaped plate 112 are connected by screws passing through the threaded holes on the bottom plate 111 and the L-shaped plate 112, so that L-shaped plates 112 of different sizes can be replaced as needed to meet different usage requirements.

[0070] This device is used very frequently at production sites. Each aluminum alloy (stainless steel) grain hopper car needs to have about 24 U-shaped beams formed. The forming inserts and handles used in the device of the present invention in the actual production process have a total weight of 1.43 kg, which is equivalent to the weight of an ordinary hand hammer and will not increase the labor intensity of employees due to the heavy weight.

[0071] Example 2

[0072] U-shaped beams mainly include thin plate-type annealed parts such as side beams, end columns, vertical columns, longitudinal beams and support beams.

[0073] In this embodiment, the U-shaped end columns of the aluminum alloy grain hopper car are shaped.

[0074] See also Figure 4-7 13-16, a method for manually shaping a thin-plate U-shaped end column for a grain hopper car, mainly comprising the following steps:

[0075] S1. Preparation of a grain hopper car sheet U-shaped end column semi-finished product, U-shaped semi-finished beam including a U-shaped beam body and a U-shaped end column U-shaped groove simmer block 1;

[0076] Please refer to Figure 4-7 In this step, a semi-finished product of a thin-plate U-shaped end column of a grain hopper car is prepared, and the process flow is as follows:

[0077] (1) According to Figure 6 Finished product drawing of parts and components, unfolding into plane drawing, compiling CAD program drawing: including tolerance processing, crack prevention holes at the folding line position and other details, such as Figure 4 ;

[0078] (2) Use CNC programming software to expand the component product drawings and import them into the programming software, and automatically (manual fine-tuning is possible) generate Figure 4 Laser cutting procedure shown;

[0079] (3) Laser cutting: The cutting program is copied into the laser equipment using a dedicated U disk. The equipment automatically runs according to the program sequence, direction, micro-connection, etc., and cuts the plate into the following shapes: Figure 4 The same semi-finished parts;

[0080] (4) Leveling: Most semi-finished parts have varying degrees of bending and deformation after laser cutting, plasma cutting, or shearing, and need to be leveled using dedicated leveling equipment. Unleveled parts can lead to significant quality risks such as flatness or related dimensional deviations during drilling, bending, or assembly (welding) with other parts in subsequent processes.

[0081] (5) Bending and pressing: On a special bending and pressing device, the semi-finished parts after being flattened are bent and pressed to become new semi-finished parts. Generally, 4 bending and pressing are required, such as Figure 4 ① and ② are the bending and pressing orders on the same side, ③ and ④ are the bending and pressing orders after the workpiece is turned over after ① and ② are completed. After the bending and pressing is completed, the following is formed: Figure 5 The formed U-shaped beam body and U-shaped end column U-shaped groove simmering block 1 are shown.

[0082] in,

[0083] a1 is the inner spacing of the U-shaped groove of the U-shaped end column;

[0084] b1 is the net height of the U-shaped groove of the U-shaped end column;

[0085] S2. The U-shaped groove of the main body of the U-shaped beam is formed downward into the fixing groove of the auxiliary tooling 11, the U-shaped end column U-shaped groove simmering block 1 is located outside the end of the bottom plate 111, for easy manual simmering operation, such as Figure 11 As shown;

[0086] S3. Insert the U-shaped beam manual simmering device into the slot 93 of the U-shaped end column U-shaped groove simmering block 1, and turn the handle 10 clockwise to make the U-shaped end column U-shaped groove simmering block 1 along the U-shaped end column U-shaped groove facade 3 on both sides of the arc bending, such as Figure 13 As shown;

[0087] Among them, the width m2 of the U-shaped end column and U-shaped groove forming block 1 is 50 mm.

[0088] S4. Continue to rotate the handle 10 clockwise to bend the U-shaped end column U-shaped groove block 1 along the arc of the U-shaped end column U-shaped groove facade 3, and position weld the U-shaped end column U-shaped groove block 1 and the U-shaped end column U-shaped groove facade 3 on both sides of the arc tangent point E2, such as Figure 15 As shown;

[0089] S5. Continue to rotate the handle 10 clockwise to bend the U-shaped end column U-shaped groove simmering block 1 along the arc of the U-shaped end column U-shaped groove vertical surface 3, and position weld the U-shaped end column U-shaped groove simmering block 1 and the U-shaped end column U-shaped groove vertical surface 3 on both sides of the arc tangent point E3, E3 is at the end of the U-shaped end column U-shaped groove simmering block 1 and the U-shaped end column U-shaped groove vertical surface 3 on both sides of the arc corner, as shown in FIG. Figure 16 As shown;

[0090] S6. After completing the forming and tack welding, remove the manual forming device for the U-beam;

[0091] S7. After the forming is completed, the fillet welds between the U-shaped end column U-shaped groove forming block 1 and the arcs on both sides of the U-shaped end column U-shaped groove vertical surface 3 are fully welded.

[0092] In this embodiment, in step S3, during the bending process of the U-shaped end column U-shaped groove annealing block 1 along the arcs on both sides of the U-shaped end column U-shaped groove facade 3, the U-shaped end column U-shaped groove annealing block 1 and the tangent point E1 of the arcs on both sides of the U-shaped end column U-shaped groove facade 3 can be positioned and welded before the tangent point E2 as needed. Figure 14 As shown, E1 is 5 mm in front of the middle of the U-shaped end column and U-shaped groove simmering block 1, and E2 is 5 mm behind the middle of the U-shaped end column and U-shaped groove simmering block 1.

[0093] Of course, the position of E1 and / or E2 is not limited to 5 mm in front and 5 mm behind the middle of the U-shaped end column U-groove forming block 1, and can be adjusted accordingly according to the actual construction situation. For example, E1 and / or E2 can be within the range of 5 to 10 mm in the middle of the arc on both sides of the U-shaped end column U-groove forming block 1 and the U-shaped end column U-groove vertical surface 3.

[0094] In this embodiment, in S6, before removing the manual U-beam simmering device, the simmering insert 9 is fine-tuned, specifically:

[0095] When the simmering shape is not enough to open the mouth and the teeth are misaligned, continue to rotate the handle 10 degrees clockwise, m3 becomes smaller, so that the U-shaped simmering block fits tightly with the vertical surfaces on both sides of the U-shaped groove.

[0096] When the teeth are too far off, rotate the handle counterclockwise by 10 degrees, m3 will increase, and the U-shaped groove forming block will fit tightly with the vertical surfaces on both sides of the U-shaped groove.

[0097] Example 3

[0098] U-shaped beams mainly include thin plate-type annealed parts such as side beams, end columns, vertical columns, longitudinal beams and support beams.

[0099] In this embodiment, the U-shaped fulcrum cross beam of the aluminum alloy grain hopper car is annealed.

[0100] A method for manually forming a thin-plate U-shaped fulcrum crossbeam for a grain hopper car mainly comprises the following steps:

[0101] S1. Preparation of a thin-plate U-shaped fulcrum beam semi-finished food hopper car, a U-shaped fulcrum beam semi-finished product includes a U-shaped beam body and a U-shaped fulcrum beam U-shaped groove simmering block 5;

[0102] Please refer to Figure 8-10 In this step, a semi-finished product of a thin-plate U-shaped fulcrum beam of a grain hopper car is prepared, and the process flow is as follows:

[0103] (1) According to Figure 10 Finished product drawing of parts and components, unfolding into plane drawing, compiling CAD program drawing: including tolerance processing, crack prevention space at folding line position and other details, such as Figure 8 ;

[0104] (2) Use CNC programming software to expand the component product drawings and import them into the programming software, and automatically (manual fine-tuning is possible) generate Figure 8 Laser cutting procedure shown;

[0105] (3) Laser cutting: The cutting program is copied into the laser equipment using a dedicated U disk. The equipment automatically runs according to the program sequence, direction, micro-connection, etc., and cuts the plate into the following shapes: Figure 8 The same semi-finished parts;

[0106] (4) Leveling: Most semi-finished parts have varying degrees of bending and deformation after laser cutting, plasma cutting, or shearing, and need to be leveled using dedicated leveling equipment. Unleveled parts can lead to significant quality risks such as flatness or related dimensional deviations during drilling, bending, or assembly (welding) with other parts in subsequent processes.

[0107] (5) Bending and pressing: On a special bending and pressing device, the semi-finished parts after being flattened are bent and pressed to become new semi-finished parts. Generally, 4 bending and pressing are required, such as Figure 4 ① and ② are the bending and pressing orders on the same side, ③ and ④ are the bending and pressing orders after the workpiece is turned over after ① and ② are completed. After the bending and pressing is completed, the following is formed: Figure 9 The formed U-shaped beam body and U-shaped fulcrum beam U-shaped groove simmering block 5 are shown.

[0108] in,

[0109] a2 is the distance between the inner sides of the U-shaped groove of the U-shaped support beam;

[0110] b2 is the net height of the U-shaped groove of the U-shaped support beam;

[0111] S2. The U-shaped groove of the main body of the U-shaped beam is formed downwardly into the fixing groove of the auxiliary tooling 11, the U-shaped fulcrum beam U-shaped groove simmering block 5 is located outside the end of the bottom plate 111, for easy manual simmering operation, such as Figure 12 As shown;

[0112] S3. Insert the U-shaped beam manual simmering device into the slot 93 of the U-shaped fulcrum beam U-shaped groove simmering block 5, and turn the handle 10 clockwise to bend the U-shaped fulcrum beam U-shaped groove simmering block 5 along the arc on both sides of the U-shaped fulcrum beam U-shaped groove facade 7, and tack weld the U-shaped fulcrum beam U-shaped groove simmering block 5 and the U-shaped fulcrum beam U-shaped groove facade 7 on both sides of the arc tangent point E1, E1 in the U-shaped fulcrum beam U-shaped groove simmering block 5 3mm in front of the middle;

[0113] Among them, the width m2 of the U-shaped fulcrum beam U-shaped groove forming block 5 is 50mm.

[0114] S4. Continue to rotate the handle 10 clockwise to make the U-shaped fulcrum beam U-shaped groove simmer block 5 continue to bend along the arc of the U-shaped fulcrum beam U-shaped groove facade 7, and tack weld the U-shaped fulcrum beam U-shaped groove simmer block 5 and the U-shaped fulcrum beam U-shaped groove facade 7 on both sides of the arc tangent point E2, E2 in the U-shaped fulcrum beam U-shaped groove simmer block 5 4mm behind the middle;

[0115] S5. Continue to rotate the handle 10 clockwise to bend the U-shaped fulcrum beam U-shaped groove simmering block 5 along the arc of the U-shaped fulcrum beam U-shaped groove facade 7, and tack weld the U-shaped fulcrum beam U-shaped groove simmering block 5 and the U-shaped fulcrum beam U-shaped groove facade 7 on both sides of the arc tangent point E3, E3 in the U-shaped fulcrum beam U-shaped groove simmering block 5 and the U-shaped fulcrum beam U-shaped groove facade 7 on both sides of the arc at the end corner joint;

[0116] S6. After completing the forming and tack welding, remove the manual forming device for the U-beam;

[0117] Before removing the U-beam manual simmering device, fine-tune the simmering insert 9, specifically:

[0118] When the simmering shape is not enough to open the mouth and the teeth are misaligned, continue to rotate the handle 10 degrees clockwise, m3 becomes smaller, so that the U-shaped simmering block fits tightly with the vertical surfaces on both sides of the U-shaped groove.

[0119] When the teeth are too far off, rotate the handle counterclockwise by 10 degrees, m3 will increase, and the U-shaped groove forming block will fit tightly with the vertical surfaces on both sides of the U-shaped groove.

[0120] S7. After the forming is completed, the fillet welds between the U-shaped support beam U-shaped groove forming block 5 and the U-shaped support U-shaped groove 7 vertical arcs on both sides are fully welded.

[0121] In summary, the present invention has a simple structure, is easy to manufacture, has low cost, is highly versatile, and is lightweight, making it easy to operate manually. Furthermore, the shaping process is easy to control, and no surface oil or scratches are generated during the shaping process. Furthermore, the shaping surface can be adjusted to prevent misalignment between the shaping surface and the vertical surfaces on both sides of the U-shaped groove, thereby effectively ensuring the shaping quality. Therefore, the present invention effectively overcomes the various shortcomings of the prior art and has high industrial utilization value.

[0122] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. A device for manually shaping thin-plate U-shaped beams for grain hopper cars, characterized by: The invention comprises a detachably connected simmering insert (9) and a handle (10), wherein the simmering insert (9) comprises an insert body, wherein one end of the insert body away from the handle (10) protrudes outward to form an arc working surface (91), wherein the radius of the arc working surface (91) is equal to the radius of the U-shaped beam simmering product, and the upper and lower ends of the insert body are respectively connected to horizontal blocks (92), an adjustment space (94) is reserved between the suspended end of the upper horizontal block (92) and the arc top of the arc working surface (91), and a slot (93) is formed between the lower horizontal block (92) and the arc working surface (91).

2. The device for manually shaping thin-plate U-shaped beams for grain hopper cars according to claim 1 is characterized in that: The width of the simmering insert (9) is m2, m2≤a-30mm, wherein a is the maximum inner side spacing of the U-shaped groove.

3. The device for manually shaping thin-plate U-shaped beams for grain hopper cars according to claim 1 is characterized in that: The width of the slot (93) is t1, t1=t+0.5 mm, wherein t is the thickness of the U-shaped slot forming block.

4. The device for manually shaping thin-plate U-shaped beams for grain hopper cars according to claim 1 is characterized in that: The distance of the adjustment space (94) is m3, m3=1.5t, wherein t is the thickness of the U-shaped groove simmering block.

5. The device for manually shaping thin-plate U-shaped beams for grain hopper cars according to claim 1 is characterized in that: The device further comprises an auxiliary tooling (11), wherein the auxiliary tooling (11) comprises a base plate (111) and an L-shaped plate (112) connected to the base plate (111), wherein a fixing groove is formed between the L-shaped plate (112) and the base plate (111).

6. A method for manually forming thin-plate U-shaped beams for grain hopper cars, comprising the manual forming device according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1. Preparation of a thin-plate U-shaped semi-finished grain hopper car, the U-shaped semi-finished beam includes a U-shaped beam body and a U-shaped groove simmer block; S2. The U-shaped groove of the main body of the U-shaped beam is formed downward into the auxiliary tooling (11); S3. Insert the U-shaped beam manual simmering device into the slot (93) of the U-shaped groove simmering block, and turn the handle clockwise (10) to make the U-shaped groove simmering block bend along the arc on both sides of the U-shaped groove facade; S4 continue to rotate the handle clockwise (10) to make the U-shaped groove simmer block continue to bend along the arc of the U-shaped groove facade, and position the weld U-shaped groove simmer block and the U-shaped groove facade on both sides of the arc tangent point E2; S5 continue to rotate the handle clockwise (10) to make the U-shaped groove simmer block continue to bend along the arc of the U-shaped groove facade, and position the weld U-shaped groove simmer block and the U-shaped groove facade on both sides of the arc tangent point E3; S6. After completing the forming and tack welding, remove the U-beam manual forming device; S7. After the forming is completed, fully weld the fillet welds between the U-groove forming blocks and the arcs on both sides of the facade.

7. The method for manually shaping thin-plate U-shaped beams for grain hopper cars according to claim 6, characterized in that: In the step S3, during the bending process of the U-shaped groove forming block along the arcs on both sides of the U-shaped groove vertical surface, the tangent point E1 of the U-shaped groove forming block and the arcs on both sides of the U-shaped groove vertical surface is positioned and welded.

8. The method for manually shaping thin-plate U-shaped beams for grain hopper cars according to claim 7, characterized in that: The E1 and / or E2 are located 5 to 10 mm from the middle of the U-shaped groove simmering block.

9. The method for manually shaping thin-plate U-shaped beams for grain hopper cars according to claim 6, characterized in that: The E3 is located at the extreme corner joint between the U-shaped groove simmering block and the arcs on both sides of the U-shaped groove vertical surface.

10. The method for manually shaping thin-plate U-shaped beams for grain hopper cars according to claim 6, characterized in that: In the step S6, before removing the U-beam manual simmering device, the simmering insert (9) is fine-tuned, specifically: When the mouth opening is insufficient and the teeth are misaligned, continue to rotate the handle (10) clockwise to make the U-shaped groove block fit tightly with the vertical surfaces on both sides of the U-shaped groove. When the teeth are too far apart, the handle (10) is rotated counterclockwise to make the U-shaped groove shaping block fit tightly with the vertical surfaces on both sides of the U-shaped groove.

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