Multi-stage forming device for hidden door handle mounting area of aluminum alloy vehicle door and application method of multi-stage forming device

Abstract

The invention discloses an aluminum alloy vehicle door hidden type door handle installation area multi-stage forming device and an application method. The aluminum alloy vehicle door hidden type door handle installation area multi-stage forming device comprises a pressure buffering shaping block arranged on a base, and the shaping surface of the upper end of the pressure buffering shaping block is a shaping block molded surface of a hidden type door handle area; in the stamping direction, a pressure buffering spring, a side moving spring, a shallow hole spring, a deep hole spring and a material returning screw are arranged between the base and the pressure buffering shaping block, and the shallow hole spring and the deep hole spring are matched with a shallow hole forming block and a deep hole forming block which penetrate through the pressure buffering shaping block respectively. The upper end parts, extending to the shaping surface, of the shallow hole forming block and the deep hole forming block are respectively a shallow hole molded surface and a deep hole molded surface; in the direction perpendicular to the punching direction, a side moving block driven by a side moving spring is arranged between the base and the pressure buffering and shaping block, and the side moving block and the pressure buffering and shaping block are in sliding fit through mutually-matched slopes. The invention provides a low-cost and high-stability solution for high-quality application of the hidden door handle.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile door handle installation area molding, and in particular to a multi-stage molding device and application method for a concealed door handle installation area of ​​an aluminum alloy vehicle door. Background Art

[0002] With the rapid adoption of new energy vehicles and the iterative upgrades of automotive design, concealed door handles are gradually becoming a mainstream feature in the industry, moving from a differentiated feature on high-end models. The global automotive concealed door handle market is expanding at an average annual compound growth rate of 18.7%, generating a market value of tens of billions of yuan. Concealed door handles have complex internal structures, requiring extremely high mold precision to ensure their appearance quality and performance.

[0003] The concealed door handle installation area of ​​the door outer panel (hereinafter referred to as the door handle area) is not only the focus of the exterior display area, but also the installation area and electronic control area for the complex door handle structure. Therefore, it requires extremely high dimensional accuracy and appearance accuracy. However, during the mold forming process of this area, due to its complex structure, small support platforms and uneven depth installation surfaces, and the smooth curved surface of the door outer panel, arranging complex shapes of uneven depths on the smooth curved surface will cause uneven material flow and force, resulting in a series of problems such as regional distortion, deformation, misalignment, and springback. At the same time, it also brings quality defects such as warping and disconnection in the surrounding areas, seriously affecting product quality. With the rise of new energy vehicles, lightweight materials such as aluminum alloy and magnesium alloy are widely used. Due to the inherent problems of poor ductility, large springback, and easy cracking of lightweight materials, the door handle area made of lightweight materials has increased the problems of easy cracking and difficulty in forming. This makes mold forming in the door handle area extremely difficult and has become a major problem hindering the large-scale application of concealed door handles.

[0004] In the traditional manufacturing model, in order to solve the series of problems in the door handle area, traditional materials have to be used, or large numbers of craftsmen have to debug and trim, and the appearance quality standards of this area have to be lowered, and defects have to be internalized. However, these methods will lead to poor quality or very expensive mold development costs, and the molds need to be frequently trimmed, the application and maintenance costs are high, and the demand for high-end craftsmanship is high, resulting in a series of problems such as high cost, long cycle and unsatisfactory quality. These problems seriously hinder the rapid promotion and application of hidden door handles, and have become an important obstacle for hidden door handles to shift from a differentiated configuration of high-end models to a mainstream choice in the industry.

[0005] It should be 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 in any form of implication that the above technical information constitutes prior art already known to those skilled in the art. Summary of the Invention

[0006] In response to the deficiencies in the above-mentioned background technology, the present invention proposes a multi-stage forming device and application method for the hidden door handle installation area of ​​an aluminum alloy vehicle door. The technical problems to be solved are: how to solve problems such as misalignment, distortion, deformation, rebound, cracking, and poor quality during the high-speed forming process of the hidden door handle installation area of ​​an aluminum alloy vehicle door, and how to improve the forming accuracy and forming performance while significantly reducing the number of mold modifications and the workload of craftsmen in debugging.

[0007] The technical solution of the present invention is: A multi-stage forming device for the hidden door handle installation area of ​​an aluminum alloy vehicle door includes a pressure-relieving shaping block arranged on a base, and the shaping surface of the upper end of the pressure-relieving shaping block is the shaping block surface of the hidden door handle area; in the stamping direction: a pressure-relieving spring, a side-moving spring, a shallow-hole spring, a deep-hole spring, and a stripping screw are arranged between the base and the pressure-relieving shaping block, and the shallow-hole spring and the deep-hole spring are respectively adapted to the shallow-hole forming block and the deep-hole forming block passing through the pressure-relieving shaping block, and the upper ends of the shallow-hole forming block and the deep-hole forming block extending to the shaping surface are respectively shallow-hole surfaces and deep-hole surfaces; in the direction perpendicular to the stamping direction: a side-moving block driven by the side-moving spring is arranged between the base and the pressure-relieving shaping block, and the side-moving block and the pressure-relieving shaping block are slidably matched through mutually matching inclined surfaces.

[0008] Furthermore, the shallow hole profile and the deep hole profile are both profile shapes of shallow hole bosses.

[0009] Furthermore, the lower end of the shallow hole forming block is provided with a shallow hole pier dead surface adapted to the forming block pier dead surface on the base, a shallow hole spring driving surface adapted to the upper end of the shallow hole spring, and a shallow hole sliding surface adapted to the shallow hole forming block sliding surface in the pressure relief shaping block.

[0010] Furthermore, the lower end of the deep hole forming block is provided with a deep hole pier dead surface adapted to the forming block pier dead surface on the base, a deep hole spring driving surface adapted to the upper end of the deep hole spring, and a deep hole sliding surface adapted to the deep hole forming block sliding surface in the pressure relief shaping block.

[0011] Furthermore, there are two shallow hole springs and they are respectively adapted to two shallow hole forming blocks, and there is one deep hole spring. The two shallow hole springs are symmetrically arranged and are respectively located on both sides of the deep hole spring. Both the shallow hole spring and the deep hole spring are nitrogen springs and are connected in series through an air string pipe.

[0012] Furthermore, the lower part of the pressure-relieving shaping block is an inverted concave structure, and the middle part of the concave structure is arranged with a shallow hole forming block sliding surface, a deep hole forming block sliding surface, and a material removal screw mounting hole. The two sides of the concave structure are symmetrical structures and both include a pressure-relieving bottom surface that is adapted to the dead surface of the pressure-relieving shaping block on the base, and a side sliding surface that slides with the side moving surface of the side moving block.

[0013] Furthermore, the stripping screw includes a sliding section adapted to the stripping screw through hole on the base, the top of the sliding section is provided with a stripping screw mounting thread adapted to the stripping screw mounting hole on the pressure relief shaping block, and the bottom is provided with a stripping screw limit surface adapted to cooperate with the base stop.

[0014] Furthermore, the base is provided with a side moving block sliding surface which is parallel to and higher than the dead surface of the pressure relief shaping block pier, and an inclined surface adapted to the side sliding surface is provided between the dead surface of the pressure relief shaping block pier and the side moving block sliding surface.

[0015] A method for using a multi-stage forming device for a hidden door handle installation area of ​​an aluminum alloy vehicle door, wherein the multi-stage forming device for a hidden door handle installation area of ​​an aluminum alloy vehicle door described in any of the above technical solutions is installed on the upper mold body of the mold, and the lower mold is formed according to traditional processes.

[0016] 3.1, When the mold starts working, the upper mold moves downward, and the pressing core performs the pressing operation first; 3.2. When the mold starts working, the upper mold moves downward. At this time, the pressure relief shaping block is held up and pressurized by the pressure relief spring, so its height is higher than the normal molding area. It starts to touch the material first and, as the mold continues to move downward, it performs pressure relief primary molding on the overall shape of the door handle area. 3.3, when the upper die continues to move downward, the pressure relief shaping block gradually moves downward, the pressure relief spring begins to accumulate force and provides gradually increasing pressure to the pressure relief shaping block, the side moving block is subject to the pressure of the side sliding surface on the side moving surface, and is restricted by the side moving block sliding sideways on the base, while applying pressure to the side moving spring to store energy; 3.4. As the upper die continues to move downward, the pressure-relief shaping block moves downward, and the shallow-hole forming block and the deep-hole forming block begin to touch the material at the same time. Affected by the pressure of the shallow-hole spring and the deep-hole spring, the shallow-hole profile and the deep-hole profile begin to touch the material at the same time. Because the shallow-hole spring and the deep-hole spring are connected in series by the air pipe, the shallow-hole forming block and the deep-hole forming block are evenly stressed and begin secondary preforming. At the same time, the shallow-hole spring and the deep-hole spring accumulate force at the same time. 3.5. The upper die continues to move downward. At this time, the shallow hole forming block is close to the bottom. Due to the difficulty of material deformation, the forming force increases. The air string transmits the pressure to the deep hole spring, which increases the force on the deep hole spring and pushes the deep hole forming surface on the deep hole forming block to accelerate the forming of the deep hole, thus achieving three-level forming of the deep hole. 3.6, when the upper die moves to the bottom, the pressure relief shaping block moves down to the bottom, and the pressure relief bottom surface contacts the dead surface of the pressure relief shaping block, driving the shaping surface to perform strong pressure shaping on the upper shallow area, completing the shaping of the molding surface and achieving four-level molding; at this time, the energy storage of the pressure relief spring and the side spring reaches the maximum value; 3.7. When the pressure relief shaping block reaches the bottom, the shallow hole forming block and the deep hole forming block also move to the bottom. At this time, the dead surface of the shallow hole and the deep hole contact and die with the dead surface of the forming block, driving the shallow hole profile and the deep hole profile to die with the corresponding profile of the lower die, completing the simultaneous forming of the shallow hole and deep hole areas. At the same time, the pressure of the shallow hole spring and the deep hole spring is also stored to the maximum value. 3.8. When the mold is in place and starts to move upward, the pressure decreases and the upper mold begins to separate. Under the influence of the energy stored in the pressure relief spring, side spring, shallow hole spring and deep hole spring, the pressure relief shaping block, shallow hole forming block and deep hole forming block begin to release the stored energy, maintaining and slowly releasing the pressure in the door handle area. 3.9. When the upper die of the mold continues to move upward, the pressure is fully released. The pressure relief shaping block is reset by the pressure relief spring; the side moving block is reset by the side moving spring; the shallow hole forming block and the deep hole forming block are reset by the shallow hole spring and the deep hole spring. The entire device begins to reset and prepares to enter the next round of cyclic forming operation.

[0017] Furthermore, it also includes: 1. Changes in process radius - Process treatment of drawing and shaping processes: Changes in process radius mainly involve changes in the process radius of the large arc surface of the drawing process and the device application process in the door handle area and the forming area, thereby forming a force-reinforced inflection point, thereby reducing the rebound, warping, disconnection and forming cracking problems of the large arc surface area, and introducing forming allowance for the use of the device.

[0018] 2. Strong pressing of the pressing core - shaping process: Strong pressing of the pressing core mainly promotes the reduction of material flow in the large arc area during the multi-stage movement of the device by strong pressing of the material in the peripheral area of ​​the device, so that the material flow in the door handle area is concentrated inside, reducing the quality problems of the surface while making the molding of the device area more complete, thereby reducing the defects of internal molding caused by multi-directional material flow.

[0019] Compared with the prior art, the multi-stage forming device and method for the installation area of ​​the hidden door handle of an aluminum alloy vehicle door provided by this technical solution have the following beneficial effects: 1. Through a simple integrated device, multi-stage molding is achieved, which integrates and solves the systematic molding defects in the door handle area caused by material properties and shape structure factors. The molding difficulties that plague the application of hidden door handles are conveniently solved by solving the corresponding causes of the problems, providing a low-cost, high-stability solution for the high-quality application of hidden door handles.

[0020] 2. This innovation has high molding precision and stable surface quality, which greatly reduces the number of mold modifications and the workload of craftsmen in debugging, expands the complexity space of subsequent design of hidden door handles, and provides a technical foundation for the subsequent high-standard and complex application of hidden door handles.

[0021] 3. The integrated multi-stage forming mode provides a reference solution for the uneven stress forming mode with large forming volume in a small area. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0023] Figure 1 This is the general assembly drawing of the device, including base 1, pressure relief spring 2, side moving block 3, side moving spring 4, pressure relief shaping block 5, shallow hole forming block 8, deep hole forming block 9, and stripping screw 10.

[0024] Figure 2 It is an exploded view of the device, including base 1, pressure relief spring 2, side moving block 3, side moving spring 4, pressure relief shaping block 5, shallow hole spring 6, deep hole spring 7, shallow hole forming block 8, deep hole forming block 9, and stripping screw 10.

[0025] Figure 3 This is the parts drawing of base 1, including the pressure relief spring mounting hole 1.1, the pressure relief shaping block pier dead surface 1.2, the side moving block sliding surface 1.3, the side moving spring mounting surface 1.4, the forming block pier dead surface 1.5, the shallow hole forming block mounting hole 1.6, the deep hole forming block mounting hole 1.7, and the stripping screw through hole 1.8.

[0026] Figure 4 This is the parts drawing of the side moving block 3, including the side moving surface 3.1, the sliding surface 3.2, and the return surface 3.3.

[0027] Figure 5 This is the parts drawing of the pressure relief shaping block 5, including the pressure relief bottom surface 5.1, the side sliding surface 5.2, the shallow hole forming block sliding surface 5.3, the deep hole forming block sliding surface 5.4, the stripping screw mounting hole 5.5, and the shaping surface 5.6.

[0028] Figure 6 These are the parts drawings of the shallow hole forming block 8 and the deep hole forming block 9, including the shallow hole profile 8.1, the shallow hole sliding surface 8.2, the shallow hole pier dead surface 8.3, the shallow hole spring driving surface 8.4, the deep hole profile 9.1, the deep hole sliding surface 9.2, the deep hole pier dead surface 9.3, and the deep hole spring driving surface 9.4.

[0029] Figure 7 This is the parts drawing of shallow hole spring 6 and deep hole spring 7, including shallow hole spring 6, deep hole spring 7, and air string pipe 7.1.

[0030] Figure 8This is the part drawing of the stripping screw 10, including the stripping screw mounting thread 10.1 and the stripping screw limit surface 10.2. DETAILED DESCRIPTION

[0031] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the core concept of the present invention and the following embodiments, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] The present application provides these embodiments to make this application thorough and complete, and to fully express the scope of this application to those skilled in the art. It should be noted that: unless otherwise specifically stated, the relative arrangement of parts and steps, the composition of materials, numerical expressions and numerical values ​​set forth in these embodiments should be interpreted as merely exemplary, and not as limiting.

[0033] It should be noted that, in the description of this application, unless otherwise specified, "several" means greater than or equal to two; the terms "upper," "lower," "left," "right," "inner," "outer," "axial," "radial," and the like, indicating orientations or positional relationships, are intended solely to facilitate the description of this application and simplify the description, and do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. When the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0034] In addition, the terms "first," "second," and similar terms used in this application do not denote any order, quantity, or importance, but are simply used to distinguish different parts. "Perpendicular" does not mean perpendicular in the strict sense, but rather means within the tolerance range. "Parallel" does not mean parallel in the strict sense, but rather means within the tolerance range. "Include" or "comprising" and similar terms mean that the elements preceding the word include the elements listed after the word, and do not exclude the possibility of other elements being included.

[0035] It should also be noted that in the description of this application, unless otherwise clearly specified and limited, the terms "installed", "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 a direct connection, or it can be indirectly connected through an intermediate medium, or it can be internal communication between two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to the specific circumstances. When a specific device is described as being 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.

[0036] All terms used in this application have the same meaning as understood by one of ordinary skill in the art to which this application belongs, unless otherwise specifically defined. It should also be understood that terms defined in, for example, common dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology and should not be interpreted in an idealized or highly formal sense, unless explicitly defined as such herein.

[0037] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0038] The patent of this invention relates to the field of automotive molds. It is a device and application method used in the molding process of the hidden door handle area of ​​the vehicle door outer panel to reduce the molding misalignment, cracking and molding surface quality problems in the hidden door handle installation area, and to achieve high-precision molding.

[0039] In order to solve the above problems, through a comprehensive analysis of the door handle area forming process and regional surface structure, with typical characteristics and typical feature forming difficulties as the solution direction, the solution analysis and multi-faceted experimental improvements were carried out for the uneven material flow, uneven force, complex regional shape and large material rebound caused by its structure; an innovative multi-stage forming device for the hidden door handle area of ​​aluminum alloy vehicle door outer panel and its application method were developed; this technical innovation consists of two parts: the device and the application method. The device mainly adopts the installation of a slow-pressure shaping block on the base to perform slow-pressure graded forming on the shallow shape of the door handle area, and uses the slow-pressure shaping block to form the shallow shape of the door handle area. The pressure-graded forming method transforms the shallow area from instantaneous rapid forming to two-stage slow-pressure forming, thereby resolving the problems of poor peripheral surface quality caused by high-speed forming and the misalignment, distortion, and poor quality of the shaping area. By utilizing shallow-hole forming blocks and deep-hole forming blocks in conjunction with a series of nitrogen springs, a balanced force-bearing, two-stage forming model is formed. This reduces and eliminates the distortion, cracking, poor facade, and rebound problems caused by the large-scale and complex forming of the internal claws in the door handle area, as well as the uneven claw depth and unbalanced force. This allows a simple device to form a multi-stage slow-pressure forming mode, achieving high-precision forming. At the same time, the core pressing mode and surface treatment mode of the forming mold have been improved to accommodate the device application. Strong pressure and arc changes are used to stabilize the surface quality of the peripheral area. A systematic application method is formed in conjunction with the device to comprehensively improve the forming performance of the door handle area. This eliminates a series of problems such as regional distortion, deformation, misalignment, rebound, cracking, and poor surface quality, significantly reducing the number of mold modifications and the workload of craftsmen in debugging, providing a low-cost, highly stable solution for the high-quality application of concealed door handles.

[0040] A multi-stage forming device and application method for the hidden door handle installation area of ​​an aluminum alloy vehicle door outer panel includes two parts: a simple integrated multi-stage forming device and an application method. The device part includes a base 1, a pressure relief spring 2, a side moving block 3, a side moving spring 4, a pressure relief shaping block 5, a shallow hole spring 6, a deep hole spring 7, a shallow hole forming block 8, a deep hole forming block 9, and a stripping screw 10. The base 1 is fixed on the upper mold body of the mold, and the pressure relief spring 2 (left-right symmetrical) is installed in the pressure relief spring installation hole 1.1 of the base 1, and the side moving spring 4 (left-right symmetrical, nitrogen cylinder standard part) is installed in the base 1. On the side-moving spring mounting surface 1.4, place the side-moving block 3 (left-right symmetrical) on the side-moving block sliding surface 1.3 of the base 1, so that it can slide back and forth on the side-moving block sliding surface 1.3 under the thrust of the side-moving spring 4 and the pressure of the side sliding surface 5.2 of the pressure-relief shaping block 5. Install the shallow-hole spring 6 (nitrogen cylinder in series, standard part) on the shallow-hole forming block mounting hole 1.6 of the base 1, and install the deep-hole spring 7 (nitrogen cylinder in series, standard part) on the deep-hole forming block mounting hole 1.7 of the base 1. Connect the shallow-hole spring 6 and the deep-hole spring 7 in series through the air string pipe 7.1; the assembly of the base 1 is completed.

[0041] The shaping surface 5.6 of the pressure-relief shaping block 5 is processed into the shaping block surface of the door handle area; the shallow hole forming block 8 is inserted into the shallow hole forming block sliding surface 5.3 of the pressure-relief shaping block 5, so that the shallow hole sliding surface 8.2 and the shallow hole forming block sliding surface 5.3 cooperate and can slide up and down, and the shallow hole profile 8.1 at the end of the shallow hole forming block 8 is processed into the profile shape of a shallow hole boss; the deep hole forming block 9 is inserted into the deep hole forming block sliding surface 5.4 of the pressure-relief shaping block 5, so that the deep hole sliding surface 9.2 and the deep hole forming block sliding surface 5.4 cooperate and can slide up and down, and the deep hole profile 9.1 at the end of the deep hole forming block 9 is processed into the profile shape of a shallow hole boss; the assembly of the pressure-relief shaping block set of the multi-stage forming device is completed.

[0042] Install the pressure-relief shaping block set on the base 1, so that the shallow hole spring driving surface 8.4 of the shallow hole forming block 8 cooperates with the upper end of the shallow hole spring 6; the deep hole spring driving surface 9.4 of the deep hole forming block 9 cooperates with the upper end of the deep hole spring 7; the side sliding surface 5.2 of the pressure-relief shaping block 5 cooperates with the side moving surface 3.1 of the side moving block 3; finally, pass the stripping screw 10 through the stripping screw through hole 1.8 on the base 1, and screw it into the stripping screw mounting hole 5.5 of the pressure-relief shaping block 5 through the stripping screw mounting thread 10.1. The other end of the stripping screw mounting thread 10.1 is provided with a stripping screw limiting surface 10.2 that cooperates with the axial stop of the base 1, so that the pressure-relief shaping block set can only slide up and down within a limited stroke range, thus completing the installation of the entire device.

[0043] The main projection of the side moving block 3 is a trapezoidal structure, and its end away from the side moving surface 3.1 is a sliding surface 3.2 for connecting the side moving spring 4, and its bottom surface is a return surface 3.3, which slides with the side moving block sliding surface 1.3.

[0044] The method of use is mainly to cooperate with the device and eliminate the door handle area molding defects. It includes three parts: process radius change, core pressing and device application. The specific contents are as follows: 1. Process Radius Change: This process radius change primarily involves creating a change in the radius of the large arc surface and the forming area during the drawing process and the device application process in the door handle area. This creates a stress-reinforced inflection point, thereby reducing springback, warping, disconnection, and forming cracking in the large arc area, and introducing a forming margin for device use. Specifically, during the drawing process, the transition contour radius between the large arc surface of the door and the door handle forming area is sharpened by 0.5-1mm. In the shaping die, the radius of this area is restored to its original state and enlarged by 0.1mm. By changing the process radius, the force applied to the flat surface and the forming area is concentrated on the arc during device application, thereby reducing a series of surrounding forming issues.

[0045] 2. Strong pressing of the pressing core: Strong pressing of the pressing core mainly reduces the material flow in the large curved area during the multi-stage movement of the device by strongly pressing the material around the device. This allows the material flow in the door handle area to be concentrated inside, reducing surface quality issues while making the molding of the device area more complete, thereby reducing defects in internal molding caused by multi-directional material flow. The specific method is to transfer the pressing core part along the transition contour radius of the large curved surface of the car door and the door handle molding area outward by 35-60mm to create a strong pressing area. The strong pressing area is arranged in a strong coloring method to make it more effective in bearing the pressure.

[0046] 3. The application of the device is detailed in the following examples.

[0047] A multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door, such as Figure 1 As shown, it mainly includes: base 1, pressure relief spring 2, side moving block 3, side moving spring 4, pressure relief shaping block 5, shallow hole spring 6, deep hole spring 7, shallow hole forming block 8, deep hole forming block 9, and stripping screw 10.

[0048] Specific as Figures 1-8 As shown: 1. Install the pressure relief spring 2 (symmetrical on both sides, standard part of nitrogen cylinder) in the pressure relief spring mounting hole 1.1 of the base 1, so that the upper retractable part of the pressure relief spring 2 is exposed from the pressure relief spring mounting hole 1.1 and the main body is embedded in the pressure relief spring mounting hole 1.1, so that when the pressure relief spring 2 is pressed to the bottom, the pressure relief shaping block pier dead surface 1.2 can contact the pressure relief bottom surface 5.1 to achieve a strong pressure pier dead effect.

[0049] 2. Install the side-moving spring 4 (symmetrical on both sides, standard part of nitrogen cylinder) on the side-moving spring mounting surface 1.4 of the base 1 so that it can stably provide thrust and return force for the side-moving block 3.

[0050] 3. Place the side moving block 3 (symmetrically on both sides) on the side moving block sliding surface 1.3 of the base 1, so that it can slide back and forth on the side moving block sliding surface 1.3 under the thrust of the side moving spring 4 and the pressure of the side sliding surface 5.2 of the pressure relief shaping block 5. This allows the pressure relief shaping block 5 to be subjected to bidirectional force, thereby increasing the graded pressure while ensuring the stability of the system.

[0051] 4. Install the shallow hole spring 6 (nitrogen cylinder in series, standard parts) in the shallow hole forming block mounting hole 1.6 of the base 1, so that the upper retractable portion of the shallow hole spring 6 is exposed from the shallow hole forming block mounting hole 1.6 and the main body is embedded in the shallow hole forming block mounting hole 1.6. Ensure that the shallow hole forming block 8 is subjected to slow pressure forming during the process. Before the spring is compressed to the bottom, the deep hole forming block 9 is first subjected to boosting secondary buffer forming through the stringing pipe 7.1. Then, the shallow hole pier dead surface 8.3 contacts the pier dead surface 1.5 of the forming block to perform the shallow hole forming operation.

[0052] 5. Install the deep hole spring 7 (nitrogen cylinder in series, standard part) on the deep hole forming block mounting hole 1.7 of the base 1, so that the upper retractable part of the deep hole spring 7 is exposed from the deep hole forming block mounting hole 1.7, and the main body is embedded in the deep hole forming block mounting hole 1.7 to ensure that the deep hole forming block 9 is subjected to slow pressure forming during its movement.

[0053] 6. Connect the shallow hole spring 6 and the deep hole spring 7 in series through the air string pipe 7.1; make the pressure of the shallow hole spring 6 and the deep hole spring 7 always consistent, in the early stage of forming, the shallow hole forming block 8 and the deep hole forming block 9 maintain the same pressure and touch the material at the same time, to ensure the force balance and avoid distortion, in the middle stage, when the shallow hole forming block 8 is about to bottom out, the pressure increases, at this time the pressure is transmitted to the deep hole forming block 9 to achieve secondary pressure enhancement for deep hole forming, thereafter the shallow hole forming block 8 bottoms out to achieve shallow hole forming, and then the deep hole forming block 9 bottoms out, the deep hole pier dead surface 9.3 contacts the pier dead surface 1.5 of the forming block to perform the pier dead operation on the shallow hole forming, thereby achieving three-level forming of the deep hole.

[0054] 7. Process the shaping surface 5.6 of the pressure-relieving shaping block 5 into a shaping block profile of the door handle area so that the pressure-relieving shaping block 5 can perform the shaping operation.

[0055] 8. Insert the shallow hole forming block 8 into the shallow hole forming block sliding surface 5.3 of the pressure relief shaping block 5, so that the shallow hole sliding surface 8.2 and the shallow hole forming block sliding surface 5.3 fit together and can slide up and down, and process the shallow hole profile 8.1 at the end of the shallow hole forming block 8 into the profile shape of a shallow hole boss.

[0056] 9. Insert the deep hole forming block 9 into the deep hole forming block sliding surface 5.4 of the pressure relief shaping block 5, so that the deep hole sliding surface 9.2 cooperates with the deep hole forming block sliding surface 5.4 and can slide up and down. The deep hole profile 9.1 at the end of the deep hole forming block 9 is processed into the profile shape of a shallow hole boss.

[0057] 10. The assembly consisting of the pressure-relief shaping block 5, shallow-hole forming block 8, and deep-hole forming block 9 is defined as a pressure-relief shaping block set. The pressure-relief shaping block set is mounted on base 1 so that the shallow-hole spring driving surface 8.4 of shallow-hole forming block 8 mates with the upper end of shallow-hole spring 6; the deep-hole spring driving surface 9.4 of deep-hole forming block 9 mates with the upper end of deep-hole spring 7; and the side sliding surface 5.2 of the pressure-relief shaping block 5 mates with the side moving surface 3.1 of the side moving block 3.

[0058] 11. Finally, pass the stripping screw 10 through the stripping screw through hole 1.8 on the base 1 and screw it into the stripping screw mounting hole 5.5 of the pressure relief shaping block 5 through the stripping screw mounting thread 10.1, so that the pressure relief shaping block set can only slide up and down within a limited stroke range. At this time, the entire device is installed.

[0059] Application examples: 1. Changes in process radius - Process treatment of drawing and shaping processes: Changes in process radius mainly involve changes in the process radius of the large arc surface of the drawing process and the device application process in the door handle area and the forming area, thereby forming a force-reinforced inflection point, thereby reducing the rebound, warping, disconnection and forming cracking problems of the large arc surface area, and introducing forming allowance for the use of the device.

[0060] The specific approach is to sharpen the corners of the transition contour between the large arc surface of the car door and the door handle forming area by 0.5 to 1 mm during the drawing process, and restore the corners of this area to their original state and enlarge them by 0.1 mm in the shaping mold. By changing the corners during the process, the force on the plane and the forming area is concentrated on the arc when the device is applied, thereby reducing the series of surrounding forming problems.

[0061] 2. Strong pressing of the pressing core - shaping process: Strong pressing of the pressing core mainly promotes the reduction of material flow in the large arc area during the multi-stage movement of the device by strong pressing of the material in the peripheral area of ​​the device, so that the material flow in the door handle area is concentrated inside, reducing the quality problems of the surface while making the molding of the device area more complete, thereby reducing the defects of internal molding caused by multi-directional material flow.

[0062] The specific method is to transition the core of the pressing material outward 35-60mm along the transition contour radius between the large arc surface of the car door and the door handle molding area to create a strong pressing area. The strong pressing area is arranged in a strong coloring manner to make it more effective in bearing the pressure of the pressing material.

[0063] 3. Application of the device: The device is used in the shaping process. The device is installed on the upper mold body of the mold, and the lower mold is carried out according to the traditional process.

[0064] 3.1. When the mold starts working, the upper mold moves downward and the pressing core is first pressed. At this time, due to the strong pressure of the pressing core in step 2, the external locking material is strengthened, and the molding focus of the door handle area is on the material extension and deformation of the device area, reducing peripheral deformation, warping, and surface quality defects.

[0065] 3.2. When the mold starts working, the upper mold moves downward. At this time, the pressure relief shaping block 5 is held up and pressurized by the pressure relief spring 2, so its height is higher than the normal molding area. It starts to touch the material first and as the mold continues to move downward, the overall shape of the door handle area is subjected to pressure relief molding. The pressure relief can reduce the problems of cracking, misalignment and poor precision caused by high-speed and heavy-load molding.

[0066] 3.3. When the upper die continues to descend, the pressure relief shaping block 5 gradually moves downward, the pressure relief spring 2 begins to accumulate force and provides gradually increasing pressure to the pressure relief shaping block 5. The side moving block 3 is subjected to the pressure of the side sliding surface 5.2 on the side moving surface 3.1, and is restricted by the side moving block sliding surface 1.3 to slide laterally on the base 1, while applying pressure to the side moving spring 4 to store energy.

[0067] 3.4. As the upper die continues to move downward, the pressure-relief shaping block 5 is driven downward, and the shallow-hole forming block 8 and the deep-hole forming block 9 begin to touch the material at the same time. Affected by the pressure of the shallow-hole spring 6 and the deep-hole spring 7, the shallow-hole profile 8.1 and the deep-hole profile 9.1 begin to touch the material at the same time. Because the air string 7.1 connects the shallow-hole spring 6 and the deep-hole spring 7 in series, the shallow-hole forming block 8 and the deep-hole forming block 9 are evenly stressed and start secondary pre-forming, avoiding distortion caused by differences in forming forces. At the same time, the shallow-hole spring 6 and the deep-hole spring 7 accumulate force at the same time.

[0068] 3.5. The upper die continues to descend. At this time, the shallow hole forming block 8 is close to the bottom. At this time, due to the difficulty of material deformation, the forming force increases. The air string 7.1 transmits the pressure to the deep hole spring 7, which increases the force on the deep hole spring and pushes the deep hole profile 9.1 on the deep hole forming block 9 to accelerate the forming of the deep hole, thus achieving three-stage forming of the deep hole.

[0069] 3.6. When the upper die reaches its bottom, the pressure-relieving shaping block 5 descends to its lowest point. The pressure-relieving bottom surface 5.1 now contacts the pressure-relieving shaping block's dead surface 1.2, driving the shaping surface 5.6 to apply strong pressure to the upper shallow area, completing the finalization of the molded surface. Simultaneously, while the fillet was reduced in step 1, it is enlarged in this step, causing the sharp corner between the door handle area's vertical surface and the large curved surface to undergo cold work hardening. This strengthens the fillet, ensuring the quality of the surrounding surface and the arc strength of the door handle area, improving the stability of the area, and achieving four-stage forming. At this point, the energy stored in the pressure-relieving spring 2 and the side spring 4 reaches its maximum value.

[0070] 3.7, when the pressure-relieving shaping block 5 reaches the bottom, the shallow hole forming block 8 and the deep hole forming block 9 also run to the bottom. At this time, the shallow hole pier dead surface 8.3 and the deep hole pier dead surface 9.3 are in contact with the forming block pier dead surface 1.5, driving the shallow hole profile 8.1 and the deep hole profile 9.1 to pier with the corresponding profile of the lower die, completing the simultaneous forming of the shallow hole and deep hole areas. The entire door handle area is precisely pressure-relieving formed under the action of four-level forming, achieving good surface quality and quality effects; at the same time, the pressure of the shallow hole spring 6 and the deep hole spring 7 is also stored to the maximum value.

[0071] 3.8. When the mold is in place and starts to move upward, the pressure decreases and the upper mold begins to separate. Under the influence of the stored energy of the pressure-relief spring 2, the side spring 4, the shallow hole spring 6, and the deep hole spring 7, the pressure-relief shaping block 5, the shallow hole forming block 8, and the deep hole forming block 9 begin to release the stored energy, maintaining and slowly releasing the pressure on the door handle area to prevent the rebound problem caused by the sudden loss of pressure and the rapid separation of the forming blocks, thereby achieving the effect of pressure-retaining molding.

[0072] 1, 3.9, when the upper die of the mold continues to move upward, the pressure is fully released, and the pressure relief shaping block 5 is reset by the pressure relief spring 2; the side moving spring 4 is used to reset the side moving block 3; the shallow hole spring 6 and the deep hole spring 7 are used to reset the shallow hole forming block 8 and the deep hole forming block 9. The entire device begins to reset and prepares to enter the next round of forming operation.

[0073] The above content shows and describes the basic principles, 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 substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the scope of protection of the present invention.

Claims

1. A multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door, characterized by: The invention comprises a pressure-reducing shaping block (5) arranged on a base (1), wherein a shaping surface (5.6) at the upper end of the pressure-reducing shaping block (5) is a shaping block profile of a hidden door handle area; in the stamping direction: a pressure-reducing spring (2), a side spring (4), a shallow hole spring (6), a deep hole spring (7), and a stripping screw (10) are arranged between the base (1) and the pressure-reducing shaping block (5), wherein the shallow hole spring (6) and the deep hole spring (7) are respectively connected to the side spring (5) passing through the pressure-reducing shaping block (5). The shallow hole forming block (8) and the deep hole forming block (9) are adapted, and the upper ends of the shallow hole forming block (8) and the deep hole forming block (9) extending to the shaping surface (5.6) are respectively the shallow hole profile surface (8.1) and the deep hole profile surface (9.1); in a direction perpendicular to the stamping direction: a side moving block (3) driven by a side moving spring (4) is provided between the base (1) and the pressure relief shaping block (5), and the side moving block (3) and the pressure relief shaping block (5) are slidably matched through mutually matching inclined surfaces.

2. The multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door according to claim 1, characterized in that: The shallow hole profile (8.1) and the deep hole profile (9.1) are both profile shapes of shallow hole bosses.

3. The multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door according to claim 1 or 2, characterized in that: The lower end of the shallow hole forming block (8) is provided with a shallow hole pier dead surface (8.3) adapted to the forming block pier dead surface (1.5) on the base (1), a shallow hole spring driving surface (8.4) adapted to the upper end of the shallow hole spring (6), and a shallow hole sliding surface (8.2) adapted to the shallow hole forming block sliding surface (5.3) in the pressure relief shaping block (5).

4. The multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door according to claim 3, characterized in that: The lower end of the deep hole forming block (9) is provided with a deep hole pier dead surface (9.3) adapted to the forming block pier dead surface (1.5) on the base (1), a deep hole spring driving surface (9.4) adapted to the upper end of the deep hole spring (7), and a deep hole sliding surface (9.2) adapted to the deep hole forming block sliding surface (5.4) in the pressure relief shaping block (5).

5. The multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door according to claim 4, characterized in that: Two shallow hole springs (6) are provided and are respectively adapted to two shallow hole forming blocks (8), and one deep hole spring (7) is provided. The two shallow hole springs (6) are symmetrically arranged and are respectively located on both sides of the deep hole spring (7). Both the shallow hole spring (6) and the deep hole spring (7) are nitrogen springs and are connected in series via a gas string pipe (7.1).

6. The multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door according to any one of claims 1, 2, 4, and 5, characterized in that: The lower portion of the pressure-relief shaping block (5) is an inverted concave structure, and the middle portion of the concave structure is provided with a shallow hole forming block sliding surface (5.3), a deep hole forming block sliding surface (5.4), and a material removal screw mounting hole (5.5). Both sides of the concave structure are symmetrical structures and both include a pressure-relief bottom surface (5.1) adapted to the dead surface (1.2) of the pressure-relief shaping block on the base (1), and a side sliding surface (5.2) slidably matched with the side moving surface (3.1) of the side moving block (3).

7. The multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door according to claim 6, characterized in that: The stripping screw (10) comprises a sliding section adapted to the stripping screw through hole (1.8) on the base (1); a stripping screw mounting thread (10.1) adapted to the stripping screw mounting hole (5.5) on the pressure relief shaping block (5) is provided at the top of the sliding section; and a stripping screw limit surface (10.2) adapted to stop the base (1) is provided at the bottom.

8. The multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door according to claim 7, characterized in that: The base (1) is provided with a side moving block sliding surface (1.3) that is parallel to the dead surface (1.2) of the pressure relief shaping block pier and higher than the dead surface (1.2) of the pressure relief shaping block pier. An inclined surface that is adapted to the side sliding surface (5.2) is provided between the dead surface (1.2) of the pressure relief shaping block pier and the side moving block sliding surface (1.3).

9. A method for using a multi-stage forming device for the installation area of ​​a hidden door handle of an aluminum alloy vehicle door, characterized in that: The multi-stage forming device for the hidden door handle installation area of ​​an aluminum alloy vehicle door according to any one of claims 1 to 8 is installed on the upper mold body of the mold, and the lower mold is made according to the traditional process; 3.1, When the mold starts working, the upper mold moves downward, and the pressing core performs the pressing operation first; 3.

2. When the mold starts working, the upper mold moves downward. At this time, the pressure relief shaping block is held up and pressurized by the pressure relief spring, so its height is higher than the normal molding area. It starts to touch the material first and, as the mold continues to move downward, it performs pressure relief primary molding on the overall shape of the door handle area. 3.3, when the upper die continues to move downward, the pressure relief shaping block gradually moves downward, the pressure relief spring begins to accumulate force and provides gradually increasing pressure to the pressure relief shaping block, the side moving block is subject to the pressure of the side sliding surface on the side moving surface, and is restricted by the side moving block sliding sideways on the base, while applying pressure to the side moving spring to store energy; 3.

4. As the upper die continues to move downward, the pressure-relief shaping block moves downward, and the shallow-hole forming block and the deep-hole forming block begin to touch the material at the same time. Affected by the pressure of the shallow-hole spring and the deep-hole spring, the shallow-hole profile and the deep-hole profile begin to touch the material at the same time. Because the shallow-hole spring and the deep-hole spring are connected in series by the air pipe, the shallow-hole forming block and the deep-hole forming block are evenly stressed and begin secondary preforming. At the same time, the shallow-hole spring and the deep-hole spring accumulate force at the same time. 3.

5. The upper die continues to move downward. At this time, the shallow hole forming block is close to the bottom. Due to the difficulty of material deformation, the forming force increases. The air string transmits the pressure to the deep hole spring, which increases the force on the deep hole spring and pushes the deep hole forming surface on the deep hole forming block to accelerate the forming of the deep hole, thus achieving three-level forming of the deep hole. 3.6, when the upper die moves to the bottom, the pressure relief shaping block moves down to the bottom, and the pressure relief bottom surface contacts the dead surface of the pressure relief shaping block, driving the shaping surface to perform strong pressure shaping on the upper shallow area, completing the shaping of the molding surface and achieving four-level molding; at this time, the energy storage of the pressure relief spring and the side spring reaches the maximum value; 3.

7. When the pressure relief shaping block reaches the bottom, the shallow hole forming block and the deep hole forming block also move to the bottom. At this time, the dead surface of the shallow hole and the deep hole contact and die with the dead surface of the forming block, driving the shallow hole profile and the deep hole profile to die with the corresponding profile of the lower die, completing the simultaneous forming of the shallow hole and deep hole areas. At the same time, the pressure of the shallow hole spring and the deep hole spring is also stored to the maximum value. 3.

8. When the mold is in place and starts to move upward, the pressure decreases and the upper mold begins to separate. Under the influence of the energy stored in the pressure relief spring, side spring, shallow hole spring and deep hole spring, the pressure relief shaping block, shallow hole forming block and deep hole forming block begin to release the stored energy, maintaining and slowly releasing the pressure in the door handle area. 3.

9. When the upper die of the mold continues to move upward, the pressure is fully released. The pressure relief shaping block is reset by the pressure relief spring; the side moving block is reset by the side moving spring; the shallow hole forming block and the deep hole forming block are reset by the shallow hole spring and the deep hole spring. The entire device begins to reset and prepares to enter the next round of cyclic forming operation.

10. The method for using the multi-stage forming device for the installation area of ​​the hidden door handle of an aluminum alloy vehicle door according to claim 9 is characterized in that Also includes:

1. Process radius change - Process treatment of drawing and shaping process: The process radius change mainly constructs the process radius change of the large arc surface of the drawing process and the device application process in the door handle area and the forming area, thereby forming a stress-reinforced inflection point, thereby reducing the rebound, warping, disconnection and forming cracking problems of the large arc surface area, and introducing forming allowance for the use of the device; 2. Strong pressing of the pressing core - shaping process: Strong pressing of the pressing core mainly promotes the reduction of material flow in the large arc area during the multi-stage movement of the device by strong pressing of the material in the peripheral area of ​​the device, so that the material flow in the door handle area is concentrated inside, reducing the quality problems of the surface while making the molding of the device area more complete, thereby reducing the defects of internal molding caused by multi-directional material flow.

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