Combined roller for forming frame with n-shaped section and forming process method

Abstract

The invention belongs to the technical field of roll bending forming, and relates to a combined roller for forming a frame with an n-shaped section, which comprises a main wheel set and two guide wheel sets, and the two guide wheel sets are matched with the main wheel set to realize radian and trimming of a formed part; wherein the main wheel set comprises a roll bending main wheel and a roll cutting main wheel, the roll bending main wheel comprises a roll bending concave main wheel and a roll bending convex main wheel which are matched with each other, and the roll cutting main wheel comprises a roll cutting concave main wheel and a roll cutting convex main wheel which are matched with each other; the guide wheel set comprises a concave guide wheel and a convex guide wheel which are matched with each other. The invention further discloses a forming method applying the combined roller, aiming at plate frame parts with the same part wall thickness, section height and inward bending radius R and different section widths, a roll bending forming method is adopted, the roller structure and the technological method are reasonably designed, the production economy is improved, multiple sets of rollers are prevented from being machined, the occupied mold storage space is reduced, and the production cost is reduced. Meanwhile, the maintenance cost is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of roll bending and forming, and relates to a combined roller for forming an X-shaped cross-section frame and a forming process method. Background Art

[0002] Plate frames of various cross-sections have been widely used in the aerospace field, among which there is at least one type of plate frame with an I-shaped cross-section. The wall thickness, cross-section height and inner bending radius R of these plate frame parts are the same, but the cross-section width or cross-section bending edge length are different, resulting in multiple cross-section specifications, and some parts have different radii.

[0003] Common forming methods for sheet metal frames include die stamping, integral steel die bending and roll bending. Die stamping and integral steel die bending are restricted by the springback of parts, and usually a set of dies can only form parts with one cross-section, one radius and one material. Roll bending has high flexibility and can form parts with different radii and different materials, but the rollers used for forming can only form parts with one cross-section. In addition, once the rollers are severely worn, they need to be repaired or remade, which is very costly.

[0004] There is still a lack of effective solutions for the low-cost production of sheet metal frame parts with consistent wall thickness and cross-sectional height but different cross-sectional widths or cross-sectional bending lengths. Summary of the Invention

[0005] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a combined roller and forming process method for forming a cross-shaped cross-section frame. For plate frame parts with the same wall thickness, cross-section height and inner bending radius R but different cross-section width or cross-section bending edge length, a rolling forming method is adopted, and the roller structure and process method are reasonably designed to improve the economy of production, avoid processing multiple sets of rollers, reduce the space occupied by mold storage, and reduce maintenance costs.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A combined roller for forming a cross-section frame includes a main wheel group and two guide wheel groups. The main wheel group and the guide wheel group have the same center height along the main axis direction of the machine tool. The two guide wheel groups cooperate with one main wheel group to achieve the curvature and trimming of the formed parts; the main wheel group includes a rolling main wheel and a rolling main wheel, the rolling main wheel includes a rolling concave main wheel and a rolling convex main wheel that cooperate with each other, and the rolling main wheel includes a rolling concave main wheel and a rolling convex main wheel that cooperate with each other; the guide wheel group includes a concave guide wheel and a convex guide wheel that cooperate with each other.

[0008] Furthermore, the rolled concave main wheel includes a concave main wheel gasket, a concave main wheel sheet, and a concave main wheel rolling sheet; the rolled convex main wheel includes a convex main wheel first rolling sheet, a convex main wheel sheet, and a convex main wheel gasket;

[0009] The rolled concave main wheel includes a concave main wheel gasket, a concave main wheel sheet, and a concave main wheel rolled section; the rolled convex main wheel includes a convex main wheel rolled section, a convex main wheel second rolled bending sheet, a convex main wheel sheet, and a convex main wheel gasket.

[0010] Furthermore, the outer diameters of the concave main wheel bending piece and the concave main wheel rolling slice are consistent with the diameter of the concave main wheel piece, the outer diameter of the concave main wheel gasket is consistent with the diameter of the concave main wheel piece, and the outer diameter of the convex main wheel gasket is consistent with the diameter of the convex main wheel piece, and the end faces of each part are perpendicular to the axis.

[0011] Furthermore, the concave main wheel gasket, concave main wheel plate, concave main wheel rolled plate, convex main wheel first rolled plate, convex main wheel plate, and convex main wheel gasket are all provided with keyways for connecting to the main shaft of the equipment.

[0012] Furthermore, the concave main wheel rolling slice and the convex main wheel rolling slice are respectively provided with a concave main wheel rolling slice cutting edge and a convex main wheel rolling slice cutting edge along the circumferential direction.

[0013] Furthermore, the concave guide wheel includes a concave guide wheel rolled plate and a concave guide wheel plate, and the convex guide wheel includes a convex guide wheel rolled plate, a convex guide wheel plate, and a convex guide wheel gasket; the outer diameter of the convex guide wheel gasket is consistent with the diameter of the convex guide wheel plate, and the end faces of each part are perpendicular to the axis.

[0014] Furthermore, the main wheel assembly and the guide wheel assembly are both made of die steel.

[0015] A forming method of a combined roller for forming an "X"-shaped cross-section frame includes the following steps:

[0016] Step 1: Bending the cross section: After taking out the long strip, use a bending machine to bend the long strip into a straight material close to the shape of a "J";

[0017] Step 2: Assemble the rollers. Select the parts according to the cross-sectional shape of the frame product and install all the parts on the main shaft of the six-axis roller bed in order. The driving wheel group is installed on the middle driving shaft, and the guide wheel group is installed on the follower shafts on both sides. Use fasteners to lock the two ends of the main wheel group and the guide wheel group in the height direction to ensure that the center heights of the two guide wheel groups and the main wheel group are consistent;

[0018] Step 3: Roll the straight material, use a hammer to correct one end of the straight material so that it can be inserted into the roller, start the roller bed, and roll the cross-section of the straight material along its entire length to make it into a regular "F" shape. At this time, the cross-section bending length B has a process allowance of no less than 3mm.

[0019] Step 4: Full annealing: Use heat treatment equipment to fully anneal the straight material to eliminate the material hardening during the bending and rolling process and prevent subsequent rolling cracking;

[0020] Step 5: Multi-pass rolling and bending. Insert the sheet frame into each wheel group and adjust the position of the guide wheel group several times to roll and bend the sheet frame so that the radius is gradually formed from large to small, and the sheet frame is continuously close to the finished product requirements. The forming passes are no less than 5 times, and the last press is the smallest to avoid wrinkles and excessive rolling.

[0021] Step 6: Quenching: using heat treatment equipment to perform solution heat treatment on the sheet frame after roll bending;

[0022] Step 7: Roll and bend the quenched plate frame using rollers to correct the curvature and flatness;

[0023] Step 8: With the rolling cutting allowance unchanged, without changing the positions of the main shafts of the roller bed, select appropriate concave main wheel rolling slices, concave main wheel spacers, convex main wheel rolling slices, and convex main wheel second bending slices according to the cross-sectional dimensions of the plate frame product. Insert the plate frame into a guide wheel assembly and when it reaches the intersection of the convex main wheel slice and the concave main wheel slice, rotate the driving shaft to drive the plate frame through the concave main wheel rolling slice cutting edge and the convex main wheel rolling slice cutting edge to complete the edge trimming.

[0024] Step 9: Correction: Use a hammer, curved pads and inspection molds to correct the parts.

[0025] Step 10: Aging treatment: Depending on the material grade of the plate frame product, the corrected plate frame is subjected to natural aging or artificial aging using heat treatment equipment. 2A12 material requires natural aging, and 7A09 material requires artificial aging.

[0026] The present invention has the following advantages:

[0027] (1) The present invention simplifies the design of rollers for roll-bending a certain type of sheet material frame through a modular tooling design. Rolling and precise trimming can be achieved by replacing different parts. This improves the versatility of parts, their replaceability and maintainability, saves tooling costs, saves mold storage space, and reduces mold repair costs.

[0028] (2) The forming process method provided by the present invention has reasonable settings for each forming and heat treatment process. Complete annealing before rolling can avoid cracking due to rolling, multiple rolling passes can prevent wrinkling of parts, and rolling cutting after rolling correction can eliminate asymmetric material movement caused by quenching deformation, thereby ensuring the length of the bending edge of the cross section, better ensuring the forming accuracy, and preventing forming defects. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a schematic diagram of the assembly of the combined roller main wheel assembly for forming the cross-section frame provided by the present invention, showing the rolling cross section and the rolling bending forming state;

[0030] Figure 2This is a schematic cross-sectional view of the assembly of the combined roller main wheel assembly for forming the cross-shaped cross-section frame provided by the present invention in a rolling cutting state;

[0031] Figure 3 This is a schematic diagram of the assembly of a combined roller guide wheel assembly for forming an X-shaped cross-section frame provided by the present invention;

[0032] Figure 4 A partial enlarged view of the cutting edge of the combined roller for forming the cross-section frame provided by the present invention;

[0033] Figure 5 This is a schematic diagram of a cross-sectional view of a sheet material frame applicable to the combined roller for forming an X-shaped cross-sectional frame provided by the present invention;

[0034] Figure 6 This is a flow chart of the forming process method provided by the present invention.

[0035] Among them, 1 is the concave main wheel gasket, 2 is the concave main wheel plate, 3 is the concave main wheel rolling plate, 4 is the convex main wheel first rolling plate, 5 is the convex main wheel plate, 6 is the convex main wheel gasket, 7 is the concave main wheel rolling slice, 8 is the concave main wheel heightening plate, 9 is the convex main wheel rolling slice, 10 is the convex main wheel second rolling plate, 11 is the concave guide wheel rolling plate, 12 is the concave guide wheel plate, 13 is the convex guide wheel rolling plate, 14 is the convex guide wheel plate, 15 is the convex guide wheel gasket, 71 is the concave main wheel rolling slice cutting edge, and 91 is the convex main wheel rolling slice cutting edge. DETAILED DESCRIPTION

[0036] The present invention will be described in detail below with reference to the accompanying drawings.

[0037] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0038] The present invention provides a combined roller for forming a cross-section frame, comprising a main wheel assembly and two guide wheel assemblies, wherein the main wheel assembly is as follows: Figure 1 and Figure 2As shown, it includes a concave main wheel gasket 1, two concave main wheel pieces 2, two concave main wheel rolling pieces 3, two convex main wheel first rolling pieces 4, two convex main wheel pieces 5, a convex main wheel gasket 6, two concave main wheel rolling slices 7, two concave main wheel shim pieces 8, two convex main wheel rolling slices 9, and two convex main wheel second rolling bending pieces 10, wherein the concave main wheel rolling bending piece 3 and the convex main wheel first rolling bending piece 4 are used for rolling correction of the cross-sectional shape of the sheet material frame in the straight state, the rolling curvature in the bent state, and the rolling correction after quenching, while the concave main wheel rolling slice 7, the concave main wheel shim 8, the convex main wheel rolling slice 9 and the convex main wheel second rolling bending piece 10 are used for trimming the sheet material frame in the rolling cutting state, and the concave main wheel rolling slice 7 and the convex main wheel rolling slice 9 are respectively provided with a concave main wheel rolling slice cutting edge 71 and a convex main wheel rolling slice cutting edge 91 along the circumferential direction, and the cutting edge position is as shown in FIG. Figure 4 shown.

[0039] All parts are made of die steel to ensure structural rigidity, and chamfers are set on the inner holes to facilitate assembly.

[0040] All main wheel assembly components are equipped with keyways, ensuring they rotate synchronously when driven by the equipment's main shaft and transmitting the shaft's torque to drive the sheet frame's rolling motion through friction. The main wheel assembly must meet the following processing and assembly requirements: the outer diameters of the concave main wheel bending piece 3 and the concave main wheel rolling piece 7 must be consistent with the corresponding diameters of the concave main wheel piece 2; the outer diameter of the concave main wheel spacer 1 must be consistent with the corresponding diameter of the concave main wheel piece 2; the outer diameter of the convex main wheel spacer 6 must be consistent with the corresponding diameter of the convex main wheel piece 5; and the end faces of each component must be perpendicular to the axis.

[0041] Guide wheel assembly Figure 3 As shown, it includes a concave guide wheel rolled piece 11, a concave guide wheel piece 12, a convex guide wheel rolled piece 13, a convex guide wheel piece 14, and a convex guide wheel gasket 15. The processing and assembly relationship that needs to be ensured in the guide wheel assembly is that the outer diameter of the convex guide wheel gasket 15 is consistent with the diameter of the corresponding position of the convex guide wheel piece 14, and the end faces of each part are perpendicular to the axis.

[0042] The dimensional relationship between the main wheel group and the guide wheel group must be consistent along the center height of the machine tool spindle. The two guide wheel groups cooperate with a convex guide wheel group to achieve the curvature and cutting edge of the formed parts. Figure 4 As shown, the features include: section height H, section width W, section bending length B, section thickness t, and inner bending radius R.

[0043] The combined roller for forming a cross-section frame provided by the present invention is applicable to the following situations: the part section height H, section thickness t, and inner bending radius R are the same, and the materials can be different.

[0044] When the cross-sectional width W of the parts is different, it is necessary to replace the concave main wheel gasket 1, the convex main wheel gasket 6, the concave guide wheel rolling piece 11, and the convex guide wheel gasket 15 with different thicknesses;

[0045] When the length B of the bending edge of the part section is different, it is necessary to replace the concave main wheel rolling piece 3, the convex main wheel first rolling piece 4, the concave main wheel second rolling piece 7, and the convex main wheel second rolling piece 10 with different thicknesses;

[0046] The process method of forming by using the above combined roller is as shown in the flow chart. Figure 6 As shown, the specific steps include:

[0047] Step 1: Bending the cross section: After taking out the long strip, use a bending machine to bend the long strip into a straight material close to the shape of a "J";

[0048] Step 2: Assemble the rollers. Select the parts according to the cross-sectional shape of the frame product and install all the parts on the main shaft of the six-axis roller bed in order. The driving wheel group is installed on the middle driving shaft, and the guide wheel group is installed on the follower shafts on both sides. Use fasteners to lock the two ends of the main wheel group and the guide wheel group in the height direction to ensure that the center heights of the two guide wheel groups and the main wheel group are consistent;

[0049] Step 3: Roll the straight material, use a hammer to correct one end of the straight material so that it can be inserted into the roller, start the roller bed, and roll the cross-section of the straight material along its entire length to make it into a regular "F" shape. At this time, the cross-section bending length B has a process allowance of no less than 3mm.

[0050] Step 4: Full annealing: Use heat treatment equipment to fully anneal the straight material to eliminate the material hardening during the bending and rolling process and prevent subsequent rolling cracking;

[0051] Step 5: Multi-pass rolling and bending. Insert the sheet frame into each wheel group and adjust the position of the guide wheel group several times to roll and bend the sheet frame so that the radius is gradually formed from large to small, and the sheet frame is continuously close to the finished product requirements. The forming passes are no less than 5 times, and the last press is the smallest to avoid wrinkles and excessive rolling.

[0052] Step 6: Quenching: using heat treatment equipment to perform solution heat treatment on the sheet frame after roll bending;

[0053] Step 7: Roll and bend the quenched plate frame using rollers to correct the curvature and flatness;

[0054] Step 8: Allow for rolling cutting allowance. Without changing the positions of the main shafts of the rolling bed, select appropriate concave main wheel rolling slices 7, concave main wheel spacer 8, convex main wheel rolling slices 9, and convex main wheel second bending slices 10 according to the cross-sectional dimensions of the sheet frame product. Insert the sheet frame into a guide wheel assembly and when it reaches the intersection of the convex main wheel slice 5 and the concave main wheel slice 2, rotate the driving shaft to drive the sheet frame through the concave main wheel rolling slice cutting edge 71 and the convex main wheel rolling slice cutting edge 91 to complete the edge trimming.

[0055] Step 9: Correction: Use a hammer, curved pads and inspection molds to correct the parts.

[0056] Step 10: Aging treatment: Depending on the material grade of the plate frame product, the corrected plate frame is subjected to natural aging or artificial aging using heat treatment equipment. 2A12 material requires natural aging, and 7A09 material requires artificial aging.

[0057] The present invention is not limited to the aforementioned specific embodiments, but extends to any new features or any new combination disclosed in this specification, as well as any new method or process steps or any new combination disclosed.

Claims

1. A combined roller for forming a cross-section frame, characterized in that: It includes a main wheel group and two guide wheel groups. The center heights of the main wheel group and the guide wheel group along the main axis of the machine tool are consistent. The two guide wheel groups cooperate with one main wheel group to achieve the curvature and trimming of the formed parts. The main wheel group includes a rolling main wheel and a rolling main wheel, the rolling main wheel includes a rolling concave main wheel and a rolling convex main wheel that cooperate with each other, and the rolling main wheel includes a rolling concave main wheel and a rolling convex main wheel that cooperate with each other; the guide wheel group includes a concave guide wheel and a convex guide wheel that cooperate with each other.

2. The combined roller for forming an X-shaped cross-section frame according to claim 1, characterized in that: The rolled concave main wheel includes a concave main wheel gasket, a concave main wheel sheet, and a concave main wheel rolling sheet; the rolled convex main wheel includes a convex main wheel first rolling sheet, a convex main wheel sheet, and a convex main wheel gasket; The rolled concave main wheel includes a concave main wheel gasket, a concave main wheel sheet, and a concave main wheel rolled section; the rolled convex main wheel includes a convex main wheel rolled section, a convex main wheel second rolled bending sheet, a convex main wheel sheet, and a convex main wheel gasket.

3. The combined roller for forming an X-shaped cross-section frame according to claim 2, characterized in that: The outer diameters of the concave main wheel bending piece and the concave main wheel rolling slice are consistent with the diameter of the concave main wheel piece, the outer diameter of the concave main wheel gasket is consistent with the diameter of the concave main wheel piece, and the outer diameter of the convex main wheel gasket is consistent with the diameter of the convex main wheel piece. The end faces of each part are perpendicular to the axis.

4. The combined roller for forming an X-shaped cross-section frame according to claim 2, characterized in that: The concave main wheel gasket, concave main wheel piece, concave main wheel rolled piece, convex main wheel first rolled piece, convex main wheel piece, and convex main wheel gasket are all provided with keyways for connecting with the main shaft of the equipment.

5. The combined roller for forming an X-shaped cross-section frame according to claim 2, characterized in that: The concave main wheel rolling slice and the convex main wheel rolling slice are respectively provided with a concave main wheel rolling slice cutting edge and a convex main wheel rolling slice cutting edge along the circumferential direction.

6. The combined roller for forming an X-shaped cross-section frame according to claim 1, characterized in that: The concave guide wheel includes a concave guide wheel rolled piece and a concave guide wheel piece, and the convex guide wheel includes a convex guide wheel rolled piece, a convex guide wheel piece, and a convex guide wheel gasket; the outer diameter of the convex guide wheel gasket is consistent with the diameter of the convex guide wheel piece, and the end faces of each part are perpendicular to the axis.

7. The combined roller for forming an X-shaped cross-section frame according to claim 1, characterized in that: The main wheel set and the guide wheel set are both made of die steel.

8. A forming method using the combined roller for forming an X-shaped cross-section frame according to any one of claims 1 to 7, characterized in that: The following steps are included: Step 1: Bending the cross section, after taking out the long strip, use a bending machine to bend the long strip into a straight material close to the shape of a "J"; Step 2: Assemble the rollers, select the parts according to the cross-sectional shape of the plate frame product, and install all the parts in order on the main shaft of the six-axis roller bed; Step 3: Roll the straight material, use a hammer to correct one end of the straight material so that it can be inserted into the roller, start the roller bed, and roll the straight material along its entire length; Step 4: Full annealing: Use heat treatment equipment to fully anneal the straight material; Step 5: Multi-pass rolling and bending. Insert the sheet frame into each wheel group and adjust the position of the guide wheel group several times to roll and bend the sheet frame so that the radius of the sheet frame gradually forms from large to small. Step 6: Quenching: using heat treatment equipment to perform solution heat treatment on the sheet frame after roll bending; Step 7: Roll and bend the quenched plate frame using rollers to correct the curvature and flatness; Step 8: With the rolling cutting allowance unchanged, without changing the positions of the main shafts of the roller bed, select appropriate concave main wheel rolling slices, concave main wheel spacers, convex main wheel rolling slices, and convex main wheel second bending slices according to the cross-sectional dimensions of the plate frame product. Insert the plate frame into a guide wheel assembly and when it reaches the intersection of the convex main wheel slice and the concave main wheel slice, rotate the driving shaft to drive the plate frame through the concave main wheel rolling slice cutting edge and the convex main wheel rolling slice cutting edge to complete the edge trimming. Step 9: Correction: Use a hammer, curved pads and inspection molds to correct the parts; Step 10: Aging treatment: Depending on the material grade of the plate frame product, the corrected plate frame is subjected to natural aging or artificial aging using heat treatment equipment.

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