Discrete Die Two-Stage Progressive Forming Equipment and Method

Abstract

This invention provides a discrete mold two-stage progressive forming device and method. The split upper module includes multiple independent upper mold blocks. Each upper mold block has a central step structure and side step structures. Initially, the upper surfaces of the side step structures of the multiple upper mold blocks are at the same height, while the upper surfaces of the central step structures of the multiple upper mold blocks gradually decrease in height from the center to both sides, forming a stepped shape. The hydraulic auxiliary device includes a central pressure block, side pressure blocks, a central pressure head, and side pressure heads. The central pressure block corresponds to the central step structure; the side pressure blocks correspond to the side step structures; the central pressure head is connected to the central pressure block and can drive the central pressure block to move up and down; the side pressure head is connected to the side pressure block and can drive the side pressure block to move up and down. This invention solves the problem that high-strength steel parts with multi-arc variable cross-sections are difficult to produce using traditional forming processes.

Description

Technical Field

[0001] This invention relates to the field of processing and forming technology, specifically to a discrete mold two-stage progressive forming equipment and method, and more particularly to a multi-module double-action low-load progressive forming equipment and method. Background Technology

[0002] As the modern automotive industry continues to demand both lightweight structures and high crash safety performance, the roof load-bearing beam, as a core component of the vehicle's collision energy dissipation system, is facing revolutionary challenges in terms of structural strength and geometric tolerances. For variable curvature spatial beam structures constructed from ultra-high strength steel (UTS≥1000MPa), simultaneous improvements in mass reduction and buckling resistance under multi-axis loads can be achieved through integrated control of material mechanical properties and cross-sectional morphology parameters. However, the synergistic control of the material system's low plastic deformation capacity and complex geometric features presents multi-dimensional breakthrough challenges to existing manufacturing technologies.

[0003] First, while traditional cold molding can ensure dimensional accuracy, it is constrained by the work hardening characteristics and anisotropy of materials, requiring the use of ultra-high tonnage presses, resulting in a non-linear increase in production equipment investment and energy consumption. Second, conventional roll forming technology, based on a simplified planar bending theory, is only suitable for the mass production of straight components with uniform curvature, and is difficult to adapt to the three-dimensional spatial forming requirements of multiple curvature intersections and irregular cross-sections. Third, although the roll punching composite process attempts to remove the limitation of continuous deformation through segmented processing, the uneven distribution of the surface stress field leads to process defects such as workpiece trajectory drift and morphological deviations, significantly affecting the product qualification rate.

[0004] Patent document CN102211121A discloses a precision progressive forming device and method for sheet metal processing. The device includes a five-axis CNC forming machine tool, a sheet metal fixture, a data acquisition system, and an optimization control module. The sheet metal fixture is mounted on the machine tool's worktable. The data acquisition system is connected to both the five-axis CNC forming machine tool and the optimization control module, transmitting processing parameters and control commands. The end of the spindle of the five-axis CNC forming machine tool is equipped with a forming pressure head or a laser ranging system, which is connected to the data acquisition system and transmits laser ranging signals. However, this patent document still has the limitation of only being able to achieve continuous forming of planar components with a single curvature. Summary of the Invention

[0005] In view of the deficiencies in the prior art, the purpose of this invention is to provide a discrete mold two-stage progressive forming device and method.

[0006] A discrete mold two-stage progressive forming device provided by the present invention includes: a split upper module, an integrated base, and a hydraulic auxiliary device;

[0007] The split upper module includes multiple independent upper mold blocks, which can be lifted and moved on the integrated base to extrude and form the sheet material.

[0008] The upper mold block is provided with a middle step structure and a side step structure. In the initial state, the upper surface of the side step structure of the multiple upper mold blocks has the same height, and the upper surface of the middle step structure of the multiple upper mold blocks gradually decreases from the middle to both sides, presenting a stepped shape.

[0009] The hydraulic auxiliary device includes:

[0010] An intermediate pressing block is provided corresponding to the intermediate step structure, which can abut against the upper surface of the intermediate step structure and push the intermediate step structure.

[0011] A side pressure block is provided corresponding to the side step structure, which can abut against the upper surface of the side step structure and push the side step structure.

[0012] An intermediate pressure head, which is connected to the intermediate pressure block, is capable of driving the intermediate pressure block to move up and down.

[0013] A side pressure head, which is connected to the side pressure block, is capable of driving the side pressure block to move up and down.

[0014] Preferably, a pull ring is provided on the upper surface of the intermediate step structure;

[0015] The intermediate pressure block is provided with a pull ring receiving cavity corresponding to the pull ring, and the pull ring receiving cavity is used to accommodate the pull ring;

[0016] A pull pin is provided inside the pull ring receiving cavity, and the pull pin passes through the pull ring;

[0017] When the intermediate pressure block rises, the pull pin can drive the pull ring to rise, which in turn drives the upper mold block to rise.

[0018] Preferably, the side pressure block is provided with a moving groove;

[0019] The intermediate pressure block is installed in the movable groove and can move within the movable groove;

[0020] The side pressing block has a side abutting surface for abutting the side step structure, and the middle pressing block has a middle abutting surface for abutting the middle step structure.

[0021] Preferably, the side pressure block is an inverted concave three-dimensional structure with an inverted U-shaped cross-section;

[0022] The groove of the inverted concave three-dimensional structure forms the moving groove, and the intermediate pressure block has a rectangular structure;

[0023] The intermediate pressure head and the side pressure head are located at the top of the inverted concave three-dimensional structure, and the top of the inverted concave three-dimensional structure is provided with a through hole;

[0024] The side pressure head is a ring structure, and the middle pressure head is set corresponding to the inner circle opening of the ring structure and can pass through the inner circle opening;

[0025] The intermediate pressure block is provided with a connecting structure, one end of which passes through the perforation and the inner circular opening and is connected to the intermediate pressure head.

[0026] Preferably, the intermediate pressure head is connected to the connecting structure via a connecting plate.

[0027] Preferably, the integrated base includes:

[0028] A bottom mold, which is used together with the upper mold block to extrude and shape the sheet metal;

[0029] Multiple guide pillars are provided on the bottom mold for mounting the upper mold block;

[0030] Multiple springs are sleeved on the guide post and located between the bottom mold and the upper mold block;

[0031] The upper mold block is mounted on the guide post, and multiple upper mold blocks are arranged sequentially along the length of the sheet material, each capable of independently moving up and down on the guide post.

[0032] Preferably, the bottom mold is provided with a positioning pin, which is used for positioning the sheet metal;

[0033] The upper mold block is provided with a positioning pin hole corresponding to the positioning pin.

[0034] Preferably, the effective mold surfaces of the split upper module and the integrated base are set according to the shape of the target part.

[0035] The present invention also provides a discrete mold two-stage progressive forming method, which uses the above-mentioned discrete mold two-stage progressive forming equipment and includes the following steps:

[0036] Step S1: Install the discrete mold two-stage progressive forming equipment on the double-acting press, connect the integrated base to the fixed end of the press, and connect the mechanical auxiliary device to the execution end of the press;

[0037] Step S2: Press down the first press execution end, drive the middle pressure block to press down through the middle pressure head. The upper surface of the middle step structure of the upper mold block located in the middle first contacts the pressure block, so that the middle part of the sheet material begins to be formed. After the upper mold block located in the middle is pressed to the bottom, this step ends. At this time, the pressing degree of the multiple upper mold blocks from the middle to both sides decreases sequentially. The height of the upper surface of the middle step structure of the multiple upper mold blocks is the same, and the height of the upper surface of the side step structure of the multiple upper mold blocks from the middle to both sides increases, presenting a stepped shape.

[0038] Step S3: Maintain pressure with the intermediate pressure head, and press down with the execution end of the second press. Drive the side pressure blocks down through the side pressure head. The upper surfaces of the side step structures of the upper mold blocks located at the two outermost edges first contact the side pressure blocks, so that the two ends of the sheet metal begin to form. As the execution end of the second press continues to press down, the forming area of ​​the sheet metal gradually extends from the two ends to the middle. The upper surfaces of the side step structures of the multiple upper mold blocks are flat. This step ends.

[0039] Step S4: Raise the press execution end. The pull pin on the intermediate pressure block will drive the pull ring on the intermediate step structure of the upper mold block, causing multiple upper mold blocks to rise to the initial position. The target part is demolded, and the full forming process ends.

[0040] Preferably, in step S2, before the first press is pressed down, the height of the upper surface of the middle step structure of the upper mold block located in the middle is the largest, and the height of the upper surface of the middle step structure of the multiple upper mold blocks decreases from the middle to both sides.

[0041] In step S3, before the second press is pressed down, the height of the upper surface of the side step structure of the upper mold block located in the middle is the smallest, and the height of the upper surface of the side step structure of the multiple upper mold blocks increases from the middle to both sides.

[0042] Compared with the prior art, the present invention has the following beneficial effects:

[0043] 1. This invention divides the overall upper die into multi-module upper die units with stepped height differences. Combined with a dual-stroke hydraulic drive system, the progressive forming of each module is completed sequentially during the two stamping strokes of the press. The first stroke drives the middle press head to press down on the higher steps to complete the initial deformation. The second stroke uses the side press heads to press down on the side steps to achieve complete forming. This invention adopts an integrated base and a discrete upper die unit architecture, based on a dual-action press platform. Low-load forming is achieved through three-stage timing control. First, the middle press head of the press presses down normally to flatten the upper die. The first stage ends when the middle mold block is pressed to the bottom and the pressure is maintained. In the second stage, the outer pressure head presses down on the side pressure block to flatten the side steps of the upper mold block. In the third stage, the outer pressure head first lifts up, and then the middle pressure head drives all mold blocks to lift up through the pull ring to realize the demolding process. Through the multi-level triggering strategy of timing control, the forming stress gradient is optimized and the overall stress level of the system is significantly reduced. It can be applied to the high-precision morphology control of ultra-high strength alloy three-dimensional curved surface components.

[0044] 2. This invention proposes a stepped forming system based on feature decoupling, which decomposes a three-dimensional complex curved surface into reconfigurable basic morphological units and adopts a time-controllable progressive forming mechanism to achieve single-step deformation energy efficiency optimization and forming of complex double-curvature parts, laying a technological foundation for the large-scale production of high-performance roof load-bearing beams.

[0045] 3. This invention solves the problem that high-strength steel parts with multi-arc variable cross-sections are difficult to produce using traditional forming processes.

[0046] 4. The process of this invention is flexible and applicable to the forming of various complex-shaped parts.

[0047] 5. This invention has a simple structure, controllable cost, and no special requirements for operating conditions. Attached Figure Description

[0048] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0049] Figure 1 This is a cross-sectional view of the discrete mold two-stage progressive forming device of the present invention;

[0050] Figure 2 This is a front view of the discrete mold two-stage progressive forming apparatus of the present invention;

[0051] Figure 3 This is a side view of the discrete mold two-stage progressive forming device of the present invention;

[0052] Figure 4 This is an isometric view of the discrete mold two-stage progressive forming device of the present invention;

[0053] Figure 5 This is a schematic diagram of sheet metal positioning for the discrete mold two-stage progressive forming device of the present invention;

[0054] Figure 6 This is a schematic diagram of the forming process of the discrete mold two-stage progressive forming device of the present invention.

[0055] The diagram shows:

[0056] Split-type upper module 1, intermediate pressure block 31

[0057] Upper mold block 11 pull ring receiving cavity 311

[0058] Intermediate step structure 111 pull pin 312

[0059] Side step structure 112 connecting structure 313

[0060] Pull ring 113 side pressure block 32

[0061] Flange linear bearing 114 moving groove 321

[0062] Integrated base 2 perforated 322

[0063] Bottom mold 21, intermediate pressure head 33

[0064] Positioning pin 211 side pressure head 34

[0065] Guide post 22 sheet 4

[0066] Hydraulic auxiliary device 3 connecting plate 5 Detailed Implementation

[0067] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0068] Example 1

[0069] like Figures 1 to 6As shown, this embodiment provides a discrete mold two-stage progressive forming device, including: a split upper module 1, an integrated base 2, and a hydraulic auxiliary device 3. The split upper module 1 includes multiple independent upper mold blocks 11. The upper mold blocks 11 can move up and down on the integrated base 2 to extrude and form the sheet material 4. The upper mold blocks 11 are provided with a middle step structure 111 and a side step structure 112. In the initial state, the height of the upper surface of the side step structure 112 of the multiple upper mold blocks 11 is the same, and the height of the upper surface of the middle step structure 111 of the multiple upper mold blocks 11 gradually decreases from the middle to both sides, presenting a stepped shape.

[0070] The integrated base 2 includes a bottom mold 21 and multiple guide pillars 22. The bottom mold 21 is used to extrude and form the sheet metal 4 together with the upper mold block 11; the guide pillars 22 are disposed on the bottom mold 21 and are used to mount the upper mold block 11; the upper mold block 11 is mounted on the guide pillars 22, and the multiple upper mold blocks 11 are arranged sequentially along the length direction of the sheet metal 4, and can move independently up and down on the guide pillars 22. The bottom mold 21 is provided with positioning pins 211, which are used for positioning the sheet metal 4; the upper mold block 11 is provided with positioning pin holes corresponding to the positioning pins 211. The effective mold surfaces of the split upper mold assembly 1 and the integrated base 3 are set according to the shape of the target part.

[0071] The hydraulic auxiliary device 3 includes: a central pressure block 31, a side pressure block 32, a central pressure head 33, and a side pressure head 34. The central pressure block 31 is disposed corresponding to the central step structure 111, and can abut against the upper surface of the central step structure 111 and push the central step structure 111; the side pressure block 32 is disposed corresponding to the side step structure 112, and can abut against the upper surface of the side step structure 112 and push the side step structure 112; the central pressure head 33 is connected to the central pressure block 31 and can drive the central pressure block 31 to move up and down; the side pressure head 34 is connected to the side pressure block 32 and can drive the side pressure block 32 to move up and down.

[0072] A pull ring 113 is provided on the upper surface of the intermediate step structure 111; a pull ring receiving cavity 311 is provided on the intermediate pressure block 31 corresponding to the pull ring 113, and the pull ring receiving cavity 311 is used to receive the pull ring 113; a pull pin 312 is provided in the pull ring receiving cavity 311, and the pull pin 312 passes through the pull ring 113; when the intermediate pressure block 31 rises, the pull pin 312 can drive the pull ring 113 to rise, thereby driving the upper mold block 11 to rise.

[0073] The side pressure block 32 has a moving groove 321; the middle pressure block 31 is installed in the moving groove 321 and can move within the moving groove 321; the side pressure block 32 has a side abutting surface for abutting the side step structure 112, and the middle pressure block 31 has a middle abutting surface for abutting the middle step structure 111. The side pressure block 32 is an inverted concave three-dimensional structure with an inverted U-shaped cross section; the groove of the inverted concave three-dimensional structure forms the moving groove 321, and the middle pressure block 31 is a rectangular structure; the middle pressure head 33 and the side pressure head 34 are located at the top of the inverted concave three-dimensional structure, and the top of the inverted concave three-dimensional structure has a through hole 322; the side pressure head 34 is an annular structure, and the middle pressure head 33 is set corresponding to the inner circle opening of the annular structure and can pass through the inner circle opening; the middle pressure block 31 is provided with a connecting structure 313, one end of the connecting structure 313 passes through the through hole 322 and the inner circle opening and connects to the middle pressure head 33. The intermediate pressure head 33 is connected to the connecting structure 313 via the connecting plate 5.

[0074] This embodiment provides a discrete mold two-stage progressive forming method, using the aforementioned discrete mold two-stage progressive forming equipment, and includes the following steps:

[0075] Step S1: Install the discrete mold two-stage progressive forming equipment on the double-action press, connect the integrated base 2 to the fixed end of the press, and connect the mechanical auxiliary device 3 to the execution end of the press.

[0076] Step S2: Press down the first press execution end, drive the middle pressure block 31 to press down through the middle pressure head 33. The upper surface of the middle step structure 111 of the middle upper mold block 11 is the first to contact the pressure block 31, so that the middle part of the sheet 4 begins to form. After the middle upper mold block 31 is pressed to the bottom, this step ends. At this time, the pressing degree of the multiple upper mold blocks 31 from the middle to both sides decreases in sequence. The height of the upper surface of the middle step structure 111 of the multiple upper mold blocks 31 is the same. The height of the upper surface of the side step structure 112 of the multiple upper mold blocks 31 from the middle to both sides increases, presenting a stepped shape.

[0077] In step S2, before the first press is pressed down, the height of the upper surface of the middle step structure 111 of the upper mold block 31 located in the middle is the largest, and the height of the upper surface of the middle step structure 111 of the multiple upper mold blocks 31 decreases from the middle to both sides.

[0078] Step S3: Maintain pressure in the intermediate pressure head 33, press down the execution end of the second press, and drive the side pressure block 32 to press down through the side pressure head 34. The upper surface of the side step structure 112 of the upper mold block 31 located on both sides first contacts the side pressure block 32, so that the two ends of the sheet 4 begin to form. As the execution end of the second press continues to press down, the forming area of ​​the sheet 4 gradually extends from the two ends to the middle. The upper surfaces of the side step structures 112 of the multiple upper mold blocks 31 are flat. This step ends.

[0079] In step S3, before the second press is pressed down, the height of the upper surface of the side step structure 112 of the upper mold block 31 located in the middle is the smallest, and the height of the upper surface of the side step structure 112 of the multiple upper mold blocks 31 increases from the middle to both sides.

[0080] Step S4: Raise the press execution end, and the pull pin 312 on the intermediate pressure block 31 will drive the pull ring 113 on the intermediate step structure 111 of the upper mold block 11, so that multiple upper mold blocks 11 are raised to the initial position, the target part is demolded, and the full forming process ends.

[0081] This embodiment belongs to the field of metal plastic forming technology, specifically involving a metal progressive forming process and equipment based on modular and sequential stamping. It addresses the technical challenges of traditional integral stamping forming, such as high load, easy cracking, easy die wear, and the inability of roll forming to process variable cross-section parts. It proposes an innovative solution that combines discrete die segmented forming with stepped punch timing control.

[0082] In this embodiment, the overall upper mold is divided into a multi-module upper mold with stepped height differences. With the help of a dual-stroke hydraulic drive system, the progressive forming of each module is completed in two stamping strokes of the press. The first stroke drives the middle press head to press down the high step to complete the initial deformation. The second stroke uses the side press head to press down the side step to achieve complete forming.

[0083] This embodiment adopts an integrated base and a discrete upper module architecture, based on a dual-action press platform, and achieves low-load forming through three-stage timing control:

[0084] In the first stage, the middle press head of the press first presses down in the normal direction to flatten the step difference in the middle of the upper module. After the middle mold block is pressed to the bottom, the pressing stops and the pressure is maintained. The first stage ends.

[0085] In the second stage, the outer pressure head presses down on the side pressure block to flatten the side steps of the upper mold block, and the second stage ends.

[0086] In the third stage, the outer pressure head is raised first, and then the middle pressure head drives all the mold blocks to rise through the pull ring, thus realizing the demolding process.

[0087] This embodiment achieves optimized distribution of forming stress gradient through a multi-level triggering strategy with timing control, which significantly reduces the overall stress level of the system and can be applied to high-precision morphology control of ultra-high strength alloy three-dimensional curved surface components.

[0088] Example 2

[0089] Those skilled in the art can understand this embodiment as a more specific description of Embodiment 1.

[0090] This embodiment provides a multi-module dual-action low-load progressive forming device, including: a mechanical auxiliary device, a split upper module, and an integrated base.

[0091] The mechanical auxiliary device includes: a pressure block, a side pressure block, a pull ring, a pull pin, and related standard parts. The pressure block is fixedly connected to the intermediate pressure head and, driven by the intermediate pressure head, flattens the stepped head of the upper mold block; the side pressure block fits onto the pressure block and, driven by the outer pressure head, flattens the stepped side surface of the upper mold block; the pull ring is threadedly connected to the upper mold block, and the pull pin is inserted into the pressure block and passes through the pull ring, used for lifting the upper mold after forming is completed.

[0092] The split upper module includes: several independent upper mold blocks, flange linear bearings, and related standard parts; the several independent mold blocks are divided from the overall upper mold; the flange linear bearings are connected to the split mold blocks and are used for the independent up and down sliding of the upper mold blocks.

[0093] The integrated base includes an integral bottom mold, guide pillars, and positioning pins. The guide pillars are interference-fitted to the bottom mold to provide a movement track for the split upper module. The positioning pins are bolted to the integral bottom mold.

[0094] Furthermore, the power-providing press is capable of independently driving the intermediate press head and the outer press head.

[0095] Furthermore, the head heights of the various upper mold blocks are different, but the side step heights are consistent.

[0096] Furthermore, the pull ring engages with the pull pin via a slotted hole, ensuring that the pull pin and the pull ring do not interfere with each other during the step-flattening process.

[0097] Furthermore, the integral bottom mold has three positioning pin holes for installing the positioning pins, and the split upper module is machined with corresponding positioning pin holes.

[0098] Furthermore, under the constraint of the guide post and the flange linear bearing, the split upper module can only move relative to the integral bottom mold along the axial direction of the guide post.

[0099] Furthermore, the effective mold surfaces of the split upper module and the integrated base are designed according to the morphology of the target part.

[0100] This embodiment also provides a forming method for the above-mentioned novel multi-module dual-action low-load progressive forming equipment, which includes the following steps:

[0101] Step S1: Determine the basic dimensions of the multi-module double-action low-load progressive forming equipment based on installation conditions, load conditions, and operating environment; design and manufacture each non-standard part; and purchase each standard part.

[0102] Step S2: Perform initial assembly of each part and check whether the relative movement between each part can occur according to the preset plan;

[0103] Step S3: Install the multi-module double-action low-load progressive forming equipment onto a double-action press, such as a hydraulic press or a stamping press. The integrated base is connected to the fixed end of the press, such as the fixed template of the hydraulic press or the worktable of the stamping press. The mechanical auxiliary device is connected to the execution end of the press, such as the piston of the hydraulic press or the die of the stamping press.

[0104] Step S4: The press actuator presses down, causing the pressure block to press down. The heights of the heads of the upper die blocks are different, with the middle upper die block being the tallest, decreasing sequentially towards both sides. The middle upper die block contacts the pressure block first, and the middle of the sheet metal begins to form. This step ends after the middle upper die block is pressed to the bottom. At this point, the pressure of the upper die blocks on both sides decreases sequentially, and the head steps are flattened. At this time, the side steps of the upper die blocks with the same height appear stepped, and this step ends.

[0105] In step S5, the intermediate pressure head maintains pressure, and the outer pressure head of the press drives the side pressure block to press down. The side pressure block first contacts the outermost step of the upper mold block, and the two ends of the sheet metal begin to form. As the press continues to press down, the forming area of ​​the sheet metal gradually extends from the two ends to the middle. This step ends after the step of the upper mold block is flattened.

[0106] In step S6, the intermediate press head of the press is raised, which drives the pull ring to pull the mold block up to the initial position, and the target part is demolded, thus ending the full forming process.

[0107] To address the limitations of existing multi-arc variable cross-section workpiece forming methods, this embodiment aims to provide a novel multi-module double-action low-load progressive forming equipment and method to solve the problem of producing high-strength steel multi-arc variable cross-section workpieces using traditional forming methods.

[0108] Example 3

[0109] Those skilled in the art can understand this embodiment as a more specific description of Embodiment 1.

[0110] like Figure 1 , Figure 2 and Figure 3 As shown, this embodiment provides a novel multi-module dual-action low-load progressive forming device, including: a mechanical auxiliary device 3, a split upper module 1, and an integrated base 2.

[0111] like Figure 1 As shown, the mechanical auxiliary device 3 includes: an intermediate pressure block 31, a side pressure block 32, a pull ring 113, a pin 312, and related standard parts. The intermediate pressure block 31 is fixedly connected to the intermediate pressure head 33, and under the drive of the intermediate pressure head 33, it flattens the stepped head of the upper mold block 11. The side pressure block 32 fits around the intermediate pressure block 31, and under the drive of the side pressure head 34, it flattens the stepped side of the upper mold block 11. The pull ring 113 is threadedly connected to the upper mold block 11, and the pull pin 312 is inserted into the intermediate pressure block 31 and passes through the pull ring 113, used for lifting the upper mold 5 after forming is completed. Among them, the side pressure block 32 is not fixedly connected to the other parts. Its downward pressure is driven by the side pressure head 34, and its upward lifting is driven by the intermediate pressure head 33, which drives the intermediate pressure block 31 and the upper mold block 11, thereby driving the side pressure block 32 to lift.

[0112] like Figure 2 As shown, the split upper module 1 includes: several independent upper mold blocks 11, flange linear bearings 114 and related standard parts; the several independent upper mold blocks 11 are divided from the overall upper mold; the flange linear bearings 114 are threadedly connected to the split mold blocks 1 and are used for the independent up and down sliding of the upper mold blocks 11.

[0113] like Figure 3 As shown, the integrated base 2 includes: a bottom mold 21, a guide post 22, and a positioning pin 211. The positioning pin 211 includes a short positioning pin and a long positioning pin. The guide post 22 is interference-fitted to the bottom mold 21 to provide a movement track for the upper mold block 11. The short positioning pin and the long positioning pin are bolted to the bottom mold 21.

[0114] like Figure 5 As shown, the sheet metal 4 is positioned using a three-hole positioning method. Oval holes are prepared at both ends of the sheet metal 4 to engage with long positioning pins, allowing the long positioning pins to move relative to the sheet metal 4 within the oval holes. A round hole is prepared in the middle of the sheet metal 4 to engage with a short positioning pin. The round hole constrains the horizontal movement of the sheet metal 4, while the oval hole constrains the rotation of the sheet metal 4 around the short positioning pin.

[0115] Under the constraint of the guide post 22 and the flange linear bearing 114, the upper mold block 11 can only move relative to the bottom mold 21 along the axial direction of the guide post 22. The effective mold surfaces of the upper mold block 11 and the bottom mold 21 are designed according to the shape of the target part.

[0116] The following is a detailed description of the specific implementation method for forming roof beam parts using the novel modular multi-level gradient forming equipment of this embodiment. The specific implementation method of this embodiment includes the following steps:

[0117] Step S1: Determine the basic dimensions of the multi-module double-action low-load progressive forming equipment based on installation conditions, load conditions, and operating environment; design and manufacture each non-standard part; and purchase each standard part.

[0118] Step S2: Perform initial assembly of each part and check whether the relative movement between each part can occur according to the preset plan;

[0119] Step S3: Install the multi-module double-action low-load progressive forming equipment onto a double-action press, such as a hydraulic press or a stamping press. The integrated base 2 is connected to the fixed end of the press, such as the fixed template of the hydraulic press or the worktable of the stamping press. The mechanical auxiliary device 3 is connected to the execution end of the press, such as the piston of the hydraulic press or the die of the stamping press.

[0120] In step S4, the press's actuator presses down, causing the intermediate pressing block 31 to press down as well. The heights of the heads of the upper die blocks 11 are different, with the middle upper die block 11 being the tallest, decreasing sequentially towards both sides. The middle upper die block 11 is the first to contact the intermediate pressing block 31, and the middle of the sheet metal 4 begins to form. This step ends when the middle upper die block 11 is pressed to the bottom. At this point, the pressure of the upper die blocks 11 on both sides decreases sequentially, and the head steps are flattened. At this time, the side steps of the upper die blocks 11, which are of uniform height, appear stepped, and this step ends.

[0121] In step S5, the intermediate pressure head 33 maintains pressure, and the side pressure head 34 of the press drives the side pressure block 32 to press down. The side pressure block 32 first contacts the side step of the outermost upper mold block 11, and the two ends of the sheet metal 4 begin to form. As the press continues to press down, the forming area of ​​the sheet metal 4 gradually extends from the two ends to the middle. This step ends after the side step of the upper mold block 11 is flattened.

[0122] In step S6, the middle pressing head 33 is raised, which drives the pull ring 113 to pull the upper mold block 11 to the initial position, and the target part is demolded, thus ending the full forming process.

[0123] This invention solves the problem that high-strength steel parts with multi-arc variable cross-sections are difficult to produce using traditional forming processes.

[0124] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0125] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A discrete die two-stage incremental forming apparatus, characterised in that, include: The components include a split upper module (1), an integrated base (2), and a hydraulic auxiliary device (3). The split upper module (1) includes multiple independent upper mold blocks (11), which can move up and down on the integrated base (2) to extrude and form the sheet material (4); The upper mold block (11) is provided with a middle step structure (111) and a side step structure (112). In the initial state, the height of the upper surface of the side step structure (112) of the multiple upper mold blocks (11) is the same, and the height of the upper surface of the middle step structure (111) of the multiple upper mold blocks (11) gradually decreases from the middle to both sides, presenting a stepped shape. The hydraulic auxiliary device (3) includes: An intermediate pressure block (31) is provided corresponding to the intermediate step structure (111), and can abut against the upper surface of the intermediate step structure (111) and push the intermediate step structure (111). Side pressure block (32), which is provided corresponding to the side step structure (112), can abut against the upper surface of the side step structure (112) and push the side step structure (112). The intermediate pressure head (33) is connected to the intermediate pressure block (31) and can drive the intermediate pressure block (31) to move up and down. A side pressure head (34) is connected to the side pressure block (32) and can drive the side pressure block (32) to move up and down; The side pressure block (32) is provided with a moving groove (321); The intermediate pressure block (31) is installed in the movable slot (321) and is able to move within the movable slot (321); The side pressure block (32) has a side abutting surface for abutting the side step structure (112), and the middle pressure block (31) has a middle abutting surface for abutting the middle step structure (111). The side pressure block (32) is an inverted concave three-dimensional structure with an inverted concave cross-section; The groove of the inverted concave three-dimensional structure forms the moving groove (321), and the intermediate pressing block (31) is a rectangular structure; The intermediate pressure head (33) and the side pressure head (34) are located at the top of the inverted concave three-dimensional structure, and the top of the inverted concave three-dimensional structure is provided with a perforation (322). The side pressure head (34) is a ring structure, and the middle pressure head (33) is provided corresponding to the inner circle opening of the ring structure and can pass through the inner circle opening; The intermediate pressure block (31) is provided with a connecting structure (313), one end of which passes through the perforation (322) and the inner circle opening and is connected to the intermediate pressure head (33).

2. The discrete mold two-stage progressive forming device according to claim 1, characterized in that, A pull ring (113) is provided on the upper surface of the intermediate step structure (111). The intermediate pressure block (31) is provided with a pull ring receiving cavity (311) corresponding to the pull ring (113), and the pull ring receiving cavity (311) is used to receive the pull ring (113). A pull pin (312) is provided inside the pull ring receiving cavity (311), and the pull pin (312) passes through the pull ring (113). When the intermediate pressure block (31) rises, the pull pin (312) can drive the pull ring (113) to rise, thereby driving the upper mold block (11) to rise.

3. The discrete mold two-stage progressive forming device according to claim 1, characterized in that, The intermediate pressure head (33) is connected to the connecting structure (313) via the connecting plate (5).

4. The discrete mold two-stage progressive forming device according to claim 1, characterized in that, The integrated base (2) includes: Bottom mold (21), the bottom mold (21) is used together with the upper mold block (11) to extrude and form the sheet material (4); Multiple guide pillars (22) are provided on the bottom mold (21) for mounting the upper mold block (11). The upper mold block (11) is installed on the guide post (22), and multiple upper mold blocks (11) are arranged in sequence along the length direction of the sheet material (4), and can move up and down independently on the guide post (22).

5. The discrete mold two-stage progressive forming device according to claim 4, characterized in that, The bottom mold (21) is provided with a positioning pin (211), which is used for positioning the sheet metal (4); The upper mold block (11) is provided with a positioning pin hole corresponding to the positioning pin (211).

6. The discrete mold two-stage progressive forming device according to claim 1, characterized in that, The effective surfaces of the split upper module (1) and the integrated base (2) are set according to the shape of the target part.

7. A discrete mold two-stage progressive forming method, characterized in that, The discrete mold two-stage progressive forming apparatus according to any one of claims 1 to 6 includes the following steps: Step S1: Install the discrete mold two-stage progressive forming equipment on the double-acting press, connect the integrated base (2) to the fixed end of the press, and connect the hydraulic auxiliary device (3) to the execution end of the press; Step S2: Press down the first press execution end, drive the intermediate pressing block (31) to press down through the intermediate pressing head (33), the upper surface of the intermediate step structure (111) of the middle upper mold block (11) located in the middle first contacts the intermediate pressing block (31), so that the middle part of the sheet (4) begins to form. After the middle upper mold block (11) is pressed to the bottom, this step ends. At this time, the pressing degree of the multiple upper mold blocks (11) from the middle to both sides decreases in sequence, the height of the upper surface of the intermediate step structure (111) of the multiple upper mold blocks (11) is the same, and the height of the upper surface of the side step structure (112) of the multiple upper mold blocks (11) from the middle to both sides increases, presenting a stepped shape; Step S3: Keep the intermediate pressure head (33) under pressure, press down the second press execution end, drive the side pressure block (32) to press down through the side pressure head (34), the upper surface of the side step structure (112) of the upper mold block (11) located at the two outermost sides first contacts the side pressure block (32), so that the two ends of the sheet (4) begin to form. As the second press execution end continues to press down, the forming area of ​​the sheet (4) gradually extends from the two ends to the middle, and the upper surfaces of the side step structures (112) of the multiple upper mold blocks (11) are flat. This step ends. Step S4: Raise the press execution end, and the pull pin (312) on the intermediate pressure block (31) will drive the pull ring (113) on the intermediate step structure (111) of the upper mold block (11), so that multiple upper mold blocks (11) are raised to the initial position, the target part is demolded, and the full forming process ends.

8. The discrete mold two-stage progressive forming method according to claim 7, characterized in that, In step S2, before the first press is pressed down, the height of the upper surface of the middle step structure (111) of the middle upper mold block (11) is the largest, and the height of the upper surface of the middle step structure (111) of the multiple upper mold blocks (11) decreases from the middle to both sides. In step S3, before the second press is pressed down, the height of the upper surface of the side step structure (112) of the upper mold block (11) located in the middle is the smallest, and the height of the upper surface of the side step structure (112) of the multiple upper mold blocks (11) increases from the middle to both sides.

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