Aluminum alloy handle radian servo pressure forming method

Abstract

According to the aluminum alloy handle radian servo pressure forming method, a middle die capable of being pressed downwards is arranged in the middle of a rack and corresponds to the middle bending position of a workpiece, side dies capable of being pressed downwards are arranged on the two sides of the middle die and correspond to the bending positions of the two sides of the workpiece, and supporting columns are arranged on the two sides of the bottom of the rack and used for supporting the two ends of the workpiece; a middle sensor is arranged below the middle die, and a side sensor is arranged below one side die; bending is carried out through three forming stages including test pressing, forming pressing and compensation pressing. The laser displacement sensor is used for measuring the height position parameter of the lower surface of the aluminum workpiece, the split type pressing die is used for conducting multiple times of pressing radian forming machining on the aluminum alloy handle, the radian value of the obtained workpiece is accurate, and the bending production efficiency, accuracy and yield of the aluminum alloy handle are greatly improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of aluminum profile processing, in particular to a servo pressure forming method for aluminum alloy handle arc. BACKGROUND

[0002] High-end household appliances often use aluminum profiles to make handle or frame components, so that they have a metallic texture and a high-end feel. The aluminum alloy handle is formed after the aluminum profile is bent and curved. During the bending and curving process, the aluminum profile is pressed and curved. After the bending, due to the bending resistance of the aluminum alloy material, a certain degree of springback will occur. The arc of the aluminum alloy handle after springback is the arc of the final aluminum handle product. The final aluminum handle also needs to be inspected. The arc meets the design requirements and can be qualified for storage.

[0003] However, the bent aluminum profile is obtained by extruding different batches of aluminum profiles. The alloy composition of each batch of extruded production of the ingot raw material will have some differences. The difference in alloy composition leads to differences in material parameters such as yield strength, elastic modulus, and springback stress of the aluminum alloy material. Therefore, when bending different batches of aluminum profiles, the arc of the bent aluminum handle needs to be frequently inspected. When different batches of raw materials are bent, the one-piece bending die often needs to be padded, that is, the bending surface is increased by a flexible gasket to change the amount of pressure or the bending arc of the bending die so that it can meet the final product requirements after springback. However, the above method of operation tests the experience of the bending workers. The thickness and position of the gasket need to be carefully considered. After changing the die, the bent product needs to be tested several times to determine the usability of the die, which is a complex and time-consuming process.

[0004] Secondly, since there are many specifications and models of handle products, the size and bending arc of some products may differ slightly, but new sets of bending dies still need to be opened to accurately match product production, resulting in high mold costs. SUMMARY

[0005] The present application provides a servo pressure forming method for aluminum alloy handle arc, which uses the height position parameter of the lower surface of the aluminum workpiece measured by the laser displacement sensor to perform several times of lower pressure arc forming processing on the aluminum alloy handle by using the split lower pressure die. The obtained workpiece has accurate arc value, which greatly improves the bending production efficiency, accuracy and yield of the aluminum alloy handle.

[0006] To achieve the above purpose, the technical scheme of the present application is as follows: A servo pressure forming method for aluminum alloy handle arc, a middle die capable of being pressed is arranged in the middle of the rack to correspond to the middle bending position of the workpiece, side dies capable of being pressed are arranged on both sides of the middle die to correspond to the bending positions on both sides of the workpiece, and support columns are arranged on both sides of the bottom of the rack to support both ends of the workpiece. The middle sensor is arranged below the middle die, and the side sensor is arranged below one of the side dies; the sensor is a laser triangulation sensor.

[0007] The forming method comprises the following steps: S1, obtaining the positions of the middle sensor and the side sensor through a drawing, obtaining the theoretical lower pressing stroke of the middle die and the side die according to the theoretical height of the lower surface of the workpiece, and obtaining the ranging height of the middle lower surface of the workpiece as Hzl and the ranging height of the side lower surface of the workpiece as Hcl; S2, the first time of lower pressing is middle die lower pressing: the middle die lower pressing fixed value, the ranging height of the middle lower surface of the workpiece is H1, and H1> Hzl; after the middle die is reset and the workpiece is stable, the ranging height of the middle lower surface of the workpiece is H1t, and the rebound coefficient A1 of the workpiece is calculated as 1- (H1t-H1) / H1; S3, the second time of lower pressing is side die lower pressing: the ranging height H2 of the side die lower pressing is Hcl*A1, after the side die is reset and the workpiece is stable, the ranging height of the side lower surface of the workpiece is H2ct, and the ranging height of the middle lower surface of the workpiece is H2zt; if H2ct=Hcl and H2zt=Hzl, the program ends; S4, the third time is compensation lower pressing: after the second time of lower pressing, if H2ct>Hcl and H2zt>Hzl, the rebound coefficient A2 is calculated as 1- (H2ct-H2) / H2, the ranging height H3z of the middle die lower pressing is Hzl*A2, and the ranging height H3c of the side die lower pressing is Hcl*A2; that is, the program ends.

[0008] In the step S3, if H2ct≤Hcl or H2zt≤Hzl, the program ends, and an alarm is displayed to indicate that the workpiece forming fails and is scrapped.

[0009] In the step S4, if the final H2ct≤Hcl or H2zt≤Hzl, the program alarm displays that the workpiece forming fails and is scrapped.

[0010] In the step S2, the value of H1 is 1.2-1.3 times the value of Hzl. The value of H1 is close to the value of Hzl, and the rebound coefficient measured is closer to the actual rebound in the second pressing stage.

[0011] The above steps generally go through three forming stages: test lower pressing, forming lower pressing and compensation lower pressing. The test lower pressing can test the rebound capacity of the handle workpiece, and provide the basis for the deformation in the subsequent forming stage. In the forming lower pressing process, according to the rebound data in the first stage, the die is pressed to the position, and more than 90% of the forming effect can be achieved. In the compensation stage, for some workpieces that have not been completely pressed to the position, the rebound data is calculated again on the basis of the second stage, and a small amount of pressing compensation is given, and finally more than 99% of the workpiece pressing forming can be achieved.

[0012] The main servo motor is installed on the top of the frame, the output shaft of the main servo motor is connected with the middle screw rod, the middle screw rod is engaged with the screw hole of the middle screw block, the middle screw block is fixedly connected with the lower pressing beam, the lower pressing beam is slidably connected with the vertical side rail of the frame through the sliding block at both ends, and the middle die is arranged on the lower end surface of the lower pressing beam; the vice servo motor is installed on the side support at both sides of the upper end surface of the lower pressing beam, the output shaft of the vice servo motor is downwardly connected with the side screw rod, the side screw rod is engaged with the screw hole of the side screw block, the upper end of the side screw rod is installed on the side support through the bearing, the lower end of the side screw rod is installed on the lower pressing beam through the bearing, and the side surface of the side screw block is fixedly connected with the upper end of the side die (51).

[0013] The main servo motor provides the pressing force of all the pressing blocks and the restoring power of the upward movement through the lower pressing beam; the vice servo motor is used for adjusting the relative position relationship between the side die and the middle die, and the adjustment of the shape of the bending die and the control of the accurate pressing amount are realized through the lead of the servo motor and the screw rod.

[0014] The integrated bending die of the whole length is divided into the combined bending die of the middle die and the two side dies, the aluminum handle is supported at both ends of the supporting column, the pressing amount of the middle die and the two side dies is controlled separately, the width of the middle die accounts for about half of the whole combined bending die, the side die on the two sides accounts for the other half of the whole combined bending die, and the lower curved surface of the combined bending die is approximately the same as the curvature of the workpiece to be pressed and bent.

[0015] The two sides of the middle screw block are slidably connected with the sliding rail of the middle support through the sliding block, and the middle support is fixed on the frame. The vertical sliding of the middle screw block is more smooth and accurate through the guiding effect of the sliding block and the guide rail.

[0016] The side screw block is slidably connected with the sliding rail of the middle support through the sliding block, and the middle support is fixed on the frame. The vertical sliding of the middle screw block is more smooth and accurate through the guiding effect of the sliding block and the guide rail.

[0017] The top end of the supporting column is provided with a supporting wheel. The supporting wheel makes the contact between the supporting column and the aluminum handle rolling contact, so that the slight displacement of the end part does not scratch the surface of the aluminum handle when the aluminum handle is pressed and bent.

[0018] One of the supporting columns is provided with a pushing cylinder which pushes the aluminum handle inward, and the other supporting column is provided with a positioning plate. The pushing cylinder pushes the end part of the aluminum handle inward, and the other end of the workpiece is tightly pressed against the positioning plate, so that the position of the workpiece is uniform during each pressing and bending.

[0019] The advantages of the present application are as follows:

[0020] 1. The present application designs: test down - forming down - compensation down three stages of bending forming steps, instead of the traditional handle workpiece bending forming process, not only suitable for any elliptical arc handle workpiece bending; and avoid the cumbersome steps of bending die early adjustment, almost avoid the process of trial and adjustment, also save a lot of trial workpiece, reduce the cost.

[0021] 2. The bending die in the present application improves the traditional integral bending die into a split type bending die, which realizes the processing of different bending radii of aluminum alloy handles without changing the bending die, and a set of die can be used for a variety of similar shaped workpieces, so that the die opening composition is greatly reduced.

[0022] 3. The present application adopts servo motor to control the downward pressure and displacement of each part of the bending die, so that the precision is greatly guaranteed, and the bending radius is accurately controllable.

[0023] 4. The present application has high degree of automation, and can realize semi-automatic bending operation by automatic calculation and control of PLC, so that workers only need to focus on feeding and discharging materials, and almost no production training cost is needed. BRIEF DESCRIPTION OF DRAWINGS Figure 1 It is a pressure forming step block diagram of the present application; Figure 2 It is a front perspective structure diagram of the equipment of the present application; Figure 3 It is a perspective side view structure diagram of the equipment of the present application; Figure 4 It is a front perspective structure diagram of the side pressure mechanism part; Figure 5 It is Figure 4 A-A section structure diagram in the middle; Figure 6 It is an elevation appearance structure diagram of the equipment of the present application; Figure 7 It is Figure 6 The local enlarged structure diagram of I in the middle; Figure 8 It is a front appearance structure diagram of the equipment of the present application; The serial number and component name in the figure are: 1 - rack; 2 - main servo motor; 21 - middle die; 22 - middle lead screw; 23 - middle support; 3 - side rail; 4 - down beam; 5 - auxiliary servo motor; 51 - side die; 52 - side lead screw; 53 - side silk block; 54 - side support; 55 - guide rod; 56 - guide sleeve; 6 - support column; 61 - top wheel; 71 - middle sensor; 72 - side sensor; 81 - pushing cylinder; 82 - positioning plate. DETAILED DESCRIPTION

[0024] Example 1

[0025] The aluminum alloy handle arc servo pressure forming method, the middle die 21 corresponding to the middle bending position of the workpiece is arranged in the middle of the rack 1, the side die 51 corresponding to the bending position of the two sides of the workpiece is arranged on both sides of the middle die 21, and the support column 6 is arranged at the bottom of the rack 1 for supporting the two ends of the workpiece; The middle sensor 71 is arranged below the middle die 21, and the side sensor 72 is arranged below one of the side dies 51; The forming method comprises the following steps: S1, the positions of the middle sensor and the side sensor are obtained through a drawing, the theoretical downstroke of the middle die and the side die is obtained according to the theoretical height of the lower surface of the workpiece, the distance measuring height of the middle lower surface of the workpiece is Hzl=183mm, and the distance measuring height of the side lower surface of the workpiece is Hcl=196mm; S2, the first downstroke is middle die downstroke: the middle die downstroke fixed value, the value of H1 is 1.2 times the value of Hzl, the distance measuring height of the middle lower surface of the workpiece corresponding to H1 is 196*1.2=235.2mm, the distance measuring height of the middle lower surface of the workpiece is H1t=250.4 after the workpiece rebounds stably after the middle die resets, and the rebound coefficient A1 of the workpiece is 1-(H1t-H1) / H1=1-(250.4-235.2) / 235.2=1-0.065=0.935; S3, the second downstroke is side die downstroke: the distance measuring height H2 of the side die downstroke is Hcl*A1=196*0.935=183.26mm, the distance measuring height of the side lower surface of the workpiece is H2ct=208mm after the workpiece rebounds stably after the side die resets, and the distance measuring height of the middle lower surface of the workpiece is H2zt=190mm; S4, the third is compensation downstroke: after the second downstroke, H2ct>Hcl; and H2zt>Hzl; the rebound coefficient A2 is calculated as 1-(H2ct-H2) / H2=1-(208-183.26) / 183.26=1-0.135=0.865, the distance measuring height H3z of the middle die downstroke is Hzl*A2=183*0.865=158.3mm; and the distance measuring height H3c of the side die downstroke is Hcl*A2=196*0.865=169.54mm; that is, the program ends.

[0026] In the step S3, if H2ct≤Hcl or H2zt≤Hzl, the program ends, and the workpiece forming failure is reported and scrapped.

[0027] In the step S4, if the final H2ct≤Hcl or H2zt≤Hzl, the program reports and displays that the workpiece forming fails.

[0028] The main servo motor 2 is installed on the top of the frame 1, the output shaft of the main servo motor 2 is connected with the middle lead screw 22, the middle lead screw 22 is engaged with the lead hole of the middle lead block 23, the middle lead block 23 is fixedly connected with the lower pressing beam 4, the lower pressing beam 4 is slidably connected with the vertical side rail 3 of the frame 1 through the sliding block at both ends, and the middle die 21 is arranged on the middle of the lower end surface of the lower pressing beam 4; the vice servo motor 5 is installed on the upper end surface of the lower pressing beam 4 through the side support 53, the output shaft of the vice servo motor 5 is downwardly connected with the side lead screw 52, the side lead screw 52 is engaged with the lead hole of the side lead block 53, the upper end of the side lead screw 52 is installed on the side support 53 through the bearing, the lower end of the side lead screw 52 is installed on the lower pressing beam 4 through the bearing, and the side of the side lead block 53 is fixedly connected with the upper end of the side die 51.

[0029] The two sides of the middle lead block 23 are slidably connected with the slide rail of the middle support 24 through the sliding block, and the middle support 24 is fixed on the frame.

[0030] The side lead block is provided with the guide rod on both sides, and the guide rod is engaged with the guide sleeve installed on the lower pressing beam 4.

[0031] The top end of the support column 6 is provided with the supporting wheel 61.

[0032] The inward pushing pushing material air cylinder 81 is installed on one of the support columns 6, and the positioning plate 82 is installed on the outer side of the other support column 6.

[0033] Application example: The qualified rate of the handle workpiece pressed and bent by the embodiment of the application is compared with the advantages of the original integrated pressing and bending die: Press bend yield Materials required for trial molding Trial production equipment setup time Example ≥99% 2 units Average 20 min Comparative Example 96.7% 15-20 units ≤ 5 min

Claims

1. A method for servo pressure forming of the arc of an aluminum alloy handle, characterized in that, The frame (1) has a middle mold (21) that can be pressed down in the middle to correspond to the middle bending position of the workpiece. The middle mold (21) has side molds (51) that can be pressed down on both sides to correspond to the bending positions on both sides of the workpiece. The frame (1) has support columns (6) on both sides at the bottom to support the two ends of the workpiece. A middle sensor (71) is provided below the middle mold (21), and a side sensor (72) is provided below one of the side molds (51). The molding method includes the following steps: S1. Obtain the positions of the middle sensor and the side sensor through the drawings. Based on the theoretical height of the lower surface of the workpiece, obtain the theoretical pressing stroke of the middle mold and the side mold. The corresponding measurement height of the lower surface of the middle workpiece is Hzl; and the measurement height of the lower surface of the side of the workpiece is Hcl. S2. The first pressing is the middle die pressing: the middle die pressing is a fixed value, and the corresponding distance height of the lower surface of the workpiece is H1, and H1 > Hzl. After the middle die resets and the workpiece rebounds and stabilizes, the distance height of the lower surface of the workpiece is H1t. The springback coefficient of the workpiece is calculated as A1 = 1 - (H1t - H1) / H1. S3. The second pressing is the side mold pressing: the side mold pressing distance measurement height H2=Hcl*A1. After the side mold resets and the workpiece rebounds and stabilizes, the distance measurement height of the lower surface of the side of the workpiece is H2ct, and the distance measurement height of the lower surface of the middle of the workpiece is H2zt. If H2ct=Hcl and H2zt=Hzl, then the program ends. S4. The third compression is a compensation compression: After the second compression, if H2ct > Hcl and H2zt > Hzl, then calculate the springback coefficient A2 = 1 - (H2ct - H2) / H2, the compression distance measurement height of the middle mold H3z = Hzl * A2, and the compression distance measurement height of the side mold H3c = Hcl * A2; then the program ends.

2. The aluminum alloy handle arc servo pressure forming method according to claim 1, characterized in that: In step S3, if H2ct≤Hcl or H2zt≤Hzl, the program ends and an alarm is triggered to indicate that the workpiece forming has failed and should be scrapped.

3. The servo press for forming the arc of an aluminum alloy handle according to claim 1, characterized in that: In step S4, if the final H2ct≤Hcl or H2zt≤Hzl, the program will alarm and display that the workpiece forming has failed and should be scrapped.

4. The aluminum alloy handle arc servo pressure forming method according to claim 1, characterized in that: In step S2, the value of H1 is 1.2-1.3 times the value of Hzl.

5. The aluminum alloy handle arc servo pressure forming method according to claim 1, characterized in that: The main servo motor (2) is installed on the top of the frame (1). The output shaft of the main servo motor (2) is connected to the intermediate lead screw (22). The intermediate lead screw (22) is engaged with the thread hole of the intermediate lead block (23). The intermediate lead block (23) is fixedly connected to the lower pressure beam (4). The two ends of the lower pressure beam (4) are slidably connected to the vertical side rail (3) inside the frame (1) through the slider. The middle mold (21) is set in the middle of the lower end face of the lower pressure beam (4). The auxiliary servo motors (5) are installed on both sides of the upper end face of the lower pressure beam (4) through the side brackets (53). The output shaft of the auxiliary servo motor (5) is connected downward to the side lead screw (52). The side lead screw (52) is engaged with the thread hole of the side lead block (53). The upper end of the side lead screw (52) is mounted on the side bracket (53) through the bearing. The lower end of the side lead screw (52) is mounted on the lower pressure beam (4) through the bearing. The side of the side lead block (53) is fixedly connected to the upper end of the side mold (51).

6. The aluminum alloy handle arc servo pressure forming method according to claim 5, characterized in that: The two sides of the intermediate wire block (23) are slidably connected to the slide rail of the intermediate support (24) by a slider, and the intermediate support (24) is fixed on the frame.

7. The aluminum alloy handle arc servo pressure forming method according to claim 5, characterized in that: Guide rods (55) are installed on both sides of the side wire block, and the guide rods (55) are connected to the guide sleeves (56) installed on the lower pressure beam (4).

8. The aluminum alloy handle arc servo pressure forming method according to claim 1, characterized in that: A support wheel (61) is provided at the top of the support column (6).

9. The aluminum alloy handle arc servo pressure forming method according to claim 1, characterized in that: An inwardly pushing cylinder (81) is installed on one of the support columns (6), and a positioning plate (82) is installed on the outside of the other support column (6).

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