Stepped part and forming device and forming method thereof

Abstract

The invention provides a stepped part and a forming device and method thereof, and relates to the technical field of plate forming, the forming device comprises a male die, an edge pressing part, a female die, a left supporting block capable of moving up and down and a right supporting block capable of moving up and down; the female die is provided with an upper cavity defined by a second step and a lower cavity defined by a first step, the left supporting block is arranged at the left end of the upper surface of the first step of the female die, the right supporting block is arranged at the right end of the upper surface of the first step of the female die, and the left supporting block and the right supporting block define a hollow part. The hollow component and the lower concave cavity jointly form a large concave cavity, the shape of the large concave cavity is matched with the shape of the protrusion at the lower end of the male die, and the outer wall of the hollow component is attached to the inner wall of the upper concave cavity. When the stepped part forming device is used for forming the stepped part, excessive thinning of a plate and a plate suspension area corresponding to the two layers of stepped fillets of the male die can be avoided, and wrinkling of the plate suspension area is avoided.

Description

Technical Field

[0001] This invention relates to the field of sheet metal forming technology, and more specifically, to a stepped part, its forming apparatus, and its forming method. Background Technology

[0002] In the traditional deep drawing process of stepped parts, such as Figure 1 As shown, in the stepped portion of the punch (the gap area between two steps, i.e.), Figure 1 Area A in the middle section will form a suspended area of ​​sheet metal, which is very prone to wrinkling defects. If wrinkling is suppressed by increasing the blank holder force, it will cause wrinkling defects at the two-layer stepped fillet corners of the punch. Figure 1 The sheet metal and its suspended areas (as indicated by position B) have been excessively thinned or even cracked. Additionally, as... Figure 1 As shown, due to the presence of the suspended area in the sheet metal, during the forming process, the total length of the forming path of the sheet metal and the suspended area corresponding to the two-layer stepped fillet of the punch is often greater than the actual length of the blank in the suspended area. This causes strong tensile deformation of the material at this location, making it prone to localized excessive thinning and tearing. Furthermore, existing stepped part forming processes generally require multiple deep drawing passes, with the number of deep drawing passes corresponding to the number of steps. Multiple-pass processes not only require multiple sets of molds, making the process cumbersome, but also result in low production efficiency and high manufacturing costs. Summary of the Invention

[0003] The problem solved by this invention is at least one of the following: (1) how to obtain stepped parts by deep drawing in one pass using a single mold. (2) how to avoid excessive thinning of the sheet metal and the suspended area of ​​the sheet metal at the two-layer stepped rounded corners of the punch, and to avoid wrinkling of the suspended area of ​​the sheet metal.

[0004] To solve the above problems, the present invention provides a stepped part forming device, including a punch, a pressing part, a die, a left support block that can move up and down, and a right support block that can move up and down; the die has an upper cavity surrounded by a second step and a lower cavity surrounded by a first step, the left support block is disposed at the left end of the upper surface of the first step of the die, and the right support block is disposed at the right end of the upper surface of the first step of the die, the left support block and the right support block together form a hollow component, the hollow component and the lower cavity together form a large cavity, the shape of the large cavity matches the shape of the lower protrusion of the punch, and the outer wall of the hollow component fits against the inner wall of the upper cavity.

[0005] Compared with related technologies, when using the stepped part forming apparatus provided by this invention to form stepped parts, during the formation of the first-stage cavity, both the left and right support blocks move upwards, so that their upper surfaces contact the bottom of the sheet metal. The left and right support blocks are locked to ensure their positions remain unchanged, thus supporting the stepped portion of the punch and preventing the formation of a suspended area of ​​sheet metal at the stepped portion of the punch, thereby avoiding wrinkling or cracking. During the formation of the second-stage cavity, the locking of the left and right support blocks is released, and the punch continues to move downwards. The left and right support blocks move downwards under the pressure of the punch. During this process, the left and right support blocks remain in continuous contact with the sheet metal, providing beneficial friction and preventing excessive thinning of the sheet metal corresponding to the two stepped fillets of the punch and the sheet metal between the two stepped fillets (i.e., the suspended area of ​​sheet metal in related technologies). In summary, using the stepped part forming apparatus provided by this invention for stepped part forming can avoid excessive thinning of the sheet metal and the suspended area of ​​the sheet metal at the two-layer stepped rounded corners of the punch, and avoid wrinkling in the suspended area of ​​the sheet metal. Moreover, using the stepped part forming apparatus provided by this invention, stepped parts can be produced in one deep drawing operation with a single die, making the process simpler.

[0006] Optionally, a left cylinder is provided at the left end of the first step of the die, and the left support block is provided at the upper end of the piston rod of the left cylinder.

[0007] Optionally, the stepped part forming device further includes a left locking assembly, which, when in a locked state, prevents the piston rod of the left cylinder from moving up and down.

[0008] Optionally, the left locking assembly includes a left threaded hole on the side wall of the upper concave cavity, a left through hole on the piston rod of the left cylinder, and a left screw. When the left threaded hole and the left through hole are aligned, the left screw passes sequentially through the left through hole and the left threaded hole.

[0009] Optionally, a right cylinder is provided at the right end of the first step of the die, and the right support block is provided at the upper end of the piston rod of the right cylinder.

[0010] Optionally, the stepped part forming device further includes a right locking assembly, which, when in a locked state, prevents the piston rod of the right cylinder from moving up and down.

[0011] Optionally, the right locking assembly includes a right threaded hole on the side wall of the upper concave cavity, a right through hole on the piston rod of the right cylinder, and a right screw. When the right threaded hole and the right through hole are aligned, the right screw passes sequentially through the right through hole and the right threaded hole.

[0012] The present invention also provides a method for forming a stepped part, based on the above-mentioned stepped part forming apparatus, comprising: Step S1: Place the sheet metal on the upper surface of the second step of the die, press the edge of the sheet metal with the edge clamping member, and then make the upper end face of the left support block and the upper end face of the right support block contact the bottom of the sheet metal to form support. Lock the left support block and the right support block to keep their positions unchanged, and make the punch move downward to squeeze the sheet metal until the punch abuts and limits the left support block and the right support block, so that the sheet metal forms the first-level cavity. Step S2: Release the locking of the left support block and the right support block, so that the punch continues to move downward and press the sheet metal until the punch abuts against the lower cavity and is limited, so that the sheet metal forms a second-level cavity; wherein, during the process of the punch continuing to move downward, the left support block and the right support block move downward under the pressure of the punch.

[0013] The stepped part forming method provided by this invention can avoid excessive thinning of the sheet metal and the suspended area of ​​the sheet metal at the two-layer stepped rounded corners of the punch, and avoid wrinkling in the suspended area of ​​the sheet metal. Moreover, the stepped part forming method provided by this invention can produce stepped parts in one deep drawing operation with a single die, making the process simpler.

[0014] Optionally, both the first-stage cavity and the second-stage cavity are cylindrical or cuboid.

[0015] The present invention also provides a stepped part, which is manufactured by the stepped part forming method described above. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the existing stepped part forming process; Figure 2 This is a schematic diagram of the stepped part forming device in an embodiment of the present invention; Figure 3 This is a schematic diagram of the initial state during the forming process of the stepped part in an embodiment of the present invention; Figure 4 This is a schematic diagram of the formation of the first-stage cavity in an embodiment of the invention; Figure 5 This is a perspective view of the sample during the formation of the first-stage cavity in an embodiment of the invention. Figure 6 This is a schematic diagram illustrating the formation of the second-stage cavity in an embodiment of the invention; Figure 7 This is a three-dimensional view of the sample during the formation of the second-stage cavity in an embodiment of the invention.

[0017] Explanation of reference numerals in the attached figures: 1. Punch; 2. Blank holder; 3. Die; 31. Upper cavity; 32. Lower cavity; 33. First step; 4. Left support block; 5. Right support block; 6. Large cavity; 7. Left cylinder; 8. Left screw; 9. Right cylinder; 10. Right screw; 11. First-stage cavity; 12. Second-stage cavity; 13. Sheet metal. Detailed Implementation

[0018] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Although some embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the present invention. It should be understood that the accompanying drawings and embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0019] Unless otherwise defined, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0020] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this invention are used to distinguish different objects, not to describe a specific order or hierarchy. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0021] In response to the problems existing in the aforementioned related technologies, such as Figures 2 to 4 As shown, this embodiment provides a stepped part forming apparatus, such as... Figure 2 As shown, it includes a punch 1, a blank holder 2, a die 3, a left support block 4 that can move up and down, and a right support block 5 that can move up and down; Figure 3As shown, the concave mold 3 has an upper concave cavity 31 formed by a second step and a lower concave cavity 32 formed by a first step 33. The left support block 4 is disposed at the left end of the upper surface of the first step 33 of the concave mold 3, and the right support block 5 is disposed at the right end of the upper surface of the first step 33 of the concave mold 3. The left support block 4 and the right support block 5 together form a hollow component, as shown. Figure 2 and Figure 6 As shown, the hollow component and the lower recess 32 together form a large recess 6. The shape of the large recess 6 matches the shape of the lower end protrusion of the punch 1. The outer wall of the hollow component fits against the inner wall of the upper recess 31.

[0022] For example, the left support block 4 and the right support block 5 are used to form a cylindrical hollow component. For instance, when the first-level cavity 11 and the second-level cavity 12 formed by the sheet metal 13 are both cylindrical cavities, the hollow component can specifically be a cylindrical structure. The large cavity 6 refers to the cavity formed by the hollow component and the lower cavity 32 when the hollow component is located at the lowest point, that is, when the hollow component abuts against the upper surface of the first step 33. The shape of the large cavity 6 matches the shape of the lower end protrusion of the punch (1), so that when the lower end protrusion of the punch 1 abuts against the bottom wall of the lower cavity 32, the lower end protrusion of the punch 1 can perform mold closing matching with the large cavity 6.

[0023] like Figures 2 to 4 As shown, when forming a stepped part using the stepped part forming apparatus provided in this embodiment of the invention, during the formation of the first-stage cavity 11, the left support block 4 and the right support block 5 are both moved upwards so that their upper surfaces contact the bottom of the sheet metal 13, and the left support block 4 and the right support block 5 are locked to ensure that their positions remain unchanged, thereby providing support for the stepped portion of the punch 1 and preventing the formation of a suspended area of ​​sheet metal in the stepped portion of the punch 1, thus avoiding wrinkling or cracking. During the formation of the second-stage cavity 12, the locking of the left support block 4 and the right support block 5 is released, and the punch 1 continues to move downwards. The left support block 4 and the right support block 5 move downwards under the pressure of the punch 1. During this process, the left support block 4 and the right support block 5 are in continuous contact with the sheet metal 13, providing beneficial friction to the sheet metal 13, thereby preventing excessive thinning of the sheet metal 13 corresponding to the two-layer stepped rounded corners of the punch 1 and the sheet metal between the two-layer stepped rounded corners (i.e., the suspended area of ​​sheet metal in the related art). In summary, using the stepped part forming apparatus provided in this embodiment of the invention for stepped part forming can avoid excessive thinning of the sheet metal 13 and the suspended area of ​​the sheet metal corresponding to the two-layer stepped rounded corners of the punch 1, and avoid wrinkling in the suspended area of ​​the sheet metal. Moreover, using the stepped part forming apparatus provided in this embodiment of the invention, stepped parts can be produced in one deep drawing operation with a single mold, making the process simpler.

[0024] In some embodiments of the present invention, exemplarily, such as Figure 2 As shown, a left cylinder 7 is provided at the left end of the first step 33 of the concave mold 3, and the left support block 4 is provided at the upper end of the piston rod of the left cylinder 7.

[0025] In some embodiments of the present invention, such as Figure 3 and Figure 4 As shown, the stepped forming device further includes a left locking assembly. When the left locking assembly is in a locked state, it prevents the piston rod of the left cylinder 7 from moving up and down, thereby preventing the left support block 4 from moving up and down. Exemplarily, the left locking assembly includes a left threaded hole on the side wall of the upper cavity 31, a left through hole on the piston rod of the left cylinder 7, and a left screw 8. When the left threaded hole and the left through hole are aligned, the left screw 8 is inserted sequentially into the left through hole and the left threaded hole to lock the piston rod of the left cylinder 7, thus preventing the left support block 4 from moving up and down. Specifically, when the left threaded hole and the left through hole are aligned, the upper surface of the left support block 4 is aligned with the upper surface of the second step of the die 3, jointly supporting the sheet metal 13.

[0026] In some embodiments of the present invention, exemplarily, such as Figure 2 As shown, a right cylinder 9 is provided at the right end of the first step 33 of the concave mold 3, and the right support block 5 is provided at the upper end of the piston rod of the right cylinder 9.

[0027] In some embodiments of the present invention, such as Figure 3 and Figure 4 As shown, the stepped forming device further includes a right locking assembly. When the right locking assembly is in a locked state, it prevents the piston rod of the right cylinder 9 from moving up and down, thereby preventing the right support block 5 from moving up and down. Exemplarily, the right locking assembly includes a right threaded hole on the side wall of the upper cavity 31, a right through hole on the piston rod of the right cylinder 9, and a right screw 10. When the right threaded hole and the right through hole are aligned, the right screw 10 is inserted into the right through hole and the right threaded hole in sequence to lock the piston rod of the right cylinder 9, thus preventing the right support block 5 from moving up and down. Specifically, when the right threaded hole and the right through hole are aligned, the upper surface of the right support block 5 is aligned with the upper surface of the second step of the die 3, jointly supporting the sheet metal 13.

[0028] This invention also provides a method for forming a stepped part, based on the above-mentioned stepped part forming apparatus, comprising: Step S1, as follows Figure 3As shown, sheet metal 13 is placed on the upper surface of the second step of the die 3. The edge of sheet metal 13 is pressed together by the edge clamping member 2. Then, the upper end face of the left support block 4 and the upper end face of the right support block 5 are respectively brought into contact with the bottom of sheet metal 13 to form support. The left support block 4 and the right support block 5 are locked to keep their positions unchanged. The punch 1 moves downward to press the sheet metal 13 until the punch 1 abuts and limits the contact with the left support block 4 and the right support block 5, so that the sheet metal 13 forms the first-stage cavity 11. Figure 4 and Figure 5 As shown; specifically, the left support block 4 is locked by the left locking assembly, and the right support block 5 is locked by the right locking assembly.

[0029] Step S2: Release the lock on the left support block 4 and the right support block 5, allowing the punch 1 to continue moving downwards and pressing the sheet metal 13 until the punch 1 abuts against the lower cavity 32, thereby forming a second-level cavity 12 on the sheet metal 13. Figure 6 and Figure 7 As shown; during the downward movement of the punch 1, under the pressure of the punch 1, the piston rods of the left cylinder 7 and the right cylinder 9 move downward, thereby driving the left support block 4 and the right support block 5 to move downward.

[0030] The stepped part forming method provided in this embodiment of the invention can avoid excessive thinning of the sheet metal 13 and the suspended area of ​​the sheet metal at the two-layer stepped rounded corners of the punch 1, and avoid wrinkling in the suspended area of ​​the sheet metal. Moreover, the stepped part forming method provided in this embodiment of the invention can produce the stepped part in one deep drawing with a single die, making the process simpler.

[0031] In some embodiments of the present invention, both the first-stage cavity 11 and the second-stage cavity 12 are cylindrical or cuboid.

[0032] This invention also provides a stepped part, which is manufactured using the stepped part forming method described above.

[0033] While the present invention has been disclosed above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A stepped part forming device, characterized in that, It includes a punch (1), a pressing part (2), a die (3), a left support block (4) that can move up and down, and a right support block (5) that can move up and down; the die (3) has an upper cavity (31) surrounded by a second step and a lower cavity (32) surrounded by a first step (33); the left support block (4) is located at the left end of the upper surface of the first step (33) of the die (3); the right support block (5) is located at the right end of the upper surface of the first step (33) of the die (3); the left support block (4) and the right support block (5) together form a hollow component; the hollow component and the lower cavity (32) together form a large cavity (6); the shape of the large cavity (6) matches the shape of the lower end protrusion of the punch (1); the outer wall of the hollow component fits against the inner wall of the upper cavity (31).

2. The stepped part forming apparatus according to claim 1, characterized in that, The left end of the first step (33) of the die (3) is provided with a left cylinder (7), and the upper end of the piston rod of the left cylinder (7) is provided with the left support block (4).

3. The stepped part forming apparatus according to claim 2, characterized in that, It also includes a left locking assembly, which, when in a locked state, prevents the piston rod of the left cylinder (7) from moving up and down.

4. The stepped part forming apparatus according to claim 3, characterized in that, The left locking assembly includes a left threaded hole on the side wall of the upper cavity (31), a left through hole on the piston rod of the left cylinder (7), and a left screw (8). When the left threaded hole and the left through hole are aligned, the left screw (8) is used to pass through the left through hole and the left threaded hole in sequence.

5. The stepped part forming apparatus according to claim 1, characterized in that, The right end of the first step (33) of the die (3) is provided with a right cylinder (9), and the upper end of the piston rod of the right cylinder (9) is provided with the right support block (5).

6. The stepped part forming apparatus according to claim 5, characterized in that, It also includes a right locking assembly, which, when in a locked state, prevents the piston rod of the right cylinder (9) from moving up and down.

7. The stepped part forming apparatus according to claim 6, characterized in that, The right locking assembly includes a right threaded hole on the side wall of the upper cavity (31), a right through hole on the piston rod of the right cylinder (9), and a right screw (10). When the right threaded hole and the right through hole are aligned, the right screw (10) is used to pass through the right through hole and the right threaded hole in sequence.

8. A method for forming a stepped part, based on the stepped part forming apparatus according to any one of claims 1 to 7, characterized in that, include: Step S1: Place the sheet metal (13) on the upper surface of the second step of the die (3), press the edge of the sheet metal (13) with the edge clamping member (2), and then make the upper end face of the left support block (4) and the upper end face of the right support block (5) contact the bottom of the sheet metal (13) to form support. Lock the left support block (4) and the right support block (5) to keep their positions unchanged, and make the punch (1) move downward to squeeze the sheet metal (13) until the punch (1) abuts and limits the left support block (4) and the right support block (5) so that the sheet metal (13) forms the first-level cavity (11). Step S2: Release the lock on the left support block (4) and the right support block (5), so that the punch (1) continues to move downward to squeeze the sheet metal (13) until the punch (1) abuts against the lower cavity (32) and is limited, so that the sheet metal (13) forms a second-level cavity (12); wherein, during the process of the punch (1) continuing to move downward, the left support block (4) and the right support block (5) move downward under the pressure of the punch (1).

9. The method for forming a stepped part according to claim 8, characterized in that, Both the first-stage cavity (11) and the second-stage cavity (12) are cylindrical or cuboid.

10. A stepped component, characterized in that, It is manufactured using the stepped part forming method as described in claim 8 or 9.

Images