Stretching forming method and device for thin plate heat shield of engine supercharger

Abstract

The invention discloses a stretching forming method and device for a thin-plate heat shield of an engine supercharger, and relates to the technical field of thin-plate heat shields of engine superchargers. A thin-plate material is selected, pretreated and preliminarily stretched through a mold of stretching equipment; and the sheet material forms a semi-finished product close to the outline of the heat shield, quality detection is conducted on the semi-finished product obtained after first-time stretching and the blank obtained after second-time stretching, workpieces with defects are removed, and stretching parameters or the die state are fed back and adjusted. By means of two-time staged stretching and precise control over the material deformation process, the problems that one-time stretching forming precision of a heat shield in a complex shape is insufficient, and defects are prone to occurring are effectively solved, a high-hardness wear-resisting die, a precise guiding structure and a real-time monitoring control system are adopted in the device, the stability and consistency of the stretching process are ensured, and the production efficiency is improved. And the die loss and the maintenance cost are reduced.

Description

Technical Field

[0001] This invention relates to the field of heat shield technology for thin plate heat shields for engine turbochargers, specifically to a stretching forming method and apparatus for a heat shield for thin plate heat shields for engine turbochargers. Background Technology

[0002] The engine turbocharger heat shield is a key protective component in the engine compartment of a car. It can effectively block the high temperature generated when the turbocharger is working, protect surrounding wiring harnesses, electronic devices and other components from heat damage, and ensure stable engine operation. As the automotive industry continues to improve its requirements for engine performance and lightweighting, the shape design of the heat shield has become more and more complex, often including various curvatures and curved surface structures. In traditional manufacturing processes, most heat shields are produced by one-time stretching molding.

[0003] However, the above process has obvious defects: because it is difficult to achieve ideal deformation of multiple arcs of complex shapes in a single stretching, it is easy to cause insufficient or excessive stretching of the material in some areas, which in turn leads to problems such as cracking, wrinkling, and uneven thickness. As a result, the product's dimensional and shape accuracy cannot meet the design requirements, and the yield rate is low. At the same time, a single stretching places extremely high demands on the mold structure, which not only increases the mold manufacturing cost and maintenance difficulty, but also limits the improvement of production efficiency, making it difficult to meet the market's demand for high-quality and high-efficiency production. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a stretching forming method and apparatus for a thin plate heat shield for an engine turbocharger, solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A method for stretch forming a thin sheet heat shield for an engine turbocharger, comprising the following steps: S1. Raw material preparation: Select thin sheet materials that meet the preset mechanical and forming properties, and pre-treat the thin sheet materials; S2. First stretching: The pre-treated sheet material is placed on the worktable of the stretching equipment and positioned and aligned. The sheet material is initially stretched through the mold of the stretching equipment to form a semi-finished product that is close to the outline of the heat insulation cover. During the stretching process, the stretching parameters are dynamically adjusted to control the uniform deformation of the material. S3. Second stretching: The semi-finished product after the first stretching is stretched again with precision. The surface of the stretching die is treated and the local structure of the die is finely adjusted according to the actual shape of the semi-finished product. The stretching parameters are set in sections to adapt to the forming requirements of different parts of the heat insulation cover, so that the semi-finished product is formed into a heat insulation cover blank that meets the design precision requirements. S4. Quality Inspection: Conduct quality inspections on the semi-finished products after the first stretching and the blanks after the second stretching, remove defective workpieces, and provide feedback to adjust the stretching parameters or mold status.

[0006] Preferably, the sheet material is an aluminized sheet, and the pretreatment includes surface cleaning and dimensional cutting.

[0007] Preferably, the stretching equipment for the first stretching is a frame hydraulic press, and the stretching parameters include a punch-die gap of 0.8-1.2mm, a stretching speed of 12-18mm / s, an initial stretching force of 1000-1500kN, which are dynamically adjusted based on the material thickness variation and stress distribution data.

[0008] A method and apparatus for performing the stretch forming, comprising: The fuselage provides support for the overall structure; The main hydraulic cylinder, mounted on the top of the machine body, is used to provide stretching power; The stretching die is connected to the piston rod of the main hydraulic cylinder and includes an upper die and a lower die that cooperate with each other. The upper die is provided with a concave die and the lower die is provided with a convex die. The shapes of the concave die and the convex die are adapted to the forming requirements of the heat insulation cover. The workbench, fixed to the machine body, is used to place the materials to be stretched and semi-finished products; The control system is used to set and adjust the tensile parameters and monitor the material deformation and equipment operation status in real time during the tensile process.

[0009] Preferably, the upper mold includes an upper mold base, a die, and a guide post, and the lower mold includes a lower mold base, a punch, and a stripping device. The die and the punch are made of Cr12MoV mold steel.

[0010] Preferably, the guide post cooperates with the guide sleeve on the lower mold base to ensure the smoothness and accuracy of the upper mold movement.

[0011] Preferably, the unloading device includes an unloading plate and a push rod. The unloading plate is adapted to the punch. After stretching is completed, the unloading plate is driven by the push rod to push the workpiece out of the punch.

[0012] Compared with the prior art, the present invention has the following advantages: by stretching in two stages, the material deformation process is precisely controlled, which effectively solves the problem of insufficient precision and easy defects in the one-time stretching of complex-shaped heat insulation covers. The device adopts high-hardness wear-resistant molds, precise guiding structures and real-time monitoring and control systems to ensure the stability and consistency of the stretching process and reduce mold wear and maintenance costs. Attached Figure Description

[0013] Figure 1 This is the front view of the present invention. Figure 2This is a partial perspective view of the present invention; Figure 3 Partial cross-section of the present invention Figure 1 ; Figure 4 Partial cross-section of the present invention Figure 2 .

[0014] Reference numerals: 1. Machine body; 2. Main hydraulic cylinder; 3. Stretching die; 31. Upper die; 311. Upper die base; 312. Die; 313. Guide post; 32. Lower die; 321. Lower die base; 322. Punch; 323. Unloading device; 3231. Unloading plate; 324. Guide sleeve; 4. Worktable; 5. Control system. Detailed Implementation

[0015] The following will refer to the appendices in the embodiments of the present invention. Figure 1-4 The technical solutions in the embodiments of the present invention will be clearly and completely described. Example

[0016] A method for stretch forming a thin sheet heat shield for an engine turbocharger, comprising the following steps: S1. Raw material preparation: Select thin sheet materials that meet the preset mechanical and forming properties, and pre-treat the thin sheet materials; S2. First stretching: The pre-treated sheet material is placed on the worktable of the stretching equipment and positioned and aligned. The sheet material is initially stretched through the mold of the stretching equipment to form a semi-finished product that is close to the outline of the heat insulation cover. During the stretching process, the stretching parameters are dynamically adjusted to control the uniform deformation of the material. S3. Second stretching: The semi-finished product after the first stretching is stretched again with precision. The surface of the stretching die is treated and the local structure of the die is finely adjusted according to the actual shape of the semi-finished product. The stretching parameters are set in sections to adapt to the forming requirements of different parts of the heat insulation cover, so that the semi-finished product is formed into a heat insulation cover blank that meets the design precision requirements. S4. Quality Inspection: Conduct quality inspections on the semi-finished products after the first stretching and the blanks after the second stretching, remove defective workpieces, and provide feedback to adjust the stretching parameters or mold status.

[0017] Preferably, the thin plate material is an aluminized plate, which has good high temperature resistance, formability and lightweight characteristics, and can meet the requirements of the heat insulation cover. The pretreatment includes surface cleaning and size cutting. Ultrasonic cleaning is used to remove oil, dust and other impurities from the surface of the thin plate to avoid impurities affecting the material flow and forming quality during the stretching process. According to the design size of the heat insulation cover, the thin plate is precisely cut by CNC cutting equipment to ensure that the size error of the plate is controlled within ±0.1mm.

[0018] Preferably, the stretching equipment for the first stretching is a frame hydraulic press, and the stretching parameters include a punch-die gap of 0.8-1.2mm, a stretching speed of 12-18mm / s, an initial stretching force of 1000-1500kN, which are dynamically adjusted based on the material thickness variation and stress distribution data.

[0019] This embodiment controls material deformation in stages through two stretching processes. The first stretching uses a large stretching force and a moderate stretching speed to quickly shape the main outline of the heat insulation cover. The stretching force is dynamically adjusted to avoid local stress concentration. The second stretching optimizes the surface condition of the mold and sets stretching parameters in different zones to accurately shape complex parts. The stretching speed is reduced to improve the deformation control accuracy. The control system and sensors work together to achieve real-time monitoring and adaptive adjustment of parameters during the stretching process, ensuring uniform material deformation and ultimately obtaining a high-precision heat insulation cover blank. Example

[0020] A method and apparatus for performing the stretch forming, comprising: The fuselage provides support for the overall structure; The main hydraulic cylinder, mounted on the top of the machine body, is used to provide stretching power; The stretching die is connected to the piston rod of the main hydraulic cylinder and includes an upper die and a lower die that cooperate with each other. The upper die is provided with a concave die and the lower die is provided with a convex die. The shapes of the concave die and the convex die are adapted to the forming requirements of the heat insulation cover. The workbench, fixed to the machine body, is used to place the materials to be stretched and semi-finished products; The control system is used to set and adjust the tensile parameters and monitor the material deformation and equipment operation status in real time during the tensile process.

[0021] Preferably, the upper mold includes an upper mold base, a die, and a guide post, and the lower mold includes a lower mold base, a punch, and a stripping device. The die and the punch are made of Cr12MoV mold steel.

[0022] Preferably, the guide post cooperates with the guide sleeve on the lower mold base to ensure the smoothness and accuracy of the upper mold movement.

[0023] Preferably, the unloading device includes an unloading plate and a push rod. The unloading plate is adapted to the punch. After stretching is completed, the unloading plate is driven by the push rod to push the workpiece out of the punch.

[0024] The stretch forming apparatus in this embodiment provides stable support through a high-strength machine body, achieves precise power output through the main hydraulic cylinder, and adopts a high-hardness and high-precision design for the stretching die. The cooperation between the guide column and the guide sleeve ensures the accuracy of the upper die movement and reduces the impact of die offset on the forming quality. The control system integrates sensor data to monitor the material state and equipment operating status in real time during the stretching process. Uniform material deformation is achieved through dynamic parameter adjustment. The unloading device ensures that the workpiece is smoothly removed and avoids secondary damage. The coordinated action of all components of the apparatus provides a reliable guarantee for the implementation of the two stretching processes, achieving efficient and high-precision production.

[0025] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for stretch forming a thin sheet heat shield for an engine turbocharger, characterized in that: Includes the following steps: S1. Raw material preparation: Select thin sheet materials that meet the preset mechanical and forming properties, and pre-treat the thin sheet materials; S2. First stretching: The pre-treated sheet material is placed on the worktable of the stretching equipment and positioned and aligned. The sheet material is initially stretched through the mold of the stretching equipment to form a semi-finished product that is close to the outline of the heat insulation cover. During the stretching process, the stretching parameters are dynamically adjusted to control the uniform deformation of the material. S3. Second stretching: The semi-finished product after the first stretching is stretched again with precision. The surface of the stretching die is treated and the local structure of the die is finely adjusted according to the actual shape of the semi-finished product. The stretching parameters are set in sections to adapt to the forming requirements of different parts of the heat insulation cover, so that the semi-finished product is formed into a heat insulation cover blank that meets the design precision requirements. S4. Quality Inspection: Conduct quality inspections on the semi-finished products after the first stretching and the blanks after the second stretching, remove defective workpieces, and provide feedback to adjust the stretching parameters or mold status.

2. The stretch forming method for a thin plate heat shield for an engine turbocharger according to claim 1, characterized in that: The sheet material is aluminized sheet, and the pretreatment includes surface cleaning and dimensional cutting.

3. The stretch forming method for a thin plate heat shield for an engine turbocharger according to claim 2, characterized in that: The first stretching is performed using a frame hydraulic press. The stretching parameters include a punch-die gap of 0.8-1.2 mm, a stretching speed of 12-18 mm / s, and an initial stretching force of 1000-1500 kN, which are dynamically adjusted based on the material thickness variation and stress distribution data.

4. An apparatus for performing the stretch forming as described in claim 1, characterized in that: include: The fuselage provides support for the overall structure; The main hydraulic cylinder, mounted on the top of the machine body, is used to provide stretching power; The stretching die is connected to the piston rod of the main hydraulic cylinder and includes an upper die and a lower die that cooperate with each other. The upper die is provided with a concave die and the lower die is provided with a convex die. The shapes of the concave die and the convex die are adapted to the forming requirements of the heat insulation cover. The workbench, fixed to the machine body, is used to place the materials to be stretched and semi-finished products; The control system is used to set and adjust the tensile parameters and monitor the material deformation and equipment operation status in real time during the tensile process.

5. The apparatus for realizing the stretch forming method according to claim 4, characterized in that: The upper mold includes an upper mold base, a die, and guide pillars, and the lower mold includes a lower mold base, a punch, and a stripping device. The die and punch are made of Cr12MoV mold steel.

6. The apparatus for realizing the stretch forming method according to claim 5, characterized in that: The guide post engages with the guide sleeve on the lower mold base to ensure the smoothness and accuracy of the upper mold movement.

7. The apparatus for realizing the stretch forming method according to claim 6, characterized in that: The unloading device includes an unloading plate and a push rod. The unloading plate is adapted to the punch. After stretching, the unloading plate is driven by the push rod to push the workpiece out of the punch.

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