An inner supporting device, a new energy automobile G-shaped part forming continuous die and a stamping method

Abstract

The present application relates to a kind of inner support device, new energy automobile G-shaped piece forming continuous die and stamping method, device includes floating block, strip-shaped inner support and several pillow blocks, strip-shaped inner support extends along material belt conveying direction and passes through multiple steps, its feeding end is fixed to floating block, discharge end is suspended, pillow block is fixed to lower die and each is located between adjacent step. Inner support device meets the need of bending forming of G-shaped piece. Continuous die is sequentially provided with punching unit, trimming unit, bending unit, shaping station and blanking station along the material belt conveying direction, and the inner support device is arranged at the rear section of the second bending section, and the strip-shaped inner support extends from the second bending section to the shaping station. Continuous die realizes the continuous processing of G-shaped piece. The processing method steps include: punching positioning hole, cutting outer edge, front bending, rear bending, shaping and blanking. The stamping method uses new energy automobile G-shaped piece forming continuous die to process G-shaped piece, and the processing is simple, and the manufacturing efficiency is high.

Description

Technical Field

[0001] This invention relates to the field of stamping technology, and in particular to an internal support device, a progressive die for forming G-shaped parts for new energy vehicles, and a stamping method. Background Technology

[0002] Metal stamping is a common process in the processing of many metal products. With the diversification of customer needs, mold design must also meet the requirements of various products.

[0003] like Figure 1 and Figure 2 As shown, the tailgate welding plate is a G-shaped part used on the tailgate lock cover, which is a pair of mirror-image parts (first G-shaped part 1a, second G-shaped part 1b). The tailgate lock cover, viewed from the side, has a G-shaped multi-bend structure, including a base portion 11, a first side portion 12a, a first flat portion 13a, a second side portion 12b, a second flat portion 13b, a third flat portion 13c, and a downward folded portion 15. The base portion 11 has a U-shaped structure. The upper edges of the first side portion 12a and the second side portion 12b are respectively connected to the left and right sides of the base portion 11. The base portion 11, the first side portion 12a, and the first flat portion 13a are sequentially connected to form a U-shaped bend structure. The base portion 11, the second side portion 12b, and the second flat portion 13c are connected to form a U-shaped bend structure. The face portion 13b is sequentially connected to form a second U-shaped bend structure, and the base portion 11, the second side portion 12b, and the third planar portion 13c are sequentially connected to form a third U-shaped bend structure. The second planar portion 13b and the third planar portion 13c are staggered and have a height difference. The first planar portion 13a, the second planar portion 13b, and the third planar portion 13c are all parallel to the base portion 11 and overlap with the lower projection range of the base portion 11 to varying degrees. The upper projection range of the first planar portion 13a overlaps with the base portion 11, the second planar portion 13b, and the third planar portion 13c to varying degrees. The lower fold portion 15 is formed by folding down from the inside of the base portion 11. The base portion 11 is provided with a plurality of base surface through holes 111, and the lower projection range of some of the base surface through holes 111 overlaps with the first planar portion 13a. The first planar portion 13a is provided with a plurality of planar through holes 131, and the upper projection range of the planar through holes 131 does not overlap with the base portion 11, the second planar portion 13b, and the third planar portion 13c. The second planar portion 13b is provided with a convex hull 132, and the upper projection range of the convex hull 132 overlaps with the base portion 11.

[0004] The workpiece presents the following technological challenges:

[0005] 1. The integrity of the base surface 11 is poor, and there are C-shaped bending structures on both sides. The left and right sides of the base surface 11 are parallel. When bending, the base surface 11 itself is prone to warping and deformation, which makes it difficult to guarantee the parallelism of the first plane part 13a, the second plane part 13b and the third plane part 13c.

[0006] 2. The base surface 11, the first flat part 13a, the second flat part 13b and the third flat part 13c have a height difference and overlap in their vertical positions. The first flat part 13a can only be bent after the second flat part 13b and the third flat part 13c are bent in place, otherwise there will be interference.

[0007] 3. The base through hole 111, the plane through hole 131 and the convex hull 132 cannot be manufactured after all bending is completed, because the plane materials of different heights will interfere with each other and affect the punch setting;

[0008] 4. The presence of the lower fold 15 restricts the conveying method of the material strip. It cannot be conveyed by linear translation, but must float up and down. Otherwise, during the step-by-step bending process of the lower fold 15, the mold will hinder its forward movement.

[0009] Chinese patent CN116765276A discloses a high-precision C-shaped workpiece extrusion molding method and a progressive die. To obtain the C-shaped workpiece, a rolled insert is used on the lower die. The rolled insert is an inner core with its axis aligned with the conveying direction of the material strip, providing inner arc support for the C-shaped structure. The rolled insert extends to multiple stations, thus employing a single-sided suspension structure with a gradually changing cross-section. The height of the rolled insert cannot change, restricting the movement trajectory of the material strip. Therefore, in this molding method, the material strip as a whole does not move vertically, which is unsuitable for many products with complex bending structures. This is because the bending step will cause some parts of the material to fall below the base surface area by 11 mm, requiring vertical movement before horizontal translation is possible.

[0010] Chinese patent CN207026197U discloses a bridge-type rolling device that uses an integral molded insert as an inner support for bending, the height of which is floating. Because the product structure is cylindrical, the molded insert is a columnar structure with a gradually decreasing cross-section, which gives it good structural rigidity. During the final rolling process, the forces on both sides are balanced, so even if the structure is suspended on one side, there is no risk of breakage. However, when bending the welded panel of a car tailgate, the inner support structure can only be a flat and long structure. The downward component force during bending is difficult to balance, which can easily lead to the inner support breaking.

[0011] Therefore, it is necessary to design a new molding method to solve the above problems. Summary of the Invention

[0012] The first main objective of this invention is to provide an internal support device that can provide internal support for the forming of the corners on both sides of the base surface, while avoiding the strip internal support from breaking under stress, thus ensuring the smooth progress of continuous stamping.

[0013] The present invention achieves the above-mentioned objective through the following technical solution: an internal support device, comprising a floating support block, a strip-shaped internal support, and several pillow blocks. The floating support block can move up and down within the lower mold. The strip-shaped internal support extends along the conveying direction of the material belt and passes through multiple steps. Its feeding end is fixed to the floating support block, and its discharging end is suspended. The pillow blocks are fixed to the lower mold and are each located between adjacent steps. When the floating support block descends to the lowest point, all the pillow blocks support the lower part of the strip-shaped internal support.

[0014] The second main objective of this invention is to provide a continuous molding die for G-shaped parts of new energy vehicles, which can use an internal support device to complete the continuous molding of G-shaped parts and realize the automated processing of G-shaped parts.

[0015] The present invention achieves the above-mentioned objective through the following technical solution: a continuous mold for forming G-shaped parts for new energy vehicles, used to process G-shaped parts, wherein the G-shaped part includes a base part, a first side part, a first flat part, a second side part, a second flat part, and a third flat part. The upper edge of the first side part and the upper edge of the second side part are respectively connected to the left and right sides of the base part. The base part, the first side part, and the first flat part are sequentially connected to form a U-shaped bending structure. The base part, the second side part, and the second flat part are sequentially connected to form a second U-shaped bending structure. The base part, the second side part, and the third flat part are sequentially connected to form a third U-shaped bending structure. The second flat part and the third flat part are staggered and have a height difference. The first flat part, the second flat part, and the third flat part are all parallel to the base part.

[0016] The continuous die is sequentially provided with a punching unit, a trimming unit, a bending unit, a shaping station, and a blanking station along the material conveying direction. The punching unit is used to cut out positioning holes on the material strip. The processing unit of the material strip includes a connecting area and a forming area. The positioning holes are located within the connecting area. The trimming unit is used to cut out blanks in the forming area. The bending unit is used to bend the blanks into the G-shaped parts. The shaping station shapes the G-shaped parts. The blanking station cuts off the G-shaped parts.

[0017] The direction of all the bends between the base portion, the first side portion, the first planar portion, the second side portion, the second planar portion, and the third planar portion is along the conveying direction of the material belt;

[0018] The base surface has a U-shaped structure, and the blank has three connection points with the connection area. Two of the connection points are located at the front two ends of the base surface, and the third connection point is located at the rear of the base surface.

[0019] The bending unit includes a first bending section and a second bending section arranged sequentially. The first bending section bends out a first angle between the first side portion and the first flat portion, a second angle between the second side portion and the second flat portion, and a third angle between the second side portion and the third flat portion. The second bending section bends out a fourth angle between the base portion and the first side portion and a fifth angle between the base portion and the second side portion. The inner support device is located at the rear section of the second bending section, and the strip inner support extends from the second bending section to the shaping station.

[0020] Specifically, the G-shaped component further includes a folded portion, which is formed by folding down from the inside of the base surface; the upper part of the strip-shaped inner support is provided with a clearance groove that matches the movement trajectory of the folded portion.

[0021] Furthermore, the bending unit includes a lower fold forming section, which is located between the first bending section and the second bending section. The lower fold forming section includes a pre-punching waste station, a punching station, a third half-folding station, and a third full-folding station arranged sequentially. The pre-punching waste station removes two side edge wastes on the inner side of the base surface to obtain a connecting bridge containing the lower fold. The punching station punches the connecting bridge, leaving only a single cantilever bridge. The third half-folding station folds the single cantilever bridge down by 30-60°, and the third full-folding station folds the single cantilever bridge down by 90° to obtain the lower fold.

[0022] Specifically, the first bending section includes a first half-bending station and a first full-bending station set up front and back. The first half-bending station bends the first, second, and third folds to 30-60°, and the first full-bending station bends the first, second, and third folds to 90°. The second bending section includes a second half-bending station and a second full-bending station set up front and back. The second half-bending station bends the fourth and fifth folds to 30-60°, and the second full-bending station bends the fourth and fifth folds to 90° sequentially.

[0023] Furthermore, the base surface is provided with a plurality of base surface through holes, and a base surface punching station is provided between the second half-folding station and the second full-folding station, wherein the base surface punching station punches out the base surface through holes on the base surface.

[0024] The third main objective of this invention is to provide a G-shaped part stamping process that can use a continuous die for forming G-shaped parts for new energy vehicles to complete the continuous forming of G-shaped parts, thus ensuring product quality and processing efficiency.

[0025] This invention achieves the above objective through the following technical solution: a G-shaped part stamping process, implemented using the aforementioned new energy vehicle G-shaped part forming progressive die, comprising the following steps:

[0026] S1. Punching positioning holes: Using both sides of the strip as positioning references, the punching unit cuts out a number of positioning holes on the strip. The processing unit range in the design includes a U-shaped connection area and a forming area located in the connection area. All positioning holes are located in the connection area.

[0027] S2. Cutting the outer edge: Using the positioning hole as the positioning reference, the cutting edge unit cuts out the blank in the forming area;

[0028] S3, Front bend: Using the positioning hole as the positioning reference, bend out the first bend angle, the second bend angle and the third bend angle within the first bend section;

[0029] S4. Rear bending: Using the positioning hole as the positioning reference and the strip inner support as the inner core, the fourth and fifth bends are folded out in the second bending section.

[0030] S5. Shaping: Using the positioning hole as the positioning reference and the strip inner support as the inner core, the blank is shaped into the G-shaped part at the shaping station.

[0031] S6. Blanking: Using the positioning hole as the positioning reference, the G-shaped part is cut off from the strip at the blanking station.

[0032] Specifically, the forming area is designed with two blanks that are mirror-symmetrical. The cutting unit is divided into multiple stations to remove the waste material on the front, back and outer sides of the blanks, and finally removes the connecting waste material between the two blanks.

[0033] Furthermore, the punching unit punches a central positioning hole, two side positioning holes, and several blank positioning holes on the connecting area. The central positioning hole is located at the conveying center of the material strip, the side positioning holes are located at the edge of the connecting area, and the blank positioning holes are located between the three connecting positions of the blank and the connecting area.

[0034] The beneficial effects of the technical solution of this invention are:

[0035] 1. The inner support device uses a strip inner support as an auxiliary base surface for the full bending and forming of the inner core structure. The pillow block supports the strip inner support so that it can remain horizontal when the mold is closed. This can resist the punching force and meet the bending and forming requirements of the G-shaped part.

[0036] 2. The continuous die for forming G-shaped parts for new energy vehicles uses a punching unit to cut out positioning holes on the strip, a trimming unit to cut out blanks in the forming area, a bending unit to bend the blanks into G-shaped parts, a shaping station to shape the G-shaped parts, and a blanking station to cut the G-shaped parts off the strip, thus realizing continuous processing of G-shaped parts.

[0037] 3. The stamping method utilizes a continuous die for forming G-shaped parts for new energy vehicles to obtain G-shaped parts, which is simple to process and has high manufacturing efficiency. Attached Figure Description

[0038] Figure 1 A perspective view of the first G-shaped component and the second G-shaped component;

[0039] Figure 2 The front view of the first G-shaped part and the second G-shaped part;

[0040] Figure 3 This is a diagram showing the structural changes of the material strip;

[0041] Figure 4 A diagram showing the positional relationship between the lower die and the strip in a progressive die for forming G-shaped parts for new energy vehicles.

[0042] Figure 5 A three-dimensional view of the lower die of a progressive die for forming G-shaped parts for new energy vehicles;

[0043] Figure 6 for Figure 5 A magnified view of a portion of position A in the middle;

[0044] Figure 7 This diagram shows the connection relationship between the floating support block and the strip internal support.

[0045] Figure 8 This is a diagram showing the positional relationship between the internal support device and the shaping station.

[0046] The diagram is marked as follows:

[0047] 1a-First workpiece, 1b-Second workpiece, 11-Base surface, 111-Base surface through hole, 12a-First side surface, 12b-Second side surface, 13a-First planar surface, 13b-Second planar surface, 13c-Third planar surface, 131-Planar through hole, 132-Protrusion, 14a-First bend, 14b-Second bend, 14c-Third bend, 14d-Fourth bend, 14e-Fifth bend, 15-Lower bend;

[0048] 2-Material strip, 21-Connecting area, 211-Central positioning hole, 212-Side positioning hole, 213-Blank positioning hole, 22-Forming area, 221-Blank, 222-Connecting waste, 223-Side edge waste, 224-Connecting bridge, 225-Single suspension bridge;

[0049] 3-Continuous forming die for G-shaped parts of new energy vehicles, 31-Punching unit, 32-Edge trimming unit, 33-Bending unit, 331-First bending section, 3311-First half-bending station, 3312-First full-bending station, 332-Lower bending section forming section, 3321-Pre-punching scrap station, 3322-Blanking station, 3323-Third half-bending station, 3324-Third full-bending station, 333-Second bending section, 3331-Second half-bending station, 3332-Base surface punching station, 3333-Second full-bending station, 34-Shaping station, 35-Blanking station, 36-Internal support device, 361-Floating support block, 362-Strip internal support, 3621-Allowing groove, 363-Pillow block. Detailed Implementation

[0050] The present invention will be further described in detail below with reference to specific embodiments.

[0051] Example:

[0052] like Figure 1 and Figure 2 As shown, the tailgate lock cover is a pair of mirror-image parts (first G-shaped part 1a, second G-shaped part 1b), which includes a base part 11, a first side part 12a, a first flat part 13a, a second side part 12b, a second flat part 13b, a third flat part 13c, and a downward folding part 15. The base part 11 has a U-shaped structure. The upper edge of the first side part 12a and the upper edge of the second side part 13b are respectively connected to the left and right sides of the base part 11. The base part 11, the first side part 12a, and the first flat part 13a are sequentially connected to form a U-shaped bending structure. The base part 11 and the second side part 12b... The second planar portion 13b is sequentially connected to form a second U-shaped bending structure, and the base portion 11, the second side portion 12b, and the third planar portion 13c are sequentially connected to form a third U-shaped bending structure. The second planar portion 13b and the third planar portion 13c are staggered and have a height difference. The first planar portion 13a, the second planar portion 13b, and the third planar portion 13c are all parallel to the base portion 11 and overlap with the lower projection range of the base portion 11 to varying degrees. The upper projection range of the first planar portion 13a overlaps with the base portion 11, the second planar portion 13b, and the third planar portion 13c to varying degrees. The lower fold portion 15 is formed by folding down from the inside of the base portion 11. The base portion 11 is provided with a plurality of base surface through holes 111, and the lower projection range of some of the base surface through holes 111 overlaps with the first planar portion 13a. The first planar portion 13a has a plurality of planar through holes 131, the upper projection range of which does not overlap with the base portion 11, the second planar portion 13b, and the third planar portion 13c. The second planar portion 13b has a convex hull 132, the upper projection range of which overlaps with the base portion 11.

[0053] The following processing method prioritizes obtaining the G-shaped structure of the product. Some products may not have the base surface through hole 111, the convex hull 132 may not be present, or it may be on other planar parts or more than one planar part. Some products may not have the planar through hole 131, or it may be on other planar parts or more than one planar part. This does not affect the main processing flow.

[0054] like Figure 4 and Figure 5 As shown, a continuous die 3 for forming G-shaped parts for new energy vehicles according to the present invention is used to process G-shaped parts (in the embodiment, the first G-shaped part 1a and the second G-shaped part 1b are processed simultaneously). The continuous die is provided with a punching unit 31, a trimming unit 32, a bending unit 33, a shaping station 34 and a blanking station 35 in sequence along the conveying direction of the material strip 2. The punching unit 31 is used to cut out positioning holes on the material strip 2. The processing unit range of the material strip 2 includes a connecting area 21 and a forming area 22. The positioning holes are located within the range of the connecting area 21. The trimming unit 32 is used to cut out blanks 221 in the forming area 22. The bending unit 33 is used to bend the blanks 221 into G-shaped parts. The shaping station 34 shapes the G-shaped parts. The blanking station 35 cuts the G-shaped parts off the material strip 2. All the bends between the base surface 11, the first side surface 12a, the first flat surface 13a, the second side surface 12b, the second flat surface 13b and the third flat surface 13c are in the direction of conveying the material belt 2; the base surface 11 has a U-shaped structure, and the blank 221 has three connection positions with the connection area 21, two of which are located at the front ends of the base surface 11, and the third connection position is located at the rear of the base surface 11.

[0055] The continuous die 3 for forming G-shaped parts for new energy vehicles enables continuous processing of G-shaped parts. Forming a G-shaped part is a process of "rolling" a strip of material (blank 221) into a G-shaped structure. The continuous die 3 for forming G-shaped parts for new energy vehicles requires the strip 2 to be conveyed along the wide side of the strip material, so all bending is completed from the side. This also makes it possible to install the inner support device 36 (if the blank 221 rotates 90°, the strip inner support 362 cannot extend to several stations). The final structure of the base surface 11 is U-shaped. If the structure of the base surface 11 is obtained in advance, there is a risk of large structural deformation during bending. Therefore, until the blank is unloaded, the base surface 11 needs to be connected to the connecting area 21 through two connection points. This way, even if the integrity of the base surface 11 decreases, it can still form a loop connection with the connecting area 21, which helps maintain the material's position. Meanwhile, the base surface 11 is also temporarily connected to the connection area 21 at the rear, which constitutes a bridge-like connection with both the front and rear connected to the connection area 21. This will also help maintain the shape of the base surface 11 when bending.

[0056] like Figures 4 to 6As shown, the bending unit 33 includes a first bending section 331 and a second bending section 333 arranged sequentially. The first bending section 331 bends out a first angle 14a between the first side surface 12a and the first flat surface 13a, a second angle 14b between the second side surface 12b and the second flat surface 13b, and a third angle 14c between the second side surface 12b and the third flat surface 13c. The second bending section 333 bends out a fourth angle 14d between the base surface 11 and the first side surface 12a, and a fifth angle 14e between the base surface 11 and the second side surface 12b. The first bending section 331 includes a first half-bending station 3311 and a first full-bending station 3312 set up front and back. The first half-bending station 3311 bends the first bend angle 14a, the second bend angle 14b and the third bend angle 14c to 30-60°. The first full-bending station 3312 bends the first bend angle 14a, the second bend angle 14b and the third bend angle 14c to 90°. The second bending section 333 includes a second half-bending station 3331 and a second full-bending station 3333 set up front and back. The second half-bending station 3331 bends the fourth bend angle 14d and the fifth bend angle 14e to 30-60°. The second full-bending station 3333 bends the fourth bend angle 14d and the fifth bend angle 14e to 90° one after the other. Between the second half-folding station 3331 and the second full-folding station 3333, there is also a base surface punching station 3332, which punches out a base surface through hole 111 on the base surface 11.

[0057] Both the first bending section 331 and the second bending section 333 employ a step-by-step bending method to complete right-angle bends. After passing through the first bending section 331, the material of the base surface 11, the first side surface 12a, and the second side surface 12b are flush, while the first flat surface 13a, the second flat surface 13b, and the third flat surface 13c are rotated to a vertically downward direction (the first bend angle 14a, the second bend angle 14b, and the third bend angle 14c complete the bend). At this point, the vertical direction of the base surface 11 is unobstructed. After passing through the second bending section 333, the first side surface 12a and the second side surface 12b are rotated to a vertically downward direction (the fourth bend angle 14d and the fifth bend angle 14e complete the bend). The reason why the base surface punching station 3332 is inserted between the second half-bending station 3331 and the second full-bending station 3333 when there is a base surface through hole 111 is because the precision requirement of the base surface through hole 111 is relatively high, and it is better to cut it after the structure of the base surface 11 has stabilized. After processing at the second half-bending station 3331, the fourth bend angle 14d and the fifth bend angle 14e have initially formed obtuse angles. Without affecting the punching range, the fourth bend angle 14d and the fifth bend angle 14e provide deformation-resistant support for the base surface 11. The second full-bending station 3333 continues to bend the fourth bend angle 14d and the fifth bend angle 14e after they have already been bent at a small angle. At this time, the deformation resistance of the fourth bend angle 14d and the fifth bend angle 14e themselves is relatively weak. Therefore, after full bending, the impact on the position of the base surface through hole 111 is minimal (the position of the three planes after full bending may make it impossible to punch the base surface through hole 111).

[0058] like Figures 6 to 8 As shown, the inner support device 36 includes a floating support block 361, a strip-shaped inner support 362, and several support blocks 363. The floating support block 361 can move up and down within the lower die. The strip-shaped inner support 362 extends along the conveying direction of the material belt 2 and passes through multiple steps. Its feeding end is fixed to the floating support block 361, and its discharging end is suspended. The support blocks 363 are fixed to the lower die and are located between adjacent steps. When the floating support block 361 descends to its lowest point, all the support blocks 363 support the lower part of the strip-shaped inner support 362. The inner support device 36 is located at the rear of the second bending section 333, and the strip-shaped inner support 362 extends from the second bending section 333 to the forming station 34.

[0059] The floating support block 361 and the strip inner support 362 form a "jump platform" structure. During continuous stamping, the floating support block 361 allows this "jump platform" structure to move up and down freely without detaching from the lower die. The strip inner support 362 is surrounded inside the G-shaped part, so when the strip 2 moves up and down, the strip inner support 362 also moves up and down. When bending at the fourth fold angle 14d and the fifth fold angle 14e, the upper two edges of the strip inner support 362 are supported on the inside of the two fold angles, so it can serve as an inner core structure to assist in the full bending of the fold angles on both sides of the base surface 11. The shaping step is to reduce material rebound after bending, and its action is actually the same as the full bending, so the strip inner support 362 is also used as an inner core structure. During stamping, the strip inner support 362 cannot maintain a single-sided suspended structure, otherwise it cannot provide enough reaction force for bending. Therefore, the pillow block 363 is needed to support the strip inner support 362, which has moved to the lowest point. Pillow block 363 is offset from bending punch and forming punch. If strip inner support 362 is regarded as "bridge plate", then pillow block 363 is a lot of "bridge piers". The base surface 11 is on the "bridge surface" and the fourth and fifth folds are located at the two "bridge edges" respectively. Pillow block 363 supports strip inner support 362 so that strip inner support 362 can remain horizontal when the mold is closed. This can resist the punching force and meet the bending and forming requirements of G-shaped parts.

[0060] like Figure 1 , Figure 2 , Figure 6 , Figure 7 and Figure 8 As shown, the G-shaped part also includes a lower fold 15, which is formed by folding down from the inside of the base surface 11; the upper part of the strip inner support 362 is provided with a relief groove 3621 that matches the movement trajectory of the lower fold 15.

[0061] The lower fold 15 is a structure on the tailgate lock cover of the car. In the embodiment, the direction of its fold is inclined (neither along the conveying direction of the material belt 2 nor perpendicular to the conveying direction of the material belt 2). However, regardless of the direction of the fold, it will turn to the inner side of the G-shaped part where the strip inner support 362 is located. Therefore, a clearance groove 3621 should be designed on the strip inner support 362 to allow the lower fold 15 to pass smoothly, so as to avoid the lower fold 15 being bent during the forward feeding of the material belt 2.

[0062] like Figure 5 and Figure 6As shown, the bending unit 33 has a lower fold forming section 332, which is located between the first bending section 331 and the second bending section 333. The lower fold forming section 332 includes a pre-punching waste station 3321, a punching station 3322, a third half-folding station 3323, and a third full-folding station 3324 arranged sequentially. The pre-punching waste station 3321 removes two side edge wastes 223 on the inner side of the base surface 11 to obtain a connecting bridge 224 containing the lower fold 15. The punching station 3322 punches the connecting bridge 224, leaving only a single cantilever bridge 225. The third half-folding station 3323 folds the single cantilever bridge 225 downward by 30-60°. The third full-folding station 3324 folds the single cantilever bridge 225 downward by 90° to obtain the lower fold 15.

[0063] With the presence of the lower fold 15, an additional processing section—the lower fold forming section 332—is required. This is related to the removal of surrounding waste and bending forming. The lower fold 15 is a peninsula-shaped structure located inside the base surface 11. The waste area around it is originally C-shaped, resulting in a high removal rate on the plane of the base surface 11, but it is also prone to waste jamming. Therefore, the waste cutting is divided into two steps: removing the side edge waste 223 (waste from two convex polygonal structures) and punching (removing waste from another convex polygonal structure). This is because the connecting bridge 224 can maintain the relationship between the two sides of the base surface 11, reduce overall deformation, and avoid the problem of waste jamming. Subsequently, the lower fold 15 is obtained through a third half fold and a third full fold. In this embodiment, the base surface punching station 3332 is actually merged with the third full fold station 3324 into the same station.

[0064] like Figures 2 to 8 As shown, this embodiment of the G-shaped part stamping process utilizes a progressive die 3 for forming G-shaped parts for new energy vehicles, resulting in simple processing and high manufacturing efficiency. The steps include:

[0065] S1. Punching positioning holes: Using the two sides of the strip 2 as positioning references, the punching unit 31 cuts out a number of positioning holes on the strip 2. The processing unit range in the design includes the U-shaped connection area 21 and the forming area 22 located in the connection area 21. The positioning holes are all located in the connection area 21.

[0066] The punching unit 31 punches a central positioning hole 211, two side positioning holes 212 and several blank positioning holes 213 on the connecting area 21. The central positioning hole 211 is located at the conveying center of the material belt 2, the side positioning holes 212 are located at the edge of the connecting area 21, and the blank positioning holes 213 are located between the three connection positions of the blank 221 and the connecting area 21.

[0067] The central positioning hole 211 and the two side positioning holes 212 will be relatively far from the blank 221 in the later stages of processing, so only rough positioning is possible. On the strip 2, from the perspective of a single processing unit, although the three connection positions are located on the front and back sides of the connection area 21, in adjacent processing units, the three connection positions are close together. The blank positioning hole 213 is located near the direct connection position between the connection area 21 and the blank 221. Therefore, positioning these three connection positions by the blank positioning hole 213 will be more accurate, ensuring higher precision in punching and bending.

[0068] When planar through holes 131 and / or protrusions 132 exist in the first planar portion 13a, the second planar portion 13b, and the third planar portion 13c, they can be cut or punched together during the punching stage to save steps and improve accuracy. Because the integrity of the entire strip 2 is relatively high at this stage, the structural accuracy of these structures themselves will be relatively high.

[0069] S2. Cutting the outer edge: Using the positioning holes (referring to one central positioning hole 211, two side positioning holes 212 and several blank positioning holes 213, the same below) as the positioning reference, the blank 221 is cut out in the forming area 22 by the cutting edge unit 32.

[0070] The blank 221 is a pre-formed structure of a single G-shaped part. In the initial stage of processing of the strip 2, it is in a planar state. Most of the area between the blank 221 and the connecting area 21 needs to be disconnected, so that part of the blank 221 becomes a peninsula structure, so that subsequent bending operations can be carried out.

[0071] Theoretically, G-shaped parts can be processed one by one. However, in this embodiment, the forming area 22 is designed with two blanks 221 that are mirror-symmetrical. The trimming unit 32 cuts off the waste material on the front, back, and outer sides of the blanks 221 at multiple stations, and finally cuts off the connecting waste material 222 between the two blanks 221. Because the automotive tailgate welding plate is used in pairs (first G-shaped part 1a, second G-shaped part 1b), and the two G-shaped parts are mirror-symmetrical, they can be completed together through the same processing steps. This design allows one mold to process two products simultaneously. In addition, the connecting waste material 222 temporarily connects the two blanks 221 into a whole. During the trimming process, the two blanks 221 can hold each other and are connected to the connecting area 21 through four connection points (the front and back positions of the two blank positioning holes 213). They are only disconnected (the connecting waste material 222 is cut off) before the two blanks 221 need to be bent independently, which helps to improve the trimming accuracy.

[0072] S3. Forward Bending: Using the positioning hole as the positioning reference, the first bend angle 14a, the second bend angle 14b, and the third bend angle 14c are formed within the first bending section 331. The forward bending is divided into two steps: the first half bend and the first full bend. That is, the first half bend station 3311 is used to bend the first bend angle 14a, the second bend angle 14b, and the third bend angle 14c to 30-60°, and the first full bend station 3312 is used to bend the first bend angle 14a, the second bend angle 14b, and the third bend angle 14c to 90°.

[0073] S4. Forming the lower fold: Using the positioning hole as the positioning reference, the two side edge scraps 223 on the inner side of the base surface 11 are removed using the pre-punching scrap station 3321 to obtain the connecting bridge 224 of the material containing the lower fold 15; the connecting bridge 224 is punched off using the punching station 3322, leaving only the single cantilever bridge 225; the single cantilever bridge 225 is folded down 30-60° using the third half-folding station 3323; the single cantilever bridge 225 is folded down 90° using the third full-folding station 3324 to obtain the lower fold 15.

[0074] S5. Post-bending: Using the positioning hole as the positioning reference and the strip inner support 362 as the inner core, the fourth bend angle 14d and the fifth bend angle 14e are folded out in the second bending section 333. The post-bending is divided into two steps: the second half bend and the second full bend. That is, the fourth bend angle 14d and the fifth bend angle 14e are folded to 30-60° using the second half bend station 3331, and the fourth bend angle 14d and the fifth bend angle 14e are folded to 90° successively using the second full bend station 3333.

[0075] The initial bending operation forms an L-shaped bending structure, while the subsequent bending operation forms a U-shaped bending structure. The fourth bend 14d and the fifth bend 14e are directly adjacent to the base surface 11, while the first bend 14a, second bend 14b, and third bend 14c are not directly adjacent to the base surface 11. For the product as a whole, a G-shaped structure is achieved through two bending stages from the outside in. Because the first flat portion 13a is farther from the base surface 11 than the second flat portion 13b and the third flat portion 13c in this embodiment, although the fourth bend 14d and the fifth bend 14e can be completely bent out in the same step, the order of bending during mold closing must be considered. In this embodiment, the fifth bend 14e is bent to 90° first, and then the fourth bend 14d is bent to 90°.

[0076] When there is a downward fold 15 on the base surface 11, the forming step of the downward fold 15 is preferably inserted into the front bending step and the rear bending step. Because at this time the first flat part 13a, the second flat part 13b and the third flat part 13c are still in a vertical state, it will not affect the trimming and bending operation of the downward fold 15.

[0077] When there is a base surface through hole 111 on the base surface 11, the punching operation of the base surface through hole 111 is preferably inserted between the second half-fold and the second full-fold. This is because after the second full-fold operation, the first flat portion 13a, the second flat portion 13b, and the third flat portion 13c may interfere with the punching of the base surface through hole 111, while the second half-fold operation can control the three flat portions from entering the lower projection range of the base surface through hole 111. In this way, the second half-fold allows the fourth fold angle 14d and the fifth fold angle 14e to produce small-angle bends, but does not affect the punching of the base surface through hole 111.

[0078] S6. Shaping: Using the positioning hole as the positioning reference and the strip inner support 362 as the inner core, the blank 221 is shaped into a G-shaped part (first G-shaped part 1a, second G-shaped part 1b) at the shaping station 34.

[0079] Both the second full fold and the shaping rely on the strip-shaped inner support 362 as the inner core structure. The designed bending angles at both stations (for the fourth fold angle 14d and the fifth fold angle 14e) are 90°. However, during the second full fold, the material stress is not fully released, and the angle will have some springback. During the shaping process, the first side portion 12a and the second side portion 12b are squeezed from both sides to ensure that the angles of the fourth fold angle 14d and the fifth fold angle 14e reach the target accuracy. When there is a lower fold portion 15 on the base surface 11, a relief groove 3621 is provided on the strip-shaped inner support 362 to allow the lower fold portion 15 to move.

[0080] S7. Blanking: Using the positioning hole as the positioning reference, cut the G-shaped part from the material strip 2 at the blanking station 35.

[0081] After steps S1-S7, the G-shaped part is fully formed and can then be cut off from the strip 2. The break point is the two connection points at the front of the base surface 11 and the connecting area 21.

[0082] The above descriptions are merely some embodiments of the present invention. Those skilled in the art can make various modifications and improvements without departing from the inventive concept of the present invention, and these all fall within the scope of protection of the present invention.

Claims

1. An internal support device for a continuous die for forming G-shaped parts in new energy vehicles, used to process G-shaped parts, wherein the G-shaped part includes a base portion and a lower fold portion, the lower fold portion being formed by folding down from the inside of the base portion; characterized in that: The continuous die is provided with a punching unit, a trimming unit, a bending unit, a shaping station and a blanking station in sequence along the conveying direction of the material strip. The bending unit is used to bend the blank into the G-shaped part. The shaping station shapes the G-shaped part. The bending unit includes a first bending section and a second bending section arranged in sequence. The internal support device is located at the rear section of the second bending section. The inner support device includes a floating support block, a strip-shaped inner support, and several pillow blocks. The floating support block can move up and down within the lower die. The strip-shaped inner support extends along the conveying direction of the material belt and passes through multiple steps. Its feeding end is fixed to the floating support block, and its discharging end is suspended. The pillow blocks are fixed to the lower die and are located between adjacent steps. When the floating support block descends to the lowest point, all the pillow blocks support the lower part of the strip-shaped inner support. The strip-shaped inner support extends from the second bending section to the forming station. The upper part of the strip-shaped inner support is provided with a clearance groove that matches the movement trajectory of the lower bending part.

2. A continuous molding die for forming a G-shaped component of a new energy vehicle, comprising the internal support device of claim 1, wherein the G-shaped component further comprises a first side portion, a first flat portion, a second side portion, a second flat portion, and a third flat portion, the upper edge of the first side portion and the upper edge of the second side portion are respectively connected to the left and right sides of the base portion, the base portion, the first side portion, and the first flat portion are sequentially connected to form a U-shaped bending structure, the base portion, the second side portion, and the second flat portion are sequentially connected to form a second U-shaped bending structure, and the base portion, the second side portion, and the third flat portion are sequentially connected to form a third U-shaped bending structure, the second flat portion and the third flat portion are staggered and have a height difference, and the first flat portion, the second flat portion, and the third flat portion are all parallel to the base portion; characterized in that: The punching unit is used to cut out positioning holes on the strip. The processing unit of the strip includes a connecting area and a forming area. The positioning holes are located within the connecting area. The trimming unit is used to cut out blanks in the forming area. The blanking station cuts the G-shaped part off the strip. The direction of all the bends between the base portion, the first side portion, the first planar portion, the second side portion, the second planar portion, and the third planar portion is along the conveying direction of the material belt; The base surface has a U-shaped structure, and the blank has three connection points with the connection area. Two of the connection points are located at the front two ends of the base surface, and the third connection point is located at the rear of the base surface. The first bending section folds out a first angle between the first side portion and the first flat portion, a second angle between the second side portion and the second flat portion, and a third angle between the second side portion and the third flat portion. The second bending section folds out a fourth angle between the base portion and the first side portion, and a fifth angle between the base portion and the second side portion.

3. The continuous die for forming G-shaped parts for new energy vehicles according to claim 2, characterized in that: The bending unit has a lower fold forming section, which is located between the first bending section and the second bending section. The lower fold forming section includes a pre-punching waste station, a punching station, a third half-folding station, and a third full-folding station arranged sequentially. The pre-punching waste station removes two side edge wastes on the inner side of the base surface to obtain a connecting bridge of material containing the lower fold. The punching station punches the connecting bridge, leaving only a single cantilever bridge. The third half-folding station folds the single cantilever bridge down by 30-60°, and the third full-folding station folds the single cantilever bridge down by 90° to obtain the lower fold.

4. The continuous die for forming G-shaped parts for new energy vehicles according to claim 2, characterized in that: The first bending section includes a first half-bending station and a first full-bending station arranged front and back. The first half-bending station bends the first, second, and third folds to 30-60°, and the first full-bending station bends the first, second, and third folds to 90°. The second bending section includes a second half-bending station and a second full-bending station arranged front and back. The second half-bending station bends the fourth and fifth folds to 30-60°, and the second full-bending station bends the fourth and fifth folds to 90° sequentially.

5. The continuous die for forming G-shaped parts for new energy vehicles according to claim 4, characterized in that: The base surface is provided with a plurality of base surface through holes, and a base surface punching station is provided between the second half-folding station and the second full-folding station, wherein the base surface punching station punches out the base surface through holes on the base surface.

6. A method for stamping G-shaped parts, implemented using the continuous die for forming G-shaped parts for new energy vehicles as described in any one of claims 2-5, characterized in that the steps include... include: S1. Punching positioning holes: Using both sides of the strip as positioning references, the punching unit cuts out a number of positioning holes on the strip. The processing unit range in the design includes a U-shaped connection area and a forming area located in the connection area. All positioning holes are located in the connection area. S2. Cutting the outer edge: Using the positioning hole as the positioning reference, the cutting edge unit cuts out the blank in the forming area; S3, Front bend: Using the positioning hole as the positioning reference, bend out the first bend angle, the second bend angle and the third bend angle within the first bend section; S4. Rear bending: Using the positioning hole as the positioning reference and the strip inner support as the inner core, the fourth and fifth bends are folded out in the second bending section. S5. Shaping: Using the positioning hole as the positioning reference and the strip inner support as the inner core, the blank is shaped into the G-shaped part at the shaping station. S6. Blanking: Using the positioning hole as the positioning reference, the G-shaped part is cut off from the strip at the blanking station.

7. The G-shaped part stamping method according to claim 6, characterized in that: The forming area is designed with two blanks that are mirror-symmetrical. The cutting unit is divided into multiple stations to remove the waste material on the front, back and outer sides of the blanks, and finally removes the connecting waste material between the two blanks.

8. The G-shaped part stamping method according to claim 6 or 7, characterized in that: The punching unit punches a central positioning hole, two side positioning holes, and several blank positioning holes in the connecting area. The central positioning hole is located at the center of the conveying strip, the side positioning holes are located at the edge of the connecting area, and the blank positioning holes are located between the three connection positions of the blank and the connecting area.

9. The G-shaped part stamping method according to claim 6, characterized in that: The first planar portion, the second planar portion, or the third planar portion is provided with a planar through hole and / or a convex bulge, and the planar through hole and / or the convex bulge are machined in the punching unit.

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