Fluid-solid multi-medium supported thin-wall component multidirectional loading device and method

Abstract

The invention belongs to the technical field of plastic forming of metal thin-wall components, and discloses a fluid-solid multi-medium supported thin-wall component multi-directional loading device and a fluid-solid multi-medium supported thin-wall component multi-directional loading method. The fluid-solid multi-medium supported thin-wall component multidirectional loading device comprises an upper pressing module, a lower pressing module, a front pressing module, a rear pressing module and an axial sealing loading unit, the upper pressing module and the lower pressing module are symmetrically arranged in the Y direction, the front pressing module and the rear pressing module are symmetrically arranged in the Z direction, and the two axial sealing loading units are symmetrically arranged at the two ends of the pipe in the X direction. A multi-medium fluid-solid coupling pressure forming mode is adopted, different from a traditional single-liquid and single-gas forming process, a gas, liquid and solid multi-medium combined structure is adopted, and through the synergistic effect of the three media, the compression characteristic can be flexibly adjusted; the problems that traditional single medium forming compression characteristics are fixed and pressure change fluctuation is large are effectively solved, it is ensured that pressure change in a die cavity is stable, the stability of the forming process is remarkably improved, and forming defects are reduced.

Description

Technical Field

[0001] This invention belongs to the field of plastic forming technology of thin-walled metal components, and relates to a multi-directional loading device and method for thin-walled components supported by fluid-solid multi-media. Background Technology

[0002] With the rapid development of lightweight and high-reliability technologies in the automotive, aerospace, and energy equipment industries, the market demand and forming precision requirements for complex integral thin-walled hollow tubular components such as vehicle body frames, aircraft hydraulic lines, and heat exchanger tube bundles are continuously increasing. The forming quality of these components directly determines the overall performance and service reliability of the final equipment. Currently, equipment structures are evolving towards extreme lightweighting and increasingly complex configurations. The integral forming of complex hollow components with large thin walls, high ribs, large diameter ratios, and axial minute features faces dual technical challenges of "shape control" and "property control," and traditional forming processes are no longer sufficient to meet their processing requirements.

[0003] Currently, the forming methods for thin-walled components mainly include two categories: rigid compression molding and single-medium bulging. Both have certain technical drawbacks: In the rigid compression molding process, stress concentration occurs when the mold contacts the component surface, which can easily lead to forming defects such as wrinkling, cracking, and uneven wall thickness in thin-walled components. For complex curved thin-walled components, there are also problems such as high mold processing difficulty, high manufacturing cost, and poor forming flexibility, making it unable to meet the processing needs of multiple varieties and variable configuration components. The single-medium bulging process uses a single gas or liquid medium as the force transmission medium for bulging and forming. Although it can alleviate the stress concentration problem to some extent, the forming force is large and difficult to adjust in real time, resulting in large equipment tonnage and high scrap rate.

[0004] Fluid-solid multi-media hybrid low-pressure forming technology is a plastic forming method that uses a gas-liquid mixture to provide supporting pressure and a solid medium to achieve precise support for minute feature areas. It can form seamless hollow parts with complex curved surfaces and minute features at a lower initial internal pressure. Compared to traditional processes, the overall strength and service life of the formed parts are significantly improved, while also offering advantages such as high production efficiency and low manufacturing cost. It has become one of the core technological directions for forming complex thin-walled tubular components.

[0005] In addition, current forming technologies mostly adopt a top-down unidirectional loading mode, which has significant limitations in the pressing and forming of tubes: First, unidirectional loading greatly limits the structural complexity of the formed pipe fittings. It can only form simple pipe fittings with small changes in cross-sectional perimeter and smooth, featureless axis, and cannot meet the forming requirements of complex pipe fittings with large radial diameter ratios and small axial features. Second, under unidirectional loading mode, the material has poor fluidity and plastic deformation is concentrated in local areas. When conventional thin-walled tubes are molded and pressed, the performance of the tubes is easily affected by local thinning. Third, for difficult-to-form materials with a small difference between yield strength and tensile strength, the deformation mechanism dominated by uniaxial stress is very likely to cause the component to become unstable, wrinkled or cracked during the forming process, making it impossible to achieve precise control of material flow and resulting in extremely poor process adaptability. In summary, in order to overcome the technical bottleneck of unidirectional loading forming, realize the precision forming of complex thin-walled tubes with large radial diameter ratios and small axial features, and at the same time ensure the uniformity of the circumferential wall thickness of the components, so as to meet the high-end manufacturing needs of aerospace, automotive and energy equipment fields, it is urgent to develop a fluid-solid multi-media supported thin-walled component multidirectional loading forming device and supporting forming method. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a multi-directional loading device and method for thin-walled components supported by fluid-solid multi-media, solving the technical problems in the existing forming technology such as single loading direction, poor adjustability of medium support, difficulty in controlling material flow, uneven wall thickness of formed components, easy occurrence of wrinkling and cracking defects, and inability to adapt to the precision forming of complex-shaped thin-walled pipes.

[0007] The technical solution of the present invention: A multi-directional loading device for thin-walled components supported by fluid-solid multi-media includes an upper pressure module A, a lower pressure module B, a front pressure module C, a rear pressure module D, and an axial sealing loading unit. Define the pipe's axial direction as X, the vertical direction of the pipe's radial direction as Y, and the horizontal direction of the pipe's radial direction as Z; the upper pressure module A and the lower pressure module B are arranged symmetrically along the Y direction, the front pressure module C and the rear pressure module D are arranged symmetrically along the Z direction, and two axial sealing loading units are arranged symmetrically at both ends of the pipe along the X direction.

[0008] The upper pressing module A includes an upper plate 2, a fixed wedge 3, a nitrogen spring 4, a hydraulic clamp 5, an upper mold positioning groove 17, an upper mold left part 7, an upper mold middle part 8, and an upper mold right part 9. The upper plate 2 is fixedly connected to the lower surface of the press slide block 1 by the hydraulic clamp 5. The upper mold left part 7 is connected to the upper plate 2 by the nitrogen spring 4, the fixed wedge 3, and the flexible connecting rope 6, wherein the fixed wedge 3 and the flexible connecting rope 6 can move freely in the Y direction. The connection method between the upper mold right part 9 and the upper plate 2 is the same as the connection method between the upper mold left part 7 and the upper plate 2. The upper mold middle part 8 is fixedly connected to the upper mold positioning groove opened on the lower surface of the upper plate 2 by the hydraulic clamp 5.

[0009] The pressing module B includes a lower plate 15, a lower mold positioning groove 16 and a lower mold 20. The lower plate 15 is fixedly connected to the press worktable 14. The upper surface of the lower plate 15 has a lower mold positioning groove, which contains an electromagnet. The lower mold 20 is fixed to the lower plate 15 by the electromagnet in the lower mold positioning groove. After the upper pressure module A and the lower pressure module B are closed, the left part 7, the middle part 8, the right part 9, and the lower mold 20 of the upper mold form a mold cavity that matches the shape of the target component, so as to realize the loading of the pipe in the Y direction.

[0010] The axial sealing loading unit includes a cylinder 10, a punch 11, a cylinder base 12, and a cylinder support 13. The cylinder base 12 includes a first cylinder base 1201 and a second cylinder base 1202. The cylinder support 13 includes a first cylinder support 1301 and a second cylinder support 1302. The cylinder 10 includes a first cylinder 1001 and a second cylinder 1002. The punch 11 includes a first punch 1101 and a second punch 1102. The first cylinder support 1301 and the second cylinder support 1302 are symmetrically welded to both ends of the press worktable 14 in the X direction. The first cylinder base 1201 and the second cylinder base 1202 are symmetrically fixed to both ends of the press worktable 14 in the X direction. The first cylinder 1001 is fixedly connected to the first cylinder support 1301. The surface of cylinder 1001 contacts the support inside the first cylinder base 1201. The second cylinder 1002 is fixedly connected to the second cylinder support 1302, and the surface of the second cylinder 1002 contacts the support inside the second cylinder base 1202. The first punch 1101 is connected to the first cylinder 1001, and the second punch 1102 is connected to the second cylinder 1002. The first cylinder 1001 and the second cylinder 1002 are connected to the air source, which pushes the first punch 1101 and the second punch 1102 to translate in the X direction to load the pipe in the X direction and continuously pressurize when the first punch 1101 and the second punch 1102 penetrate into the pipe to achieve the sealing of the pipe. The first punch 1101 has an air inlet, and the second punch 1102 has a liquid inlet to achieve the filling of the gas-liquid mixed fluid medium.

[0011] The front pressing module C includes a third cylinder base 1203, a third cylinder support 1303, a third cylinder 1003, a third punch 1103, and a front die 18. The third punch 1103 is a dual-axis punch. The third cylinder support 1303 is welded to the Z-direction front end of the press worktable 14. The third cylinder base 1203 is symmetrically fixed to the Z-direction front end of the press worktable 14. The third cylinder 1003 is fixedly connected to the third cylinder support 1303. The surface of the third cylinder 1003 contacts the support inside the third cylinder base 1203. The third punch 1103 is connected to the third cylinder 1003. The front die 18 is connected to the I-beam guide rail on the upper surface of the lower plate 15 in the Z-direction through the I-beam groove on the lower surface and has translational freedom in the Z-direction. The third cylinder 1003 is connected to the air source and pushes the third punch 1103 to translate in the Z-direction to push the front die 18 to translate in the Z-direction. The structure of the rear pressure module D is the same as that of the front pressure module C, except that the front mold 18 is replaced by the rear mold 19. After the front pressure module C and the rear pressure module D are molded together, the front mold 18 and the rear mold 19 are molded together to form a mold cavity that matches the shape of the target component, so as to realize the loading of the pipe in the Z direction.

[0012] A multi-directional loading method for thin-walled members supported by fluid-structure interaction (FSI) includes the following steps: Step 1: Install the mold: Install the multi-directional loading device for the thin-walled component supported by fluid-solid multi-media; Step 2: Solid medium filling: Fill the tube blank with solid medium and place it on the lower mold 20; Step 3: Press descends: Press slide 1 descends to the left 7, middle 8, and right 9 of the upper die, where it contacts the lower die 20; Step 4: Sealing the tube blank: Start the first cylinder 1001 and the second cylinder 1002 to advance the first punch 1101 and the second punch 1102 to penetrate deep into the end of the tube blank and apply pressure to seal it; Step 5: Pre-loading mold closing: 1) Y-axis pre-loading contact: Control the press slide 1 to move downward, driving the upper mold left 7, upper mold middle 8, and upper mold right 9 of the Y-axis upper pressing module A to move downward until they lightly contact the surface of the tube blank, completing the Y-axis pre-loading positioning. At this time, the nitrogen spring 4 is in a naturally extended state; 2) Z-axis lateral loading mold closing: The third cylinder 1003 of the front pressing module C and the fourth cylinder 1004 of the rear pressing module D push the corresponding third punch 1103 and fourth punch 1104 to translate along the Z-axis and push the front mold 18 and rear mold 19 to move closer to the tube blank until the front mold 18 and rear mold 19 contact the surface of the tube blank. At the same time, the cylinder pressure is adjusted to apply a preset value of Z-axis lateral loading force to the tube blank to achieve Z-axis flexible loading; Step 6: Liquid and gas filling: Through the air filling port on the first punch 1101 and the liquid filling port on the second punch 1102 located on both sides of the axial sealing loading unit, a preset proportion of gas-liquid mixed medium is filled into the sealed tube blank. Combined with the pre-filled solid medium, a gas-liquid-solid three-medium coupling system is formed. The internal solid medium pressure is adjusted to the preset initial value to provide flexible internal support for the tube blank. Step 7: Loading and Forming: After the mold is closed, continue to control the press slide 1 to move downward to apply load. At this time, the left part 7 and the right part 9 of the upper mold reach the limit, and the corresponding nitrogen spring 4 begins to compress. The middle part 8 of the upper mold continues to move downward to pressurize the tube blank. At the same time, continue to control all cylinders 10 to drive the corresponding punch 11 to continue to move forward in the predetermined direction. Adjust the loading pressure of the X and Z cylinders 10 in real time to load synchronously with the middle part 8 of the upper mold. At the same time, adjust the pressure of the gas-liquid mixed fluid medium inside the tube blank to achieve the coordinated matching of external multi-directional mechanical loading and internal multi-medium pressure, guide the orderly flow of metal material, and complete the multi-directional flexible loading and forming of the tube blank. Step 8: Depressurization: After the pipe fitting is completely molded, depressurize the first cylinder 1001 and the second cylinder 1002 and activate the pressure relief valve to discharge the gas and liquid inside the pipe fitting. Step 9: Mold Separation: Control the press slide 1 to move upward and control all cylinders 10 to move backward, so that the left part 7, the middle part 8, and the right part 9 of the upper mold are separated from the lower mold 20, the front mold 18, and the rear mold 19. Step 10: Removal: Move the front mold 18 and rear mold 19 along the guide rail of the lower plate 15 and remove the pressed finished pipe from the lower mold 20.

[0013] The beneficial effects of this invention are: 1. The multi-medium fluid-structure interaction pressure forming mode is adopted, which is different from the traditional single liquid or single gas forming process. It adopts a multi-medium combination structure including gas, liquid and solid. Through the synergistic effect of the three media, the compression characteristics can be flexibly adjusted, which effectively solves the problem of fixed compression characteristics and large pressure fluctuations in traditional single-medium forming. It ensures stable pressure changes in the mold cavity, significantly improves the stability of the forming process, and reduces forming defects.

[0014] 2. Non-uniform loading and precise forming of complex features: Construct a fluid-solid multi-media support system. Solid media filling units provide precise rigid support for local complex feature areas, while gas-liquid mixed media provide flexible support for ordinary areas, realizing non-uniform loading. This fundamentally solves the problems of difficult forming of local complex features, overall warping, and uneven wall thickness. It can form complex concave, small rounded corners, right angles and other local shape features that are difficult to achieve with traditional processes, with high forming accuracy.

[0015] 3. Low internal pressure, small equipment tonnage, and low cost: The internal support uses a gas-liquid mixed medium and a solid medium working together, which significantly reduces the internal support pressure. There is no need for ultra-high pressure equipment, and a small tonnage press can be selected, which greatly reduces equipment investment and production costs.

[0016] 4. Forming Multi-directional Micro Features: A flexible loading structure is designed to meet the forming requirements of circular tubes or complex thin-walled parts. A flexible loading system is formed with upper die pressing, lower die support, and left and right lateral pressing to achieve all-round synchronous loading. This effectively solves the defects of uneven forming and large wall thickness deviation of traditional single and bi-directional loading when forming tubes with micro features in multiple directions. It can significantly reduce the degree of uneven wall thickness of components, improve the forming integrity of complex cross sections, and improve the forming accuracy and shape consistency of components. It is especially suitable for forming thin-walled components with complex cross sections.

[0017] 5. Improve the performance of formed components: Establish a scientific fluid-structure interaction forming mechanism. Through the synergistic effect and precise matching of external mechanical pressure (flexible loading pressure) and internal multi-medium pressure (solid, liquid, and gas pressure), a stable force system is formed, realizing stable plastic deformation of the billet. This solves the problem of deformation runaway caused by single pressure in traditional forming technology. It takes into account both forming dynamics and flexible support, further improving the forming quality and mechanical properties of components. At the same time, by utilizing the micro-region cumulative strain effect, the orderly and rational flow of metal materials is controlled, achieving uniform strengthening and toughening of materials and improving material utilization. Attached Figure Description

[0018] Figure 1 This is an isometric view of a multi-directional loading device for a thin-walled component supported by a fluid-solid multi-media system according to the present invention. Figure 2 This is a front view of a multi-directional loading device for a thin-walled component supported by a fluid-solid multi-media system according to the present invention. Figure 3 This is a left view of a multi-directional loading device for thin-walled components supported by a fluid-solid multi-media system according to the present invention. Figure 4 This is a schematic diagram of the upper pressure module of a multi-directional loading device for a thin-walled component supported by a fluid-solid multi-media system according to the present invention. Figure 5 This is a schematic diagram of the left and right pressure modules of a multi-directional loading device for a thin-walled component supported by a fluid-solid multi-media structure according to the present invention. Figure 6 This is a schematic diagram of the axial sealing loading unit of a multi-directional loading device for thin-walled components supported by fluid-solid multi-media according to the present invention; Figure 7 This is a schematic diagram of the pressing module of a multi-directional loading device for a thin-walled component supported by a fluid-solid multi-media structure according to the present invention. Figure 8 A partial sectional view of the middle section of the upper plate and upper mold for fixing the hydraulic caliper; Figure 9 A schematic diagram of a multi-directional loading mold adapted to this invention; Figure 10 Cross-sectional views of complex curved pipe fittings and molds; In the diagram: 1-Press slide block, 2-Upper plate, 3-Fixed wedge, 301-First fixed wedge, 302-Second fixed wedge, 303-Third fixed wedge, 304-Fourth fixed wedge, 4-Nitrogen spring, 401-First nitrogen spring, 402-Second nitrogen spring, 403-Third nitrogen spring, 404-Fourth nitrogen spring, 5-Hydraulic caliper, 501-First hydraulic caliper, 502-Second hydraulic caliper, 503-Third hydraulic caliper, 504-Fourth hydraulic caliper, 505-Fifth hydraulic caliper, 506-Sixth hydraulic caliper, 6-Flexible connecting rope, 601-First flexible connecting rope, 602-Second flexible connecting rope, 7-Left part of upper die, 8-Middle part of upper die, 9-Right part of upper die, 10-Cylinder, 1001-First cylinder, 1002-Second cylinder, 1003-... Three cylinders, 1004-Fourth cylinder, 11-Punch, 1101-First punch, 1102-Second punch, 1103-Third punch, 1104-Fourth punch, 12-Cylinder base, 1201-First cylinder base, 1202-Second cylinder base, 1203-Third cylinder base, 1204-Fourth cylinder base, 13-Cylinder support, 1301-First cylinder support, 1302-Second cylinder support, 1303-Third cylinder support, 1304-Fourth cylinder support, 14-Press machine worktable, 15-Lower plate, 16-Lower die positioning groove, 17-Upper die positioning groove, 18-Front die, 19-Rear die, 20-Lower die, A-Upper pressing module, B-Lower pressing module, C-Left pressing module, D-Right pressing module, E-First axial sealing loading unit, F-Second axial sealing loading unit. Detailed Implementation

[0019] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and technical solutions.

[0020] Example 1 like Figures 1-7 As shown, a multi-directional loading device for thin-walled components supported by fluid-solid multi-media according to the present invention includes an upper pressure module A, a lower pressure module B, a front pressure module C, a rear pressure module D, a first axial sealing loading unit E, and a second axial sealing loading unit F. Define the pipe's axial direction as X (horizontal left-right direction), the pipe's radial direction as the vertical direction as Y (up-down direction), and the pipe's radial direction as the horizontal direction as Z (front-back direction); the upper pressure module A and the lower pressure module B are symmetrically arranged along the Y direction, the front pressure module C and the rear pressure module D are symmetrically arranged along the Z direction, and the first axial sealing loading unit E and the second axial sealing loading unit F are symmetrically arranged at both ends of the pipe along the X direction. The upper pressing module A includes an upper plate 2, a fixing wedge 3, a nitrogen spring 4, a hydraulic caliper 5, an upper die positioning groove 17, a left part of the upper die 7, a middle part of the upper die 8, and a right part of the upper die 9. The fixing wedge 3 includes a first fixing wedge 301, a second fixing wedge 302, a third fixing wedge 303, and a fourth fixing wedge 304. The nitrogen spring includes a first nitrogen spring 401, a second nitrogen spring 402, a third nitrogen spring 403, and a fourth nitrogen spring 404. The hydraulic caliper 5 includes a first hydraulic caliper 501, a second hydraulic caliper 502, a third hydraulic caliper 503, a fourth hydraulic caliper 504, a fifth hydraulic caliper 505, and a sixth hydraulic caliper 506. The upper plate 2 is fixedly connected to the lower surface of the press slide block 1 via the first hydraulic caliper 501, the second hydraulic caliper 502, the third hydraulic caliper 503, and the fourth hydraulic caliper 504. The left part of the upper die 7 is connected to the first nitrogen spring 401 and the second nitrogen spring 402. The first fixed wedge 301, the second fixed wedge 302, and the first flexible connecting rope 601 are connected to the upper plate 2, wherein the first fixed wedge 301, the second fixed wedge 302, and the first flexible connecting rope 601 can move freely in the Y direction; the connection method between the right part 9 of the upper mold and the upper plate 2 is the same as the connection method between the left part 7 of the upper mold and the upper plate 2; the middle part 8 of the upper mold is fixedly connected to the upper mold positioning groove opened on the lower surface of the upper plate 2 through the fifth hydraulic clamp 505 and the sixth hydraulic clamp 506; The pressing module B includes a lower plate 15, a lower mold positioning groove 16 and a lower mold 20. The lower plate 15 is fixedly connected to the press worktable 14. The upper surface of the lower plate 15 has a lower mold positioning groove, which contains an electromagnet. The lower mold 20 is fixed to the lower plate 15 by the electromagnet in the lower mold positioning groove. After the upper pressure module A and the lower pressure module B are closed, the left part 7 of the upper mold, the middle part 8 of the upper mold, the right part 9 of the upper mold, and the lower mold 20 form a mold cavity that matches the shape of the target component, so as to realize the loading of the pipe in the Y direction; The axial sealing loading unit includes a cylinder 10, a punch 11, a cylinder base 12, and a cylinder support 13. The cylinder base 12 includes a first cylinder base 1201 and a second cylinder base 1202. The cylinder support 13 includes a first cylinder support 1301 and a second cylinder support 1302. The cylinder 10 includes a first cylinder 1001 and a second cylinder 1002. The punch 11 includes a first punch 1101 and a second punch 1102. The first cylinder support 1301 and the second cylinder support 1302 are symmetrically welded to both ends of the press worktable 14 in the X direction. The first cylinder base 1201 and the second cylinder base 1202 are symmetrically fixed to both ends of the press worktable 14 in the X direction. The first cylinder 1001 is fixedly connected to the first cylinder support 1301. The surface of cylinder 1001 contacts the support inside the first cylinder base 1201. The second cylinder 1002 is fixedly connected to the second cylinder support 1302, and the surface of the second cylinder 1002 contacts the support inside the second cylinder base 1202. The first punch 1101 is connected to the first cylinder 1001, and the second punch 1102 is connected to the second cylinder 1002. The first cylinder 1001 and the second cylinder 1002 are connected to the air source, which pushes the first punch 1101 and the second punch 1102 to translate in the X direction to load the pipe in the X direction and continuously pressurize when the first punch 1101 and the second punch 1102 penetrate into the pipe to achieve the sealing of the pipe. The first punch 1101 has an air inlet, and the second punch 1102 has a liquid inlet to achieve the filling of the gas-liquid mixed fluid medium.

[0021] The front pressing module C includes a cylinder base 12, a cylinder support 13, a cylinder 10, a punch 11, and a front mold 18. The cylinder base is a third cylinder base 1203, the cylinder support is a third cylinder support 1303, the cylinder is a third cylinder 1003, and the punch is a third punch 1103. The third punch 1103 is a dual-axis punch. The third cylinder support 1303 is welded to the Z-direction front end of the press worktable 14, and the third cylinder base 1203 is symmetrically fixed to the Z-direction front end of the press worktable 14. At the end, the third cylinder 1003 is fixedly connected to the third cylinder support 1303 by bolts. The surface of the third cylinder 1003 contacts the support inside the third cylinder base 1203. The third punch 1103 is connected to the third cylinder 1003 by bolts. The front mold 18 is connected to the I-beam guide rail on the upper surface of the lower plate 15 in the Z direction through the I-beam groove opened at the lower end and has translational freedom in the Z direction. The third cylinder 1003 is connected to the air source and pushes the third punch 1103 to translate in the Z direction to push the front mold 18 to translate in the Z direction.

[0022] The rear pressure module D includes a cylinder base, a cylinder support, a cylinder, a punch, and a rear mold. Specifically, the cylinder base is the fourth cylinder base 1204, the cylinder support is the fourth cylinder support 1304, the cylinder is the fourth cylinder 1004, and the punch is the fourth punch 1104. The structure is the same as that of the front pressure module C.

[0023] After the front pressure module C and the rear pressure module D are closed, the front mold 18 and the rear mold 19 form a mold cavity that matches the shape of the target component, so as to realize the loading of the pipe in the Z direction.

[0024] A multi-directional loading method for thin-walled members supported by fluid-structure interaction (FSI) includes the following steps: Step 1: Install the mold: Install the thin-walled component multi-directional loading device with fluid-solid multi-media support onto the mold.

[0025] Step 2: Solid medium filling: Fill the tube blank with solid medium and place it on the lower mold 20.

[0026] Step 3: Press descends: Press slide 1 descends to contact the left part 7, the middle part 8, the right part 9, and the lower mold 20.

[0027] Step 4: Sealing the tube blank: Start the first cylinder 1001 and the second cylinder 1002 to advance the first punch 1101 and the second punch 1102 to the end of the tube blank and apply pressure to seal it.

[0028] Step 5: Pre-loading mold closing: Y-axis pre-loading contact: Control the press slide 1 to move downward, driving the upper mold left 7, upper mold middle 8, and upper mold right 9 of the Y-axis upward pressing module to move downward until they lightly contact the surface of the tube blank, completing the Y-axis pre-loading positioning. At this time, the first nitrogen spring 401, the second nitrogen spring 402, the third nitrogen spring 403, and the fourth nitrogen spring 404 are in a naturally extended state; Z-axis lateral loading mold closing: The third cylinder 1003 and the fourth cylinder 1004 push the third punch 1103 and the fourth punch 1104 to translate along the Z-axis and push the front mold 18 and the rear mold 19 to move closer to the tube blank until the front mold 18 and the rear mold 19 contact the surface of the tube blank. At the same time, the cylinder pressure is adjusted to apply a preset value of Z-axis lateral loading force to the tube blank to achieve Z-axis flexible loading; Step 6: Liquid and gas filling: Through the air filling port on the first punch 1101 and the liquid filling port on the second punch 1102 on both sides of the axial sealing loading unit, a preset proportion of gas-liquid mixed medium is filled into the sealed tube blank. Combined with the pre-filled solid medium, a gas-liquid-solid three-medium coupling system is formed. The internal medium pressure is adjusted to the preset initial value to provide flexible internal support for the tube blank. Step 7: Loading and Forming: After mold closing, continue to control the press slide 1 to move downwards to apply load. At this time, the left part 7 and the right part 9 of the upper mold reach the limit, and the first nitrogen spring 401, the second nitrogen spring 402, the third nitrogen spring 403, and the fourth nitrogen spring 404 begin to compress. The middle part 8 of the upper mold continues to move downwards to precisely pressurize the small feature areas of the tube blank. At the same time, continue to control the first cylinder 1001, the second cylinder 1002, the third cylinder 1003, and the fourth cylinder 1004 to drive the first punch 1101, the second punch 1102, the third punch 1103, and the fourth punch 1104 to continue to move forward in the predetermined direction. The loading pressure of the X and Z direction cylinders is adjusted in real time to load synchronously with the middle part 8 of the upper mold. At the same time, the pressure of the gas-liquid mixed fluid medium inside the tube blank is adjusted to achieve the coordinated matching of external multi-directional mechanical loading and internal multi-medium pressure, guide the orderly flow of metal material, and complete the multi-directional flexible loading and forming of the tube blank. Step 8: Depressurization: After the pipe fitting is completely molded, depressurize the first cylinder 1001 and the second cylinder 1002 and activate the depressurization valve to discharge the gas and liquid inside the pipe fitting into the filling device. Step 9: Mold Separation: Control the press slide 1 to move upward and control the first cylinder 1001, the second cylinder 1002, the third cylinder 1003, and the fourth cylinder 1004 to move backward, so that the left part 7, the middle part 8, and the right part 9 of the upper mold are separated from the lower mold 20, the front mold 18, and the rear mold 19.

[0029] Step 10: Removal: Move the front mold 18 and rear mold 19 along the guide rail of the lower plate and remove the pressed finished pipe fitting from the lower mold 20.

[0030] Example 2 The multi-directional loading method for thin-walled components with fluid-solid multi-media support provided in this embodiment uses an electric lead screw structure to replace the guide rail on the lower plate 15 in Embodiment 1. The electric lead screw structure guides the front mold 18 and the rear mold 19 and controls mold closing and opening. The third punch 1103 and the fourth punch 1104 do not need to be connected to the front mold 18 and the rear mold 19; they only need to apply force to the front mold 18 and the rear mold 19 when a load is applied. The other steps are the same as in Embodiment 1.

[0031] Example 3 The multi-directional loading method for thin-walled components with fluid-solid multi-media support provided in this embodiment has a mold positioning groove in the lower plate 15, and an electromagnet is used in the mold positioning groove to fix and position the lower mold 20; other steps are the same as in embodiment 1.

[0032] Example 4 This embodiment provides a multi-directional loading device and method for thin-walled components with fluid-solid multi-media support. A hydraulic device is installed in the positioning groove of the lower mold. The lower mold 20 is connected to the hydraulic device through the positioning groove. The hydraulic cylinder can load upwards, allowing the lower mold 20 to actively apply load to the tube blank. This changes the situation in Embodiment 1 where the lower mold only exists as a support and cannot actively intervene in the material flow. The lower mold can be lifted to compensate for the thinned area, improving the uniformity of the wall thickness of the formed part. Other steps are the same as in Embodiment 1.

Claims

1. A multi-directional loading device for thin-walled components supported by fluid-solid multi-media, characterized in that, The fluid-solid multi-media supported thin-walled component multi-directional loading device includes an upper pressure module (A), a lower pressure module (B), a front pressure module (C), a rear pressure module (D), and an axial sealing loading unit; Define the pipe's axial direction as X, the vertical direction of the pipe's radial direction as Y, and the horizontal direction of the pipe's radial direction as Z; the upper pressure module (A) and the lower pressure module (B) are arranged symmetrically along the Y direction, the front pressure module (C) and the rear pressure module (D) are arranged symmetrically along the Z direction, and two axial sealing loading units are arranged symmetrically at both ends of the pipe along the X direction.

2. The multi-directional loading device for thin-walled components supported by fluid-solid multi-media according to claim 1, characterized in that, The upper pressing module (A) includes an upper plate (2), a fixed wedge (3), a nitrogen spring (4), a hydraulic caliper (5), an upper mold positioning groove (17), an upper mold left part (7), an upper mold middle part (8), and an upper mold right part (9); the upper plate (2) is fixedly connected to the lower surface of the press slide (1) by the hydraulic caliper (5); the upper mold left part (7) is connected to the upper plate (2) by the nitrogen spring (4), the fixed wedge (3), and the flexible connecting rope (6), wherein the fixed wedge (3) and the flexible connecting rope (6) can move freely in the Y direction; the connection method between the upper mold right part (9) and the upper plate (2) is the same as the connection method between the upper mold left part (7) and the upper plate (2); the upper mold middle part (8) is fixedly connected to the upper mold positioning groove opened on the lower surface of the upper plate (2) by the hydraulic caliper (5).

3. The multi-directional loading device for thin-walled components supported by fluid-solid multi-media according to claim 2, characterized in that, The pressing module (B) includes a lower plate (15), a lower die positioning groove (16) and a lower die (20). The lower plate (15) is fixedly connected to the press worktable (14). The upper surface of the lower plate (15) has a lower die positioning groove, which contains an electromagnet. The lower die (20) is fixed to the lower plate (15) by the electromagnet in the lower die positioning groove. After the upper pressure module (A) and the lower pressure module (B) are closed, the left part (7), the middle part (8), the right part (9), and the lower mold (20) of the upper mold form a mold cavity that matches the shape of the target component, so as to realize the loading of the pipe in the Y direction.

4. The multi-directional loading device for thin-walled components supported by fluid-solid multi-media according to claim 1, characterized in that, The axial sealing loading unit includes a cylinder (10), a punch (11), a cylinder base (12), and a cylinder support (13). The cylinder base (12) includes a first cylinder base (1201) and a second cylinder base (1202). The cylinder support (13) includes a first cylinder support (1301) and a second cylinder support (1302). The cylinder (10) includes a first cylinder (1001) and a second cylinder (1002). The punch (11) includes a first punch (1101) and a second punch (1102). The first cylinder support (1301) and the second cylinder support (1302) are symmetrically welded to both ends of the X-direction of the press worktable (14). The first cylinder base (1201) and the second cylinder base (1202) are symmetrically fixed to both ends of the X-direction of the press worktable (14). The first cylinder (1001) and the first cylinder support (1301) are fixed together. The first cylinder (1001) is fixedly connected to the support inside the first cylinder base (1201), and the second cylinder (1002) is fixedly connected to the second cylinder support (1302). The surface of the second cylinder (1002) is in contact with the support inside the second cylinder base (1202). The first punch (1101) is connected to the first cylinder (1001), and the second punch (1102) is connected to the second cylinder (1002). (1001) The second cylinder (1002) is connected to the air source and pushes the first punch (1101) and the second punch (1102) to translate in the X direction to load the pipe in the X direction. When the first punch (1101) and the second punch (1102) penetrate into the pipe, they continuously pressurize to achieve the sealing of the pipe. The first punch (1101) has an air inlet and the second punch (1102) has a liquid inlet to achieve the filling of the gas-liquid mixed fluid medium.

5. The multi-directional loading device for thin-walled components supported by fluid-structure interaction as described in claim 1, characterized in that, The front pressing module (C) includes a third cylinder base (1203), a third cylinder support (1303), a third cylinder (1003), a third punch (1103), and a front die (18); the third punch (1103) is a dual-axis punch, the third cylinder support (1303) is welded to the Z-direction front end of the press worktable (14), the third cylinder base (1203) is symmetrically fixed to the Z-direction front end of the press worktable (14), and the third cylinder (1003) and the third cylinder support... The base (1303) is fixedly connected, the surface of the third cylinder (1003) contacts the support inside the third cylinder base (1203), the third punch (1103) is connected to the third cylinder (1003), the front mold (18) is connected to the I-beam guide rail on the upper surface of the lower plate (15) through the I-beam groove on the lower surface and has translational freedom in the Z direction, the third cylinder (1003) is connected to the air source, and pushes the third punch (1103) to translate in the Z direction to push the front mold (18) to translate in the Z direction; The structure of the rear pressure module (D) is the same as that of the front pressure module (C), except that the front mold (18) is replaced by the rear mold (19). After the front pressure module (C) and the rear pressure module (D) are molded together, the front mold (18) and the rear mold (19) are molded together to form a mold cavity that matches the shape of the target component, so as to realize the loading of the pipe in the Z direction.

6. A multi-directional loading method for thin-walled components supported by fluid-structure interaction, characterized in that, The steps are as follows: Step 1: Install the mold: Install the multi-directional loading device for the thin-walled component supported by fluid-solid multi-media; Step 2: Solid medium filling: Fill the tube blank with solid medium and place it on the lower mold (20); Step 3: Press descends: The press slide (1) descends to the left (7), middle (8), and right (9) parts of the upper die, and contacts the lower die (20); Step 4: Sealing the tube blank: Start the first cylinder (1001) and the second cylinder (1002) to advance the first punch (1101) and the second punch (1102) to the end of the tube blank and pressurize it to seal; Step 5: Pre-loading mold closing: 1) Y-direction pre-loading contact: Control the press slide (1) to move downward, driving the upper mold left (7), upper mold middle (8), and upper mold right (9) of the Y-direction pressing module (A) to move downward until they lightly contact the surface of the tube blank, completing the Y-direction pre-loading positioning. At this time, the nitrogen spring (4) is in a natural extension state; 2) Z-direction lateral loading mold closing: The third cylinder (1003) of the front pressing module (C) and the fourth cylinder (10) 04 of the rear pressing module (D) push the corresponding third punch (1103) and fourth punch (11) 04 to translate along the Z-direction and push the front mold (18) and rear mold (19) to approach the tube blank until the front mold (18) and rear mold (19) contact the surface of the tube blank. At the same time, adjust the cylinder air pressure to apply a preset value of Z-direction lateral loading force to the tube blank to achieve Z-direction flexible loading; Step 6: Liquid and gas filling: Through the air filling port on the first punch (1101) and the liquid filling port on the second punch (1102) on both sides of the axial sealing loading unit, a preset proportion of gas-liquid mixed medium is filled into the sealed tube blank. Combined with the pre-filled solid medium, a gas-liquid-solid three-medium coupling system is formed. The internal solid medium pressure is adjusted to the preset initial value to provide flexible internal support for the tube blank. Step 7: Loading and forming: After the mold is closed, continue to control the press slide (1) to move down to apply load. At this time, the left part (7) and the right part (9) of the upper mold reach the limit, and the corresponding nitrogen spring (4) begins to compress. The middle part (8) of the upper mold continues to move down to pressurize the tube blank. At the same time, continue to control all cylinders (10) to drive the corresponding punch (11) to continue to move forward in the predetermined direction. Adjust the loading pressure of the X and Z cylinders (10) in real time and load synchronously with the middle part (8) of the upper mold. At the same time, adjust the pressure of the gas-liquid mixed fluid medium inside the tube blank to achieve the coordinated matching of external multi-directional mechanical loading and internal multi-medium pressure, guide the orderly flow of metal material, and complete the multi-directional flexible loading and forming of the tube blank. Step 8: Depressurization: After the pipe fitting is completely molded, depressurize the first cylinder (1001) and the second cylinder (1002) and activate the depressurization valve to discharge the gas and liquid inside the pipe fitting; Step 9: Mold Separation: Control the press slide (1) to move upward and control all cylinders (10) to move backward so that the left part (7), middle part (8), and right part (9) of the upper mold are separated from the lower mold (20), front mold (18), and rear mold (19); Step 10: Remove parts: Move the front mold (18) and rear mold (19) along the guide rail of the lower plate (15) and remove the finished pipe fitting after pressing from the lower mold (20).

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