A heat sink profile cutting and boss forming integrated processing method

Abstract

The application relates to the technical field of manufacturing engineering, and specifically discloses a heat radiator profile cutting and boss forming integrated processing method. The method comprises the following steps: S1, pre-strain treatment: pre-tensioning deformation is performed on a metal plate strip base material to obtain a pre-strain profile; S2, aging treatment: the pre-strain profile obtained in S1 is subjected to aging treatment to obtain a time-strengthened profile; S3, positioning and clamping: the time-strengthened profile is conveyed to a working area along a track and is clamped and fixed; S4, cutting and shaping: the profile is cut according to a required length by a cutting steel saw; after cutting, the cutting steel saw is lifted, the rear clamping device and the base thereof drive the cut profile to move backward and horizontally to one side of a forming steel saw; and S5, stress compensation and discharging. The processing method can be used for large-scale production of heat radiators, and has the advantages of improving material performance, improving processing efficiency, ensuring size precision and low residual stress.

Description

Technical Field

[0001] This application relates to the field of manufacturing engineering technology, and more specifically, it relates to an integrated processing method for radiator profile cutting and boss forming. Background Technology

[0002] The application of manufacturing engineering in radiator production mainly manifests in the integration of precision machining processes such as CNC machining, stamping, extrusion, and welding to transform design schemes into physical components. Its advantage lies in the integration and optimization of the process chain, realizing an integrated and automated process from cutting and forming to subsequent processing. This approach helps to improve production cycle time and product consistency, while reducing manufacturing costs and time consumption. On this basis, the complex geometric features of the radiator can achieve higher dimensional accuracy and form and position tolerance control, thereby ensuring the reliability and functionality of the structure, and ultimately promoting the improvement of the overall performance and quality of heat dissipation components.

[0003] The radiators are manufactured through step-by-step production. However, this method involves complicated procedures, the materials are not specifically enhanced during processing, and there are large cumulative errors and residual stresses from multiple processes. As a result, the final components have poor dimensional consistency, incomplete boss filling, or unstable cut surface quality, which affects the assembly accuracy and long-term service reliability of the radiators. Summary of the Invention

[0004] To address the issues of inconsistent dimensions, incomplete boss filling, or unstable cut surface quality in the final components caused by the step-by-step manufacturing of related radiators, this application provides an integrated processing method for radiator profile cutting and boss forming.

[0005] This application provides an integrated processing method for radiator profile cutting and boss forming, employing the following technical solution:

[0006] A method for integrated processing of radiator profile cutting and boss forming includes the following steps:

[0007] S1. Pre-strain treatment: The metal sheet / strip substrate is pre-stretched and deformed to obtain a pre-strained profile;

[0008] S2. Aging treatment: The pre-strained profiles obtained in S1 are subjected to aging treatment to obtain aging-strengthened profiles;

[0009] S3. Positioning and clamping: The age-strengthened profile obtained in S2 is transported to the working area along the track. The front clamping device clamps the rear end of the profile, and the rear clamping device holds the front end of the profile and applies pre-tightening force to clamp and fix it.

[0010] S4. Cutting and Shaping: The profile is cut to the required length by the cutting hacksaw. After cutting, the cutting hacksaw rises, and the rear clamping device and its base drive the cut profile to move backward and horizontally to the side of the forming hacksaw. The rear clamping device drives the profile to rotate, and the forming hacksaw descends according to the CNC programming. The rotation makes the profile one end processed into a boss of the required shape.

[0011] S5, Stress-compensated unloading: Apply a reverse compensation force to the formed component obtained in S4, and then unload it.

[0012] By adopting the above technical solutions, pre-strain strengthening, aging treatment, precision cutting and rotational forming, and stress compensation unloading are integrated into a continuous automated process. Pre-strain and aging treatment macroscopically enhance the strength and rigidity of the profile, making it sufficient to withstand the mechanical stress in the subsequent cutting and forming processes. Integrated cutting and forming avoids positioning errors and secondary clamping damage caused by intermediate transfer. Stress compensation unloading ultimately releases and homogenizes the internal stress of the workpiece, thereby significantly improving processing efficiency and the consistency of finished product performance while ensuring the dimensional accuracy and shape complexity of the product.

[0013] Preferably, in step S1, the pre-stretch deformation causes the substrate to have a pre-strain of 0.5% to 2.5%.

[0014] By adopting the above technical solution, since the pre-strain is controlled within a certain range, the plastic deformation within this range is sufficient to introduce a considerable dislocation density inside the material, providing sufficient nucleation sites for the dispersed precipitation of the strengthening phase in the subsequent aging treatment. At the same time, it avoids excessive pre-strain leading to excessive work hardening of the material and a sharp decrease in plasticity reserve, which would affect the subsequent extrusion molding process. Therefore, a pre-strained billet with both high strength and subsequent molding capability is obtained.

[0015] Preferably, before step S1, the substrate is further subjected to gradient preheating: the substrate is heated to 200-250°C at a rate of 10-20°C / min, held at that temperature for 5 minutes, and then naturally cooled to room temperature.

[0016] By adopting the above technical solution, a gradient preheating step is added before pre-straining, and a controllable rate of heating is used to uniformly heat the substrate to 200-250°C and hold it at that temperature for a short time. This process can eliminate some of the residual internal stress in the cast or cold-rolled strip, and allow the crystal structure to relax and homogenize to a certain extent. This reduces the peak flow stress and the tendency for uneven deformation in the subsequent pre-stretching deformation of the material. Therefore, a pre-processed billet with a more uniform internal stress state and a more consistent deformation response is obtained, laying the foundation for high-quality forming.

[0017] Preferably, in step S2, the aging treatment temperature is 80–150°C and the time is 10–40 min.

[0018] By adopting the above technical solution, after pre-straining, the material is aged for 10 to 40 minutes within a temperature range of 80 to 150°C. This temperature range can effectively activate the diffusion of solute atoms in age-hardening metals such as aluminum alloys, causing fine strengthening phase particles to precipitate in the high dislocation density region and grain boundaries introduced by pre-straining. These particles can pin dislocation movement, thereby achieving precipitation strengthening effect and improving the overall strength and stiffness of the material. Therefore, the age-hardened profile with improved strength is obtained, which is sufficient to withstand the high stress in the subsequent cutting process.

[0019] Preferably, in step S2, the aging treatment adopts a segmented temperature control process: first, it is kept at 80-100℃ for 20 minutes, and then the temperature is raised to 120-150℃ and kept for 10 minutes.

[0020] By adopting the above technical solution, the segmented aging process of first low temperature and then high temperature is used. First, the temperature is kept at a lower temperature, which is conducive to the formation of a large number of small and dispersed GP zones or transition phases, which serve as the core of the strengthening phase. Then, the temperature is raised and kept at a higher temperature, which allows the formed core to grow appropriately and transform into a more stable strengthening phase. At the same time, the coarsening of the strengthening phase caused by long-term treatment at a single high temperature is avoided. Therefore, profiles with improved strengthening phase size distribution and improved strengthening effect are obtained, which can improve strength while maintaining better toughness.

[0021] Preferably, in step S3, the clamping devices are multiple and distributed along the length of the profile.

[0022] By adopting the above technical solution, multiple clamping devices are spaced apart along the profile conveying direction, which can provide uniform and sufficient constraint force from multiple points throughout the entire process of profile conveying, positioning and clamping. This distributed clamping method effectively suppresses the vibration, warping or axial movement that may occur in long profiles due to force during processing, and provides a crucial positioning reference and rigid support for subsequent high-precision cutting and forming processes, ensuring the accuracy and consistency of the final component dimensions.

[0023] Preferably, in step S4, the cutting hacksaw and the forming hacksaw are arranged in series, and the rear clamping device drives the cut profile to move to the processing position of the forming hacksaw and then starts to rotate.

[0024] By adopting the above technical solution, the cutting station and the forming station are arranged in a serial straight line, which allows the cut profile to be directly moved along the track to the adjacent forming station by the same set of rear clamping devices without intermediate transfer or change of clamps. This layout greatly shortens the material flow path and waiting time between processes, and realizes seamless connection and continuous operation from fixed-length cutting to boss forming. It not only improves the overall production efficiency, but also reduces the errors that may be introduced by repeated positioning.

[0025] Preferably, in step S4, the boss is circular, square, square with chamfer, or other shapes, achieved by coordinating the rotation of the profile with dynamic adjustment of the hacksaw's descent height.

[0026] By adopting the above technical solution, the forming hacksaw, under the control of the computer numerical control system, can adjust its descent depth in real time and precisely according to the rotation angle of the profile. For every tiny rotation of the profile, the hacksaw moves to the corresponding preset depth for cutting. Through this linkage interpolation motion of rotation and axial feed, complex three-dimensional contours can be milled layer by layer at the end of the profile, thereby flexibly realizing the processing of various boss shapes from simple circles to chamfered squares, giving this integrated processing method a high degree of shape adaptability and flexibility.

[0027] Preferably, in step S5, the reverse compensation force is applied by multiple independently controlled push rods, each push rod having an ejection force of 50 to 200 N, and the ejection sequence is first the middle and then the edge.

[0028] By adopting the above technical solution, multiple independently controllable ejector rods are used to apply reverse compensation force during the unloading stage, and the process is carried out in the order of first ejecting the middle of the component and then ejecting the edge. The subsequent edge ejection ensures that the component is released smoothly and without twisting. Therefore, a finished product with a smooth unloading process, a final shape and size of the component that matches the design mold cavity height, and minimal residual stress and deformation is obtained.

[0029] Preferably, after step S5, the molding component is further subjected to a pulsed electromagnetic field treatment: the molding component is placed in an alternating pulsed magnetic field of 0.5 to 2T for 5 to 15 minutes, and the magnetic field frequency is 10 to 50Hz.

[0030] By adopting the above technical solution, a pulsed electromagnetic field treatment process is added after final unloading, in which the formed component is placed in an alternating pulsed magnetic field. Under the action of a strong alternating pulsed magnetic field, eddy currents are induced inside the component and Joule heating is generated. At the same time, the changing magnetic field force will exert Lorentz force on the dislocations, vacancies and other crystal defects inside the material, promoting their directional movement and reorganization under the thermo-mechanical coupling effect. This reduces and homogenizes the microscopic residual stress accumulated during the cutting process, especially the concentrated stress in high-stress areas such as the root of the boss. Therefore, a heat sink product with higher dimensional stability and better resistance to stress relaxation is obtained.

[0031] In summary, this application has the following beneficial effects:

[0032] 1. The method of this application arranges the cutting hacksaw and the forming hacksaw in series, and drives the cut profile to the forming station and rotates it by the same rear clamping device. With the help of CNC programming, the descent height of the forming hacksaw is dynamically adjusted to achieve the connection and continuous processing from fixed-length cutting to boss forming. Since this process shortens the material flow path and reduces repeated positioning errors, stress compensation unloading is achieved by applying reverse force through multiple independent control top rods in the order of first the middle and then the edge to ensure that the product is released smoothly. Therefore, a radiator product with high processing flexibility, high dimensional accuracy and small residual stress and deformation is obtained.

[0033] 2. In this application, a combination of gradient preheating and pre-stretching deformation is preferred. Since gradient preheating raises the temperature at a controllable rate and holds it at that temperature, it eliminates the residual internal stress formed in the substrate during casting or cold rolling, and relaxes and homogenizes the crystal structure. This reduces the peak flow stress and the tendency for uneven deformation in the subsequent pre-stretching deformation. This preheating step provides a basis for the introduction of a uniform dislocation structure in the pre-strain, which makes the strengthening phase more dispersed in the subsequent aging treatment. Therefore, a pre-processed billet with a more uniform internal stress state and a more consistent deformation response is obtained, laying the foundation for the shape accuracy and performance uniformity of the final component.

[0034] 3. Because this application adopts an integrated processing flow of pre-strain treatment, aging treatment, cutting and shaping and stress compensation unloading, the pre-strain introduces a high dislocation density inside the material to provide nucleation sites for the strengthening phase precipitated during aging, thereby improving the overall strength and stiffness of the profile through precipitation strengthening, making it sufficient to withstand the high stress in the subsequent cutting and forming processes. The integrated process integrates multiple processes into a continuous automated production line, avoiding positioning errors and secondary clamping damage caused by intermediate transfer. Therefore, it achieves the effects of improved processing efficiency, consistent product dimensional accuracy and stable mechanical properties. Attached Figure Description

[0035] Figure 1 This is a flowchart of an integrated processing method for radiator profile cutting and boss forming proposed in this application. Detailed Implementation

[0036] The present application will be further described in detail below with reference to the accompanying drawings and embodiments.

[0037] Technical concept:

[0038] The radiators are manufactured through step-by-step production. However, this method involves complicated procedures, the materials are not specifically enhanced during processing, and there are large cumulative errors and residual stresses from multiple processes. As a result, the final components have poor dimensional consistency, incomplete boss filling, or unstable cut surface quality, which affects the assembly accuracy and long-term service reliability of the radiators.

[0039] This application discloses an integrated processing method for radiator profile cutting and boss forming. It includes the following steps: S1, pre-strain treatment: pre-stretching and deforming the metal strip substrate to obtain a pre-strained profile; S2, aging treatment: aging the pre-strained profile obtained in S1 to obtain an age-strengthened profile; S3, positioning and clamping: conveying the age-strengthened profile along a track to the working area and clamping it in place; S4, cutting and shaping: cutting the profile to the required length using a cutting hacksaw; after cutting, the cutting hacksaw rises, and the rear clamping device and its base drive the cut profile to move backward and horizontally to one side of the forming hacksaw; S5, stress-compensated unloading.

[0040] The method of this application arranges the cutting hacksaw and the forming hacksaw in series, and drives the cut profile to the forming station and rotate it by the same rear clamping device. With the help of CNC programming, the descent height of the forming hacksaw is dynamically adjusted to achieve the connection and continuous processing from fixed-length cutting to boss forming. Because this process shortens the material flow path and reduces repeated positioning errors, stress compensation unloading is achieved by applying reverse force through multiple independent control push rods in the order of first the middle and then the edge to ensure that the product is released smoothly. Therefore, a radiator product with high processing flexibility, high dimensional accuracy and small residual stress and deformation is obtained.

[0041] Example 1: This example provides an integrated processing method for heat sink profile cutting and boss forming, comprising the following steps:

[0042] S1. Pre-strain treatment: The metal sheet / strip substrate is pre-stretched and deformed to obtain a pre-strained profile.

[0043] The pre-stretch deformation causes a pre-strain of 0.5% in the substrate. Prior to this step, the substrate is preheated in a gradient: the substrate is heated to 200°C at a rate of 10°C / min, held at that temperature for 5 minutes, and then allowed to cool naturally to room temperature.

[0044] S2. Aging treatment: The pre-strained profile obtained in S1 is subjected to aging treatment to obtain an age-strengthened profile.

[0045] The aging treatment is performed at a temperature of 80℃ for 10 minutes. The aging treatment adopts a segmented temperature control process: first, it is held at 80℃ for 20 minutes, and then the temperature is increased to 120℃ and held for 10 minutes.

[0046] S3. Positioning and clamping: The age-strengthened profile obtained in S2 is transported to the working area along the track. The front clamping device clamps the rear end of the profile, and the rear clamping device holds the front end of the profile and applies pre-tightening force to clamp and fix it.

[0047] The clamping devices are multiple and distributed along the length of the profile.

[0048] S4. Cutting and Shaping: The profile is cut to the required length by the cutting hacksaw. After cutting, the cutting hacksaw rises, and the rear clamping device and its base drive the cut profile to move backward and horizontally to the side of the forming hacksaw. The rear clamping device drives the profile to rotate, and the forming hacksaw descends according to the CNC programming. The rotation makes the profile end of one end processed into a boss of the required shape.

[0049] The cutting hacksaw and the forming hacksaw are arranged in series. The rear clamping device moves the cut profile to the processing position of the forming hacksaw and then begins to rotate. The boss is circular in shape, which is achieved by coordinating the rotation of the profile with the dynamic adjustment of the hacksaw's descent height.

[0050] S5, Stress-compensated unloading: Apply a reverse compensation force to the formed component obtained in S4, and then unload it.

[0051] The reverse compensation force is applied by multiple independently controlled push rods, each with an ejection force of 50N, and the ejection sequence is from the center to the edge. Following this step, a pulsed electromagnetic field treatment is performed on the molded component: the molded component is placed in a 0.5T alternating pulsed magnetic field with a frequency of 10Hz for 5 minutes.

[0052] Example 2: This example provides an integrated processing method for heat sink profile cutting and boss forming, comprising the following steps:

[0053] S1. Pre-strain treatment: The metal sheet / strip substrate is pre-stretched and deformed to obtain a pre-strained profile.

[0054] The pre-stretch deformation causes a pre-strain of 1.5% in the substrate. Prior to this step, the substrate is preheated in a gradient: the substrate is heated to 225°C at a rate of 15°C / min, held at that temperature for 5 minutes, and then allowed to cool naturally to room temperature.

[0055] S2. Aging treatment: The pre-strained profile obtained in S1 is subjected to aging treatment to obtain an age-strengthened profile.

[0056] The aging treatment was carried out at a temperature of 115℃ for 25 minutes. The aging treatment adopted a segmented temperature control process: first, it was held at 90℃ for 20 minutes, and then the temperature was increased to 135℃ and held for 10 minutes.

[0057] S3. Positioning and clamping: The age-strengthened profile obtained in S2 is transported to the working area along the track. The front clamping device clamps the rear end of the profile, and the rear clamping device holds the front end of the profile and applies pre-tightening force to clamp and fix it.

[0058] The clamping devices are multiple and distributed along the length of the profile.

[0059] S4. Cutting and Shaping: The profile is cut to the required length by the cutting hacksaw. After cutting, the cutting hacksaw rises, and the rear clamping device and its base drive the cut profile to move backward and horizontally to the side of the forming hacksaw. The rear clamping device drives the profile to rotate, and the forming hacksaw descends according to the CNC programming. The rotation makes the profile end of one end processed into a boss of the required shape.

[0060] The cutting hacksaw and the forming hacksaw are arranged in series. The rear clamping device moves the cut profile to the processing position of the forming hacksaw and then begins to rotate. The boss is square in shape and is achieved by coordinating the rotation of the profile with the dynamic adjustment of the hacksaw's descent height.

[0061] S5, Stress-compensated unloading: Apply a reverse compensation force to the formed component obtained in S4, and then unload it.

[0062] The reverse compensation force is applied by multiple independently controlled push rods, each with an ejection force of 125N, and the ejection sequence is from the center to the edge. Following this step, a pulsed electromagnetic field treatment is performed on the molded component: the molded component is placed in an alternating pulsed magnetic field of 1.25T for 10 minutes, with a magnetic field frequency of 30Hz.

[0063] Example 3: This example provides an integrated processing method for heat sink profile cutting and boss forming, comprising the following steps:

[0064] S1. Pre-strain treatment: The metal sheet / strip substrate is pre-stretched and deformed to obtain a pre-strained profile.

[0065] The pre-stretch deformation causes a pre-strain of 2.5% in the substrate. Prior to this step, the substrate is preheated in a gradient: the substrate is heated to 250°C at a rate of 20°C / min, held at that temperature for 5 minutes, and then allowed to cool naturally to room temperature.

[0066] S2. Aging treatment: The pre-strained profile obtained in S1 is subjected to aging treatment to obtain an age-strengthened profile.

[0067] The aging treatment was carried out at a temperature of 150℃ for 40 minutes. The aging treatment adopted a segmented temperature control process: first, the temperature was held at 100℃ for 20 minutes, and then the temperature was increased to 150℃ and held for 10 minutes.

[0068] S3. Positioning and clamping: The age-strengthened profile obtained in S2 is transported to the working area along the track. The front clamping device clamps the rear end of the profile, and the rear clamping device holds the front end of the profile and applies pre-tightening force to clamp and fix it.

[0069] The clamping devices are multiple and distributed along the length of the profile.

[0070] S4. Cutting and Shaping: The profile is cut to the required length by the cutting hacksaw. After cutting, the cutting hacksaw rises, and the rear clamping device and its base drive the cut profile to move backward and horizontally to the side of the forming hacksaw. The rear clamping device drives the profile to rotate, and the forming hacksaw descends according to the CNC programming. The rotation makes the profile end of one end processed into a boss of the required shape.

[0071] The cutting hacksaw and the forming hacksaw are arranged in series. The rear clamping device moves the cut profile to the processing position of the forming hacksaw and then begins to rotate. The boss is square with chamfered edges, and its shape is achieved by coordinating the rotation of the profile with the dynamic adjustment of the hacksaw's descent height.

[0072] S5, Stress-compensated unloading: Apply a reverse compensation force to the formed component obtained in S4, and then unload it.

[0073] The reverse compensation force is applied by multiple independently controlled push rods, each with an ejection force of 200N, and the ejection sequence is from the center to the edge. Following this step, a pulsed electromagnetic field treatment is performed on the molded component: the molded component is placed in a 2T alternating pulsed magnetic field with a frequency of 50Hz for 15 minutes.

[0074] Comparative Example 1: This comparative example refers to the content of Example 1, except that in step S1, the pre-stretch deformation causes the pre-strain of the substrate to be 0.3%; the rest is the same as Example 1.

[0075] Comparative Example 2: This comparative example refers to the content of Example 1, except that in the gradient preheating process before step S1, the substrate is heated to 280°C at a rate of 25°C / min, held at that temperature for 5 minutes, and then naturally cooled to room temperature; the rest of the content is the same as Example 1.

[0076] Comparative Example 3: This comparative example refers to the content of Example 1, except that in step S2, the aging treatment adopts a single temperature process: holding at 170°C for 30 minutes; the rest is the same as Example 1.

[0077] Comparative Example 4: This comparative example refers to the content of Example 1, except that in step S4, the forming method of "the forming hacksaw descends according to the CNC programming and rotates" is cancelled, and a set of forming molds with a fixed contour is used to punch the end of the profile in one go to process a circular boss; the rest of the content is the same as Example 1.

[0078] Comparative Example 5: This comparative example refers to the content of Example 1, except that in the step after step S5, in the step of treating the molded component with a pulsed electromagnetic field, the molded component is placed in an alternating pulsed magnetic field of 0.2T for 5 minutes, and the magnetic field frequency is 10Hz; the rest is the same as Example 1.

[0079] Comparative Example 6: This comparative example refers to the content of Example 1, except that the step of performing pulsed electromagnetic field treatment on the molded component is omitted after step S5. The rest of the content is the same as that of Example 1.

[0080] Performance testing

[0081] Sample preparation: Multiple sets of heat sink profile samples were prepared according to the process parameters and steps described in Examples 1-3 and Comparative Examples 1-6. All samples used aluminum alloy sheet and strip of the same batch and grade 6063 as the initial substrate to ensure the comparability of the test results. After cleaning and drying, the prepared samples were left to stand for 24 hours under the same environmental conditions before various performance tests were conducted.

[0082] Cutting quality inspection: This experiment uses a super depth-of-field three-dimensional microscope to observe and measure the cut surface of the sample. First, the sample is fixed on the stage along the direction perpendicular to the cut surface, and three fields of view are selected for observation, including the middle and both ends of the cross-section. The average surface roughness, maximum burr height, and collapse angle width of the cross-section are measured in each field of view. The average value of the five samples is calculated as the final cutting quality data of this process. The lower the surface roughness value, the smaller the burr height and the smaller the collapse angle width, the better the cutting quality. This test is mainly based on the relevant principles of cross-sectional morphology evaluation in the national standard "Test Method for Unidirectional Torsion of Metallic Wire" and refers to the industry standard "Burr Height of Stamped Parts" for burr evaluation.

[0083] Table 1: Cutting Quality Inspection Results

[0084]

[0085] Boss Forming Quality Inspection: This experiment uses a coordinate measuring machine (CMM) to precisely inspect the formed boss. The inspection procedure first constructs a theoretical 3D model of the boss, then uses a probe to scan all feature surfaces of the boss, including the top plane, sides, and root fillet. By comparing the measured point cloud with the theoretical model, the dimensional accuracy of the boss is evaluated. The main measurement items include the boss's fill height, top diameter, and root profile. The percentage of fill height reaching the design value and the profile tolerance are indicators for evaluating the integrity and accuracy of the forming process. This inspection follows the national standard "Product Geometric Technical Specifications: Geometric Tolerances - Shape, Orientation, Position, and Runout Tolerance Marking" regarding the detection and evaluation methods for profile tolerance.

[0086] Table 2: Quality Inspection Results of Boss Forming

[0087]

[0088] Dimensional accuracy inspection: This test selected three functional dimensions on the heat sink profile for measurement: the overall length after cutting, the mounting hole spacing, and the flatness of the substrate. A high-precision electronic digital caliper was used to measure the length and hole spacing. Each dimension was measured three times on a single sample, and the average value was calculated. The average and range of five samples were then calculated. A combination of a flat plate and feeler gauge was used to measure the substrate flatness, and the maximum gap value was recorded. Finally, the accuracy and repeatability of the process were evaluated by analyzing the deviation of the average value of the key dimensions from the design value and the dimensional range of the samples within the group. This test was conducted in accordance with the relevant provisions of the national standards "Dimensional Tolerances for Stamped Parts" and "Unspecified Tolerances for Shape and Position of Stamped Parts".

[0089] Table 3: Dimensional Accuracy Inspection Results

[0090]

[0091] Residual stress and long-term stability testing: This test uses X-ray diffraction to non-destructively measure the residual stress values ​​on the sample surface, especially near the cut surface and the root region of the boss. Three high-stress-risk points are measured for each sample, and the average value is taken. To assess long-term stability, samples that have completed the initial measurements are placed in an 85℃ constant-temperature environment for 500 hours to simulate the aging process of long-term service. After aging, residual stress is measured again at the same location, and the stress relaxation rate is calculated. The key functional dimensions are also remeasured, and their changes over time are calculated. The lower the residual stress relaxation rate and the smaller the dimensional change, the more stable the internal stress state of the component. The residual stress test follows the national standard "Determination of Residual Stress in Metallic Materials by X-ray Diffraction," and the stability test refers to the basic principles of the industry standard "Test Method for Stress Relaxation of Metals after Heat Treatment."

[0092] Table 4: Results of Residual Stress and Long-Term Stability Tests

[0093]

[0094] Example Conclusion:

[0095] Based on Examples 1-3 and Comparative Example 1, and in conjunction with Tables 1 and 2, it can be seen that when the prestrain is too low, the material suffers from insufficient deformation and a low dislocation density, failing to provide sufficient nucleation sites for subsequent aging precipitation, resulting in limited improvement in the overall strength and stiffness of the matrix. This makes the material more prone to plastic tearing during subsequent cutting, leading to rough cross-sections and increased burrs. During molding, the material's insufficient resistance to deformation easily results in inadequate filling and excessive elastic recovery, leading to a decrease in boss contour and dimensional accuracy. This indicates that controlling the prestrain within the range of 0.5%-2.5% is fundamental to obtaining a uniform high dislocation structure and ensuring high-precision cutting and molding quality.

[0096] As can be seen from Examples 1-3 and Comparative Example 2, and in conjunction with Tables 1, 2, and 4, using excessively high gradient preheating parameters beyond the scope of the claims can lead to abnormal grain growth or over-aging softening within the substrate, destroying the original uniform fine-grained structure of the material. This structural deterioration results in rough cross-sectional quality and increased corner collapse during cutting; during molding, the material's excessive fluidity makes precise control difficult, leading to distorted filling shapes; simultaneously, the coarse or unstable structure becomes a source of stress concentration and relaxation during subsequent processing and long-term use, resulting in high initial residual stress in the component and increased stress relaxation rate under thermal aging conditions, affecting the long-term dimensional stability of the product. This demonstrates the effectiveness of gradient preheating parameters in eliminating internal stress and homogenizing the structure without causing overheating damage.

[0097] As can be seen from Examples 1-3 and Comparative Example 3, and Table 4, replacing the segmented aging process in the claims with a single high-temperature aging process accelerates the precipitation and coarsening of the strengthening phase. The excessively coarse strengthening phase not only weakens the precipitation strengthening effect but also reduces the ability to pin dislocations and hinder grain boundary slip, leading to greater slip and recombination of internal dislocations and grain boundaries under subsequent processing stress and long-term thermal exposure. This manifests as higher initial residual stress in the component and a higher stress relaxation rate during thermal aging compared to the examples. This indicates that the segmented aging process can promote the precipitation of fine, dispersed strengthening phases, stabilize the microstructure, and thus improve the product's resistance to stress relaxation and long-term dimensional stability.

[0098] As can be seen from Examples 1-3 and Comparative Example 4, and in conjunction with Tables 2 and 3, the one-time stamping forming using a fixed contour mold has poor process flexibility. Stamping is an instantaneous large plastic deformation, which introduces high uneven stress and micro-defects in the root region of the boss. This leads to a deterioration in the contour of the formed boss, a decrease in dimensional accuracy, and a deterioration in the flatness of the substrate. This comparison shows that the processing method proposed in this application can reduce the additional stress and deformation during the forming process through controllable progressive material removal, thereby obtaining a high-precision boss and a high-flatness substrate.

[0099] As can be seen from Examples 1-3 and Comparative Example 5, and Table 4, when the intensity of the pulsed electromagnetic field treatment is insufficient, the magnetoplastic effect and magnetic energy it can provide are insufficient to drive the directional slip and reorganization of a large number of dislocations inside the material. Therefore, the effect of this treatment on homogenizing and eliminating the residual stress accumulated inside the component in the previous process is limited. Compared with the examples, the initial residual stress level of the component in the comparative example is higher, and the stress relaxation rate after thermal aging is not significantly improved. This confirms that controlling the intensity of the pulsed magnetic field within a certain range can ensure that it can effectively play its stress elimination role and reduce the initial internal stress level of the component.

[0100] As can be seen from Examples 1-3 and Comparative Example 6 and Table 4, the various residual stresses accumulated in the component during all the preceding processing steps cannot be effectively released and homogenized. Therefore, the component exhibits a high initial residual stress level, and during the subsequent thermal aging process, these internal stresses drive dimensional changes and shape instability, resulting in a high stress relaxation rate.

[0101] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A method for integrated processing of radiator profile cutting and boss forming, characterized in that, Includes the following steps: S1. Pre-strain treatment: The metal sheet / strip substrate is pre-stretched and deformed to obtain a pre-strained profile; S2. Aging treatment: The pre-strained profiles obtained in S1 are subjected to aging treatment to obtain aging-strengthened profiles; S3. Positioning and clamping: The age-strengthened profile obtained in S2 is transported to the working area along the track. The front clamping device clamps the rear end of the profile, and the rear clamping device holds the front end of the profile and applies pre-tightening force to clamp and fix it. S4. Cutting and Shaping: The profile is cut to the required length by the cutting hacksaw. After cutting, the cutting hacksaw rises, and the rear clamping device and its base drive the cut profile to move backward and horizontally to the side of the forming hacksaw. The rear clamping device drives the profile to rotate, and the forming hacksaw descends according to the CNC programming. The rotation makes the profile one end processed into a boss of the required shape. S5, Stress-compensated unloading: Apply a reverse compensation force to the formed component obtained in S4, and then unload it.

2. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, In step S1, the pre-stretch deformation causes the substrate to have a pre-strain of 0.5% to 2.5%.

3. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, Before step S1, the substrate is preheated in a gradient: the substrate is heated to 200-250°C at a rate of 10-20°C / min, held at that temperature for 5 minutes, and then naturally cooled to room temperature.

4. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, In step S2, the aging treatment temperature is 80–150℃ and the time is 10–40 min.

5. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, In step S2, the aging process adopts a segmented temperature control process: first, it is kept at 80-100℃ for 20 minutes, and then the temperature is raised to 120-150℃ and kept for 10 minutes.

6. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, In step S3, the clamping devices are multiple and distributed along the length of the profile.

7. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, In step S4, the cutting hacksaw and the forming hacksaw are arranged in series. The rear clamping device moves the cut profile to the processing position of the forming hacksaw and then starts to rotate.

8. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, In step S4, the boss can be circular, square, square with chamfer, or other shapes, and this is achieved by rotating the profile and dynamically adjusting the descent height of the hacksaw.

9. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, In step S5, the reverse compensation force is applied by multiple independently controlled push rods, each with an ejection force of 50–200 N, and the ejection sequence is first the middle and then the edge.

10. The integrated processing method for radiator profile cutting and boss forming according to claim 1, characterized in that, Following step S5, a step of pulsed electromagnetic field treatment of the molded component is also included: the molded component is placed in an alternating pulsed magnetic field of 0.5 to 2T for 5 to 15 minutes, with a magnetic field frequency of 10 to 50Hz.

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