New energy automobile aluminum alloy door inner plate stamping forming die

Abstract

The application discloses a new energy automobile aluminum alloy door inner plate stamping forming die, relates to the stamping forming technical field, and aims to solve the technical problem that the aluminum alloy door inner plate is unevenly deformed and prone to defects in traditional vertical stamping forming in the prior art, and discloses a new energy automobile door inner plate stamping forming die. The die comprises a base, a swing die core hinged to the base, a driving assembly, a transmission mechanism and a motion conversion assembly in transmission connection with the transmission mechanism. The motion conversion assembly cooperates with the swing die core and is used for driving the swing die core to reciprocating swing around the hinge point thereof. The method uses the above-mentioned die, drives the motion conversion assembly to move through the transmission mechanism by the driving assembly, and then drives the swing die core to reciprocating swing, so that the aluminum alloy plate placed on the lower die is swing stamped and formed. According to the swing stamping forming mode, the material instantaneous deformation rate and stress concentration are reduced, the material uniform flow is promoted, and the cracking, springback and other defects of the aluminum alloy door inner plate in the forming process are effectively reduced.

Description

Technical Field

[0001] This invention relates to the field of stamping technology, and more specifically, to a stamping die for aluminum alloy inner door panels of new energy vehicles. Background Technology

[0002] In the field of new energy vehicle manufacturing, lightweighting is an important development trend, and aluminum alloy door inner panels are widely used due to their light weight and high strength. However, during the forming process, aluminum alloy materials have poorer fluidity and ductility compared to traditional steel plates. When using traditional vertical stamping forming processes, the material deforms violently and unevenly in the mold cavity, which easily leads to defects such as cracking, springback, and poor surface quality, making it difficult to meet the high-precision forming requirements.

[0003] In existing technologies, the stamping of car door inner panels mainly relies on single vertical stamping with a fixed die structure, making it impossible to precisely and dynamically control the local deformation of the material during the stamping process. This results in difficulty in guaranteeing the forming quality and a high scrap rate for aluminum alloy car door inner panel parts that require precise local forming. In view of this, we propose a stamping die for aluminum alloy inner door panels of new energy vehicles. Summary of the Invention

[0004] The purpose of this invention is to provide a stamping die and stamping method for the inner panel of a new energy vehicle door, so as to solve the technical problems of uneven material deformation and easy defects in the traditional vertical stamping process of aluminum alloy inner panel of the vehicle door, and to achieve a high-precision swing stamping effect.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a stamping die for aluminum alloy inner door panels of new energy vehicles, including a base; a swinging die core hinged to the base; a drive assembly; a transmission mechanism connected to the drive assembly; and a motion conversion assembly connected to the transmission mechanism and cooperating with the swinging die core to drive the swinging die core to swing back and forth around its hinge point.

[0006] Preferably, the transmission mechanism includes a crankshaft connecting rod assembly, a gear distribution assembly, and a screw-slider assembly. The crankshaft connecting rod assembly is drive-connected to the drive assembly. The gear distribution assembly is located between the crankshaft connecting rod assembly and the screw-slider assembly and is drive-connected to both of them. The motion conversion assembly includes an extrusion wheel and an inclined adapter groove formed on the oscillating mold core. The extrusion wheel is connected to the screw-slider assembly and makes extrusive contact with the inclined adapter groove.

[0007] Preferably, the crankshaft connecting rod assembly includes a drive spindle rotatably mounted on the base, a crankshaft fixed to the drive spindle, a piston connecting rod hinged to the crankshaft, and a piston sleeve connected to the piston connecting rod; the gear distribution assembly includes two parallel and meshing gears, and an output gear parallel between the two gears, wherein one of the gears is connected to the drive spindle, and the output gear is drivenly connected to the screw-slider assembly; the drive assembly is drivenly connected to the piston sleeve and is used to drive the piston sleeve to reciprocate.

[0008] Preferably, the screw-slider assembly includes a slide rail fixed to the base, a slider that slides with the slide rail, a threaded sleeve fixed to the slider, and a drive screw that threads with the threaded sleeve, the drive screw being connected to the output gear; the motion conversion assembly further includes an extension shaft fixed to the slider, and the extrusion wheel is rotatably disposed at the end of the extension shaft via a compensation assembly.

[0009] Preferably, the gear distribution assembly and the screw-slider assembly are symmetrically arranged in two sets, and the sliders in the two sets of screw-slider assemblies are driven by the corresponding drive screws to move synchronously and in the same direction.

[0010] Preferably, it also includes an upper mold, which is movably set via a frame lifting track, and the upper mold is provided with force-bearing wheel frames on both sides; the frame lifting track has a vertically movable state and a locked and fixed state, and the force-bearing wheel frames are in an outward and upward curved arc shape.

[0011] Preferably, it further includes a mold machine base and a lower mold disposed on the mold machine base, with the base disposed above the lower mold.

[0012] Compared with existing technologies, the beneficial effects of this invention are as follows: The core of the stamping die operation lies in the power output by the drive component 30, which is transmitted and converted step by step through the transmission mechanism, and finally acted on the swinging die core hinged to the base 10 by the motion conversion component, causing it to generate a reciprocating swinging stamping action around the hinge point. This swinging action makes the forming force of the die on the aluminum alloy sheet not a simple vertical impact, but a continuous and gradual local rolling process. This process significantly reduces the instantaneous deformation rate and stress concentration of the material, and promotes a more uniform and sufficient plastic flow of the aluminum alloy material in the die cavity, thereby effectively solving the technical problems of uneven material deformation, easy cracking and springback in traditional vertical stamping, and realizing high-precision and high-quality forming of aluminum alloy door inner panels for new energy vehicles and precision aluminum alloy forgings. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the present invention; Figure 2 This is a schematic diagram of the overall disassembled three-dimensional structure of the present invention; Figure 3 This is a schematic diagram of the three-dimensional structure of the swing mold core of the present invention; Figure 4 For the present invention Figure 3 A magnified view of the structure at point A in the middle; Figure 5 This is a three-dimensional structural diagram of the drive component of the present invention; Figure 6 For the present invention Figure 5 A magnified schematic diagram of the structure at point B in the middle.

[0014] Explanation of the labels in the diagram: 10. Base; 20. Swinging mold core; 21. Inclined adapter groove; 30. Drive assembly; 40. Transmission mechanism; 41. Crankshaft connecting rod assembly; 411. Drive spindle; 412. Crankshaft; 413. Piston connecting rod; 414. Piston sleeve; 42. Gear distribution assembly; 421. First gear; 422. Second gear; 423. Output gear; 43. Screw slider assembly; 431. Slide rail; 432. Slider; 433. Threaded sleeve; 434. Drive screw; 50. Motion conversion assembly; 51. Extrusion wheel; 52. Extension shaft; 53. Compensation assembly; 60. Upper mold; 62. Force-bearing wheel frame; 70. Upper mold core; 81. Lower mold. Detailed Implementation

[0015] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0016] This application aims to provide a high-precision stamping solution for aluminum alloy door inner panels of new energy vehicles. Addressing the problems of uneven deformation, cracking, and springback that easily occur in traditional vertical stamping of aluminum alloy materials, this solution introduces a controllable oscillating stamping motion into the mold, simulating a localized, progressive forming process similar to a rolling mill, to optimize material flow and improve forming quality and part precision.

[0017] Before describing the technical solution in detail, the core terms used in this application will be explained: Oscillating die core: refers to a die forming component that can reciprocate around a specific axis (i.e., hinge point), and the shape of its working surface is adapted to the inner door panel part being stamped.

[0018] Frame lifting rail: refers to a guiding and locking device that connects the movable part of the mold (such as the mold above) to the fixed machine base. It has two states: one is the movable state that allows the movable part to move vertically within a certain range; the other is the locked and secured state that rigidly locks the movable part in a certain position.

[0019] Force-bearing wheel frame: refers to the arc-shaped support structure installed on the outside of the movable mold (such as the mold above). It is designed to contact the external drive mechanism (such as the horizontal propulsion mechanism) and transmit lateral force to pry the mold to move up and down.

[0020] Hinged connection: refers to a connection method that allows the connected components (such as a oscillating mold core) to rotate about the connection point (i.e., the hinge point) relative to another component (such as a base).

[0021] Drive components: These are the power source components that provide initial power to the entire drive train.

[0022] Transmission mechanism: refers to a series of mechanical components that connect the drive component and the motion conversion component, and are used to transmit, convert and distribute the form of power (such as the conversion between linear motion and rotary motion).

[0023] Motion conversion component: refers to the direct execution component that converts the motion output from the transmission mechanism into the oscillating motion of the oscillating mold core.

[0024] This invention relates to a stamping die for an aluminum alloy inner door panel of a new energy vehicle. The die includes a base 10, a swinging die core 20, a drive assembly 30, a transmission mechanism 40, and a motion conversion assembly. The swinging die core 20 is hinged to the base 10; the transmission mechanism 40 is drive-connected to the drive assembly 30; the motion conversion assembly is drive-connected to the transmission mechanism 40 and cooperates with the swinging die core 20 to drive the swinging die core 20 to reciprocate around its hinge point.

[0025] According to the present invention, the core of the operation of the stamping die lies in the power output by the drive component 30, which is transmitted and converted step by step through the transmission mechanism 40, and finally acted by the motion conversion component on the swing die core 20 hinged to the base 10, causing it to generate a reciprocating swinging stamping action around the hinge point. This swinging action makes the forming force of the die on the aluminum alloy sheet not a simple vertical impact, but a continuous and gradual local rolling process. This process significantly reduces the instantaneous deformation rate and stress concentration of the material, promotes a more uniform and sufficient plastic flow of the aluminum alloy material in the die cavity, and thus effectively solves the technical problems of uneven material deformation, easy cracking and springback in traditional vertical stamping, realizing high-precision and high-quality forming of aluminum alloy door inner panels for new energy vehicles and precision aluminum alloy forgings.

[0026] In one embodiment, the transmission mechanism 40 and motion conversion assembly mentioned above specifically include a crankshaft connecting rod assembly 41, a gear distribution assembly 42, and a screw slider assembly 43. The crankshaft connecting rod assembly 41 is connected to the drive assembly 30. The gear distribution assembly 42 is located between the crankshaft connecting rod assembly 41 and the screw slider assembly 43 and is connected to both of them. The motion conversion assembly specifically includes an extrusion wheel 51 and an inclined adaptation groove 21 formed on the swing die core 20. The extrusion wheel 51 is connected to the screw slider assembly 43 and makes extrusion contact with the inclined adaptation groove 21. In detail, the linear reciprocating power provided by the drive assembly 30 first drives the crankshaft connecting rod assembly 41 to move, converting it into rotational motion. This rotational power is then distributed to the screw-slider assembly 43 via the gear distribution assembly 42, which converts the rotational motion back into linear motion. Finally, the extrusion wheel 51, connected to the screw-slider assembly 43, applies the linear motion to the inclined fitting groove 21 of the oscillating die core 20. As the contact point between the inclined surface of the fitting groove 21 and the extrusion wheel 51 changes with the movement of the slider, a torque is generated that forces the oscillating die core 20 to rotate around its hinge point, thus realizing the oscillating motion. Furthermore, this multi-stage transmission and conversion structure offers unique advantages such as a clear power transmission path, smooth motion conversion, and precise control of the oscillation amplitude and speed through mechanism parameters (such as crankshaft eccentricity, gear ratio, screw lead, and fitting groove inclination angle). As a specific implementation, the tilt angle of the tilting adapter groove 21 on the upper surface of the swing mold core 20 can be specifically designed according to the required swing angle and slider stroke, for example, selected in the range of 15° to 45°.

[0027] In one embodiment, the crankshaft connecting rod assembly 41 and gear distribution assembly 42 mentioned above specifically include a drive shaft 411 rotatably mounted on the base 10, a crankshaft 412 fixed to the drive shaft 411, a piston connecting rod 413 hinged to the crankshaft 412, and a piston sleeve 414 connected to the piston connecting rod 413; the gear distribution assembly 42 specifically includes two parallel and meshing gears (shown as a first gear 421 and a second gear 422 in the figure) and an output gear 423 parallel between the two gears, wherein one of the gears (e.g., the first gear 421) is connected to the drive shaft 411 (e.g., via a key), and the output gear 423 is drive-connected to the screw-slider assembly 43; the drive assembly 30 is drive-connected to the piston sleeve 414 and is used to drive the piston sleeve 414 to reciprocate. In detail, when the piston sleeve 414 is driven to perform linear reciprocating motion, the piston connecting rod 413 drives the crankshaft 412 to rotate, which in turn drives the drive shaft 411 and its first gear 421 to rotate. The first gear 421 drives the second gear 422, which meshes with it, to rotate in the opposite direction, forming a reciprocating rotational motion state between the two meshing gears. The output gear 423, located between the two, obtains power from this pair of meshing gears and outputs a unified direction of rotation. Furthermore, based on the above principle, this crankshaft connecting rod and gear combination structure can bring about the unique and beneficial effect of efficiently and reliably converting the linear power of the drive assembly 30 into rotational power, and achieving stable distribution and transmission of motion through the meshing gears. As a specific implementation, the drive assembly 30 can be a hydraulic cylinder, whose cylinder body or piston rod is connected to the piston sleeve 414 by a hinge to provide reciprocating driving force.

[0028] In one embodiment, the screw-slider assembly 43 and the motion conversion assembly mentioned above specifically include a slide rail 431 fixed to the base 10, a slider 432 slidably engaged with the slide rail 431, a threaded sleeve 433 fixed to the slider 432, and a drive screw 434 threadedly engaged with the threaded sleeve 433. The drive screw 434 is connected to the output gear 423 (coaxially fixed). The motion conversion assembly also includes an extension shaft 52 fixed to the slider 432, and the extrusion roller 51 is rotatably disposed at the end of the extension shaft 52 via a compensation assembly 53. In detail, the output gear 423 drives the drive screw 434 to rotate. Since the threaded sleeve 433 threadedly engaged with the drive screw 434 is restricted to linear movement only by the slide rail 431 through the slider 432, the rotational motion of the drive screw 434 is converted into the precise linear sliding of the slider 432 along the slide rail 431. The extension shaft 52, fixed to the slider 432, moves synchronously, driving the extrusion roller 51 at its end to move. Furthermore, based on the above principle, this screw-slider structure can convert the rotational motion of the gear into high-precision linear displacement. Its transmission is smooth and self-locking, facilitating precise control of the swing position of the swinging mold core 20. The compensation component 53 automatically compensates for the contact gap between the extrusion roller 51 and the sidewall of the inclined adapter groove 21, or for wear caused by long-term use, ensuring continuous and shock-free power transmission. This has a unique and beneficial effect on improving motion accuracy and equipment durability.

[0029] In one embodiment, for the aforementioned gear distribution assembly 42 and screw-slider assembly 43, two sets of each assembly are symmetrically arranged. The sliders 432 in the two sets of screw-slider assemblies 43 are driven synchronously and in the same direction by the corresponding drive screws 434. Specifically, by setting two symmetrical sets of gear distribution assemblies 42 and screw-slider assemblies 43, which act on both sides of the oscillating mold core 20 respectively, it is ensured that the extrusion rollers 51 on both sides can slide synchronously and in the same direction along their respective inclined fitting grooves 21. This symmetrical driving method ensures that the oscillating mold core 20 is subjected to balanced forces on both sides during oscillation, avoiding mold core distortion or additional stress that may be caused by unilateral driving, ensuring the smoothness of the oscillation action and the uniformity of the molding process, and has a unique and beneficial effect of improving the quality stability of the molded parts.

[0030] In one embodiment, the stamping die further includes an upper die 60, which is movably mounted via a frame lifting track, and has force-bearing wheel frames 62 on both sides. Specifically, the upper die 60, as the movable part supporting the upper die core 70 and the internal swing die core 20 mechanism, is connected to the die machine base or the base of the lower die 81 via the frame lifting track, allowing the upper die 60 to be vertically adjusted. The force-bearing wheel frames 62 on both sides provide a contact interface with an external horizontal propulsion mechanism (not shown, such as a hydraulic cylinder or servo push rod). Furthermore, combined with the swing stamping process, the liftable upper die 60 allows the die to flexibly adjust the closing gap or pressure of the upper and lower dies during the stamping process according to the material deformation state or different process requirements, optimizing flexible contact conditions to adapt to the dynamic forming process required by swing stamping.

[0031] In one embodiment, the frame lifting track and the force-bearing wheel frame 62 mentioned above have a vertically movable state and a locked and secured state, and the force-bearing wheel frame 62 is an outwardly and upwardly curved arc. Specifically, the vertically movable state of the frame lifting track allows the upper die 60 to generate a lever effect around a fulcrum when the external horizontal propulsion mechanism acts on the arc-shaped force-bearing wheel frame 62, thereby being pried up and smoothly adjusted by a small distance. When high rigidity support is required for stamping, it switches to the locked and secured state, firmly locking the upper die 60 to ensure the overall rigidity of the stamping system. The arc-shaped force-bearing wheel frame 62 not only increases the contact area with the external propulsion mechanism, making the force more uniform, but its arc-shaped guide surface also provides a smooth force transition upon contact, reducing impact. Furthermore, the configuration of this dual-state track and arc-shaped wheel frame brings unique advantages such as flexible operation, convenient adjustment, and high stability in the final locked state.

[0032] In one embodiment, the stamping die further includes an upper die core 70, which is detachably installed within the upper die 60. The upper die core 70 specifically includes a vertical stamping die core and a swing die core 20, with a base 10 disposed within the swing die core 20. More specifically, the upper die core 70 adopts a modular design, allowing for selection based on molding process requirements: either a vertical stamping die core for traditional vertical stamping, or a swing die core 20 integrating the swing stamping mechanism of this application for swing stamping, or a combination of both. The base 10 serves as the core supporting frame of the internal mechanism of the swing die core 20 and is fixedly installed therein. Furthermore, this detachable modular die core design offers unique advantages such as convenient die function switching, easy maintenance and replacement, and high production flexibility.

[0033] In one embodiment, the stamping die further includes a die set and a lower die 81 disposed on the die set, with a base 10 positioned above the lower die 81. Specifically, the die set provides a stable foundation and mounting platform for the entire stamping system, with the lower die 81 fixedly mounted thereon for placing and positioning the aluminum alloy sheet to be stamped. The oscillating stamping mechanism, supported by the base 10, is located above the lower die 81. Through the closing of the upper die 60 and the oscillation of the oscillating die core 20, the required forming actions are applied to the sheet metal on the lower die 81. This constitutes a complete stamping workstation layout.

[0034] It should be noted that, in some optional embodiments, the compensation component 53 can adopt a disc spring assembly, an elastic sleeve, or a hydraulic gap compensator, etc. Its core function is to provide a preset elastic preload or displacement compensation between the extrusion wheel 51 and the inclined adapter groove 21 to eliminate gaps and buffer impacts. The drive component 30, in addition to a hydraulic cylinder, can also adopt a servo electric cylinder, linear motor, or other power device capable of providing precise linear reciprocating motion. The piston sleeve 414 is typically movably arranged on the base 10 via a guide sleeve to limit its movement trajectory and improve movement stability. The specific implementation of the frame lifting track can include a combination of precision guide rail and lockable slider, or a combination of guide post and guide sleeve and hydraulic locking pin. The upper die core 70 and the upper mold 60, and the vertical stamping die core and the swing die core 20 and the upper mold 60, can all be fixed by detachable connections such as bolts, slots, and quick-change couplings. Key structural components such as the base 10, swing mold core 20, slide rail 431, and slider 432 can be made of high-strength alloy steel, mold steel, or high-strength aluminum alloy to ensure sufficient rigidity, strength, and wear resistance. The swing angle range of the swing mold core 20 can be determined by coordinating the design of the crankshaft 412 eccentricity, the lead of the drive screw 434, and the tilt angle of the tilting adapter groove 21, for example, achieving a swing range of ±5° to ±15° to meet the forming requirements of different part surfaces. The lubrication and sealing of the entire transmission system also need to be designed according to the specific working environment to ensure long-term stable operation.

[0035] This application also provides a method for stamping inner panels of new energy vehicle doors, which uses a stamping die for new energy vehicle door inner panels as described in any of the foregoing embodiments of this application. Specifically, it includes steps S110 and S120.

[0036] Step S110 involves placing and positioning the aluminum alloy sheet to be formed on the lower mold 81.

[0037] Step S120 involves driving the drive assembly 30, which in turn drives the motion conversion assembly via the transmission mechanism 40. This causes the extrusion wheel 51 to slide within the inclined adapter groove 21 of the swing die core 20, thereby driving the swing die core 20 to reciprocate around its hinge point and perform swing stamping on the aluminum alloy sheet. This method achieves high-precision, low-defect forming of aluminum alloy car door inner panels by replacing traditional single vertical stamping with controllable swing stamping.

[0038] The embodiments disclosed in this invention are preferred embodiments, but are not limited thereto. Those skilled in the art can easily understand the spirit of this invention based on the above embodiments and make different extensions and variations, but as long as they do not depart from the spirit of this invention, they are all within the protection scope of this invention.

Claims

1. A stamping die for aluminum alloy inner door panels of new energy vehicles, characterized in that, include: Base; The swing mold core is hinged to the base; Driver components; The transmission mechanism is connected to the drive assembly in a transmission manner; The motion conversion component is connected to the transmission mechanism and cooperates with the swing mold core to drive the swing mold core to swing back and forth around its hinge point.

2. The stamping die for an aluminum alloy inner door panel of a new energy vehicle according to claim 1, characterized in that, The transmission mechanism includes a crankshaft connecting rod assembly, a gear distribution assembly, and a screw slider assembly. The crankshaft connecting rod assembly is connected to the drive assembly, and the gear distribution assembly is located between the crankshaft connecting rod assembly and the screw slider assembly and is connected to both of them. The motion conversion component includes an extrusion wheel and an inclined adapter groove formed on the oscillating die core. The extrusion wheel is connected to the screw slider assembly and makes extrusion contact with the inclined adapter groove.

3. The stamping die for an aluminum alloy inner door panel of a new energy vehicle according to claim 2, characterized in that, The crankshaft connecting rod assembly includes a drive spindle rotatably mounted on the base, a crankshaft fixed to the drive spindle, a piston connecting rod hinged to the crankshaft, and a piston sleeve connected to the piston connecting rod. The gear distribution assembly includes two parallel and meshing gears, and an output gear parallel between the two gears, wherein one of the gears is connected to the drive spindle, and the output gear is connected to the screw slider assembly in a transmission connection. The drive assembly is connected to the piston sleeve and is used to drive the piston sleeve to reciprocate.

4. The stamping die for an aluminum alloy inner door panel of a new energy vehicle according to claim 3, characterized in that, The screw-slider assembly includes a slide rail fixed to the base, a slider that slides with the slide rail, a threaded sleeve fixed to the slider, and a drive screw that is threaded with the threaded sleeve. The drive screw is connected to the output gear. The motion conversion assembly also includes an extension shaft fixed to the slider, and the extrusion wheel is rotatably disposed at the end of the extension shaft via a compensation assembly.

5. The stamping die for an aluminum alloy inner door panel of a new energy vehicle according to claim 4, characterized in that, The gear distribution assembly and the screw-slider assembly are both symmetrically arranged in two sets, and the sliders in the two sets of screw-slider assemblies are driven by the corresponding drive screws to move synchronously and in the same direction.

6. A stamping die for an aluminum alloy door inner panel of a new energy vehicle according to any one of claims 1 to 5, characterized in that, It also includes an upper mold, which is movably set via a frame lifting track, and force-bearing wheel frames are provided on both sides of the upper mold; the frame lifting track has a vertically movable state and a locked and fixed state, and the force-bearing wheel frames are in an outward and upward curved arc shape.

7. The stamping die for an aluminum alloy inner door panel of a new energy vehicle according to claim 6, characterized in that, It also includes an upper die core, which is detachably installed inside the upper mold. The upper die core includes a vertical stamping die core and a swing die core, and the base is disposed inside the swing die core.

8. The stamping die for an aluminum alloy inner door panel of a new energy vehicle according to claim 7, characterized in that, It also includes a mold machine base and a lower mold set on the mold machine base, with the base set above the lower mold.

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