A longitudinally non-uniform thickness beam-like part and a method of manufacturing the same

Abstract

The application discloses a longitudinal unequal-thickness beam part, which comprises a longitudinal beam body, which is internally hollow; and at least one hollow reinforcing member, which is arranged in the longitudinal beam body, and the outer wall of the reinforcing member is fixedly connected with the inner wall of the longitudinal beam body to provide supporting force for the longitudinal beam body. In addition, the application further provides a manufacturing method of the longitudinal unequal-thickness beam part. The thickness distribution of the beam part can be flexibly adjusted according to requirements, so that the optimization design of the load distribution of the beam structure can be realized, and the application has high flexibility, low cost and light weight.

Description

Technical Field

[0001] This invention relates to a mechanical component and its manufacturing method, and more particularly to a beam structure component and its manufacturing method. Background Technology

[0002] Thin-walled beams are a typical load-bearing structure widely used in transportation, construction, and other industries. During service, the loads on different parts of the beam structure can vary significantly. Designing the beam thickness based on the maximum load would result in excessively high safety factors for other locations, ultimately limiting the weight and cost of the design. Beam structures with unequal thicknesses, however, can meet performance requirements while controlling weight and cost.

[0003] In existing technologies, the main methods for implementing unequal thickness beam structures are as follows:

[0004] One method involves laser welding of sheets of varying thicknesses, followed by stamping or roll forming. This method can produce closed-section beam parts, but due to manufacturing cost limitations, it offers fewer thickness options and lacks flexibility.

[0005] Another method is to use a variable thickness rolling process to roll the sheet metal, and then form it by stamping or roll forming. This method can produce closed-section beam parts, but due to the cost limitations of variable thickness rolling, the final manufacturing cost of beam parts is relatively high. Summary of the Invention

[0006] One of the objectives of this invention is to provide a longitudinal beam-type component with unequal thickness, which can flexibly adjust the thickness of the beam-type component according to requirements, thereby enabling the optimized design of the load distribution of the beam structure. It has high flexibility, and is low in cost and light in weight.

[0007] To achieve the above objectives, the present invention provides a longitudinally unequal-thickness beam-type component, comprising:

[0008] The longitudinal beam body is hollow inside;

[0009] At least one hollow reinforcing member is disposed within the longitudinal beam body, the outer wall of the reinforcing member being fixedly connected to the inner wall of the longitudinal beam body to provide support for the longitudinal beam body.

[0010] With this configuration, the present invention can flexibly adjust the wall thickness of beam-type parts by setting reinforcing members with different wall thicknesses at different positions along the length of the longitudinal beam body.

[0011] Furthermore, in the longitudinal unequal thickness beam-type parts described in this invention, the reinforcing member is fixedly connected to the longitudinal beam body by welding.

[0012] Furthermore, in the longitudinal unequal thickness beam-type parts described in this invention, multiple reinforcing members are provided, and these multiple reinforcing members are arranged at intervals with each other along the length direction of the longitudinal beam body.

[0013] Furthermore, in the longitudinal unequal thickness beam-type parts described in this invention, the reinforcing member includes at least two reinforcing members with different wall thicknesses.

[0014] Furthermore, in the longitudinal unequal thickness beam type parts described in this invention, the ratio of the wall thickness t1 of the longitudinal beam body to the wall thickness t2 of the reinforcing member is t1 / t2 ≥ 1.5.

[0015] Furthermore, the cross-section of the longitudinally unequal-thickness beam-type parts described in this invention is rectangular.

[0016] Another objective of this invention is to provide a method for manufacturing longitudinally unequal-thickness beam-like parts, which allows for flexible adjustment of the thickness of the beam-like parts according to requirements, thereby enabling optimized design of the load distribution of the beam structure. This manufacturing method has a simple process and low manufacturing cost.

[0017] Based on the above-mentioned objectives, the present invention also provides a method for manufacturing longitudinally unequal-thickness beam-type parts, comprising the following steps:

[0018] The first plate, which is to be formed into a reinforcing member, is pre-welded to the surface of the second plate, which is to be formed into the body of a longitudinal beam.

[0019] The second plate, to which the first plate is welded, is formed into the longitudinally unequal thickness beam-like part using a roll forming process.

[0020] Furthermore, in the manufacturing method described in this invention, during welding, the weld points between the first plate and the second plate are controlled to satisfy the following condition: the distance d2 from the edge of the first plate to the weld point closest to the edge of the first plate is ≤ (t1+t2), where t1 represents the wall thickness of the longitudinal beam body and t2 represents the wall thickness of the reinforcing member.

[0021] Furthermore, in the manufacturing method described in this invention, during welding, the weld points between the first plate and the second plate are controlled to satisfy the following condition: the distance d1 from the weld point closest to the bend fillet is ≥ (t1+t2), where t1 represents the wall thickness of the longitudinal beam body and t2 represents the wall thickness of the reinforcing member.

[0022] Furthermore, in the manufacturing method described in this invention, during roll forming, for roll forming passes with a bending angle α ≤ 45°, the roll gap is adjusted by adjusting the gap between the upper and lower rolls of the roll forming machine in the height direction; for roll forming passes with a bending angle α > 45°, an auxiliary roll perpendicular to the inclined surface of the workpiece is used to adjust the roll gap.

[0023] Furthermore, in the manufacturing method described in this invention, a heating step is included after the roll forming step.

[0024] The longitudinal unequal thickness beam-type parts described in this invention can flexibly adjust the longitudinal thickness distribution according to the load distribution of the parts, avoiding traditional post-forming welding points or mechanical connection methods, and achieving optimal load-bearing performance while taking into account structural lightweighting.

[0025] The process for manufacturing longitudinal beams of unequal thickness described in this invention is simple and the manufacturing cost is low. Attached Figure Description

[0026] Figure 1 The diagram shows a structural schematic of a longitudinal unequal thickness beam-type part according to one embodiment of the present invention.

[0027] Figure 2 This diagram shows a structural schematic of the longitudinal unequal thickness beam-type part according to another embodiment of the present invention.

[0028] Figure 3 The diagram shows a welding process in one embodiment of the manufacturing method for longitudinally unequal-thickness beam-type parts according to the present invention.

[0029] Figure 4 for Figure 3 A magnified view of a portion of point A in the middle.

[0030] Figure 5 The diagram shows a schematic representation of the roll gap adjustment in one embodiment of the manufacturing method for longitudinally unequal-thickness beam-type parts according to the present invention.

[0031] Figure 6 This diagram illustrates the adjustment of the roll gap in another embodiment of the manufacturing method for longitudinally unequal-thickness beam-type parts according to the present invention. Detailed Implementation

[0032] The following will further explain and illustrate the longitudinal unequal thickness beam-type parts and their manufacturing method according to the present invention with reference to specific embodiments and accompanying drawings. However, this explanation and illustration do not constitute an undue limitation on the technical solution of the present invention.

[0033] Figure 1 The diagram shows a structural schematic of a longitudinal unequal thickness beam-type part according to one embodiment of the present invention.

[0034] In some embodiments, the present invention provides a longitudinal beam of unequal thickness, comprising: a hollow longitudinal beam body 1; and a hollow reinforcing member 2 disposed within the longitudinal beam body 1, wherein the outer wall of the reinforcing member 2 is fixedly connected to the inner wall of the longitudinal beam body, thereby providing support for the longitudinal beam body.

[0035] With this configuration, the present invention can flexibly adjust the wall thickness of beam-like parts by setting reinforcing members with different wall thicknesses at different positions along the length of the longitudinal beam body. For example, in this embodiment, by setting reinforcing member 2 within the longitudinal beam body 1, beam-like parts with two different wall thickness regions can be obtained. One region has a wall thickness equal to the wall thickness of the longitudinal beam body 1, and the other region has a wall thickness t1 of the longitudinal beam body 1 plus the wall thickness t2 of the reinforcing member 2. Furthermore, the position of the reinforcing member 2 along the length of the longitudinal beam body 1 can be adjusted as needed to regulate the position of the wall thickness increase region.

[0036] In some more specific implementations, such as Figure 1 As shown, the reinforcing member 2 is welded to the longitudinal beam body through multiple weld points 3.

[0037] In other embodiments, multiple reinforcing members may be provided.

[0038] Figure 2 This diagram shows a structural schematic of the longitudinal unequal thickness beam-type part according to another embodiment of the present invention.

[0039] For example, such as Figure 2 As shown, in some other embodiments, a first reinforcing member 21 and a second reinforcing member 22 are provided inside the longitudinal beam body 1.

[0040] In some more specific embodiments, the wall thicknesses of the first reinforcing member 21 and the second reinforcing member 22 may be different.

[0041] In a specific example, the wall thickness of the first reinforcing member 21 can be 1 mm, the wall thickness of the second reinforcing member 22 can be 1.2 mm, and the wall thickness of the longitudinal beam body 1 can be 2 mm.

[0042] In some specific embodiments, multiple reinforcing members can be arranged at intervals between each other along the length of the longitudinal beam body. For example, as... Figure 2 As shown, there is a gap between the first reinforcing member 21 and the second reinforcing member 22.

[0043] Of course, in other implementations, two or more reinforcing members can be arranged close together, depending on the thickness distribution requirements.

[0044] Furthermore, in some preferred embodiments, in order to reduce the impact of thickness variation of beam-type parts with unequal thickness on the stability of the forming process, the ratio of the wall thickness t1 of the longitudinal beam body to the wall thickness t2 of the reinforcing member is t1 / t2 ≥ 1.5.

[0045] In some implementations, the cross-section of beam-type parts with unequal longitudinal thickness can be rectangular.

[0046] In some other embodiments, the cross-section of beam-type parts with unequal thickness in the longitudinal direction can also be circular.

[0047] In one embodiment, the present invention also provides a method for manufacturing the above-mentioned longitudinally unequal-thickness beam-type parts, which may include the following steps:

[0048] 100: The first plate 41, which is to be formed into a reinforcing member, is pre-welded to the surface of the second plate 42, which is to be formed into a longitudinal beam body, for example, as shown in the figure. Figure 3 shown.

[0049] 200: The roll forming process is adopted to form the second plate with the first plate welded on it into longitudinal beam-like parts with unequal thickness. During the roll forming process, the gap between the rolls in each forming pass can be dynamically servo-adjusted according to the thickness of the plate.

[0050] In some more specific embodiments, to prevent the weld joint from cracking during subsequent bending and forming, in step 100, during welding, such as Figure 4 As shown, the weld points between the first and second plates are controlled to satisfy the following condition: the distance d2 from the edge of the first plate to the weld point closest to the edge of the first plate is ≤ (t1 + t2). And / or, the weld points between the first and second plates are also controlled to satisfy the following condition: the distance d1 from the weld point closest to the bend radius R to the bend radius is ≥ (t1 + t2), where t1 represents the wall thickness of the longitudinal beam body (i.e., the thickness of the second plate), and t2 represents the wall thickness of the reinforcing member (i.e., the thickness of the first plate).

[0051] In a specific example, when the thickness of the second plate is 2mm and the thickness of the first plate is 1.2mm, the distance d2 between the weld point closest to the edge of the first plate and the edge of the first plate can be controlled to be 3mm, and the distance d1 between the weld point closest to the bending radius R and the bending radius can be controlled to be 5mm.

[0052] In some more specific embodiments, in step 200, for roll forming passes with a bending angle α ≤ 45°, for example, Figure 5 As shown, the roll gap can be adjusted by adjusting the distance between the upper roll 51 of the roll forming machine and the fixed lower roll 52 in the height direction.

[0053] For roll forming passes with a bending angle α greater than 45°, such as Figure 6 As shown, the roll gap can be adjusted using an auxiliary roller 54 that is perpendicular to the inclined surface of the workpiece. For example, keeping the lower roller 52 and the side roller 53 stationary, the auxiliary roller 54 is moved along the inclined surface of the workpiece in a direction P perpendicular to the inclined surface of the workpiece to adjust the roll gap.

[0054] 300: Use an online induction heating device to heat longitudinal beam-type parts with unequal thickness.

[0055] In some more specific implementations, the tensile strength of the longitudinally unequal-thickness beam-like parts obtained is >1300MPa.

[0056] Therefore, the longitudinal unequal thickness beam-type parts described in this invention have a stable structure and can flexibly adjust the longitudinal thickness distribution according to the load distribution of the parts, thus exhibiting high flexibility. In addition, its manufacturing method has a simple process and low manufacturing cost.

[0057] It should be noted that the combination of the technical features in this case is not limited to the combination methods described in the claims of this case or the combination methods described in the specific embodiments. All technical features described in this case can be freely combined or combined in any way, unless they contradict each other.

[0058] It should also be noted that the embodiments listed above are merely specific embodiments of the present invention. Obviously, the present invention is not limited to the above embodiments, and similar changes or modifications made thereto are those that can be directly derived or easily conceived by those skilled in the art from the content disclosed in the present invention, and should all fall within the protection scope of the present invention.

Claims

1. A longitudinal beam-like part with unequal thickness, characterized in that, include: The longitudinal beam body is hollow inside; At least one hollow reinforcing member is disposed within the longitudinal beam body, the outer wall of the reinforcing member being fixedly connected to the inner wall of the longitudinal beam body to provide support for the longitudinal beam body.

2. The longitudinally unequal thickness beam-type part as described in claim 1, characterized in that, The reinforcing member is fixedly connected to the longitudinal beam body by welding.

3. The longitudinally unequal thickness beam-like part as described in claim 1, characterized in that, The reinforcing members are provided in multiple quantities, and these multiple reinforcing members are arranged at intervals to each other along the length direction of the longitudinal beam body.

4. The longitudinally unequal thickness beam-like part as described in claim 1, characterized in that, The reinforcing member includes at least two reinforcing members with different wall thicknesses.

5. The longitudinally unequal thickness beam-like part as described in claim 1, characterized in that, The ratio of the wall thickness t1 of the longitudinal beam body to the wall thickness t2 of the reinforcing member is t1 / t2 ≥ 1.

5.

6. The longitudinally unequal-thickness beam-type part as described in claim 1, characterized in that, Its cross-section is rectangular.

7. The method for manufacturing longitudinally unequal-thickness beam-type parts as described in any one of claims 2-6, characterized in that, Including the following steps: The first plate, which is to be formed into a reinforcing member, is pre-welded to the surface of the second plate, which is to be formed into the body of a longitudinal beam. The second plate, to which the first plate is welded, is formed into the longitudinally unequal thickness beam-like part using a roll forming process.

8. The manufacturing method as described in claim 7, characterized in that, During welding, the weld points between the first plate and the second plate are controlled to satisfy the following condition: the distance d2 from the edge of the first plate to the weld point closest to the edge of the first plate is ≤ (t1+t2), where t1 represents the wall thickness of the longitudinal beam body and t2 represents the wall thickness of the reinforcing member.

9. The manufacturing method as described in claim 7, characterized in that, During welding, the weld points between the first and second plates are controlled to satisfy the following condition: the distance d1 from the weld point closest to the bend fillet is greater than or equal to (t1+t2), where t1 represents the wall thickness of the longitudinal beam body and t2 represents the wall thickness of the reinforcing member.

10. The manufacturing method as described in claim 7, characterized in that, During roll forming, for roll forming passes with a bending angle α ≤ 45°, the roll gap is adjusted by adjusting the gap between the upper and lower rolls of the roll forming machine in the height direction; for roll forming passes with a bending angle α > 45°, an auxiliary roll perpendicular to the inclined surface of the workpiece is used to adjust the roll gap.

11. The manufacturing method as described in claim 7, characterized in that, The process includes a heating step after the roll forming step.

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