General combined die for forming circular arc transition plate

Abstract

The utility model discloses a kind of general combined die of arc transition plate forming, it is related to locomotive manufacturing big curvature bending component manufacturing technical field, including upper die assembly and the lower die assembly cooperation with upper die assembly, the bottom of upper die assembly is provided with arc convex, lower die assembly upper surface is provided with the arc concave groove cooperation with arc convex;Upper die assembly includes and is provided with several detachable upper die sheet and the upper locking assembly of locking all upper die sheet, and the curvature radius of different upper die sheet arc convex is same or different;Lower die assembly includes and is provided with several detachable lower die sheet and the lower locking assembly of locking all lower die sheet, and the curvature radius of different upper die sheet arc concave groove is same or different.The utility model uses modularization combinable structure, realizes curvature self-adaption by dispersed upper die sheet and lower die sheet combination, break through the single curvature limit of traditional mould;Pre-compensation angle offsets material elastic recovery, realizes net forming.Die sheet group reusable rate reaches 95%, mould development cost reduces 70%.

Description

Technical Field

[0001] This utility model relates to the field of manufacturing technology for large curvature bending components in locomotive manufacturing, and more specifically to the field of a general-purpose combined mold for forming arc transition plates. Background Technology

[0002] In the locomotive manufacturing field, there are numerous bent components with large curvatures in the steel structure of the car body, including typical parts such as transition plates with arc radii R5-200mm, fairings, and air duct rectifiers. Traditional processes employ a step-by-step point bending forming method, gradually approximating the target curvature through multiple local bending operations. However, this process suffers from significant technical bottlenecks: Molding quality defects: High-frequency point bending causes dense creases on the surface of the sheet material, and local stress concentration causes micro-cracks, affecting the surface flatness of the component and the adhesion of the coating; Dimensional accuracy out of control: Manual point bending makes it difficult to accurately control the springback, and the consistency of arc radius is poor (tolerance zone ±3mm), which affects the assembly and fitting accuracy; Low production efficiency: On average, each piece requires 5-10 folding operations, taking 20-40 minutes per piece, and is highly dependent on the experience of the operators. High mold costs: Traditional integral molds adopt a single casting structure, costing as much as 10,000-20,000 RMB or more. A single mold weighs 1.2-2.5 tons, and the development cycle is as long as 4-6 weeks, which cannot meet the needs of multi-variety small-batch production. Utility Model Content

[0003] The purpose of this invention is to solve the above-mentioned technical problems by providing a universal combination mold for forming arc transition plates. It is applicable to the bending and forming of typical workpieces such as transition plates, air guides, and air duct rectifiers.

[0004] To achieve the above objectives, this utility model specifically adopts the following technical solution: This utility model provides a general-purpose combined mold for forming an arc transition plate, including an upper mold assembly and a lower mold assembly that cooperates with the upper mold assembly. The bottom of the upper mold assembly is provided with an arc-shaped protrusion, and the upper surface of the lower mold assembly is provided with an arc-shaped groove that cooperates with the arc-shaped protrusion. The upper mold assembly includes several detachable upper mold pieces arranged side by side and an upper locking assembly for locking all the upper mold pieces. The curvature radii of the arc protrusions of different upper mold pieces may be the same or different. The lower mold assembly includes several detachable lower mold pieces arranged side by side and a lower locking assembly for locking all the lower mold pieces. The curvature radii of the arc grooves of different upper mold pieces may be the same or different.

[0005] Specifically, this solution adopts a modular and combinable structure, achieving curvature self-adaptation through the combination of distributed upper and lower mold pieces, breaking through the single curvature limitation of traditional molds; pre-compensation angles offset the elastic recovery of materials, achieving net forming. The mold piece group (upper mold piece group and lower mold piece group) has a reusability rate of 95%, and the mold development cost is reduced by 70%.

[0006] In one embodiment, the upper mold plate includes an upper mold plate body, a protruding upper arc-shaped curve disposed at the bottom of the upper mold plate body, two secondary locking holes disposed on both sides of the top of the upper mold plate body, and a main locking hole disposed at the middle of the top of the upper mold plate body, with the two secondary locking holes symmetrically disposed on both sides of the main locking hole.

[0007] In one embodiment, both the secondary locking hole and the main locking hole are check holes with a smaller outer diameter and a larger inner diameter.

[0008] In one embodiment, the upper locking assembly includes a main pin that mates with a main locking hole and secondary pins that mate with two secondary locking holes. The cross-sectional shape of the main pin is adapted to the shape of the main locking hole, and the cross-sectional shape of the secondary pins is adapted to the shape of the secondary locking holes.

[0009] In one embodiment, the lower mold plate includes a lower mold plate body, a lower arc-shaped curve recessed at the top of the lower mold plate body, and two auxiliary locking holes on both sides of the top of the lower mold plate body.

[0010] In one embodiment, two auxiliary locking holes are symmetrically arranged on both sides of the top of the lower mold body, and the auxiliary locking holes are check holes with a smaller outer diameter and a larger inner diameter.

[0011] In one embodiment, the lower locking assembly includes auxiliary pins that engage with main pins that mate with two auxiliary locking holes, the cross-sectional shape of which is adapted to the shape of the auxiliary locking holes.

[0012] In one embodiment, the auxiliary pin, secondary pin, and main pin are all trapezoidal pins.

[0013] Specifically, this solution uses a distributed mold assembly method, rather than integral casting; trapezoidal pin pieces are tolerantly fitted to achieve rigid connection and quick assembly / disassembly.

[0014] In one embodiment, the bottom of the lower mold assembly is configured as an open or T-shaped opening, and the bottom of the lower mold assembly is provided with a mounting base that mates with the open or T-shaped opening.

[0015] Specifically, the lower die assembly of this mold is designed to be open or T-shaped to meet the shape of the lower die mounting base of the bending machine. After the mold is assembled, it can be directly placed on the bending machine for clamping and fixing, so that the mold can be used on different machine tools. During the forming process, multiple arc transition plates can be formed at one time. For some S-shaped bending objects in the production process, the overall one-time forming can be achieved by changing the mold piece, further improving production efficiency.

[0016] Working Principle: This combined mold consists of upper and lower molds and connecting pins. The upper mold assembly is composed of several stacked forming punches (the number of which is determined by the actual size of the material to be formed), which are fixed together by two connecting pins and then connected to the slider fixing pin on the bending machine. The lower mold assembly is composed of several stacked forming concave molds (the number of lower molds is the same as that of the upper molds), which are fixed together by two connecting pins and then installed on the mold mounting base of the bending machine. Each mold is laser-cut with an error of ≤0.5mm, which is sufficient to ensure the dimensional and shape accuracy of the arc transition plate and ensure the stability of product quality. It can meet the requirements of forming parts with a transition arc radius of R5-200mm and a length of less than 1000mm. Through precise design and processing of mold parts, reasonable mold structure, and the setting of limit blocks and pressure balancing mechanisms, the springback deformation can be effectively controlled during the forming process, thus effectively controlling deformation and errors.

[0017] Another aspect of this utility model provides a general-purpose combined mold manufacturing process for forming an arc transition plate, as follows: S1. Module group configuration (upper module group and lower module group): Calculate the required number of upper and lower module groups based on the target radius of curvature R; S2. Mold assembly: The upper mold plate group is connected by the main pin plate and the auxiliary pin plate, and the lower mold plate group is connected by the auxiliary pin plate. The hydraulic early warning device applies a preload force of ≥50KN. S3. Integral pressing and forming: 800T bending machine for single pressing and bending, holding pressure for 30-45 seconds; S4. Use a test template to check whether the forming curvature meets the standard. If the deviation is > ±0.5mm, adjust the pressure parameters and iteratively optimize the parameters of the upper and lower mold plates.

[0018] The innovation of this process is: single-piece integral pressing and molding, non-point-folding molding, and surface roughness Ra≤3.2um.

[0019] Technical effect.

[0020] The beneficial effects of this utility model are as follows: 1. This utility model adopts a modular and combinable structure, and achieves curvature self-adaptation through the combination of dispersed upper and lower mold pieces, breaking through the single curvature limitation of traditional molds; the pre-compensation angle offsets the elastic recovery of the material, and achieves net forming.

[0021] 2. Single molding eliminates creases and surface roughness meets assembly requirements: the radius tolerance is controlled within ±0.5mm and the angle deviation is ≤±0.3°; the distributed mold can disperse the bending force, avoiding the situation where the force of the whole mold is concentrated and breaks. The life cycle of the combinable mold is longer than that of the whole mold.

[0022] 3. Single-piece molding time is reduced to 8-10 minutes, improving efficiency by 500% compared to traditional processes; the reusability of mold sets reaches 95%, and mold development costs are reduced by 70%; 4. Curvature switching within the RR range can be completed within 20 minutes through module recombination, supporting the production of multi-specification workpieces. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram showing that the bottom of the lower mold component is set to an open shape; Figure 3 This is a schematic diagram showing the bottom of the lower mold component being set in a T-shape; Reference numerals in the attached drawings: 1. Main pin piece; 2. Secondary pin piece; 3. Upper mold plate body; 4. Lower mold plate body; 5. Auxiliary pin piece; 6. Mounting base. Detailed Implementation

[0025] To make the technical problems, technical solutions, and technical effects of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of this utility model. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0026] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0027] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0028] In the description of the embodiments of this utility model, it should be noted that the terms "inner", "outer", "upper", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the utility model product is usually placed when in use. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0029] Example 1 like Figures 1 to 3 As shown, this embodiment provides a general-purpose combined mold for forming an arc transition plate, including an upper mold assembly and a lower mold assembly that cooperates with the upper mold assembly. The bottom of the upper mold assembly is provided with an arc-shaped protrusion, and the upper surface of the lower mold assembly is provided with an arc-shaped groove that cooperates with the arc-shaped protrusion. The upper mold assembly includes several detachable upper mold pieces arranged side by side and an upper locking assembly for locking all the upper mold pieces. The curvature radii of the arc protrusions of different upper mold pieces may be the same or different. The lower mold assembly includes several detachable lower mold pieces arranged side by side and a lower locking assembly for locking all the lower mold pieces. The curvature radii of the arc grooves of different upper mold pieces may be the same or different.

[0030] Specifically, this solution adopts a modular and combinable structure, achieving curvature self-adaptation through the combination of distributed upper and lower mold pieces, breaking through the single curvature limitation of traditional molds; pre-compensation angles offset the elastic recovery of materials, achieving net forming. The mold piece group (upper mold piece group and lower mold piece group) has a reusability rate of 95%, and the mold development cost is reduced by 70%.

[0031] Example 2 This embodiment is a further optimization based on Embodiment 1, specifically: The upper mold plate includes an upper mold plate body 3, a protruding upper arc curve at the bottom of the upper mold plate body 3, two secondary locking holes on both sides of the top of the upper mold plate body 3, and a main locking hole at the middle of the top of the upper mold plate body 3. The two secondary locking holes are symmetrically arranged on both sides of the main locking hole.

[0032] Both the secondary locking hole and the main locking hole are check holes with a smaller outer diameter and a larger inner diameter.

[0033] The upper locking assembly includes a main pin 1 that mates with the main locking hole and two auxiliary pins 2 that mate with the two auxiliary locking holes. The cross-sectional shape of the main pin 1 is adapted to the shape of the main locking hole, and the cross-sectional shape of the auxiliary pins 2 is adapted to the shape of the auxiliary locking holes.

[0034] The lower mold plate includes a lower mold plate body 4, a lower arc-shaped curve recessed at the top of the lower mold plate body 4, and two auxiliary locking holes on both sides of the top of the lower mold plate body 4.

[0035] Two auxiliary locking holes are symmetrically arranged on both sides of the top of the lower mold body 4. The auxiliary locking holes are check holes with a smaller outer diameter and a larger inner diameter.

[0036] The lower locking assembly includes an auxiliary pin 5 that engages with the main pin 1, which mates with the two auxiliary locking holes. The cross-sectional shape of the auxiliary pin 5 is adapted to the shape of the auxiliary locking holes.

[0037] The auxiliary pin 5, the secondary pin 2, and the main pin 1 are all trapezoidal pins.

[0038] Specifically, this solution uses a distributed mold assembly method, rather than integral casting; trapezoidal pin pieces are tolerantly fitted to achieve rigid connection and quick assembly / disassembly.

[0039] The bottom of the lower mold assembly is designed to be either open or T-shaped. The bottom of the lower mold assembly is provided with a mounting base 6 that mates with the open or T-shaped design.

[0040] Specifically, the lower die assembly of this mold is designed to be open or T-shaped to meet the shape of the lower die mounting base 6 of the bending machine. After the mold is assembled, it can be directly placed on the bending machine for clamping and fixing, so that the mold can be used on different machines. During the forming process, multiple arc transition plates can be formed at one time. For some S-shaped bending objects in the production process, the overall one-time forming can be achieved by changing the mold piece, further improving production efficiency.

[0041] Working Principle: This combined mold consists of upper and lower molds and connecting pins. The upper mold assembly is composed of several stacked forming punches (the number of which is determined by the actual size of the material to be formed), which are fixed by two connecting pins and then connected to the slider fixing pin on the bending machine. The lower mold assembly is composed of several stacked forming concave molds (the number of lower molds is the same as that of the upper molds), which are fixed by two connecting pins and then installed on the mold mounting base 6 of the bending machine. Each mold is laser-cut with an error of ≤0.5mm, which is sufficient to ensure the dimensional and shape accuracy of the arc transition plate and ensure the stability of product quality. It can meet the requirements of forming parts with a transition arc radius of R5-200mm and a length of less than 1000mm. Through precise design and processing of mold parts, reasonable mold structure, and the setting of limit blocks and pressure balancing mechanisms, the springback deformation can be effectively controlled during the forming process, thus effectively controlling deformation and errors.

[0042] Example 3 This embodiment provides a general-purpose combined mold manufacturing process for forming an arc transition plate, with the following steps: S1. Module group configuration (upper module group and lower module group): Calculate the required number of upper and lower module groups based on the target radius of curvature R; S2. Mold assembly: The upper mold plate group is connected by the main pin plate 1 and the auxiliary pin plate 2, and the lower mold plate group is connected by the auxiliary pin plate 5. The hydraulic early warning device applies a preload force of ≥50KN. S3. Integral pressing and forming: 800T bending machine for single pressing and bending, holding pressure for 30-45 seconds; S4. Use a test template to check whether the forming curvature meets the standard. If the deviation is > ±0.5mm, adjust the pressure parameters and iteratively optimize the parameters of the upper and lower mold plates.

[0043] The innovation of this process is: single-piece integral pressing and molding, non-point-folding molding, and surface roughness Ra≤3.2um.

Claims

1. A universal combination mold for forming an arc transition plate, characterized in that, It includes an upper mold assembly and a lower mold assembly that cooperates with the upper mold assembly. The bottom of the upper mold assembly is provided with an arc-shaped protrusion, and the upper surface of the lower mold assembly is provided with an arc-shaped groove that cooperates with the arc-shaped protrusion. The upper mold assembly includes several detachable upper mold pieces arranged side by side and an upper locking assembly for locking all the upper mold pieces. The curvature radii of the arc-shaped protrusions of the different upper mold pieces may be the same or different. The lower mold assembly includes several detachable lower mold pieces arranged side by side and a lower locking assembly for locking all the lower mold pieces. The curvature radii of the arc-shaped grooves of the different upper mold pieces may be the same or different.

2. The universal combined mold for forming an arc transition plate according to claim 1, characterized in that, The upper mold plate includes an upper mold plate body (3), an upper arc-shaped curve protruding from the bottom of the upper mold plate body (3), two secondary locking holes on both sides of the top of the upper mold plate body (3), and a main locking hole located at the middle of the top of the upper mold plate body (3). The two secondary locking holes are symmetrically arranged on both sides of the main locking hole.

3. The universal combined mold for forming an arc transition plate according to claim 2, characterized in that, Both the secondary locking hole and the main locking hole are check holes that are smaller on the outside and larger on the inside.

4. The universal combined mold for forming an arc transition plate according to claim 3, characterized in that, The upper locking assembly includes a main pin (1) that mates with the main locking hole and a secondary pin (2) that mates with the two secondary locking holes. The cross-sectional shape of the main pin (1) is adapted to the shape of the main locking hole, and the cross-sectional shape of the secondary pin (2) is adapted to the shape of the secondary locking hole.

5. A universal combined mold for forming an arc transition plate according to claim 4, characterized in that, The lower mold plate includes a lower mold plate body (4), a lower arc-shaped curve recessed on the top of the lower mold plate body (4), and two auxiliary locking holes on both sides of the top of the lower mold plate body (4).

6. The universal combined mold for forming an arc transition plate according to claim 5, characterized in that, The two auxiliary locking holes are symmetrically arranged on both sides of the top of the lower mold body (4), and the auxiliary locking holes are check holes with a smaller outer diameter and a larger inner diameter.

7. A universal combined mold for forming an arc transition plate according to claim 6, characterized in that, The lower locking assembly includes an auxiliary pin (5) that engages with the main pin (1) which engages with the two auxiliary locking holes. The cross-sectional shape of the auxiliary pin (5) is adapted to the shape of the auxiliary locking holes.

8. A universal combined mold for forming an arc transition plate according to claim 7, characterized in that, The auxiliary pin (5), the secondary pin (2), and the main pin (1) are all trapezoidal pins.

9. A universal combined mold for forming an arc transition plate according to claim 6, characterized in that, The bottom of the lower mold assembly is configured as either open or T-shaped.

10. A universal combined mold for forming an arc transition plate according to claim 9, characterized in that, The bottom of the lower mold assembly is provided with a mounting base (6) that mates with the opening type or the T type.

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