A large-scale separator with Hastelloy disc progressive forming anti-rebound device

Abstract

This invention discloses a progressive forming anti-springback device for Hastelloy discs in a large-scale separator, comprising a forming platform, a high-frequency heating power supply, a forming drive mechanism, a pressing mechanism, a forming tool head, a movable electrode head, a magnetic field generator, an infrared temperature sensor, and a controller. The forming tool head and the movable electrode head are positioned vertically on opposite sides of the sheet metal. The high-frequency heating power supply connects the two to generate Joule heating in the deformation zone of the sheet metal. The magnetic field generator, driven by a low-frequency alternating power supply and integrated into the forming tool head, applies a 1-10Hz low-frequency alternating magnetic field to the deformation zone. The infrared temperature sensor monitors the temperature in real time and feeds it back to the controller, coordinating the control of the thermal and magnetic fields. This invention significantly reduces the deformation resistance of Hastelloy and promotes stress relaxation through the synergistic effect of Joule heating and magnetoplasticity, thereby stably controlling the springback angle of the disc forming within 0.3°, effectively ensuring the forming accuracy and separation efficiency of the separator discs.

Description

Technical Field

[0001] This utility model relates to the field of metal sheet plastic processing technology, specifically to a large-scale separator Hastelloy disc progressive forming anti-rebound device. Background Technology

[0002] A disc centrifuge is a high-speed sedimentation centrifuge that uses the powerful centrifugal force generated by high-speed rotation to rapidly separate mixtures such as liquid-solid and liquid-liquid-solid. Due to its high efficiency and high degree of automation, it can achieve fully automatic operation from feeding, separation, and slag discharge, and is widely used in industries such as shipbuilding, food, pharmaceuticals, chemicals, textiles, and environmental protection. A disc centrifuge typically consists of an inlet / outlet device, a rotating drum, a casing, a base, and a motor. Material separation takes place in the rotating drum, which usually consists of a drum body, drum cover, piston, main locking ring, distributor, and discs. After entering the drum, the material enters between the discs, where it settles and separates within the gaps between the upper and lower discs. Under otherwise constant conditions, the more discs there are, the larger the sedimentation area, and the better the processing capacity and separation effect. When handling highly corrosive materials, the disc material is C276 Hastelloy. Hastelloy has a strong tendency to work harden at room temperature and has a high yield strength, which leads to significant springback after incremental forming. This seriously affects the final forming angle accuracy of the disc and thus reduces the separation efficiency. Utility Model Content

[0003] This invention aims to overcome the shortcomings of existing technologies and provide a progressive forming device specifically for Hastelloy discs. This device significantly reduces the deformation resistance and springback tendency of Hastelloy, and stably controls the forming angle accuracy of the discs within 0.3°.

[0004] To achieve the above objectives, the technical solution of this utility model is to design a large-scale separator for progressive forming of Hastelloy discs with anti-rebound capability, comprising a forming platform, a high-frequency heating power supply, a forming drive mechanism, a pressing mechanism, a forming tool head, a movable electrode head, a magnetic field generator, an infrared temperature sensor, and a controller; the pressing mechanism is located above the forming platform; the forming tool head is mounted at the end of the forming drive mechanism and is located above the sheet metal; the movable electrode head is located below the sheet metal, corresponding vertically to the forming tool head, and is connected to a constant pressure mechanism below via a spring, the constant pressure mechanism being mounted on the forming platform; the infrared temperature sensor is hinged to a sensor bracket, the sensor bracket being mounted on the movable electrode head via an insulating and heat-resistant component, the probe of the infrared temperature sensor pointing towards the deformation area of ​​the sheet metal; the positive and negative terminals of the high-frequency heating power supply are respectively connected to the forming tool head and the movable electrode head; the magnetic field generator is integrated into the forming tool head; the infrared temperature sensor, high-frequency heating power supply, magnetic field generator, and constant pressure mechanism are all electrically connected to the controller.

[0005] Specifically, the magnetic field generating device includes an annular groove formed on the outer surface of the forming tool head near its end. An insulating and heat-insulating component is wrapped around the annular groove, and an electromagnetic coil is wound around the insulating and heat-insulating component. The electromagnetic coil is electrically connected to a low-frequency alternating power supply, and a protective shell is provided around the electromagnetic coil. The frequency of the alternating magnetic field of the low-frequency alternating power supply is 1–10 Hz.

[0006] C276 Hastelloy has an austenitic structure and is paramagnetic at room temperature. Under the influence of an external magnetic field, the plastic deformation capacity of C276 Hastelloy is enhanced, manifested as a reduction in flow stress and an increase in elongation. A high-frequency heating power supply can also generate a Joule heating effect at the deformation site of the sheet metal, raising the temperature at that location and controlling it between 300-400 degrees Celsius. This alters the deformation and stress state of Hastelloy during incremental forming, thereby controlling springback.

[0007] Furthermore, a cooling channel is provided inside the forming tool head. This built-in cooling channel effectively ensures the stable operation of the magnetic field generating device and extends the equipment's lifespan.

[0008] Specifically, the constant pressure mechanism includes an electric push rod, an insulating plate mounted on the piston rod of the electric push rod, and a spring-limiting post mounted between the insulating plate and the movable electrode head. A spring is mounted on the spring-limiting post. The movable electrode head has a hollow structure below it, and is fitted onto one end of the spring-limiting post and connected to one end of the spring. The other end of the spring is fixed to the insulating plate. A pressure sensor is mounted on the insulating plate. The electric push rod is mounted on a slider on a planar moving mechanism. The planar moving mechanism includes a longitudinal moving component and a transverse moving component mounted on the longitudinal moving component. The longitudinal moving component is mounted on a forming table. The planar moving mechanism, pressure sensor, and electric push rod are all electrically connected to a controller. Preferably, the longitudinal and transverse moving components of the planar moving mechanism are driven by ball screws and servo motors, and connected to the controller, thereby ensuring that they are always in a relative position with the forming tool head. The specific structures of the longitudinal and transverse moving components are existing technologies and will not be described in detail here.

[0009] Specifically, the pressing mechanism includes an upper pressing plate and a lower pressing plate. The lower pressing plate is installed on the top of the forming table. Two insulating and heat-insulating layers are provided between the upper pressing plate and the lower pressing plate. The outer edge of the sheet material is located between the two insulating and heat-insulating layers. The upper pressing plate and the lower pressing plate are connected by pressing bolts.

[0010] Furthermore, an insulating and heat-insulating component is provided between the forming tool head and the forming drive mechanism.

[0011] Preferably, the insulating and heat-insulating component, insulating and heat-insulating layer, or insulating board is a ceramic insulating layer. Mica material and polyimide, which have both heat insulation and electrical insulation functions, can also be used.

[0012] The forming drive mechanism is a robotic arm or a multi-axis CNC machine tool.

[0013] The forming tool head is made of alloy steel with high magnetic permeability. Preferably, the forming tool head is made of alloy steel with high magnetic permeability, such as low-carbon steel or specific alloy steel.

[0014] The temperature of the deformation zone of the sheet metal is controlled between 300 and 400 degrees Celsius. An infrared temperature sensor measures the real-time temperature of the deformation zone and feeds it back to the controller, which then controls the high-frequency heating power supply to maintain the temperature of the deformation zone between 300 and 400 degrees Celsius. This temperature range effectively softens the material and suppresses springback without compromising its corrosion resistance or causing excessive oxidation due to excessive heat.

[0015] The advantages and beneficial effects of this invention are as follows: Targeting the characteristics of C276 Hastelloy, a high-frequency heating power supply is used to heat the local deformation zone of the sheet metal, generating a precise heating temperature of 300-400℃. This reduces the downward pressure applied by the forming tool head during the forming process and also lowers the sheet metal's deformation resistance, reducing springback. An alternating magnetic field is applied to the deformation zone using a magnetic field generator driven by a low-frequency alternating power supply, applying a low-frequency alternating magnetic field of 1-10Hz. This generates a magnetoplastic effect in the sheet metal deformation zone, enhancing the material's plasticity. The magnetoplastic effect further promotes stress relaxation and further suppresses springback. The high-frequency heating power supply generates a Joule heating effect at the sheet metal deformation site, controlling the temperature of the deformation zone within a low-temperature heating range of 300-400℃. This range effectively softens the material and suppresses springback without compromising its corrosion resistance or causing excessive oxidation due to excessive temperature. Through the synergistic effect of Joule heating and magnetoplasticity, the deformation resistance of Hastelloy is significantly reduced and stress relaxation is promoted, thereby stabilizing the springback angle of disc forming within 0.3°, effectively ensuring the forming accuracy and separation efficiency of the separator discs. Attached Figure Description

[0016] Figure 1 This is a diagram showing the before and after the disc gradually springs back after forming; Figure 2 This is a schematic diagram of the anti-rebound device of this utility model; Figure 3 This is a schematic diagram of the anti-rebound device of this utility model; Figure 4 yes Figure 3 Enlarged view of point B; Figure 5 yes Figure 3Sectional view at point AA; Figure 6 yes Figure 5 Enlarged view of point C; Figure 7 This is a temperature distribution diagram of the deformation zone of the sheet metal.

[0017] In the diagram: 1. Forming stand; 2. High-frequency heating power supply; 3. Forming drive mechanism; 4. Edge pressing mechanism; 401. Upper pressure plate; 402. Lower pressure plate; 403. Insulating and heat-insulating layer; 404. Clamping bolt; 5. Forming tool head; 501. Cooling channel; 6. Movable electrode head; 61. Spring; 62. Constant pressure mechanism; 621. Electric push rod; 622. Piston rod; 623. Insulating plate; 624. Spring limiting post; 625. Pressure sensor; 626. Planar moving mechanism; 627. Slider; 628. Longitudinal moving assembly; 629. Lateral moving assembly; 7. Magnetic field generating device; 701. Annular groove; 702. Electromagnetic coil; 703. Low-frequency alternating power supply; 704. Protective shell; 8. Infrared temperature sensor; 801. Sensor bracket; 9. Controller; 10. Sheet metal; 11. Insulating and heat-insulating component. Detailed Implementation

[0018] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solution of this utility model and should not be construed as limiting the scope of protection of this utility model.

[0019] according to Figures 2-6 As shown, this utility model is a large-scale separator for progressive forming of Hastelloy discs with anti-rebound capability, comprising a forming platform 1, a high-frequency heating power supply 2, a forming drive mechanism 3, a pressing mechanism 4, a forming tool head 5, a movable electrode head 6, a magnetic field generator 7, an infrared temperature sensor 8, and a controller 9; the pressing mechanism 4 is located above the forming platform 1; the forming drive mechanism 3 is equipped with the forming tool head 5 at its end, and the forming tool head 5 is located above the sheet metal 10; the movable electrode head 6 is located below the sheet metal 10, corresponding vertically to the forming tool head 5, and is connected to a constant pressure below via a spring 61. The constant pressure mechanism 62 is connected to the forming table 1; the infrared temperature sensor 8 is hinged to the sensor bracket 801, and the sensor bracket 801 is mounted on the movable electrode head 6 through the insulating and heat-insulating component 11. The probe of the infrared temperature sensor 8 points to the deformation area of ​​the sheet metal 10; the positive and negative terminals of the high-frequency heating power supply 2 are respectively connected to the forming tool head 5 and the movable electrode head 6; the magnetic field generating device 7 is integrated into the forming tool head 5; the infrared temperature sensor 8, the high-frequency heating power supply 2, the magnetic field generating device 7, and the constant pressure mechanism 62 are all electrically connected to the controller 9.

[0020] according to Figure 6 As shown, the magnetic field generating device 7 includes an annular groove 701 formed on the outer surface of the forming tool head 5 near the end. The annular groove 701 is wrapped with an insulating and heat-insulating member 11. An electromagnetic coil 702 is wound around the insulating and heat-insulating member 11. The electromagnetic coil 702 is electrically connected to a low-frequency alternating power supply 703. A protective shell 704 is provided outside the electromagnetic coil 702.

[0021] according to Figure 6 As shown, the forming tool head 5 has a cooling channel 501 inside.

[0022] according to Figures 4-5 As shown, the constant pressure mechanism 62 includes an electric push rod 621, an insulating plate 623 mounted on the piston rod 622 of the electric push rod 621, and a spring limiting post 624 mounted between the insulating plate 623 and the movable electrode head 6. The spring 61 is mounted on the spring limiting post 624. The movable electrode head 6 has a hollow structure below it. The movable electrode head 6 is fitted onto one end of the spring limiting post 624 and connected to one end of the spring 61. The other end of the spring is fixed to the insulating plate 623. A pressure sensor 625 is mounted on the insulating plate 623. The electric push rod 621 is mounted on a slider 627 on a planar moving mechanism 626. The planar moving mechanism 626 includes a longitudinal moving component 628 and a transverse moving component 629 mounted on the longitudinal moving component 628. The longitudinal moving component 628 is mounted on the forming table 1. The planar moving mechanism 626, the pressure sensor 625, and the electric push rod 621 are all electrically connected to the controller 9.

[0023] The pressing mechanism 4 includes an upper pressing plate 401 and a lower pressing plate 402. The lower pressing plate 402 is installed on the top of the forming table 1. Two insulating and heat-insulating layers 403 are provided between the upper pressing plate 401 and the lower pressing plate 402. The outer edge of the sheet material 10 is located between the two insulating and heat-insulating layers 403. The upper pressing plate 401 and the lower pressing plate 402 are connected by pressing bolts 404.

[0024] An insulating and heat-insulating component 11 is provided between the forming tool head 5 and the forming drive mechanism 3.

[0025] The insulating and heat-insulating component 11, the insulating and heat-insulating layer 403, or the insulating plate 623 is a ceramic insulating layer.

[0026] The forming drive mechanism 3 is a robotic arm or a multi-axis CNC machine tool.

[0027] The forming tool head 5 is made of alloy steel with high magnetic permeability.

[0028] The temperature of the deformation zone of the sheet 10 is controlled at 300~400 degrees.

[0029] The working principle is as follows: Hastelloy sheet 10 is clamped between upper pressure plate 401 and lower pressure plate 402, and locked and fixed to forming table 1 by clamping bolts 404. An insulating and heat-insulating layer 403 is placed between them to achieve electrical isolation. Then the equipment is started. Under the preset program settings of controller 9, forming drive mechanism 3 controls forming tool head 5 to perform forming work along a predetermined path. Under the preset program settings of controller 9, planar moving mechanism 626 controls the movable electrode head 6 on it to always be opposite to forming tool head 5, and the two are on the same axis.

[0030] During forming, the positive and negative terminals of the high-frequency heating power supply 2 are respectively located on the forming tool head 5 and the movable electrode head 6. The forming tool head 5 and the movable electrode head 6 are located on the upper and lower surfaces of the sheet metal 10 and are in contact with the sheet metal 10. This generates a Joule heating effect in the contact area, which is the deformation zone of the sheet metal, causing the temperature at that location to rise. Figure 7 As shown, the temperature of the central forming zone is the optimal temperature, and the temperature decreases sequentially outwards. When the forming tool head 5 moves along the preset trajectory, it moves from the central forming zone to the intermediate transition zone. Because the temperature difference between the intermediate transition zone and the central forming zone is not significant, and because the forming tool head 5 moves relatively slowly during the forming process, the temperature of the deformation zone of the sheet metal 10 contacted by the forming tool head 5 can always be maintained within a stable temperature range throughout the entire forming process. In addition, the infrared temperature sensor 8 also monitors the temperature of the deformation zone of the sheet metal 10 in real time and feeds it back to the controller 9. The controller 9 controls the current and voltage of the high-frequency heating power supply 2 according to the temperature difference, thereby stabilizing the temperature of the deformation zone of the sheet metal 10.

[0031] During the forming process, a low-frequency alternating power supply 703 controls an electromagnetic coil 702 to generate an alternating magnetic field. A forming tool head 5, made of a high-permeability material, is used. The magnetic field lines preferentially choose the path of least magnetic resistance. The high-permeability material provides a magnetic field path with much lower magnetic resistance than air, confining and guiding most of the magnetic field lines into the forming tool head 5. This prevents the magnetic field from dissipating in the air, greatly improving the efficiency of magnetic energy utilization. Guided by the high-permeability forming tool head 5, the magnetic field is efficiently delivered to the deformation zone of the sheet metal 10. Because the tip of the forming tool head 5 suddenly becomes pointed and comes into contact with air, the magnetic field lines strongly diffuse from the tip but are highly concentrated in direction. This creates a localized strong magnetic field region at the contact point between the forming tool head 5 and the sheet metal 10, with an intensity much higher than that generated by the coil itself. This precisely focuses the magnetic energy to the point where it needs to act, thereby stimulating the magnetoplastic effect and further suppressing springback.

[0032] During the forming process, the electric push rod 621 of the constant pressure mechanism 62 will receive real-time feedback from the pressure sensor 625 installed on the insulating plate 623. This pressure is also the pressure between the movable electrode head 6 and the sheet 10. The pressure value is fed back to the controller 9. The controller 9 controls the extension length of the piston rod 622 on the electric push rod 621 based on the comparison with the preset value, so as to ensure that the compression of the spring 61 is basically constant and prevent the pressure of the movable electrode head 6 on the sheet 10 from being too large or too small.

[0033] Some of the components mentioned above also require insulation and heat insulation layers for isolation, but since this is not a point of application of this utility model, those skilled in the art can also conceive of it as needed, so it will not be described in detail here.

[0034] The bolts, nuts, screws, welding, and other related materials used in fixing and installing two or more parts described above are all known to those skilled in the art and will not be repeated here.

[0035] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A large scale progressive die Hastei alloy disc spring anti-rebound apparatus, characterized by, It includes a forming stand (1), a high-frequency heating power supply (2), a forming drive mechanism (3), a pressing mechanism (4), a forming tool head (5), a movable electrode head (6), a magnetic field generating device (7), an infrared temperature sensor (8), and a controller (9); The pressing mechanism (4) is located above the forming stand (1); The forming drive mechanism (3) is equipped with the forming tool head (5) at its end, and the forming tool head (5) is located above the sheet metal (10); The movable electrode head (6) is located below the sheet metal (10), corresponding to the forming tool head (5) above and below, and is connected to the constant pressure mechanism (62) below via a spring (61). The constant pressure mechanism (62) is mounted on the forming table (1). The infrared temperature sensor (8) is hinged on the sensor bracket (801), and the sensor bracket (801) is mounted on the movable electrode head (6) through the insulating heat insulation component (11). The probe of the infrared temperature sensor (8) points to the deformation area of ​​the sheet metal (10). The positive and negative terminals of the high-frequency heating power supply (2) are connected to the forming tool head (5) and the movable electrode head (6), respectively. The magnetic field generating device (7) is integrated on the forming tool head (5); The infrared temperature sensor (8), high-frequency heating power supply (2), magnetic field generator (7), and constant pressure mechanism (62) are all electrically connected to the controller (9).

2. A large scale separating machine Hastelloy disc gradual forming anti-rebound device according to claim 1, characterized in that, The magnetic field generating device (7) includes an annular groove (701) formed on the outer surface of the forming tool head (5) near the end. The annular groove (701) is wrapped with an insulating and heat-insulating member (11). An electromagnetic coil (702) is wound around the insulating and heat-insulating member (11). The electromagnetic coil (702) is electrically connected to a low-frequency alternating power supply (703). A protective shell (704) is provided outside the electromagnetic coil (702).

3. A large scale separating machine Hastelloy disc progressive forming anti-rebound device according to claim 2, characterized in that, The forming tool head (5) is provided with a cooling channel (501).

4. A large scale separating machine Hastelloy disc gradual forming anti-rebound device according to claim 1, characterized in that, The constant pressure mechanism (62) includes an electric push rod (621), an insulating plate (623) mounted on the piston rod (622) of the electric push rod (621), and a spring limiting post (624) mounted between the insulating plate (623) and the movable electrode head (6). The spring (61) is mounted on the spring limiting post (624). The movable electrode head (6) has a hollow structure below it. The movable electrode head (6) is fitted onto one end of the spring limiting post (624) and connected to one end of the spring (61). The other end of the spring is fixed to the insulating plate (623). Above, a pressure sensor (625) is installed on the insulating plate (623), and the electric push rod (621) is installed on the slider (627) on the planar moving mechanism (626). The planar moving mechanism (626) includes a longitudinal moving component (628) and a transverse moving component (629) installed on the longitudinal moving component (628). The longitudinal moving component (628) is installed on the forming table (1). The planar moving mechanism (626), the pressure sensor (625) and the electric push rod (621) are all electrically connected to the controller (9).

5. A large scale separating machine Hastelloy disc progressive forming anti-rebound device according to claim 1, characterized in that, The pressing mechanism (4) includes an upper pressing plate (401) and a lower pressing plate (402). The lower pressing plate (402) is installed on the top of the forming frame (1). Two insulating and heat-insulating layers (403) are provided between the upper pressing plate (401) and the lower pressing plate (402). The outer edge of the sheet material (10) is located between the two insulating and heat-insulating layers (403). The upper pressing plate (401) and the lower pressing plate (402) are connected by a clamping bolt (404).

6. A large scale separating machine Hastelloy disc progressive forming anti-rebound device according to claim 1, characterized in that, An insulating and heat-insulating component (11) is provided between the forming tool head (5) and the forming drive mechanism (3).

7. A large scale separating machine Hastelloy disc incremental forming anti-rebound device according to any one of claims 1-6, characterized in that, The insulating and heat-insulating component (11), the insulating and heat-insulating layer (403), or the insulating plate (623) is a ceramic insulating layer.

8. A large scale separating machine Hastelloy disc progressive forming anti-rebound device according to claim 1, characterized in that, The forming drive mechanism (3) is a robotic arm or a multi-axis CNC machine tool.

9. A large scale separating machine Hastelloy disc progressive forming anti-rebound device according to claim 2, characterized in that, The forming tool head (5) is made of alloy steel with high magnetic permeability.

10. A large scale separating machine Hastelloy disc progressive forming anti-rebound device according to claim 1, characterized in that, The temperature of the deformation zone of the sheet metal (10) is controlled at 300~400 degrees.

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