CA3187776C - Forming method for aerospace cover - Google Patents
Forming method for aerospace cover Download PDFInfo
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- CA3187776C CA3187776C CA3187776A CA3187776A CA3187776C CA 3187776 C CA3187776 C CA 3187776C CA 3187776 A CA3187776 A CA 3187776A CA 3187776 A CA3187776 A CA 3187776A CA 3187776 C CA3187776 C CA 3187776C
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- spinning
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- 238000000034 method Methods 0.000 title claims abstract description 66
- 238000009987 spinning Methods 0.000 claims abstract description 115
- 238000002360 preparation method Methods 0.000 claims abstract description 5
- 239000010687 lubricating oil Substances 0.000 claims description 4
- 230000007423 decrease Effects 0.000 claims description 3
- 239000004744 fabric Substances 0.000 claims description 3
- 238000005498 polishing Methods 0.000 claims description 3
- 238000003825 pressing Methods 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 2
- 206010040954 Skin wrinkling Diseases 0.000 abstract 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 7
- 229910052782 aluminium Inorganic materials 0.000 description 7
- 238000010586 diagram Methods 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/14—Spinning
- B21D22/16—Spinning over shaping mandrels or formers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/40—Weight reduction
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
A forming method of a cover for spaceflight, comprising: step 1, forming preparation; step 2, trajectory drawing; step 3, spinning forming; step 4, shape correction; and step 5, turning. All information of the spinning process of qualified parts is recorded by means of a numerical control program, curing of technological parameters is achieved, the percent of pass of the parts is greatly increased, and the forming quality of the parts is guaranteed to be stable and reliable. Starting from a spinning forming mechanism, that is, progress spinning tensile stress can make the wall thickness of a part thinner than return stroke pressure stress, contact between the part and a blank in the progress stage of the spinning process is reduced, detailed return stroke parameters capable of effectively reducing wrinkling risk are given, and a part thinning rate is effectively controlled.
Description
FORMING METHOD FOR AEROSPACE COVER
TECHNICAL FIELD
[01] The disclosure is mainly applied to the technical field of forming of various covers for aerospace equipment, and particularly relates to a common numerical control spin forming process for an aluminum cover having a thickness of 1.2 mm or 1.5 mm, a diameter of a cylinder wall of 150 mm-230 mm, a height of 60 mm-110 mm and a width of a flange of 10 mm-15 mm.
BACKGROUND ART
TECHNICAL FIELD
[01] The disclosure is mainly applied to the technical field of forming of various covers for aerospace equipment, and particularly relates to a common numerical control spin forming process for an aluminum cover having a thickness of 1.2 mm or 1.5 mm, a diameter of a cylinder wall of 150 mm-230 mm, a height of 60 mm-110 mm and a width of a flange of 10 mm-15 mm.
BACKGROUND ART
[02] In the field of aerospace equipment, a cover is one of the important structural parts of a rocket body. For a long time, covers are produced through manual spinning, correction, shape correction and turning. Manual spinning is seriously affected by technical levels and working states of producers, and a thinning rate of a wall thickness is 25%-40% (which is required to be not greater than 34.5%), such that product quality consistency is poor, a qualified rate is often 50%-90%, and high time consumption and labor intensity are caused.
[03] At present, no institution or individual in China has disclosed a forming method for a pure aluminum cover part. Similarly, in the prior art, there is an article entitled "Research on Influence of Spinning Trace and Process Parameters on Multi-pass Drawing Spin Fonning Quality" published by Zeng Chao et al. in the journal "Forging Technology". In this article, the influences of pass curves and process parameters of different traces on multi-pass drawing spin forming quality of AL6061 and SPCC
sheets having thicknesses of 2 mm and 1 mm respectively were studied. Their minimum thinning rates under optimal parameters were 9% and 7% respectively; but a formed product is a cylindrical part having a diameter (I) of 68 mm and an unspecified height, and the blank used has a diameter (1) of 140 mm. The disclosure is designed for a cylindrical part having a diameter cp of 150 mm-230 mm and a height of 60 mm-mm and having a flange with a width of about 15 mm, and uses a blank having a diameter (1) of 250 mm-380 mm. There is a significant difference in difficulty of controlling a thinning rate between them.
sheets having thicknesses of 2 mm and 1 mm respectively were studied. Their minimum thinning rates under optimal parameters were 9% and 7% respectively; but a formed product is a cylindrical part having a diameter (I) of 68 mm and an unspecified height, and the blank used has a diameter (1) of 140 mm. The disclosure is designed for a cylindrical part having a diameter cp of 150 mm-230 mm and a height of 60 mm-mm and having a flange with a width of about 15 mm, and uses a blank having a diameter (1) of 250 mm-380 mm. There is a significant difference in difficulty of controlling a thinning rate between them.
[04] In order to solve problems of time-consuming and labor-consuming, poor stability and a low qualified rate in manual spin forming, the disclosure provides a forming method for a cover, which is mainly characterized in that manual spin forming is improved into fonning through a common numerical control spinning process, and a drawing method for a trace through a numerical control spinning process and selections of process parameters are given. Through the disclosure, a labor intensity can be effectively reduced, processing efficiency can be improved, a thinning rate can be controlled within 25%, and a qualified rate of parts can be ensured to reach 99% or above.
SUMMARY
SUMMARY
[05] In order to overcome defects of existing technologies, the disclosure provides a forming method for an aerospace cover.
Date Recue/Date Received 2023-06-29
Date Recue/Date Received 2023-06-29
[06] A technical solution used for solving the technical problems of the disclosure is as follows: a forming method for an aerospace cover includes the following steps:
[07] step one, forming preparation:
[08] 1.1 generally estimating a spinning blank size 0;
[09] 1.2 selecting a fillet radius R of a spinning roller;
[10] 1.3 cutting a blank by laser, a size being the spinning blank size 0 +
(5 mm-10 mm); and
(5 mm-10 mm); and
[11] 1.4 mounting a spinning die and the spinning roller on a numerical control spinning machine;
[12] step two, trace drawing:
[13] 2.1 determining inner and outer outlines of a trace; and
[14] 2.2 drawing a plurality of passes of spinning traces;
[15] step three, spin forming:
[16] 3.1 setting a rotation speed of the spinning roller to be 500 r/min-600 r/min and a feed ratio to be 0.5 mm/r-3 mm/r;
[17] 3.2 compiling a numerical control program according to the plurality of passes of spinning traces, and parameters of the rotation speed of the spinning roller and the feed ratio;
[18] 3.3 setting wear values of a spinning roller cutter in X and Z
directions;
directions;
[19] 3.4 clamping the blank on the numerical control spinning machine, turning the blank into a required diameter 0, deburring the blank, and applying lubricating oil to the blank; and
[20] 3.5 adjusting a spindle and a feed rate to 100% so as to form a part through spinning;
[21] step four, shape correction:
[22] 4.1 correcting a flange of the part to a horizontal state; and
[23] 4.2 forming a fillet Ri of the flange by means of a shape correction tool; and
[24] step five, turning:
[25] 5.1 clamping the spinning die, an upper cushion block and the part on a lathe, and turning the flange and an inner hole of the part into Do and Oh respectively; and
[26] 5.2 using abrasive paper and polishing cloth to polish a surface of the part to be smooth and bright.
[27] Compared with the prior art, the disclosure has the beneficial effects:
[28] 1, compared with an existing forming technology, the disclosure records all information of a spinning process of qualified parts by means of a numerical control program, thus realizing solidification of process parameters, greatly improving a qualified rate of parts, and ensuring that forming quality of parts is stable and reliable and a qualified rate of products >99%; and
[29] 2, compared with an existing common spinning technology, according to a spin forming mechanism that compared with reverse pressure stress, forward spinning tensile Date Recue/Date Received 2023-06-29 stress can make a wall thickness of a part thinner, the disclosure greatly reduces contact with a blank at a forward stage of a spinning process, and provides detailed reverse parameters that can effectively reduce crinkling risks, thus effectively controlling a thinning rate of parts, and realizing a thinning rate of a wall thickness of a cover processed through a common numerical control spinning process <25%.
BRIEF DESCRIPTION OF THE DRAWINGS
BRIEF DESCRIPTION OF THE DRAWINGS
[30] The disclosure will be explained in examples and with reference to the accompanying drawings. In the drawings:
[31] FIG. 1 is a schematic diagram of a cover part;
[32] FIG. 2 is a schematic diagram of a spinning roller;
[33] FIG. 3 shows a method for determining an inner outline;
[34] FIG. 4 is diagram of a single pass of spinning trace;
[35] FIG. 5 shows a plurality of passes of spinning traces and inner and outer outlines;
[36] FIG. 6 is a schematic diagram of a forming process (blank-spinning-correction-shape correction and turning); and
[37] FIG. 7 is a schematic diagram of a shape correction tool.
[38] In the drawings, the reference numerals include: die surface 1, spinning roller 2, die end face 3, inner outline of trace 4, single pass of reciprocating trace 5, outer outline 6, spinning roller trace base point 7, spinning die 8, upper cushion block 9, lower cushion block 10, and general backing ring 11.
DETAILED DESCRIPTION OF THE EMBODIMENTS
DETAILED DESCRIPTION OF THE EMBODIMENTS
[39] A main technical solution of a forming method for an aerospace cover is as follows:
[40] 1. Forming preparation
[41] 1.1 A spinning blank size 0 is generally estimated according to a product drawing and the following formula:
0 = 11412 2dt1 HI- 2D t) t2D02 - D2)1145 d2
0 = 11412 2dt1 HI- 2D t) t2D02 - D2)1145 d2
[42]
[43] In the foitnula, t1 is an actual average thickness of a straight wall after spin forming, an actual average thickness of a straight wall of an aluminum plate having a nominal thickness of 1.5 mm is 1.2, and an actual average thickness of a straight wall of an aluminum plate having a nominal thickness of 1.2 mm is 0.9.
[44] tz is an actual average thickness of a flange after spin forming, an actual average thickness of a flange of an aluminum plate having a nominal thickness of 1.5 mm is 1.5, and an actual average thickness of a flange of an aluminum plate having a nominal thickness of 1.2 mm is 1.2.
Date Recue/Date Received 2023-06-29
Date Recue/Date Received 2023-06-29
[45] 6 is an actual thickness of a blank.
[46] H is a height of a part.
[47] d is a diameter of a bottom of the part.
[48] D is a diameter of a mouth of the part.
[49] Do is a diameter of a flange of the part.
[50] As shown in FIG. 1.
[51] 1.2 A fillet radius R of a spinning roller is selected according to a size of the part: for a part having a size of d of 150 mm-250 mm and H of 50 mm-110 mm, a radius R of the spinning roller is 8 mm-14 mm.
[52] 1.3 The blank is cut by laser, a size being the spinning blank size 0 + (5 mm-10 mm), a material being A1035 M.
[53] 1.4 A spinning die (8 in FIG. 7) and the spinning roller 2 (having a structure as shown in FIG. 2) are mounted on a numerical control spinning machine, and a radial circle run-out tolerance value is measured by a dial gauge. The spinning die is required to have a circle run-out tolerance value <0.1 mm, the spinning roller is required to have a circle run-out tolerance value <0.02 mm, and a mounting attack angle of the spinning roller is 45 .
[54] 2 Trace drawing
[55] 2.1 Inner and outer outlines of a trace are determined: it is necessary to consider compensation of the fillet radius of the spinning roller for the inner outline, a determination method is as shown in FIG. 3, a circle having a radius being S
is drawn at an end point by taking an offset distance S (equal to the fillet radius R of the spinning roller) of an outline of a die surface 1, an intersection point of vertical and horizontal lines of the circle is taken, a perpendicular line of the outline of the die surface 1 is made by passing the intersection point, the outline of the die offsets by a length AS of the perpendicular line, and horizontal extension is conducted to a die end line by taking an intersection point of an offset line and the vertical line of the circle, the offset line and a horizontal extension line forming the inner outline 4. The outer outline 6 is an elliptical line, a center of an ellipse is located at an intersection point of the inner outline and the die end line, and values a and b of a short axis and a long axis are computed according to the following formula:
a = (D0-- D)I Pt
is drawn at an end point by taking an offset distance S (equal to the fillet radius R of the spinning roller) of an outline of a die surface 1, an intersection point of vertical and horizontal lines of the circle is taken, a perpendicular line of the outline of the die surface 1 is made by passing the intersection point, the outline of the die offsets by a length AS of the perpendicular line, and horizontal extension is conducted to a die end line by taking an intersection point of an offset line and the vertical line of the circle, the offset line and a horizontal extension line forming the inner outline 4. The outer outline 6 is an elliptical line, a center of an ellipse is located at an intersection point of the inner outline and the die end line, and values a and b of a short axis and a long axis are computed according to the following formula:
a = (D0-- D)I Pt
[56]
b= (0 ¨ d)/2 _ R
b= (0 ¨ d)/2 _ R
[57]
[58] 2.2 A plurality of passes of spinning traces are drawn (FIG. 5): an initial Date Recue/Date Received 2023-06-29 rotation angle a of 13 -16 is taken; as shown in FIG. 4, a line shape of a forward process of a single pass of reciprocating trace 5 is a "straight" line, a "concave" arc is used for a reverse process, a reverse process end point and a forward process start point have a horizontal distance AX and a distance from the inner outline of 1 mm-2 mm, AX gradually increases from 0.3 mm to 5 mm, and a linear distance AT between a high point of a reverse process "concave" line and the forward process is 2 mm-3 mm; a start point of a next pass is an end point of an immediately preceding pass of reverse process, an end point of the forward process is determined according to a pressing amount of each pass AY and an intersection position of a forward process line and an immediately preceding pass of reverse process line, AY gradually decreases from 4 mm to 1.5 mm, and a distance of the intersection position is kept to be (1/4-1/3)L from an end point of a forward process length L; and repeating is conducted in this way until a Z
value is equal to about 0.95 time of a height H of the part and an X value is 0.8 time of a width of the flange, so as to complete drawing of the plurality of passes of reciprocating spinning traces. A one-way spinning trace is used for a final pass, the inner outline and a die end face 3 are taken as start points of the trace, a position, that is 0.95H away from the die end line, of a path along the inner outline is taken as a midpoint, an arc is drawn with the midpoint as a start point, an end point of the arc is outside an end point of a final pass of forward process of the reciprocating traces, and a radius of the arc is slightly smaller than a radius of a final pass of reverse process, with 1.1 times preferably.
value is equal to about 0.95 time of a height H of the part and an X value is 0.8 time of a width of the flange, so as to complete drawing of the plurality of passes of reciprocating spinning traces. A one-way spinning trace is used for a final pass, the inner outline and a die end face 3 are taken as start points of the trace, a position, that is 0.95H away from the die end line, of a path along the inner outline is taken as a midpoint, an arc is drawn with the midpoint as a start point, an end point of the arc is outside an end point of a final pass of forward process of the reciprocating traces, and a radius of the arc is slightly smaller than a radius of a final pass of reverse process, with 1.1 times preferably.
[59] 3 Spin forming
[60] 3.1 A rotation speed of the spinning roller is 500 r/min-600 r/min and a feed ratio is 0.5 mm/r-3 mm/r. A low feed ratio of a first pass is selected, a high multi-pass reciprocating spinning feed ratio is selected, and a low feed ratio of a final pass is selected.
[61] 3.2 A numerical control program is compiled according the trace in 2.2 and the parameters in 3.1.
[62] 3.3 Wear values of a spinning roller cutter in X and Z directions are set, that is, a gap between the spinning roller and the die is set to be 90% of an actual thickness of a material.
[63] 3.4 The blank is clamped on the numerical control spinning machine, the blank is turned into a required diameter 0, the blank is deburred, and lubricating oil is applied to the blank.
[64] 3.5 A spindle and a feed rate are adjusted to 100% so as to form a part through spinning.
[65] 4 Shape correction
[66] 4.1 The flange of the part is corrected to a horizontal state (FIG.
6).
6).
[67] 4.2 A fillet RI of the flange is formed by means of a shape correction tool. A
structure of the shape correction tool is as shown in FIG. 7 and includes: the spinning die 8, an upper cushion block 9, a lower cushion block 10 and a general backing ring 11.
structure of the shape correction tool is as shown in FIG. 7 and includes: the spinning die 8, an upper cushion block 9, a lower cushion block 10 and a general backing ring 11.
[68] 5 Turning
[69] 5.1 The spinning die, the upper cushion block and the part are clamped on a Date Recue/Date Received 2023-06-29 lathe, and the flange and an inner hole of the part are turned into Do and Oh respectively.
[70] 5.2 Abrasive paper is used to polish a surface of the part.
[71] The disclosure is described in detail below in conjunction with the accompanying drawings and specific embodiments.
[72] The disclosure mainly manufactures various covers for aerospace equipment through common numerical control spinning, correction, shape correction and turning.
[73] An aluminum cover having sizes of Do = 248, D = 218, d = 213, Oh = 190 and R = 2 and a nominal thickness of a blank of 1.5 mm is formed mainly through the following steps:
[74] 1 Forming preparation
[75] 1.1 A spinning blank size 0 is generally estimated according to a product drawing and the following formula:
2dt1 2Dt1) + t3(D02 - 132)]+ d2 $tt 372mat -
2dt1 2Dt1) + t3(D02 - 132)]+ d2 $tt 372mat -
[76] 6
[77] In the formula, t is 1.2, t2 is 1.5, S is an actual thickness 1.38 of the blank, and other parameters are according to sizes in a drawing.
[78] 1.2 A spinning roller (FIG. 2) has sizes of R=10, R1=122.2, R2=188.5, B=45 and L=160. R1 is a spinning roller forward process compound surface fillet, R2 is a spinning roller reverse process compound surface fillet, B is a width of the spinning roller, and L is a diameter of the spinning roller, with a unit of mm.
[79] 1.3 The blank is cut by laser, a size 0 being 380, and a material being A1035 M.
[80] 1.4 A spinning die (FIG. 7) and the spinning roller (FIG. 2) are mounted on a numerical control spinning machine, and a radial circle run-out tolerance value is measured by a dial gauge. The spinning die is required to have a circle run-out tolerance value <0.1 mm, the spinning roller is required to have a circle run-out tolerance value <0.02 mm, and a mounting attack angle of the spinning roller is 450 .
[81] 2 Trace drawing
[82] 2.1 Inner and outer outlines of a trace are determined: it is necessary to consider compensation of the fillet radius of the spinning roller for the inner outline, a determination method is as shown in FIG. 3, a circle having a radius being S=10 mm is drawn at an end point by taking an offset distance S=10 mm (equal to a fillet radius R10 of the spinning roller) of an outline of a die surface 1, an intersection point of vertical and horizontal lines of the circle is taken, a perpendicular line of the outline of the die surface 1 is made by passing the intersection point, the outline of the die offsets by a Date Recue/Date Received 2023-06-29 length AS=2.5 mm of the perpendicular line, and horizontal extension is conducted to a die end line by taking an intersection point of an offset line and the vertical line of the circle, the offset line and a horizontal extension line foiining the inner outline. The outer outline is an elliptical line, a center of an ellipse is located at an intersection point of the inner outline and the die end line, and values a and b of a short axis and a long axis are computed according to the following formula:
= (13 D3/2 H = 69.5mm
= (13 D3/2 H = 69.5mm
[83]
b = (14 R =11Smni
b = (14 R =11Smni
[84]
[85] 2.2 A plurality of passes of spinning traces are drawn (FIG. 5): an initial rotation angle a of 14 is taken; as shown in FIG. 4, each pass is a reciprocating path, a line shape of a forward process is a "straight" line, a "concave" arc is used for a reverse process, a reverse process end point and a forward process start point have a horizontal distance AX and a distance from the inner outline of 1 mm, AX gradually increases from 0.2 mm to 5 mm, and a linear distance AT between a high point of a reverse process "concave" line and the forward process is about 3 mm; a start point of a next pass is an end point of an immediately preceding pass of reverse process, an end point of the forward process is determined according to a pressing amount of each pass AY
and an intersection position of a forward process line and an immediately preceding pass of reverse process line, AY gradually decreases from 4 mm to 1.5 mm, and a distance of the intersection position is kept to be (1/4-1/3)L from an end point of a forward process length L; and repeating is conducted in this way until a Z
value is equal to about 96 and an X value is equal to about 12, so as to complete drawing of the plurality of passes of reciprocating spinning traces. A one-way spinning trace is used for a final pass, the inner outline and a die end face 3 are taken as start points of the trace, a position, that is 96 mm away from the die end line, of a path along the inner outline is taken as a midpoint, an arc is drawn with the midpoint as a start point, an end point of the arc is outside an end point of a final pass of forward process of the reciprocating traces, and a radius of the arc is R77.
and an intersection position of a forward process line and an immediately preceding pass of reverse process line, AY gradually decreases from 4 mm to 1.5 mm, and a distance of the intersection position is kept to be (1/4-1/3)L from an end point of a forward process length L; and repeating is conducted in this way until a Z
value is equal to about 96 and an X value is equal to about 12, so as to complete drawing of the plurality of passes of reciprocating spinning traces. A one-way spinning trace is used for a final pass, the inner outline and a die end face 3 are taken as start points of the trace, a position, that is 96 mm away from the die end line, of a path along the inner outline is taken as a midpoint, an arc is drawn with the midpoint as a start point, an end point of the arc is outside an end point of a final pass of forward process of the reciprocating traces, and a radius of the arc is R77.
[86] 3 Spin forming
[87] 3.1 A rotation speed of the spinning roller is 600 r/min, a feed ratio of a first pass is 2 mm/r, a multi-pass reciprocating spinning feed ratio is 3 mm/r, and a feed ratio of a final pass is 0.5 mm/r.
[88] 3.2 A numerical control program is compiled according the trace in 2.2 and the parameters in 3.1.
[89] 3.3 Wear values of a spinning roller cutter in X and Z directions are set, that is, a gap between the spinning roller and the die is 1.25.
[90] 3.4 The blank is clamped on the numerical control spinning machine, the blank is turned into a required diameter 0 of 372 mm, the blank is deburred, and lubricating oil is applied to the blank.
Date Recue/Date Received 2023-06-29
Date Recue/Date Received 2023-06-29
[91] 3.5 A spindle and a feed rate are adjusted to 100% so as to form a part through spinning.
[92] 4 Shape correction
[93] 4.1 The flange of the part is corrected to a horizontal state (FIG.
6).
6).
[94] 4.2 A fillet R1=2 of the flange of the part is formed by means of a shape correction die (FIG. 7).
[95] 5 Turning
[96] 5.1 The spinning die, the upper cushion block and the part are clamped on a lathe, and the flange and an inner hole the part are turned into a diameter D0=248 mm and a diameter i=190 mm respectively.
[97] 5.2 Abrasive paper and polishing cloth are used to polish a surface of the part to be smooth and bright.
Date Recue/Date Received 2023-06-29
Date Recue/Date Received 2023-06-29
Claims (6)
1. A forming method for an aerospace cover, comprising the following steps:
step one, forming preparation:
1.1 generally estimating a spinning blank size 0;
1.2 selecting a fillet radius R of a spinning roller;
1.3 cutting a blank using a laser, a size of the blank being the spinning blank size + (5 mm-10 mm); and 1.4 mounting a spinning die and the spinning roller on a numerical control spinning machine;
step two, trace drawing:
2.1 determining inner and outer outlines of a trace; wherein determining the inner outline of the trace comprises: drawing a circle having a radius being S at an end point by taking an offset distance S, equal to the fillet radius R of the spinning roller, of an outline of a die surface, taking a first intersection point of vertical and horizontal lines of the circle, making a perpendicular line, which passes the first intersection point, to the outline of the die surface, offsetting the outline of the die surface by a length AS
of the perpendicular line, and horizontally extending the perpendicular line to a die end line by taking a second intersection point of an offset line and the vertical line of the circle, the offset line and a horizontal extension line forming the inner outline; and 2.2 drawing a plurality of passes of spinning traces; wherein drawing the plurality of passes of spinning traces comprises: taking an initial rotation angle a of 13 46';
making each pass of the plurality of passes of spinning traces as a reciprocating path, making a line shape of a forward process as a "straight" line, using a "concave" arc for a reverse process, making a reverse process end point and a forward process start point have a horizontal distance AX and a distance from the inner outline of 1 mm-2 mm, making AX gradually increase from 0.3 mm to 5 mm, making a linear distance AT between a high point of a reverse process "concave" arc and the forward process "straight line" be 2 mm-3 mm; making a start point of a next pass an end point of an immediately preceding pass of the reverse process, determining an end point of the forward process according to a pressing amount of each pass AY and an intersection position of a forward process line and an immediately preceding pass of the reverse process "concave" arc, making AY
gradually decrease from 4 mm to 1.5 mm, making a distance of the intersection position Date Recue/Date Received 2023-11-21 be kept to be (1/4-1/3)L from an end point of a forward process length L; and repeating in this way until a Z value, which is defined as a distance between a first forward process start point and a last reverse process end point of the plurality of passes of spinning traces, is equal to 0.95 times of a height H of the aerospace cover and an X value is 0.8 times of a width of a flange of the aerospace cover, so as to complete drawing of the plurality of passes of spinning traces;
step three, spin forming:
3.1 setting a rotation speed of the spinning roller to be 500 r/min-600 r/min and a feed ratio to be 0.5 mm/r-3 mm/r;
3.2 compiling a numerical control program according to the plurality of passes of spinning traces, parameters of the rotation speed of the spinning roller, and the feed ratio;
3.3 setting wear values of a spinning roller cutter in X and Z directions, which are a gap between the spinning roller and the spinning die;
3.4 clamping the blank on the numerical control spinning machine, turning the blank into a required diameter 0, deburring the blank, and applying lubricating oil to the blank;
and 3.5 adjusting a spindle rate to 100% and a feed rate to 100% so as to form the aerospace cover through spinning;
step four, shape correction:
4.1 correcting the flange of the aerospace cover to a horizontal state; and 4.2 founing a fillet RI of the flange of the aerospace cover by means of a shape correction tool; and step five, turning:
5.1 clamping the spinning die, an upper cushion block and the aerospace cover on a lathe, and turning the flange and an inner hole of the aerospace cover into Do and Oh respectively; and 5.2 using abrasive paper and polishing cloth to polish a surface of the aerospace cover.
step one, forming preparation:
1.1 generally estimating a spinning blank size 0;
1.2 selecting a fillet radius R of a spinning roller;
1.3 cutting a blank using a laser, a size of the blank being the spinning blank size + (5 mm-10 mm); and 1.4 mounting a spinning die and the spinning roller on a numerical control spinning machine;
step two, trace drawing:
2.1 determining inner and outer outlines of a trace; wherein determining the inner outline of the trace comprises: drawing a circle having a radius being S at an end point by taking an offset distance S, equal to the fillet radius R of the spinning roller, of an outline of a die surface, taking a first intersection point of vertical and horizontal lines of the circle, making a perpendicular line, which passes the first intersection point, to the outline of the die surface, offsetting the outline of the die surface by a length AS
of the perpendicular line, and horizontally extending the perpendicular line to a die end line by taking a second intersection point of an offset line and the vertical line of the circle, the offset line and a horizontal extension line forming the inner outline; and 2.2 drawing a plurality of passes of spinning traces; wherein drawing the plurality of passes of spinning traces comprises: taking an initial rotation angle a of 13 46';
making each pass of the plurality of passes of spinning traces as a reciprocating path, making a line shape of a forward process as a "straight" line, using a "concave" arc for a reverse process, making a reverse process end point and a forward process start point have a horizontal distance AX and a distance from the inner outline of 1 mm-2 mm, making AX gradually increase from 0.3 mm to 5 mm, making a linear distance AT between a high point of a reverse process "concave" arc and the forward process "straight line" be 2 mm-3 mm; making a start point of a next pass an end point of an immediately preceding pass of the reverse process, determining an end point of the forward process according to a pressing amount of each pass AY and an intersection position of a forward process line and an immediately preceding pass of the reverse process "concave" arc, making AY
gradually decrease from 4 mm to 1.5 mm, making a distance of the intersection position Date Recue/Date Received 2023-11-21 be kept to be (1/4-1/3)L from an end point of a forward process length L; and repeating in this way until a Z value, which is defined as a distance between a first forward process start point and a last reverse process end point of the plurality of passes of spinning traces, is equal to 0.95 times of a height H of the aerospace cover and an X value is 0.8 times of a width of a flange of the aerospace cover, so as to complete drawing of the plurality of passes of spinning traces;
step three, spin forming:
3.1 setting a rotation speed of the spinning roller to be 500 r/min-600 r/min and a feed ratio to be 0.5 mm/r-3 mm/r;
3.2 compiling a numerical control program according to the plurality of passes of spinning traces, parameters of the rotation speed of the spinning roller, and the feed ratio;
3.3 setting wear values of a spinning roller cutter in X and Z directions, which are a gap between the spinning roller and the spinning die;
3.4 clamping the blank on the numerical control spinning machine, turning the blank into a required diameter 0, deburring the blank, and applying lubricating oil to the blank;
and 3.5 adjusting a spindle rate to 100% and a feed rate to 100% so as to form the aerospace cover through spinning;
step four, shape correction:
4.1 correcting the flange of the aerospace cover to a horizontal state; and 4.2 founing a fillet RI of the flange of the aerospace cover by means of a shape correction tool; and step five, turning:
5.1 clamping the spinning die, an upper cushion block and the aerospace cover on a lathe, and turning the flange and an inner hole of the aerospace cover into Do and Oh respectively; and 5.2 using abrasive paper and polishing cloth to polish a surface of the aerospace cover.
2. The forming method according to claim 1, wherein the spinning blank size 0 is generally estimated according to the following formula:
0 = .\I1H(ti2 + 2dt1 + 2Dt1) + t2(D02 ¨ D2)1/5 + d2 wherein in the formula, t1 is an actual average thickness of a straight wall after spin Date Recue/Date Received 2023-11-21 forming; t2 is an actual average thickness of the flange after spin forming; 8 is an actual thickness of the blank; H is a height of the aerospace cover; d is a diameter of a bottom of the aerospace cover; D is a diameter of a mouth of the aerospace cover; and Do is a diameter of the flange of the aerospace cover.
0 = .\I1H(ti2 + 2dt1 + 2Dt1) + t2(D02 ¨ D2)1/5 + d2 wherein in the formula, t1 is an actual average thickness of a straight wall after spin Date Recue/Date Received 2023-11-21 forming; t2 is an actual average thickness of the flange after spin forming; 8 is an actual thickness of the blank; H is a height of the aerospace cover; d is a diameter of a bottom of the aerospace cover; D is a diameter of a mouth of the aerospace cover; and Do is a diameter of the flange of the aerospace cover.
3. The forming method for an aerospace cover according to claim 1, wherein the mounting of the spinning die and the spinning roller satisfies the following requirements that a circle run-out tolerance value of the spinning die <0.1 mm, a circle run-out tolerance value of the spinning roller <0.02 mm, and a mounting attack angle of the spinning roller is 45 .
4. The forming method for an aerospace cover according to claim 1, wherein determining the outer outline of the trace comprises: making the outer outline an elliptical line, making a center of an ellipse be located at a third intersection point of the inner outline and the die end line, and computing values a and b of a short axis and a long axis according to the following formula:
a = (Do D)12 + H
b = (9) 2 ¨ R
a = (Do D)12 + H
b = (9) 2 ¨ R
5. The forming method for an aerospace cover according to claim 1, wherein when a final pass of the plurality of passes of spinning traces is drawn, a one-way spinning trace is used, the inner outline and a die end face are taken as start points, a position, that is 0.95H away from the die end line, of a path along the inner outline is taken as a midpoint, an arc is drawn with the midpoint as a start point, an end point of the arc is outside an end point of a final pass of the forward process of the reciprocating traces, and a radius of the arc is slightly smaller than a radius of a fmal pass of the reverse process.
6. The forming method for an aerospace cover according to claim 1, wherein when the feed ratio of the spinning roller is set, a feed ratio of a first pass is selected, a multi-pass reciprocating spinning feed ratio is selected that is higher than the feed ratio of the first pass, and a feed ratio of a final pass is selected that is lower than the multi-pass reciprocating spinning feed ratio.
Date Recue/Date Received 2023-11-21
Date Recue/Date Received 2023-11-21
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110629707.9 | 2021-06-07 | ||
| CN202110629707.9A CN113369362B (en) | 2021-06-07 | 2021-06-07 | Method for forming cover for spaceflight |
| PCT/CN2021/125279 WO2022257320A1 (en) | 2021-06-07 | 2021-10-21 | Forming method of cover for spaceflight |
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| CA3187776C true CA3187776C (en) | 2024-02-06 |
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| CA3187776A Active CA3187776C (en) | 2021-06-07 | 2021-10-21 | Forming method for aerospace cover |
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| CN (1) | CN113369362B (en) |
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| CN113369362B (en) * | 2021-06-07 | 2022-08-30 | 四川航天长征装备制造有限公司 | Method for forming cover for spaceflight |
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- 2021-06-07 CN CN202110629707.9A patent/CN113369362B/en active Active
- 2021-10-21 WO PCT/CN2021/125279 patent/WO2022257320A1/en active Application Filing
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| CA3187776A1 (en) | 2022-12-15 |
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