CN103071717A - Superplastic forming die for aluminum alloy coating parts for railway vehicles and forming method for superplastic forming die - Google Patents
Superplastic forming die for aluminum alloy coating parts for railway vehicles and forming method for superplastic forming die Download PDFInfo
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Abstract
The invention discloses a superplastic forming die for aluminum alloy coating parts for railway vehicles and a forming method for the superplastic forming die, and relates to a superplastic forming die and a forming method thereof. The invention solves the problems of low production efficiency and high production cost in the aluminum alloy coating parts for the railway vehicles in the prior art. An upper plate of the superplastic forming die is arranged over a female die; a male die is fixedly arranged at the lower end of the upper plate; and an aluminum alloy plate is arranged at the upper end of the female die between the male die and the female die. The superplastic forming method comprises the following steps: 1, mounting the superplastic forming die; 2, spraying a high temperature lubricant; 3, preheating the superplastic forming die; 4, preheating the aluminum alloy plate; 5, bending the aluminum alloy plate in an initial stage; 6, after the aluminum alloy plate is bent in the initial stage, forming a sealed space between the bent aluminum alloy plate and the male die; and 7, finally shaping the aluminum alloy plate. The invention is suitable for manufacturing the aluminum alloy coating parts for the railway vehicles.
Description
Technical field
The present invention relates to a kind of superplastic forming die and manufacturing process thereof, be specifically related to a kind of superplastic forming die and manufacturing process thereof of used for rail vehicle aluminium alloy cap piece.
Background technology
The locomotive lightweight is significant to promoting the bullet train performance.The mode that generally adopts both at home and abroad at present is material lightweight, and namely the high-performance locomotive all adopts high-intensity aluminum alloy materials manufacturing.Adopt large size, thin walled aluminum alloy plate materials, the aluminum alloy bodywork structural member that the rail traffic vehicles such as processing and manufacturing bullet train, subway, light rail are used is such as various in-vehicle devices and other complex structural members such as window wall, interior outside end wall, door pillar covers.The important rail traffic vehicles built-in fitting of this class should satisfy performance, precision and integration requirement attractive in appearance, many shape of products are three-dimension curved surfaces, therefore the degree of accuracy and surface quality to built-in fitting manufacturing and assembling have proposed very high requirement, the cold forming deflection is limited, spring-go is large, be difficult to meet the demands, so the superplastic air bulge technology becomes main manufacture method.Because superplastic air bulge need to be heated to higher temperature with mould and part, energy consumption is larger, and the complicated shape part that is shaped, the inflation bulging just needs dozens of minutes even several hours, this production efficiency to be difficult to satisfy the demand that the rail vehicle part is produced in enormous quantities.Many scholars improve the strain rate of superplastic aluminum alloy by grain refinement, thereby improve superplastic forming efficient, although obtain some laboratory results, also have very large distance from practical application.In sum, existing used for rail vehicle aluminium alloy cap piece exists production efficiency to hang down and the high problem of production cost.
Summary of the invention
The objective of the invention is to exist production efficiency to hang down and the high problem of production cost in order to solve existing used for rail vehicle aluminium alloy cap piece, and then a kind of superplastic forming die and manufacturing process thereof of used for rail vehicle aluminium alloy cap piece are provided.
Technical scheme of the present invention is: the superplastic forming die of used for rail vehicle aluminium alloy cap piece comprises cope match-plate pattern and die, cope match-plate pattern be arranged on die directly over, described superplastic forming die also comprises punch, punch is packed in the lower end of cope match-plate pattern, form inflatable chamber between punch and the die, alloy plate material is arranged on the die upper end, have air admission hole on the cope match-plate pattern, the lower end of die has steam vent, the lower end of described punch is provided with boss, be provided with fillet between the shoulder of boss and the sidewall of punch, the middle part of boss is provided with the second anti-compacted sealing groove.
The present invention also provides a kind of super molding process of used for rail vehicle aluminium alloy cap piece:
Step 1: the installation of superplastic forming die,
Superplastic forming die is installed on the superplastic forming machine, and the air admission hole of cope match-plate pattern is connected with pneumatic circuit on the superplastic forming machine, and the temperature control system thermocouple on the superplastic forming machine is connected respectively on cope match-plate pattern, die and the punch,
Step 2: the spraying high-temperature lubricant,
The surface of die and punch and the surface uniform of alloy plate material spraying high-temperature lubricant;
Step 3: the preheating of superplastic forming die,
Cope match-plate pattern, die and punch are in the matched moulds state, superplastic forming die are heated to 400 ℃-500 ℃ forming temperature, and pressurize 1-5min makes the temperature uniformity of cope match-plate pattern, die and punch, realizes the preheating to superplastic forming die;
Step 4: the preheating of alloy plate material,
After superplastic forming die is preheating to forming temperature, open superplastic forming die, alloy plate material is placed on the die, insulation 4-5min makes alloy plate material also reach forming temperature;
Step 5: the flexural deformation of alloy plate material initial stage,
The superplastic forming machine drives cope match-plate pattern and punch moves downward, make alloy plate material flexural deformation, pressing speed is 10-50mm/s, when depression distance is 100-150mm, cope match-plate pattern and punch stop motion, alloy plate material is clamped around die and the punch all around at this moment;
Step 6: form seal cavity after the flexural deformation of alloy plate material initial stage and between the punch,
Cope match-plate pattern continues pressurization 3-4MPa downwards, makes the first fillet seal groove on punch four limits press downward to 0.2-0.6mm, forms the needed seal cavity by forming between alloy plate material and the punch of expansive forming;
Step 7: the seal cavity pressurization in step 6 also finally is shaped,
Programming Control air pressure-time graph on the superplastic forming machine, pass into gas from the air admission hole of cope match-plate pattern, the pressure of gas is 0.5-4MPa, make alloy plate material expansive forming under the effect of gas pressure, the time of expansive forming is 10-15min, and the air between alloy plate material and the die is discharged by the steam vent of die, the inwall of final alloy plate material and die is fitted, the alloy plate material after being shaped is taken out in die sinking behind the pressurize 4-5min, and so far, the superplastic forming of alloy plate material finishes.
The present invention compared with prior art has following effect:
1. after alloy plate material of the present invention was formed into certain position, original position was carried out superplastic air bulge again, thereby the alloy plate material curring time was shortened to 10-20 minute by original 1-3 hour, significantly improved production efficiency, reduced cost.
2. the present invention is simple in structure, is easy to realize.
Description of drawings
Fig. 1 is the structural representation before the superplastic forming die superplastic forming, and Fig. 2 is the structural representation behind the superplastic forming die superplastic forming.
The specific embodiment
The specific embodiment one: present embodiment is described in conjunction with Fig. 1 and Fig. 2, the superplastic forming die of the used for rail vehicle aluminium alloy cap piece of present embodiment comprises cope match-plate pattern 1 and die 2, cope match-plate pattern 1 be arranged on die 2 directly over, described superplastic forming die also comprises punch 3, punch 3 is packed in the lower end of cope match-plate pattern 1, form inflatable chamber between punch 3 and the die 2, alloy plate material 4 is arranged on die 2 upper ends, have air admission hole 5 on the cope match-plate pattern 1, the lower end of die 2 has steam vent 6, the lower end of described punch 3 is provided with boss 7, is provided with fillet between the sidewall of the shoulder of boss 7 and punch 3, and the middle part of boss 7 is provided with the second anti-compacted sealing groove 8.
Although the present invention adopts the scheme of prebuckling shaping+superplastic forming can significantly improve production efficiency, but the difficulty of Design of Dies obviously increases, the mating surface of cope match-plate pattern 1, die 2 and punch 3 no longer is a plane, but space curved surface, in this case, how to guarantee to form gastight confined space between the mating surface of cope match-plate pattern 1, die 2 and punch 3 and the alloy plate material 4, become the key of guaranteeing forming quality.For this reason, the present invention proposes the second anti-compacted sealing groove 8, seal groove makes alloy plate material 4 distortion under the effect of pressure, formation fits tightly, gas be difficult to by, this structure is no problem in the plane, but, when adopting the curved surface edge sealing, often can't form and fit tightly, cause gas leakage, gas expansion forming can't carry out.And adopt punch 3 center bottom be provided with the second anti-compacted sealing groove 8, can be with alloy plate material 4 counter being extruded in the second anti-compacted sealing groove 8, sealing effectiveness is better.
The outer wall dimension of present embodiment punch 3 is less than the inwall size of die 2, make follow-up expansive forming shared ratio in whole forming process minimum, but can not be too near the counterdie cavity dimension, because the oversize meeting of patrix causes alloy plate material to break or dead wrinkle occurs, the concrete selection also needs to determine by finite element numerical simulation.For improving simulation precision, must accurately grasp alloy plate material pyroplastic deformability ability, method is at the load-deformation curve of drawing by high temperature airborne measurements alloy plate material under different temperatures, differently strained speed.
Air pressure-time graph during the expansive forming of present embodiment, initial gas pressure is very little, increase gradually, last air pressure is maximum, be about 0.5-4MPa, determining of best air pressure-time graph need to carry out finite element numerical simulation optimization according to the high-temperature mechanical behavior of alloy plate material, determines at last the fastest forming speed.
The specific embodiment two: in conjunction with Fig. 1 and Fig. 2 present embodiment is described, the length of the second anti-compacted sealing groove 8 of present embodiment is 1 times-2 times of alloy plate material wall thickness.So arrange, sealing effectiveness is better.Other composition is identical with the specific embodiment one with annexation.
The specific embodiment three: in conjunction with Fig. 1 and Fig. 2 present embodiment is described, the radius of corner of the first fillet seal groove 7 of present embodiment is 10 times-15 times of alloy plate material wall thickness.So arrange.Other composition is identical with the specific embodiment two with annexation.
The specific embodiment four: in conjunction with Fig. 1 and Fig. 2 present embodiment is described, the concrete steps of the super molding process of present embodiment are as follows:
Step 1: the installation of superplastic forming die,
Superplastic forming die is installed on the superplastic forming machine, and the air admission hole 5 of cope match-plate pattern 1 is connected with pneumatic circuit on the superplastic forming machine, and the temperature control system thermocouple on the superplastic forming machine is connected respectively on cope match-plate pattern 1, die 2 and the punch 3,
Step 2: the spraying high-temperature lubricant,
The surface uniform spraying high-temperature lubricant of the surface of die 2 and punch 3 and alloy plate material 4;
Step 3: the preheating of superplastic forming die,
Cope match-plate pattern 1, die 2 and punch 3 are in the matched moulds state, superplastic forming die are heated to 400 ℃-500 ℃ forming temperature, and pressurize 1-5min makes the temperature uniformity of cope match-plate pattern 1, die 2 and punch 3, realizes the preheating to superplastic forming die;
Step 4: the preheating of alloy plate material 4,
After superplastic forming die is preheating to forming temperature, open superplastic forming die, alloy plate material 4 is placed on the die 2, insulation 4-5min makes alloy plate material 4 also reach forming temperature;
Step 5: alloy plate material 4 initial stage flexural deformation,
The superplastic forming machine drives cope match-plate pattern 1 and punch 3 moves downward, make alloy plate material 4 flexural deformations, pressing speed is 10-50mm/s, when depression distance is 100-150mm, cope match-plate pattern 1 and punch 3 stop motions, alloy plate material 4 is clamped around die 2 and the punch 3 all around at this moment;
Step 6: form seal cavity after the alloy plate material 4 initial stage flexural deformation and between the punch 3,
Cope match-plate pattern 1 continues pressurization 3-4MPa downwards, makes the first fillet seal groove 7 on punch 3 four limits press downward to 0.2-0.6mm, forms the needed seal cavity by forming between alloy plate material 4 and the punch 3 of expansive forming;
Step 7: the seal cavity pressurization in step 6 also finally is shaped,
Programming Control air pressure-time graph on the superplastic forming machine, pass into gas from the air admission hole 5 of cope match-plate pattern 1, the pressure of gas is 0.5-4MPa, make alloy plate material 4 expansive forming under the effect of gas pressure, the time of expansive forming is 10-15min, air between alloy plate material 4 and the die 2 is discharged by the steam vent 6 of die 2, final alloy plate material 4 is fitted with the inwall of die 2, the alloy plate material 4 after being shaped is taken out in die sinking behind the pressurize 4-5min, so far, the superplastic forming of alloy plate material 4 finishes.
For rail vehicle headstock part, characteristics are that part integral body has larger bending, the local detailed shape that also has complexity, and the door pillar cover on the rail vehicle, integral chair etc. also have similar feature.If adopt traditional superplastic deformation, generally be that the part both sides are added process complementary surface, form box part, adopt box part superplastic air bulge process forming to go out box part, cutting away the process complementary surface of both sides, obtain part.Although Design of Dies is simple, air seal is also easy, the seal groove place in one plane, but the part deformation amount is very large, after finite element modelling is shaped after the Thickness Distribution, the plate original depth is 4mm, behind the superplastic deformation the wall thickness of thin position be reduced to 1.1mm, not only the Thickness Distribution situation is poor, and is superly to mould the aluminum alloy materials performance and see with 5000 of present use, the possibility of having broken in forming process is very large, can't finish the final mould that all pastes.Therefore, the present invention proposes the scheme of prebuckling shaping+superplastic forming, by appropriate design and the combination of two kinds of techniques, reduces the superplastic deformation amount, produces the part of acceptable quality.
The scheme upper mould plate 1 of prebuckling shaping+superplastic forming has certain simple shape, can make sheet metal bending at the distortion initial stage, enters die 2, at this moment, has more material to participate in distortion.The height of cope match-plate pattern 1 projection is slightly less than the degree of depth of counterdie die cavity, and the most advanced and sophisticated radius of corner of patrix projection can not be too small, otherwise easily makes the plate contact site produce dead wrinkle or impression.Radius of corner generally should be greater than 10 times of plate wall thickness.During the quick superplastic forming finite element modelling of subway headstock part, can find out, after being shaped through prebuckling, the plate wall thickness does not almost change, through behind the superplastic deformation, and wall thickness reduction to 3.1 millimeter, the attenuate amount is very little, and effect is better than the result of traditional superplastic forming far away.In this case, the very good shaping of part does not need to select best SPF Technology parameter, but can select, to reduce production costs highly beneficial for enhancing productivity than faster bulging speed and lower forming temperature.
The specific embodiment five: in conjunction with Fig. 1 and Fig. 2 present embodiment is described, the high-temperature lubricant in the step 2 of present embodiment is the water-based graphite breast.So arrange, can improve Thickness Distribution and surface quality of workpieces.Other composition is identical with the specific embodiment four with annexation.
The specific embodiment six: in conjunction with Fig. 1 and Fig. 2 present embodiment is described, the time of the expansive forming in the step 7 of present embodiment is 12min.So arrange, make plate fill mould fully.Other composition is identical with the specific embodiment five with annexation.
For integral body larger bending is arranged, the local used for rail vehicle aluminum alloy part that also has complicated detailed shape, adopt the scheme of prebuckling shaping+superplastic forming of the present invention to make, plate wall thickness reduction amount is very little, and evenness of wall thickness is better than the result of traditional superplastic forming.In this case, part easily is shaped, and can select, to reduce production costs highly beneficial for enhancing productivity than faster bulging speed and lower forming temperature.The improved second anti-compacted sealing groove 8 structures are also very good for the sealing effectiveness of Parts with Space Surface, for the steady production of used for rail vehicle aluminum alloy part provides powerful guarantee.
Claims (6)
1. the superplastic forming die of a used for rail vehicle aluminium alloy cap piece, it comprises cope match-plate pattern (1) and die (2), cope match-plate pattern (1) be arranged on die (2) directly over, it is characterized in that: described superplastic forming die also comprises punch (3), punch (3) is packed in the lower end of cope match-plate pattern (1), form inflatable chamber between punch (3) and the die (2), alloy plate material (4) is arranged on die (2) upper end, have air admission hole (5) on the cope match-plate pattern (1), the lower end of die (2) has steam vent (6), the lower end of described punch (3) is provided with boss (7), be provided with fillet between the sidewall of the shoulder of boss (7) and punch (3), the middle part of boss (7) is provided with the second anti-compacted sealing groove (8).
2. the superplastic forming die of used for rail vehicle aluminium alloy cap piece according to claim 1, it is characterized in that: the length of the described second anti-compacted sealing groove (8) is 1 times-2 times of alloy plate material wall thickness.
3. the superplastic forming die of used for rail vehicle aluminium alloy cap piece according to claim 1 and 2, it is characterized in that: the radius of corner of described the first fillet seal groove (7) is 10 times-15 times of alloy plate material wall thickness.
4. a right to use requires the super molding process of the used for rail vehicle aluminium alloy cap piece that 1 described superplastic forming die realizes, it is characterized in that: the concrete steps of described super molding process are as follows:
Step 1: the installation of superplastic forming die,
Superplastic forming die is installed on the superplastic forming machine, the air admission hole (5) of cope match-plate pattern (1) is connected with the pneumatic circuit on the superplastic forming machine, thermocouple on the superplastic forming machine is connected respectively on cope match-plate pattern (1), die (2) and the punch (3)
Step 2: the spraying high-temperature lubricant,
The surface uniform spraying high-temperature lubricant of the surface of die (2) and punch (3) and alloy plate material (4);
Step 3: the preheating of superplastic forming die,
Cope match-plate pattern (1), die (2) and punch (3) are in the matched moulds state, superplastic forming die is heated to 400 ℃-500 ℃ forming temperature, pressurize 1-5min, make the temperature uniformity of cope match-plate pattern (1), die (2) and punch (3), realize the preheating to superplastic forming die;
Step 4: the preheating of alloy plate material (4),
After superplastic forming die is preheating to forming temperature, open superplastic forming die, alloy plate material (4) is placed on the die (2), insulation 4-5min makes alloy plate material (4) also reach forming temperature;
Step 5: alloy plate material (4) initial stage flexural deformation,
The superplastic forming machine drives cope match-plate pattern (1) and punch (3) moves downward, make alloy plate material (4) flexural deformation, pressing speed is 10-50mm/s, when depression distance is 100-150mm, cope match-plate pattern (1) and punch (3) stop motion are clamped around die (2) and the punch (3) around alloy plate material this moment (4);
Step 6: form seal cavity after alloy plate material (4) the initial stage flexural deformation and between the punch (3),
Cope match-plate pattern (1) continues pressurization 3-4MPa downwards, make the first fillet seal groove (7) on punch (3) four limits press downward to 0.2-0.6mm, form the needed seal cavity by forming between alloy plate material (4) and the punch (3) of expansive forming;
Step 7: the seal cavity pressurization in step 6 also finally is shaped,
Programming Control air pressure-time graph on the superplastic forming machine, pass into gas from the air admission hole (5) of cope match-plate pattern (1), the pressure of gas is 0.5-4MPa, make alloy plate material (4) expansive forming under the effect of gas pressure, the time of expansive forming is 10-15min, air between alloy plate material (4) and the die (2) is discharged by the steam vent (6) of die (2), final alloy plate material (4) is fitted with the inwall of die (2), the alloy plate material (4) after being shaped is taken out in die sinking behind the pressurize 4-5min, so far, the superplastic forming of alloy plate material (4) finishes.
5. the superplastic forming method of used for rail vehicle aluminium alloy cap piece according to claim 4 is characterized in that: the high-temperature lubricant in the step 2 is the water-based graphite breast.
6. the superplastic forming method of used for rail vehicle aluminium alloy cap piece according to claim 5, it is characterized in that: the time of the expansive forming in the step 7 is 12min.
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| CN103691784A (en) * | 2013-12-24 | 2014-04-02 | 南京航空航天大学 | Method for manufacturing corrugated sandwich layer |
| CN103760930A (en) * | 2014-01-03 | 2014-04-30 | 南京航空航天大学 | Variable optimal strain rate superplastic bulging multiple-gas-channel pressure control method, control device thereof and using method |
| CN103753119A (en) * | 2013-12-09 | 2014-04-30 | 北京航星机器制造有限公司 | Lightweight wall panel superplastic forming production method |
| CN109433898A (en) * | 2018-09-28 | 2019-03-08 | 北京航星机器制造有限公司 | A kind of rail traffic aluminum alloy sheet metal component and its superplastic forming method |
| CN110328279A (en) * | 2019-05-28 | 2019-10-15 | 北京航星机器制造有限公司 | A kind of mechanical pressure loading method being applicable in SPF Technology |
| CN110538915A (en) * | 2019-01-29 | 2019-12-06 | 中车长春轨道客车股份有限公司 | Rapid superplastic forming die and method for large-curved-surface plate ridge line of high-speed motor car |
| CN110586731A (en) * | 2019-10-21 | 2019-12-20 | 中车长春轨道客车股份有限公司 | Rapid superplastic forming method for complex aluminum alloy parts for railway vehicles |
| CN110831753A (en) * | 2017-07-06 | 2020-02-21 | 鲍勃斯脱梅克斯股份有限公司 | Punching tool comprising a punch and a die |
| CN112091047A (en) * | 2020-06-29 | 2020-12-18 | 上海方柚智能科技有限公司 | Superplastic forming process for automobile parts |
| CN112935059A (en) * | 2021-02-10 | 2021-06-11 | 哈尔滨工业大学 | Titanium alloy U-shaped piece viscous medium room-temperature forming method |
| CN113118275A (en) * | 2019-12-31 | 2021-07-16 | 中国第一汽车股份有限公司 | Cylindrical ultra-deep aluminum alloy fender superplastic forming process method |
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| CN103691784A (en) * | 2013-12-24 | 2014-04-02 | 南京航空航天大学 | Method for manufacturing corrugated sandwich layer |
| CN103760930A (en) * | 2014-01-03 | 2014-04-30 | 南京航空航天大学 | Variable optimal strain rate superplastic bulging multiple-gas-channel pressure control method, control device thereof and using method |
| CN110831753B (en) * | 2017-07-06 | 2021-12-24 | 鲍勃斯脱梅克斯股份有限公司 | Punching tool comprising a punch and a die |
| CN110831753A (en) * | 2017-07-06 | 2020-02-21 | 鲍勃斯脱梅克斯股份有限公司 | Punching tool comprising a punch and a die |
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| CN109433898A (en) * | 2018-09-28 | 2019-03-08 | 北京航星机器制造有限公司 | A kind of rail traffic aluminum alloy sheet metal component and its superplastic forming method |
| CN109433898B (en) * | 2018-09-28 | 2021-03-05 | 北京航星机器制造有限公司 | Aluminum alloy sheet metal component for track traffic |
| CN110538915A (en) * | 2019-01-29 | 2019-12-06 | 中车长春轨道客车股份有限公司 | Rapid superplastic forming die and method for large-curved-surface plate ridge line of high-speed motor car |
| WO2020155881A1 (en) * | 2019-01-29 | 2020-08-06 | 中车长春轨道客车股份有限公司 | High-speed bullet train large curved-surface plate ridge fast superplastic forming die and forming method |
| CN110328279A (en) * | 2019-05-28 | 2019-10-15 | 北京航星机器制造有限公司 | A kind of mechanical pressure loading method being applicable in SPF Technology |
| CN110586731A (en) * | 2019-10-21 | 2019-12-20 | 中车长春轨道客车股份有限公司 | Rapid superplastic forming method for complex aluminum alloy parts for railway vehicles |
| CN113118275A (en) * | 2019-12-31 | 2021-07-16 | 中国第一汽车股份有限公司 | Cylindrical ultra-deep aluminum alloy fender superplastic forming process method |
| CN112091047A (en) * | 2020-06-29 | 2020-12-18 | 上海方柚智能科技有限公司 | Superplastic forming process for automobile parts |
| CN112935059A (en) * | 2021-02-10 | 2021-06-11 | 哈尔滨工业大学 | Titanium alloy U-shaped piece viscous medium room-temperature forming method |
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Application publication date: 20130501 |