CN103464536B - Vibration stress relief formation method and device under elastic deformation condition - Google Patents
Vibration stress relief formation method and device under elastic deformation condition Download PDFInfo
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Abstract
The invention relates to a vibration stress relief formation method and a vibration stress relief formation device under an elastic deformation condition. Metal flat plates are enabled to be bent under the effect of a mold, the deformation is within an elastic range, the metal plates can be restored to the original shape after the mold is removed, bending prestress is loaded to the plates under the effect of the mold, a vibration stress relief device is connected, periodic exciting force is produced through a vibration exciter, the plates are enabled to reach a resonance state under the effect of the periodic exciting force, the internal bending prestress of the plates is relieved and homogenized through resonance, the metal plates are enabled to produce certain plastic deformation through the release process of the bending prestress and bent parts with bending radius which is equivalent to the curvature radius of the mold are obtained. The vibration stress relief formation method and the vibration stress relief formation device under the elastic deformation condition have the advantages that the defects that the mold manufacturing cost is high during formation of sheet metal parts and the resilience is difficult to control are overcome, the surface friction damages of the parts and the vibration energy losses during vibration stress relief are decreased, the surface quality of formed parts is improved, the production cycle is shortened and the production cost is decreased.
Description
Technical field
The present invention relates to age forming processing technique field, the oscillating aging manufacturing process specifically under a kind of elastic deformation condition and device.
Background technology
In recent years, domestic use oscillation time-effect method and relevant device more and more, simultaneously can environmental protection, energy-conservation, efficient process workpiece stress problem, surging highlight its a little with the development prospect in future, allow more industrial producer and enterprise use oscillating aging equipment targetedly, increase work efficiency and benefit.Along with being widely used of oscillating aging, technique also achieves no small development.Oscillating aging refers to that the vibrator be clamped on workpiece produces periodically exciting force, under its effect, makes component reach resonance state, the internal stress of lax workpiece, the method for holding workpiece dimensionally stable.In fact vibratory stress reliefing is exactly superpose with inner stress of work by the dynamic stress in cycle, makes component partial produce plastic deformation and discharge stress.
Chinese patent CN102551096A(sheet metal part oscillation time-effect method and vibration ageing device) sheet metal part of machine-shaping is fixed on oscillating aging platform together with mould tire, vibrator and oscillating aging platform rigidity are fixed, the mould tire making oscillating aging platform with control system startup vibrator and be fixedly connected with it and sheet metal part vibrate simultaneously, to eliminate and the internal stress of homogenizing meal metal parts, but, the method has following shortcoming, first, directly sheet metal component bandage is bundled on mould tire, because sheet metal component is different from mould tire intrinsic frequency, different vibratory responses can be caused, cause the friction of contact surface, affect workpiece surface quality, in addition, the vibrational energy of vibrator passes to the mould tire rigidly fixed with it by oscillating aging platform, finally pass to the sheet metal part be connected with mould tire, this large-scale transmission can cause a large amount of losses of vibrational energy, be unfavorable for energy-conserving and environment-protective.Oscillating aging carries out under the elastic stage of material, but research at present mainly concentrates in the residual stress process of in type workpiece, utilize resonance to eliminate and homogenizing hardware internal residual stress, play reinforcement resistance ability, stable dimensions precision.
British scholar Ward that only effectively can prevent the formation of weld crack and the distortion of workpiece with fertile gram when vibrating, improve the fatigue life of component, welded parts first vibrate before research welding by the basis of the mechanics effect technique of enhancing weld seam, and limit vibration side weld connects, until be soldered as performance, the process of postwelding stress-removal can also be saved, shorten the production cycle, reduce production cost, after this research explanation oscillation time-effect method is not only applied to and plastic deformation occurs, part is eliminated in the process of residual stress residual stress, also can be applied to before plastic deformation in prestressed process.
Summary of the invention
High for overcoming the die manufacturing cost in sheet metal component forming process existed in prior art, the unmanageable deficiency of resilience, the present invention proposes the oscillating aging manufacturing process under a kind of elastic deformation condition and device.
The concrete steps of the oscillating aging manufacturing process under elastic deformation condition of the present invention are:
The first step, installs the plate of workpiece to be formed.
Second step, determines the resonant frequency of workpiece.Vibrator carries out frequency sweep, and swept frequency is 0-400Hz, frequency sweep power is 400W, and the frequency sweep time is 6min.Amplitude-frequency (A-f) curve of record workpiece, obtains frequency sweep curve.If the frequency sweep curve obtained has an amplitude peaks, form First formant, then using frequency corresponding to this First formant as the resonant frequency of workpiece.If the frequency sweep curve obtained has multiple amplitude peaks, then using the minimum peak of multiple amplitude peaks medium frequency as First formant, using frequency corresponding to this First formant as the resonant frequency of workpiece, frequency corresponding to subsequent amplitude peak is as higher order resonant frequencies.
3rd step, vibration shaping.In vibration shaping, the operating frequency of adjustment vibrator is consistent with the resonant frequency of workpiece, and the setting oscillating aging time is 30min.The eccentric throw of adjusting vibration exciter, makes the dynamic stress peak value at the most concentrated position of stress in the bending forming of workpiece carry out oscillating aging between 1/3 ~ 2/3 of this position workpiece prestress value.The power output of vibrator is 80% of this vibrator rated power.
4th step, after oscillating aging terminates, the bending radius of measuring workpieces, if the bending radius of workpiece meets design requirement, completes the bending forming to workpiece.If exceed error range, clamping workpiece again, repetition step 3 is carried out benefit and is shaken, until the radius of curvature of workpiece meets design requirement.
Described benefit center of percussion, if the frequency sweep curve obtained has an amplitude peaks, then gets frequency values and carries out benefit as vibrator operating frequency and shake near the workpiece resonant frequency obtained using step 2; If the frequency sweep curve obtained has multiple amplitude peaks, the higher order resonant frequencies of the workpiece obtained using step 2 carries out benefit as vibrator operating frequency and shakes.
Oscillating aging building mortion under elastic deformation condition of the present invention, comprises mold, bed die, vibrator, fixture, vibrator base, sensor and controller.Vibrator is positioned at one end of workpiece, by the upper surface of vibrator floor installation at workpiece.The upper surface of vibrator base coordinates with the base plate of vibrator; By fixture, vibrator, vibrator base and bed die are tightened up.The cambered surface of upper surface needed for Forming Workpiece of bed die.Patrix has multiple, is bar shaped.The concave surface of lower surface needed for Forming Workpiece of described mold.During use, by the upper surface of work piece at bed die; By mold from inside the vibrator in workpiece one end to uniform between the other end of workpiece, and the spacing between adjacent two mold side surfaces is 150 ~ 250mm.Sensor is placed in the upper surface of the workpiece other end; And be communicated with controller by data wire.Vibrator is all communicated with controller with sensor.
When laying workpiece, between workpiece and bed die upper surface, laying the second rubber blanket, between workpiece and mold, also laying the first rubber blanket.
The end face installing vibrator one end at described bed die has the rectangular channel clamping fixture.
The present invention realizes the oscillating aging shaping under elastic deformation condition by designing a kind of easy building mortion, concrete manufacturing process is: make metal plate material produce flexural deformation by the effect of mould, and deflection is in elastic range, after taking apart a die, metal blank can recover former state, a bending prestressing force is loaded with to plate like this by the effect of mould, connect vibration ageing device, periodically exciting force is produced by vibrator, under its effect, plate is made to reach resonance state, resonance elimination and homogenizing slab interior is utilized to bend prestressing force, by this bending prestressed dispose procedure, metal blank is made to produce certain plastic deformation, obtain the crooked part suitable with mould radius of curvature.
Experimental rig in the present invention, primarily of formations such as controller, vibrator, sensor, rubber blanket, fixture, cable, power line and moulds, when device assembles, first rubber blanket, metal blank, mold are arranged on bed die, then with fixture, vibrator is arranged on die, then by cable and power line, vibrator and oscillation pickup and power supply is connected.
The present invention uses for reference the conventional oscillating aging Forming Theory eliminating residual stress under generation Plastic Deformation Conditions, make full use of oscillating aging equipment simple, be easy to move, be not subject to the restriction of component size and material, energy-efficient, pollution-free, equipment investment is few, the feature such as simple to operate, within curring time shortens to 40min by the 20h of heat aging.Adopt rubber blanket upper and lower mould and plate to be formed to be separated simultaneously, can prevent the frictionally damage of panel surface, Forming Workpiece surface quality is good, avoids the vibrational energy of vibrator to pass to upper and lower mould, cause a large amount of losses of vibrational energy, be conducive to energy-conserving and environment-protective.In addition, plate is made to produce pre-bending deformation by the effect of mould, then vibration elimination and homogenizing slab interior bend prestressing force, eliminate the loaded down with trivial details control procedure of defects and the process of the conventional rear residual stress that is shaped such as resilience adjoint in the shaping of part routine, shorten the production cycle, reduce production cost.
Instant invention overcomes die manufacturing cost in sheet metal component forming process high, the unmanageable deficiency of resilience, and piece surface frictionally damage and vibrational energy loss when reducing oscillating aging, improve Forming Workpiece surface quality.
Accompanying drawing explanation
Below in conjunction with accompanying drawing, the present invention is described further.
Fig. 1 is the structural representation of apparatus of the present invention.
Fig. 2 is the top view of apparatus of the present invention.
Fig. 3 is the sectional view of upper and lower mould and rubber blanket and plate syndeton in apparatus of the present invention.
Fig. 4 is the side view after removing mold and the first rubber blanket in apparatus of the present invention.
Fig. 5 is lower die structure schematic diagram in apparatus of the present invention.
Fig. 6 is upper die structure schematic diagram in apparatus of the present invention.Wherein:
1. the first rubber blanket, 2. mold, 3. workpiece, 4. bed die, 5. vibrator, 6. fixture, 7. vibrator base, 8. sensor, 9. controller, 10. the second rubber blanket.
Detailed description of the invention
Embodiment one
The present embodiment is a kind of method that oscillating aging under elastic deformation condition is shaped, and concrete steps are:
The first step, installs the plate of workpiece to be formed.The plate and rubber blanket that fill workpiece to be formed are arranged between mold and bed die, and the upper surface of the first rubber blanket and the lower surface of mold are fitted, the lower surface of the second rubber blanket and the upper surface of bed die are fitted, make the plate upper surface of workpiece to be formed and the lower surface of the first rubber blanket fit, the plate lower surface of workpiece to be formed and the upper surface of the second rubber blanket are fitted simultaneously.With " C " clevis of routine, vibrator is fixed on plate.By cable and power line, vibrator and sensor and power supply are connected.Wherein ZS1000K1 type selected by vibrator, and the specified exciting force of this vibrator is 10KN, and rated power is 0.6KW, and rated speed is 10000r/min.
Second step, determines the resonant frequency of workpiece.First vibrator carries out frequency sweep, and swept frequency is 0-400Hz, frequency sweep power is 400W, and the frequency sweep time is 6min.In frequency sweep, vibrator frequency linearly increases gradually.Along with the increase gradually of swept frequency, workpiece amplitude changes.Amplitude-frequency (A-f) curve of record workpiece, obtains frequency sweep curve.If the frequency sweep curve obtained has an amplitude peaks, form First formant, then using frequency corresponding to this First formant as the resonant frequency of workpiece.If the frequency sweep curve obtained has multiple amplitude peaks, then using the minimum peak of multiple amplitude peaks medium frequency as First formant, using frequency corresponding to this First formant as the resonant frequency of workpiece, frequency corresponding to subsequent amplitude peak is as higher order resonant frequencies.
3rd step, vibration shaping.In vibration shaping, the operating frequency of adjustment vibrator is consistent with the resonant frequency of workpiece, and the setting oscillating aging time is 30min.The eccentric throw of adjusting vibration exciter, makes the dynamic stress peak value at the most concentrated position of stress in the bending forming of workpiece carry out oscillating aging between 1/3 ~ 2/3 of this position workpiece prestress value.The power output of vibrator is 80% of this vibrator rated power, and in the present embodiment, the power output of vibrator is 400W.
4th step, measures forming effect.After oscillating aging terminates, powered-down, dismounting mould, takes off workpiece, measures bending radius, contrasts with desired value.If the bending radius of workpiece meets design requirement, complete the bending forming to workpiece.If exceed error range, clamping workpiece again, repetition step 3 is carried out benefit and is shaken, until the radius of curvature of workpiece meets design requirement.Mend center of percussion, if the frequency sweep curve obtained has an amplitude peaks, get frequency values near the workpiece resonant frequency then obtained using step 2 to carry out benefit as vibrator operating frequency and shake, if the frequency sweep curve obtained has multiple amplitude peaks, the higher order resonant frequencies of the workpiece obtained using step 2 carries out benefit as vibrator operating frequency and shakes, until the bending radius of workpiece meets design requirement.
Embodiment two
The present embodiment is a kind of building mortion of the single-curvature workpiece for realizing the oscillating aging manufacturing process described in embodiment 1 under elastic deformation condition.The length of workpiece formed thereby is 1000mm, and width is 400mm, and bending radius is 1500mm.Workpiece formed thereby is aluminium alloy plate.
The building mortion of described single-curvature Al alloy parts comprises the first rubber blanket 1 of building mortion, mold 2, bed die 4, vibrator 5, fixture 6, vibrator base 7, sensor 8, controller 9 and the second rubber blanket 10.
Vibrator 5 is positioned at one end of workpiece, is arranged on the upper surface of workpiece 3 by vibrator base 7.The upper surface of vibrator base 7 coordinates with the base plate of vibrator, vibrator 5, vibrator base 7 is tightened up with bed die 4 by fixture 6.The lower surface of described vibrator base 7 is the cambered surface adapted with bed die 4 upper surface.The control line of vibrator 5 is communicated with controller 9.
The cambered surface of upper surface needed for Forming Workpiece of bed die 4.The end face installing vibrator 5 one end at described bed die 4 has the rectangular channel clamping fixture 6.Mold 2 has three, is bar shaped.The concave surface of lower surface needed for Forming Workpiece of described mold 2.During use, by the upper surface of work piece at bed die 4; By mold 2 from inside the vibrator 5 of workpiece one end to uniform between the other end of workpiece and tighten up.Spacing between adjacent two mold side surfaces is 150 ~ 250mm, and in the present embodiment, the spacing between adjacent two mold side surfaces is 180mm.
Sensor 8 is placed in the upper surface of the workpiece other end, and is communicated with controller 9 by data wire.
When laying workpiece 3, between workpiece 3 and bed die 4 upper surface, laying the second rubber blanket 10, between workpiece 3 and mold 2, also laying the first rubber blanket 1.
Vibrator 5 is fastened to the upper surface of alloy plate material 3 by fixture 6, the lower end of fixture 6 be positioned at bed die 4 end face rectangular channel, upper end is positioned at above the upper base surface of vibrator 5, and the upper base surface of fixture 6 upper end stud base end face and vibrator 5 is fitted.The lower surface of the second rubber blanket 10 and the upper surface of bed die 4 are fitted, the lower surface of alloy plate material 3 and the upper surface of the second rubber blanket 10 are fitted simultaneously, the upper surface of alloy plate material 3 and the lower surface of the first rubber blanket are fitted, and the upper surface of the first rubber blanket 1 and the lower surface of mold 2 are fitted.Sensor 8 is arranged on the upper surface of described alloy plate material 3, is positioned at the one end away from vibrator 5.Male type bed die 4 liang of side plane places have screwed hole to be connected with mold 2.
Described bed die 4 is the carrier of the present embodiment, bed die 4 is in male type, its size is determined according to required Forming Workpiece appearance and size and the rigging position of all parts and the requirement of device rigidity, material is 45 steel, plays a part to lay miscellaneous part and coordinate with mold to make plate generation elastic bending deflection.At bed die 4 sectional fixture 6 place, have the rectangular channel of 300mm × 40mm × 60mm to ensure the smooth installation and removal of fixture 6.The installing hole of mold 2 is had at bed die 4 liang of side plane places.
ZS1000K1 type selected by described vibrator 5, its parameter is as follows, and specified exciting force is 10KN, and rated power is 0.6KW, rated speed is 10000r/min, specified defeated people's electric current 1.5A, static(al) constant 0.5kg/A, moving-coil D.C. resistance about 6 Ω, maximum displacement 2mm, coil moving part quality 40g ± 10%, overall dimensions Φ 75 × 150mm, weight is about 3.5kg.
Described mold 2 is in inner concave shape, bottom has circular arc inner groovy, interior concaved circular cambered surface curvature is consistent with the outer convex arc surface curvature of Al alloy parts, the size of mold 2 is determined by the requirement of bed die appearance and size and device rigidity, material is 45 steel, coordinate the effect making plate generation elastic bending deflection with counterdie, two ends have circular hole and are used for construction bolt and coordinate with bed die 4.
Described vibrator base 7 is in inner concave shape, its size is determined by required Forming Workpiece and the appearance and size of vibrator and the requirement of building mortion rigidity, material is 45 steel, work the effect of laying vibrator, the interior concaved circular cambered surface curvature of vibrator base 7 is consistent with the outer convex arc surface curvature of Al alloy parts, both guarantees fully contact, and are connected in use procedure in order to be effective with the bottom of vibrator 5 by the mode of welding.
Described first rubber blanket 1 and the second rubber blanket 10 are rectangular block shape, because vibrator 5 is arranged on the upper surface of described alloy plate material 3, the interior concaved circular cambered surface of vibrator base 7 and the outer convex arc surface of Al alloy parts are fitted, need to reserve installing space, the size of the first rubber blanket 1 is less than the size of the second rubber blanket 10, Al alloy parts can be prevented directly with upper, bed die contacts the friction of the contact surface caused, affect workpiece surface quality, in addition, the vibrational energy of vibrator is avoided to pass to, bed die, cause a large amount of losses of vibrational energy, be conducive to energy-conserving and environment-protective.
Described fixture 6 is in " C " type, vibrator 5 is fastened to the upper surface of alloy plate material 3, the lower end of fixture 6 be positioned at bed die 4 end face rectangular channel, upper end is positioned at above the upper base surface of vibrator 5, and the upper base surface of fixture 6 upper end stud base end face and vibrator 5 is fitted.
Claims (5)
1. the oscillating aging manufacturing process under elastic deformation condition, it is characterized in that, concrete steps are:
The first step, installs the plate of workpiece to be formed;
Second step, determines the resonant frequency of workpiece; Vibrator carries out frequency sweep, and swept frequency is 0-400Hz, frequency sweep power is 400W, and the frequency sweep time is 6min; Amplitude-frequency (A-f) curve of record workpiece, obtains frequency sweep curve; If the frequency sweep curve obtained has an amplitude peaks, form First formant, then using frequency corresponding to this First formant as the resonant frequency of workpiece; If the frequency sweep curve obtained has multiple amplitude peaks, then using the minimum peak of multiple amplitude peaks medium frequency as First formant, using frequency corresponding to this First formant as the resonant frequency of workpiece, frequency corresponding to subsequent amplitude peak is as higher order resonant frequencies;
3rd step, vibration shaping; In vibration shaping, the operating frequency of adjustment vibrator is consistent with the resonant frequency of workpiece, and the setting oscillating aging time is 30min; The eccentric throw of adjusting vibration exciter, makes the dynamic stress peak value at the most concentrated position of stress in the bending forming of workpiece carry out oscillating aging between 1/3 ~ 2/3 of this position workpiece prestress value; The power output of vibrator is 80% of this vibrator rated power;
4th step, after oscillating aging terminates, the bending radius of measuring workpieces, if the bending radius of workpiece meets design requirement, completes the bending forming to workpiece; If exceed error range, clamping workpiece again, repetition step 3 is carried out benefit and is shaken, until the radius of curvature of workpiece meets design requirement.
2. the oscillating aging manufacturing process as claimed in claim 1 under elastic deformation condition, it is characterized in that, mend center of percussion, if the frequency sweep curve obtained has an amplitude peaks, then get frequency values near the workpiece resonant frequency obtained using step 2 and carry out benefit as vibrator operating frequency and shake; If the frequency sweep curve obtained has multiple amplitude peaks, carry out benefit with the immediate higher order resonant frequencies of original resonant frequency as vibrator operating frequency in the higher order resonant frequencies of the workpiece obtained using step 2 and shake.
3. for realizing a device for the oscillating aging manufacturing process under elastic deformation condition described in claim 1, it is characterized in that, comprising mold, bed die, vibrator, fixture, vibrator base, sensor and controller; Vibrator is positioned at one end of workpiece, by the upper surface of vibrator floor installation at workpiece; The upper surface of vibrator base coordinates with the base plate of vibrator; By fixture, vibrator, vibrator base and bed die are tightened up; The cambered surface of upper surface needed for Forming Workpiece of bed die; Patrix has multiple, is bar shaped; The concave surface of lower surface needed for Forming Workpiece of described mold; During use, by the upper surface of work piece at bed die; By mold from inside the vibrator in workpiece one end to uniform between the other end of workpiece, and the spacing between adjacent two mold side surfaces is 150 ~ 250mm; Sensor is placed in the upper surface of the workpiece other end; And be communicated with controller by data wire; Vibrator is all communicated with controller with sensor.
4. as claimed in claim 3 for realizing the device of the oscillating aging manufacturing process under elastic deformation condition, it is characterized in that, when laying workpiece, between workpiece and bed die upper surface, laying the second rubber blanket, between workpiece and mold, also laying the first rubber blanket.
5. as claimed in claim 3 for realizing the device of the oscillating aging manufacturing process under elastic deformation condition, it is characterized in that, the end face installing vibrator one end at described bed die has the rectangular channel clamping fixture.
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