CN109772990B - Semi-solid rheological internal high-pressure forming device and method based on low-melting-point alloy - Google Patents
Semi-solid rheological internal high-pressure forming device and method based on low-melting-point alloy Download PDFInfo
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- CN109772990B CN109772990B CN201910079845.7A CN201910079845A CN109772990B CN 109772990 B CN109772990 B CN 109772990B CN 201910079845 A CN201910079845 A CN 201910079845A CN 109772990 B CN109772990 B CN 109772990B
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Abstract
The invention discloses a semi-solid rheological internal high-pressure forming device based on low-melting-point alloy, which comprises a blank making device, a pulping device and a forming device, wherein the blank making device comprises a blank making machine and a forming device; the blank making device comprises a grouting carrier, a pipe cavity is arranged in the grouting carrier, a first heating module is arranged on the grouting carrier and surrounds the middle part of the pipe cavity, and a first cooling module is arranged on the grouting carrier and surrounds the end part of the pipe cavity; the forming device comprises a die body, a main pipe cavity and at least one branch pipe cavity are arranged in the die body, the main pipe cavity is communicated with the branch pipe cavity, and movable material pushing rods are arranged in the main pipe cavity and the branch pipe cavity. The device has the advantages of simple structure, ingenious design and good market popularization and application value.
Description
Technical Field
The invention relates to the technical field of rheoforming, in particular to a semi-solid rheoforming internal high-pressure forming device and method based on low-melting-point alloy.
Background
The high-pressure forming technology in the pipe is an advanced plastic processing technology developed for forming a hollow variable-section tubular member characterized by light weight and integration, is a perfect combination of structure light weight and flexible processing technology, and has wide application in industries such as automobile engine systems, exhaust systems, chassis systems, aerospace, air-conditioning tubing, water heating and the like.
The special-shaped pipe fittings (tee pipes) can generally adopt an elastomer or a plastomer as a bulging medium, and the required pipe fitting shape is formed by realizing the deformation of the medium through the action of a shaft end.
Lead is generally used as a bulging medium for forming a copper three-way pipe with a straight pipe having a large height, and the deformation amount is large. However, the lead expansion technique has the following problems:
1. the heating temperature is higher during filling and recovery, and the energy consumption is larger;
2. lead is volatile and harmful to human health, and is banned by national regulations.
Instead, NaCl powder has the characteristics of no pollution, easy recovery and the like, and is mostly adopted, but the forming capability is poor because the compactness and the elastic plasticity of the NaCl structure are poor, and the deformation capability is far lower than that of lead. In addition, there are bulging process using paraffin, urethane rubber and the like as media and "water bulging" process widely used in industry, but the forming ability of these media is far inferior to that of lead, and the application is limited.
Disclosure of Invention
The invention aims to provide a semi-solid rheological internal high-pressure forming device based on low-melting-point alloy, and further provides a forming method for forming a special-shaped pipe fitting by using the device.
The technical scheme adopted by the invention for solving the technical problems is as follows: the semi-solid rheological internal high-pressure forming device based on the low-melting-point alloy comprises a blank making device, a pulping device and a forming device;
the blank making device comprises a grouting carrier, a pipe cavity is arranged in the grouting carrier, a first heating module is arranged on the grouting carrier and around the middle part of the pipe cavity, and a first cooling module is arranged on the grouting carrier and around the end part of the pipe cavity;
the pulping device comprises a sliding table and a spray pipe group positioned above the sliding table, the sliding table is provided with a waveform table top with a preset inclination, the spray pipe group is arranged above the waveform table top, and the spray pipe group comprises a plurality of hot water pipes and a plurality of cold water pipes; the hot water pipes and the cold water pipes are alternately arranged side by side in the horizontal direction of the sliding table and can respectively spray hot water and cold water to the wave-shaped table top;
the forming device comprises a die body, a main pipe cavity and at least one branch pipe cavity are arranged in the die body, the main pipe cavity is communicated with the branch pipe cavity, and movable material pushing rods are arranged in the main pipe cavity and the branch pipe cavity.
Further preferred embodiments of the present invention: the main pipe cavity comprises a left end section, a right end section and a middle section, the branch pipe cavity is connected to the middle section of the main pipe cavity, the mold body is internally provided with a second heating module with controllable temperature around the branch pipe cavity and the middle section, and the mold body is internally provided with a second cooling module with controllable temperature around the left end section and the right end section. The solid-liquid phase conversion of the bulging medium (semi-solid alloy slurry) is realized by arranging a second heating module and a second cooling module, so that the bulging medium in the tube blank is in a state of high solid phase at the end part and low solid phase at the middle part;
the end part high solid phase can increase the viscosity, improve the friction force between a bulging medium and the inner wall of the tube blank and realize the pulling material supplement; the middle low solid phase increases the liquid phase fraction of the deformed part of the tube blank, improves the internal pressure of the deformed part of the tube blank and realizes the equal-pressure shaping;
and the temperature of the second heating module and the second cooling module is controllable, so that the purpose of controlling the solid fraction of the bulging medium (semi-solid alloy slurry) is achieved.
Further preferred embodiments of the present invention: the surfaces of the second heating modules, which are close to the branch pipe cavity and the middle section of the main pipe cavity, are corrugated. The arrangement of the scheme is to increase the heat exchange area and improve the heating/cooling rate of the bulging medium (semi-solid alloy slurry).
Further preferred embodiments of the present invention: the blank making device also comprises a sealing block for sealing the lumen port.
The semi-solid rheologic internal high pressure forming process based on low smelting point alloy includes the following steps:
step 1: preparing a tube blank to be processed, and selecting environment-friendly low-melting-point alloy slurry in a semi-solid state as a bulging medium;
step 2: placing the prepared tube blank in the step 1 into a tube cavity of a grouting carrier, and pouring the bulging medium selected in the step 1 into an inner cavity of the tube blank;
and step 3: sealing the tube cavity, and injecting hot water and cold water into a first heating module and a first cooling module of the grouting carrier respectively;
and 4, step 4: after waiting for a preset time, taking out the tube blank from the tube cavity of the grouting carrier;
and 5: putting the tube blank taken out in the step 4 into a sliding table for spraying;
step 6: placing the tube blank sprayed in the step 5 into a main tube cavity channel in the die body;
and 7: the material pushing rod on the main pipe cavity channel acts on the end part of the pipe blank, and the material pushing rod continuously pushes towards the middle part of the pipe blank;
and 8: the middle part of the pipe blank arches towards the cavity channel of the branch pipe to form the branch pipe;
and step 9: and (3) applying a material pushing rod on the cavity channel of the branch pipe to the end part of the branch pipe, and applying radial force to the pipe blank to finally form the special-shaped pipe fitting.
A step 10 may be added between step 6 and step 7;
step 10: hot water and cold water are respectively injected into a second heating module and a second cooling module of the die body.
Compared with the prior art, the invention has the advantages that each device has simple structure and ingenious design, and has good market popularization and application value.
A blank making device: the grouting carrier realizes solid-liquid phase conversion of a bulging medium (semi-solid alloy slurry) in the tube blank through the arranged first heating module and the first cooling module, so that the bulging medium in the tube blank is in a state of high solid phase at the end part and low solid phase at the middle part;
a pulping device: the sliding table is provided with a wave-shaped table board with inclination, so that the tube blank can freely roll along the table board, and the tube blank can be alternately cooled and heated under the spraying of the spraying tube group, so that a spherical or near-spherical semi-solid bulging medium of primary phase particles is obtained, and the bulging medium has better fluidity;
a forming device: the main pipe cavity channel in the die body is used for placing a pipe blank to be processed, the branch pipe cavity channel is used as a branch pipe forming area, and the material pushing rod arranged on the main pipe cavity channel and the material pushing rod arranged on the branch pipe cavity channel are used for applying axial force and radial force to the middle part of the pipe blank respectively;
applying axial force to the middle part of the tube blank through a material pushing rod on a main tube cavity channel, compressing a bulging medium (semi-solid alloy slurry), and enabling the bulging medium to be in solid-liquid phase separation, namely enabling the bulging medium in the end part of the tube blank to be in a high solid phase and enabling the bulging medium in the middle part of the tube blank to be in a low solid phase;
the bulging medium in the middle of the tube blank flows towards the cavity of the branch tube, and meanwhile, the bulging medium at the end of the tube blank moves towards the middle of the tube blank under the action of axial acting force, and as the bulging medium at the end of the tube blank is high in solid phase and the friction force between the bulging medium and the inner wall of the tube blank is greater than the friction force between the outer wall of the tube blank and a die, the material at the end of the tube blank is pulled to feed the cavity of the branch tube, so that the forming height of the branch tube.
Drawings
FIG. 1 is a schematic structural view of a tube blank and a special-shaped tube fitting;
FIG. 2 is a schematic view of a blank-making apparatus;
FIG. 3 is a schematic view of a pulping apparatus;
FIG. 4 is a schematic view of the forming apparatus.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
As shown in fig. 1 to 4: the semi-solid rheological internal high-pressure forming device based on the low-melting-point alloy comprises a blank making device, a pulping device and a forming device;
the blank making device comprises a grouting carrier 1, a pipe cavity 12 is arranged in the grouting carrier 1, a first heating module 13 is arranged on the grouting carrier 1 and around the middle part of the pipe cavity 12, and a first cooling module 14 is arranged on the grouting carrier 1 and around the end part of the pipe cavity 12;
the grouting carrier 1 realizes solid-liquid phase conversion of the bulging medium 113 (semi-solid alloy slurry) in the tube blank 111 through the arranged first heating module 13 and the first cooling module 14, so that the bulging medium 113 in the tube blank 111 is in a state of high solid phase at the end part and low solid phase at the middle part;
the pulping device comprises a sliding table 2 and a spray pipe group 3 positioned above the sliding table 2, the sliding table 2 is provided with a wave-shaped table surface 21 with a preset inclination, the spray pipe group 3 is arranged above the wave-shaped table surface 21, and the spray pipe group 3 comprises a plurality of hot water pipes 31 and a plurality of cold water pipes 32; wherein, a plurality of hot water pipes 31 and a plurality of cold water pipes 32 are alternately arranged side by side in the horizontal direction of the sliding table 2, and the plurality of hot water pipes 31 and the plurality of cold water pipes 32 can respectively spray hot water and cold water to the wave-shaped table surface 21;
the sliding table 2 is provided with a wave-shaped table surface 21 with inclination, so that the tube blank 111 can freely roll along the table surface, and the tube blank 111 can be alternately cooled and heated under the spraying of the spraying tube group 3, so that a semi-solid bulging medium 113 of spherical or near-spherical primary phase particles is obtained, and the bulging medium 113 has better fluidity;
the forming device comprises a die body 4, a main pipe cavity channel 41 and at least one branch pipe cavity channel 42 are arranged in the die body 4, the main pipe cavity channel 41 is communicated with the branch pipe cavity channel 42, and movable material pushing rods 43 are arranged in the main pipe cavity channel 41 and the branch pipe cavity channel 42;
the main pipe channel 41 in the die body 4 is used for placing the pipe blank 111 to be processed, the branch pipe channel 42 serves as a branch pipe forming area, and the ejector pins 43 provided in the main pipe channel 41 and the ejector pins 43 provided in the branch pipe channel 42 are used for applying axial force and radial force to the middle of the pipe blank 111, respectively.
Wherein, the main pipe cavity 41 is provided with two material pushing rods 43 which respectively act on two end parts of the tube blank 111, and the feeding speed of the two material pushing rods 43 towards the middle part of the tube blank 111 is consistent with the force acting on the end parts of the tube blank 111; the material pushing rod 43 arranged in the branch pipe cavity 42 acts on the end part of the forming branch pipe to radially force the middle part of the pipe blank 111, so that the arched end part of the branch pipe can be better attached to the die.
Axial force is applied to the middle of the tube blank 111 through the material pushing rod 43 on the main tube cavity 41, the bulging medium 113 (semi-solid alloy slurry) is compressed, the bulging medium 113 is in solid-liquid phase separation, namely the bulging medium 113 in the end part of the tube blank 111 is in a high solid phase, and the bulging medium 113 in the middle of the tube blank 111 is in a low solid phase;
the bulging medium 113 in the middle of the tube blank 111 flows towards the branch pipe cavity channel 42, meanwhile, the bulging medium 113 at the end of the tube blank 111 is bonded with the inner wall of the end of the tube blank 111 more firmly due to high solid phase, the bulging medium 113 at the end of the tube blank 111 moves towards the middle of the tube blank 111 under the axial acting force, and pulls the material on the inner wall of the end of the tube blank 111 to perform material supplement towards the branch pipe cavity channel 42, so that the forming height of the branch pipe in the branch pipe cavity channel 42 is effectively improved.
The main pipe cavity 41 includes a left end section, a right end section and a middle section, the branch pipe cavity 42 is connected to the middle section of the main pipe cavity 41, a second heating module 44 with controllable temperature is arranged around the branch pipe cavity 42 and around the middle section in the mold body 4, and a second cooling module 45 with controllable temperature is arranged around the left end section and the right end section in the mold body 4.
The solid-liquid phase conversion of the bulging medium 113 (semi-solid alloy slurry) is realized by arranging a second heating module and a second cooling module, so that the bulging medium 113 in the tube blank 111 is in a state of high solid phase at the end part and low solid phase at the middle part;
the end part high solid phase can increase the viscosity, improve the friction force between the bulging medium 113 and the inner wall of the tube blank 111 and realize the pulling material supplement; the middle low solid phase increases the liquid phase fraction of the deformed part (the middle part of the tube blank 111) of the tube blank 111, improves the internal pressure of the deformed part (the middle part of the tube blank 111) of the tube blank 111 and realizes the equal-pressure shaping;
the temperature of the selected second heating module and the second cooling module is controllable, so that the purpose of controlling the solid phase ratio of the bulging medium 113 semi-solid alloy slurry) is achieved;
in addition, the purpose of heating/cooling can be achieved by selecting a method of respectively injecting hot water and cold water into the second heating module and the second cooling module, so that the heating cost can be reduced, and the energy consumption can be reduced.
The surfaces of the second heating module 44 proximate the branch conduit channel 42 and proximate the mid-section of the main conduit channel 41 are corrugated.
The blank-making apparatus further comprises a sealing block 15 for sealing the port of the lumen 12.
The semi-solid rheologic internal high pressure forming process based on low smelting point alloy includes the following steps:
step 1: preparing a tube blank 111 to be processed, and selecting environment-friendly low-melting-point alloy slurry in a semi-solid state as a bulging medium 113;
wherein the melting point (lower than 100 ℃) of the bulging medium 113 is lower than that of the tube blank 111, and the bulging medium 113 can be selected from Pb-free Cd-free environment-friendly low-melting-point alloys, such as 30.1Bi-22.0Sn-47.9In alloy. The semisolid alloy slurry with environmental protection and low melting point (the melting point is lower than 100 ℃) is selected as the bulging medium 113, the forming advantages of liquid and solid mediums are fused, and the semisolid alloy slurry is non-toxic and harmless and has the performance of ultra-large deformation.
Step 2: placing the prepared tube blank 111 in the step 1 into a tube cavity 12 of a grouting carrier 1, and filling the bulging medium 113 selected in the step 1 into an inner cavity of the tube blank 111;
and step 3: sealing the tube cavity 12, and injecting hot water and cold water into a first heating module 13 and a first cooling module 14 of the grouting carrier 1 respectively;
and 4, step 4: after waiting for a predetermined time, taking out the tube blank 111 from the tube cavity 12 of the grouting carrier 1;
and 5: putting the tube blank 111 taken out in the step 4 into a sliding table 2 for spraying;
step 6: placing the tube blank 111 sprayed in the step 5 into a main tube cavity channel 41 in the die body 4;
and 7: the material pushing rod 43 on the main pipe cavity channel 41 acts on the end part of the pipe blank 111, and the material pushing rod 43 continuously pushes towards the middle part of the pipe blank 111;
and 8: the middle part of the tube blank 111 arches towards the branch tube cavity channel 42 to form a branch tube;
and step 9: the material pushing rod 43 on the branch pipe cavity 42 acts on the end of the branch pipe to apply radial force to the tube blank 111, and finally the special-shaped tube fitting 112 is formed.
A step 10 may be added between step 6 and step 7;
step 10: hot water and cold water are injected into the second heating module 44 and the second cooling module 45 of the mold body 4, respectively.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (6)
1. The semi-solid rheological internal high-pressure forming device based on the low-melting-point alloy is characterized by comprising a blank making device, a pulping device and a forming device;
the blank making device comprises a grouting carrier, a pipe cavity is arranged in the grouting carrier, a first heating module is arranged on the grouting carrier and around the middle part of the pipe cavity, and a first cooling module is arranged on the grouting carrier and around the end part of the pipe cavity;
the pulping device comprises a sliding table and a spray pipe group positioned above the sliding table, the sliding table is provided with a waveform table top with a preset inclination, the spray pipe group is arranged above the waveform table top, and the spray pipe group comprises a plurality of hot water pipes and a plurality of cold water pipes; the hot water pipes and the cold water pipes are alternately arranged side by side in the horizontal direction of the sliding table and can respectively spray hot water and cold water to the wave-shaped table top;
the forming device comprises a die body, a main pipe cavity and at least one branch pipe cavity are arranged in the die body, the main pipe cavity is communicated with the branch pipe cavity, and movable material pushing rods are arranged in the main pipe cavity and the branch pipe cavity.
2. A semi-solid rheological internal high pressure forming apparatus based on a low melting point alloy as claimed in claim 1, wherein the main tube cavity includes a left end section, a right end section and a middle section, the branch tube cavity is connected to the middle section of the main tube cavity, the second temperature-controllable heating module is disposed in the mold body and around the branch tube cavity, and the second temperature-controllable cooling module is disposed in the mold body and around the left end section and the right end section.
3. The semi-solid rheological internal high pressure forming apparatus based on low melting point alloy of claim 2 wherein the second heating module is corrugated proximate the branch conduit and proximate the central section of the main conduit.
4. A semi-solid rheological internal high pressure forming apparatus based on a low melting point alloy according to claim 1 wherein the blanking apparatus further comprises a sealing block for sealing the lumen port.
5. An internal high pressure forming method of a semi-solid rheological internal high pressure forming device based on a low melting point alloy according to claim 1, characterized by comprising the steps of:
step 1: preparing a tube blank to be processed, and selecting environment-friendly low-melting-point alloy slurry in a semi-solid state as a bulging medium;
step 2: placing the prepared tube blank in the step 1 into a tube cavity of a grouting carrier, and pouring the bulging medium selected in the step 1 into an inner cavity of the tube blank;
and step 3: sealing the tube cavity, and injecting hot water and cold water into a first heating module and a first cooling module of the grouting carrier respectively;
and 4, step 4: after waiting for a preset time, taking out the tube blank from the tube cavity of the grouting carrier;
and 5: putting the tube blank taken out in the step 4 into a sliding table for spraying;
step 6: placing the tube blank sprayed in the step 5 into a main tube cavity channel in the die body;
and 7: the material pushing rod on the main pipe cavity channel acts on the end part of the pipe blank, and the material pushing rod continuously pushes towards the middle part of the pipe blank;
and 8: the middle part of the pipe blank arches towards the cavity channel of the branch pipe to form the branch pipe;
and step 9: and (3) applying a material pushing rod on the cavity channel of the branch pipe to the end part of the branch pipe, and applying radial force to the pipe blank to finally form the special-shaped pipe fitting.
6. An internal high pressure forming method of a semi-solid rheological internal high pressure forming device based on a low melting point alloy according to claim 5, characterized in that step 10 is added between step 6 and step 7;
step 10: hot water and cold water are respectively injected into a second heating module and a second cooling module of the die body.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201910079845.7A CN109772990B (en) | 2019-01-28 | 2019-01-28 | Semi-solid rheological internal high-pressure forming device and method based on low-melting-point alloy |
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| CN201910079845.7A CN109772990B (en) | 2019-01-28 | 2019-01-28 | Semi-solid rheological internal high-pressure forming device and method based on low-melting-point alloy |
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| CN109772990A CN109772990A (en) | 2019-05-21 |
| CN109772990B true CN109772990B (en) | 2020-08-18 |
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| CN111826535B (en) * | 2020-06-04 | 2021-01-15 | 浙大宁波理工学院 | Forming system based on low-melting-point alloy semi-solid melt |
| CN113751588B (en) * | 2021-08-03 | 2022-10-21 | 宁波市沃瑞斯机械科技有限公司 | Special-shaped piece phase change composite forming device and machining method |
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