CN109794538B - Inner spinning forming method for cylinder with inner and outer ring reinforcing ribs - Google Patents
Inner spinning forming method for cylinder with inner and outer ring reinforcing ribs Download PDFInfo
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- CN109794538B CN109794538B CN201711136257.XA CN201711136257A CN109794538B CN 109794538 B CN109794538 B CN 109794538B CN 201711136257 A CN201711136257 A CN 201711136257A CN 109794538 B CN109794538 B CN 109794538B
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Abstract
The invention provides a cylinder internal spinning forming method with inner and outer ring reinforcing ribs, which adopts the combination of an internal spinning technology and a tension spinning technology to realize the one-step forming of the inner and outer ring reinforcing ribs in the same die and the same spinning process, and thoroughly solves the problems of split die, high die cost, low production efficiency and the like caused by the forming by adopting an internal power spinning or external power spinning process; the invention increases the axial traction movement to make the axial traction movement and the axial movement of the spinning wheel mutually independent, and realizes the arbitrary selection of the spinning position and the optimized matching of the spinning track, thereby enabling the outer annular reinforcing ribs and the inner annular reinforcing ribs at arbitrary positions to be easily formed, and also being capable of continuously forming a plurality of outer annular reinforcing ribs and a plurality of inner annular reinforcing ribs, greatly improving the adaptability of the process, and realizing the product structure which can not be realized by the prior process.
Description
Technical Field
The invention relates to a method for forming a cylinder body with inner and outer ring reinforcing ribs by internal spinning, and belongs to the technical field of spinning.
Background
The external spinning is a traditional spinning technology, and the cylindrical revolving body part with long length and external reinforcing ribs can be produced by adopting the external spinning technology, so that the external spinning technology has the characteristics of high efficiency, capability of carrying out heating spinning, capability of processing curved generatrix-shaped and conical parts and the like. However, the length of the outer spinning die is required to be longer than that of a product, the manufacturing difficulty is high, the assembly and adjustment precision is low, the production cost is high, most importantly, a split die is required to be adopted for forming the product with the inner annular reinforcing ribs by adopting an outer powerful spinning process, the die needs to be assembled and disassembled again when one product is produced, the production efficiency is extremely low, the method is not suitable for batch production, and the requirements of low cost, high efficiency, high precision and high quality of national defense industrial products cannot be met.
The inner spinning technology is a newer spinning technology, can be used for producing cylindrical revolving body parts with inner annular reinforcing ribs, has the characteristics of high product precision, high yield, high production efficiency and the like, and has certain advancement. However, the length of the die of the internal spinning technology is required to be longer than that of the product, the manufacturing difficulty is high, the assembly and adjustment precision is low, the production cost is high, most importantly, the process can only be used for producing the product with the length within 1m, if the product is too long, the contact area between the outer surface of the workpiece and the die is too large, the friction force is large, the workpiece cannot be demoulded, and the process cannot be applied to the production of large-diameter high-precision long cylindrical parts required by the national defense industrial development. Most importantly, the products with the outer circumferential reinforcing ribs formed by the inner spinning process need to adopt split molds, the molds need to be disassembled and assembled again when one product is produced, the production efficiency is extremely low, the method is not suitable for batch production, and the requirements of national defense industrial products on low cost, high efficiency, high precision and high quality cannot be met.
The existing internal spinning equipment is shown in fig. 10, (wherein, a spinning machine body 01, a core mold 02, a spinning wheel 03, a workpiece 04, a balance wheel mechanism 05, a screw 06, a material pressing ring 07, a spinning wheel arm 08 and a lateral sliding frame 09) adopts a lateral L-shaped cantilever type single-spinning-wheel internal spinning mechanism, the axial and radial feeding of the spinning wheel 03 is realized by driving the L-shaped spinning wheel arm 08 fixedly connected with the lateral sliding frame 09 to move integrally and radially under the driving of a motor, the spinning wheel arm is too long, the single-wheel spinning rigidity is extremely low, automatic centering spinning cannot be realized, the spinning pressure is small, spinning processing of thick-wall hard-forming materials cannot be performed, and the processing of high-precision products cannot be satisfied.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide the long-cylinder-shaped internal spinning forming method which has high efficiency, high precision and low cost, can continuously form a plurality of internal and external annular reinforcing ribs and has the length within 2m by only using a short annular core mould.
The technical solution of the invention is as follows: a method for forming a cylinder body with inner and outer ring reinforcing ribs by internal spinning is realized by the following steps:
firstly, processing a blank with a straight cylindrical structure and an outward convex process ring at one end;
the wall thickness t1 of the blank is determined by calculation according to the reduction rate of the reinforcing rib section and the skin section, the length of the blank is obtained by comprehensive calculation of products according to the volume invariance principle and considering the reserved process allowance, and the outer diameter phi D of the blank is determined according to the inner spinning expansion rule. The specific design is realized by the following steps:
a1.1, determining the thickness t1 of the blank,
the method comprises the steps of determining the distribution of the thinning rate of an outer reinforcing rib section during spinning and the thinning rates of a skin section and an inner reinforcing rib section, wherein the thinning rate of the outer reinforcing rib section during spinning is more than 12%, and the distribution principle of the thinning rates of the skin section and the inner reinforcing rib section is that the thinning rate of the skin section does not exceed the limiting thinning rate, and the thinning rate of the inner reinforcing rib section improves the thinning rate of the skin section and reduces the thinning rate of the reinforcing rib section while ensuring sufficient diameter expansion and mold sticking; and the thickness distribution of the thinning rates of the skin section and the inner reinforcing rib section and the thinning rate requirement of the outer reinforcing rib section are fully considered, the blank thickness is comprehensively designed, the blank thickness is unified, and the blank thickness t1 is determined. The external reinforcing rib section has the thinning rate of more than 12 percent during spinning so as to ensure that the external reinforcing rib is fully attached to the stepped die and ensure that the external reinforcing rib is formed.
A1.2, determining the theoretical length L of the blank,
according to the final product structure of the cylinder with the inner and outer ring reinforcing ribs and the blank thickness t1 determined in the step A1.1, the theoretical length of the blank is obtained according to the principle that the spinning volume is unchanged, a mounting and positioning allowance is reserved at one end of an outer convex process ring of the blank, and a process allowance is reserved at the other end of the outer convex process ring of the blank, so that the product precision is prevented from being seriously influenced by the deformation of a; generally, the installation positioning allowance is about 40mm, and the process allowance is 20-40 mm.
A1.3, using the formula Φ D ═ Φ D1Zeta determining the outer diameter PhiD of the blank, where PhiD1The outer diameter of a final product of the cylinder with the inner and outer ring reinforcing ribs is a spinning expansion amount, zeta is a gap between a blank and an outer straight line section part of the stepped die, wherein the spinning expansion amount is related to physical properties of materials and can be determined through test groping, and the gap between the blank and the outer straight line section part of the stepped die is generally 0.4-0.6 mm.
Processing: the seamless pipe purchased from a manufacturer is processed into a preset size and shape by a turning method, one end with the convex process ring requires that both side surfaces of the connecting ring have higher verticality relative to the outer surface of the blank, and the excircle of the other end can be chamfered, so that the blank is convenient to mount.
The requirements of the blank processing size and precision can be as follows, and can also be adjusted according to specific requirements:
the thickness of the convex process ring is as follows: typically 6 mm;
outer diameter of the convex process ring: outer diameter of blank phi D +12mm
Perpendicularity of two side surfaces of the convex process ring relative to the outer surface of the blank: typically 0.1mm
Wall thickness tolerance: typically 0.2mm
Diameter tolerance: typically 0.3 mm.
Secondly, performing stress relief treatment on the blank;
and a stress removing treatment process is selected for specific materials, so that the strength of the materials is reduced, and the spinning requirement is met.
Thirdly, determining a spinning track,
the spinning track comprises a spinning section, a positioning section, a skin and inner reinforcing rib transition section, an inner reinforcing rib section and an outer reinforcing rib section;
designing the forming modes of the spinning section, the positioning section, the skin and inner reinforcing rib transition section, the inner reinforcing rib section and the outer reinforcing rib section, designing the reduction rate and the reduction of spinning of each section, completing the design of spinning tracks and determining the forming process.
The specific process is as follows:
a3.1, forming the screwing-in section in an internal spinning mode, namely, keeping the traction mechanism still and moving the spinning wheel mechanism to the direction of the main shaft;
the length and the process of the screwing-in section are known technologies of an internal spinning process, the screwing-in point of the screwing-in section is arranged in the die and is 5-10mm away from the side line of the outer reinforcing rib section in the stepped die, which is close to the main shaft, and the screwing-in terminal point reaches a slope form of the pressing amount of the positioning section.
A3.2, forming the positioning section in an internal spinning mode;
the length and the process of the positioning section are known technologies of an internal spinning process, the pressing amount is consistent with the pressing amount of the first section of the product, tension spinning is started after the positioning section is spun, namely the axial position of a spinning wheel is fixed, and a traction mechanism pulls a blank to move along the direction opposite to a main shaft according to a set speed.
A3.3, spinning the outer straight line section part of the skin section in the stepped die, determining the rolling reduction according to the thickness of a product and the spinning rebound amount by adopting a straight line track, determining the spinning rebound amount through test and groping, and calculating the length of the skin section according to the volume invariance principle;
a3.4, spinning the skin section and the transition section of the inner reinforcing rib in the outer straight line section part of the stepped die, adopting a slope type track, adopting a circular interpolation fitting track when the sharp points at two sides of the inner reinforcing rib are provided with circular chamfer angles, and enabling the rolling reduction of the slope section to be consistent with that of the reinforcing rib section;
a3.5, spinning the outer straight line section part of the inner reinforcing rib section in the stepped die, determining the rolling reduction according to the thickness of a product and the spinning rebound amount by adopting a straight line track, determining the spinning rebound amount through test and search, and calculating the length of the reinforcing rib section according to the volume invariance principle;
a3.6, spinning the outer reinforcing rib section in the stepped die by adopting a traction mechanism and a spinning wheel arm to match the motion track, namely, after the front section of the external strengthening rib is spun, the spinning wheel is radially retracted to a safe position, the traction mechanism pulls the blank to move independently along the direction opposite to the main shaft to the position where the external strengthening rib is close to one end face of the external convex process ring and is in the die and 5-10mm away from the end face of the die, the arm of the spinning wheel moves to the starting point in A3.1, the spinning wheel is spun in a mode of A3.1, and the positioning section of the outer reinforced rib section is spun according to the mode A3.2, then the tension spinning is carried out, after the spinning of the outer reinforced rib section is finished, the traction mechanism is axially stopped, an inner spinning mode is adopted, and (3) according to the rolling reduction of a section behind the outer reinforcing rib section, carrying out inner spinning machining on the rear positioning section of the outer reinforcing rib, carrying out inner spinning feeding on a spinning wheel arm to the A3.2 tension spinning starting point, and then carrying out tension spinning to finish spinning of each section behind.
Fourthly, compounding and spinning,
mounting a blank, designing a spinning program on the basis of a spinning track, moving a traction mechanism to a preset spinning position, starting spinning, and programming the spinning program on the basis of the spinning track to automatically execute actions such as material ejection, pre-rotation, spinning along the preset track, stopping and the like;
the specific spinning process is as follows:
a4.1, mounting the blank on a traction mechanism of spinning equipment through a pressing ring, mounting a stepped die at the front end of an inner cavity of a die transmission cylinder, driving the blank to axially move into the stepped die by the traction mechanism, wherein the stepped die consists of an outer reinforcing rib section part and an outer straight line section part;
hoisting a spinning blank between a traction mechanism and a stepped die, pressing an outer convex process ring on the end face of the traction mechanism by a pressing ring, putting the blank into the stepped die until the axial center line of the blank is flush with the end face of the die, and adjusting and fixing the axial position of the blank by the pressing ring to realize radial and axial positioning;
a4.2, processing a screwing-in section,
the spinning section adopts internal spinning on the outer straight line section part of the stepped die;
a4.3, processing a positioning section,
the positioning section adopts internal spinning on the outer straight line section part of the stepped die;
a4.4, processing a skin section and an inner reinforcing rib section,
the skin section and the inner reinforcing rib section are processed in an outer straight line section of the stepped die by adopting tension spinning, the tension spinning refers to that the spinning wheel mechanism is axially static, the traction mechanism pulls the blank to axially move along the direction opposite to the main shaft, and the spinning wheel mechanism adopts an internal spinning process to spin;
a4.5, processing a transition section of the skin and the internal reinforcing ribs,
the transition section of the skin and the inner reinforcing rib is processed by tension spinning at the outer straight line section of the stepped die, and the transition section of the skin and the inner reinforcing rib adopts a slope track;
a4.6, processing an outer reinforcing rib section, wherein the outer reinforcing rib section consists of an outer reinforcing rib screwing-in section, an outer reinforcing rib positioning section, an outer reinforcing rib main body section and an outer reinforcing rib rear positioning section;
a4.7, repeating the steps A4.2-A4.6 according to the structure of the final product of the cylinder with the internal and external ring reinforcing ribs until the whole cylinder with the internal and external ring reinforcing ribs is formed;
in the spinning process, the blank is drawn by a traction mechanism to realize axial tension, and the spinning wheel arranged on the spinning wheel arm feeds in the radial direction to realize internal spinning; the blank mounting part of the traction mechanism adopts a bearing, so that the blank can rotate along with a die under the action of friction force of the contact between the blank and the die after being mounted, and meanwhile, the traction mechanism is hollow and used for a rotary wheel arm to pass through, so that two axial movements are realized on the same axis; the traction mechanism is driven by a servo motor arranged on the feeding box through a lead screw, so that the precise and programmable control of the axial position and the movement speed can be realized; the rotary wheel arm is arranged on the rotary arm seat and is driven by a servo motor arranged on the feeding box through a screw rod, so that the accurate and programmable control of the axial position and the movement speed can be realized.
And fifthly, machining and heat treating the cylinder body which is formed by spinning in the fourth step and is provided with the inner and outer ring reinforcing ribs.
Turning: after the product is aligned by taking the outer diameter as a reference, the allowance at two ends is cut off, and special structures such as holes, grooves and the like are processed, so that the product meets the design requirement.
And (3) heat treatment: and selecting a final heat treatment process aiming at specific materials to ensure that the heat treatment state of the product meets the design requirement.
The spinning equipment comprises a spindle box, a die transmission cylinder, a spinning wheel mechanism, a traction mechanism, a material pressing ring and a numerically-controlled machine tool body, wherein the spinning wheel mechanism comprises a spinning wheel head mechanism, a spinning wheel radial feeding structure, a spinning wheel arm, a spinning arm seat and an axial feeding structure, the traction mechanism comprises a traction mechanism rotor, a traction mechanism rotor bearing, a traction mechanism seat and a traction mechanism axial feeding structure, the die transmission cylinder is arranged on a numerically-controlled machine tool spindle, a die is arranged at the front end of an inner cavity of the die transmission cylinder, the traction mechanism rotor is arranged in the traction mechanism seat through the traction mechanism rotor bearing, the traction mechanism seat is arranged on a guide rail of the numerically-controlled machine tool body, a blank is arranged on the traction mechanism rotor through the material pressing ring, the traction mechanism seat realizes axial movement through the traction mechanism axial feeding structure, the rear end of the spinning wheel arm is fixedly connected with the spinning arm seat, the rotary wheel radial feeding structure is arranged in an inner cavity of the rotary wheel arm, the rotary wheel head mechanism is connected with the rotary wheel radial feeding structure, and the rotary arm seat is arranged on a guide rail of the numerical control machine tool body and is connected with the axial feeding structure.
The spinning roller head mechanism comprises a spinning roller head main body, a wedge and three groups of spinning roller assemblies which are uniformly distributed in the circumferential direction, each spinning roller assembly comprises a support rolling element, a spinning roller, a connecting rod and a connecting rod shaft, the spinning roller head main body is fixedly connected with the front end of a spinning roller arm, the wedge is of a triangular wedge-shaped structure in cross section, one end of the connecting rod is connected with the support rolling element, the other end of the connecting rod is connected onto the spinning roller head main body through the connecting rod shaft, the spinning roller is installed in the middle of the connecting rod, the support rolling element is pressed on an inclined plane of the wedge, and the rear end of the wedge is fixedly connected.
The cross section of the wedge iron is in a regular triangle shape, and three vertexes are rounded.
And adjacent connecting rods in the rotary wheel head mechanism are connected through springs.
The axial feeding structure comprises an axial feeding lead screw and an axial feeding driving motor.
The traction mechanism axial feeding structure comprises a traction mechanism axial feeding lead screw and a traction mechanism axial feeding driving motor.
The rotary wheel radial feeding structure comprises a rotary wheel radial feeding lead screw and a rotary wheel radial feeding driving motor.
The invention has the beneficial effects that:
(1) the invention adopts the inner spinning technology and the tension spinning technology, realizes the one-step forming of the inner and outer annular reinforcing ribs in the same die and the same spinning process, and thoroughly solves the problems of split die, high die cost, low production efficiency and the like caused by the forming by adopting the inner power spinning or the outer power spinning process;
(2) the invention increases the axial traction movement to make the axial traction movement and the axial movement of the spinning wheel mutually independent, realizes the arbitrary selection of the spinning position and the optimized matching of the spinning track, thereby leading the outer annular reinforcing ribs and the inner annular reinforcing ribs at arbitrary positions to be easily formed, and also being capable of continuously forming a plurality of outer annular reinforcing ribs and a plurality of inner annular reinforcing ribs, greatly improving the adaptability of the process and realizing the product structure which can not be realized by the prior process;
(3) according to the invention, a long cylindrical part with the length within 2m can be formed by only using one annular step core die with the length of 400mm, so that the manufacturing difficulty and the manufacturing cost of a long cylinder die are greatly reduced, the problem that the coaxiality of the inner and outer reinforcing ribs is influenced by low rigidity and low use precision of the long die is avoided, the die assembly and adjustment difficulty is reduced, the use precision is improved, and a guarantee is provided for forming a high-precision product;
(4) the invention optimizes the straightness accuracy and roundness accuracy of the product through tension spinning, optimizes the diameter accuracy and wall thickness accuracy of the product through inner spinning, particularly the diameter accuracy of the outer reinforcing rib section, and further improves the overall accuracy of the product through improving the accuracy of the die, thereby obtaining the accuracy higher than the traditional inner spinning and outer spinning;
(5) the product has strong interchangeability, can be used for spinning forming of the long cylinder body with the internal circumferential reinforcing rib, and can integrally form the long cylinder body with the internal circumferential reinforcing rib by the process, and has good comprehensive performance, high forming precision and low cost;
(6) the invention adopts spinning equipment to realize two axial movements on the same axis, provides a movement space for the composite process of internal spinning and tension spinning by adopting the traction mechanism, realizes that the traction mechanism and the spinning wheel mechanism of the internal spinning move coaxially and independently, and provides guarantee for realizing the composite spinning process;
(7) the spinning equipment adopts a 120-degree symmetrical three-spinning-wheel structure, and the spinning wheel head mechanism can automatically center and obtain balanced stress under the conditions that the length of a spinning arm reaches 2m and the powerful spinning pressure reaches more than ten tons, so that the rigidity of a spinning system is greatly improved;
(8) the spinning equipment adopts a cluster type cantilever structure with a built-in radial driving system on the overall design, and solves the problems of more functional parts and narrow working space of a spinning wheel mechanism;
(9) according to the spinning equipment, the wedge iron is matched with the spinning wheel assembly, so that the axial and radial motion capable of being accurately controlled is converted into the radial motion of the spinning wheel head, and the accurate numerical control of the radial feeding of the spinning wheel is realized, so that the accurate axial and radial motion conversion of the spinning wheel in a narrow space is realized, and the accurate control of the radial feeding amount of the spinning wheel is met;
(10) the spinning equipment adopts the spinning roller seat as the integral axial moving carrier of the spinning roller head mechanism and the spinning roller arm, can realize the digital and accurately controlled axial feeding movement, realizes the integration of the axial and radial feeding functions of the spinning roller on the same mechanism, and provides guarantee for realizing the axial feeding in the internal spinning process.
Drawings
FIG. 1 is a diagram of a manufacturing process of the present invention;
FIG. 2 is a diagram of the construction of the blank of the present invention;
FIG. 3 is a schematic structural diagram of the cylinder with the inner and outer ring reinforcing ribs according to the present invention;
FIG. 4 is a schematic view of a spinning apparatus of the present invention;
FIG. 5 is a schematic view of the spinning roller mechanism of the present invention;
FIG. 6 is a schematic view of the combination of the spinning roller mechanism and the pulling mechanism of the present invention;
FIG. 7 is a schematic view of a rotary head structure according to the present invention;
FIG. 8 is a schematic view of the wedge and spinning roller assembly of the present invention;
FIG. 9 is a schematic illustration of a spinning track according to the present invention;
fig. 10 is a schematic structural view of a conventional internal spinning apparatus.
Detailed Description
The present invention is described in detail below with reference to specific examples and the attached drawings.
Processing the cylinder body with the inner and outer ring reinforcing ribs as shown in FIG. 3, wherein the manufacturing length L1 is 1300mm, the length L2 is 150mm, the length L3 is 175mm, the length L4 is 480mm, the length L5 is 743.75mm, the length L6 is 210mm, and the length L7 is 380 mm; thickness T1 is 10mm, T2 is 7.5mm, T3 is 10mm, T4 is 7.5mm, T5 is 10mm, T6 is 7.5mm, T7 is 10 mm; the outer diameter phi D1 is 550mm, and phi D2 is 560 mm; the outer diameter phi D of the process ring is 562mm, and the material is 5A06 aluminum alloy.
The processing technology is as shown in figure 1 and is realized by the following steps:
1. blank design
The spinning blank 5 is designed into a straight cylindrical structure with a convex process ring at one end as shown in figure 2, the wall thickness t1 of the spinning blank is determined by calculation according to the reduction rate of a reinforcing rib section and a skin section, the length of the spinning blank 5 is obtained by product comprehensive calculation according to the volume invariance principle and the consideration of the reserved process allowance, and the outer diameter phi D of the spinning blank is determined according to the inner spinning diameter expansion rule.
The specific process is as follows:
(1) as can be seen from FIG. 2, the height of the rib of the outer reinforcing rib section is 2.5mm, and the thickness ratio of the rib to the section is 1: 4, according to the design principle that the section is ensured to have the thinning rate of more than 12 percent during spinning so as to ensure that the outer reinforcing rib is fully attached to the stepped die, the thickness of the blank of the section is at least 11.36mm so as to ensure the forming of the outer reinforcing rib;
(2) and determining the distribution of the thinning rates of the skin section and the inner reinforcing rib section, wherein the distribution principle is that the thinning rate of the skin section does not exceed the limit thinning rate, and the thinning rate of the skin section is improved and the thinning rate of the inner reinforcing rib section is reduced on the premise that the inner reinforcing rib section can ensure the full expansion diameter and the sticking of the section. According to the thickness T1-T7 of each section of the product, the difference between the thickness of the skin section and the thickness of the inner reinforcing rib section is 2.5mm, the limit reduction rate of the 5A06 aluminum alloy during internal rotation is within 40%, the reduction amount is more than 10%, the expansion fit mold can be realized, meanwhile, the thickness of the blank determined above is comprehensively considered to be not less than 11.36mm, so that the reduction rate of the skin section is designed to be 36.4%, the reduction rate of the inner reinforcing rib section is 15.3%, the reduction rate of the outer reinforcing rib section is 15.3%, the uniform thickness T1 of the blank 5 is determined to be 11.8mm, and the reduction rate distribution principle is met;
(3) according to the structure of a final product and the determined thickness t1 of the blank, the theoretical length of the blank 5 is 1012mm according to the principle that the spinning volume is unchanged, a 40mm length allowance needs to be reserved at one end of the convex process ring for installation and positioning, a 20-40mm process allowance needs to be reserved at the other end of the convex process ring, so that the product precision is prevented from being seriously affected by the deformation of a mouth part, the length L of the blank is determined to be 1082mm, the length of the convex process ring is added, and the total length of the blank 5 is 1088.
(4) The outer diameter PhiD of the blank 5 is mainly determined by three parameters of the outer diameter of a product, the spinning expansion and diameter amount and the gap between the blank 5 and the outer straight line section 31 of the stepped die, wherein the spinning expansion and diameter amount is related to the physical performance of the material and is determined to be 0.3mm through test groping, and the gap between the blank 5 and the outer straight line section 31 of the stepped die is 0.4mm, so the outer diameter PhiD of the blank 5 is designed to be 549.3 mm.
(5) Machining of blanks
The seamless pipe purchased from a manufacturer is processed into a preset size and shape by a turning method, one end with the convex process ring requires that both side surfaces of the connecting ring have higher flatness precision, and the excircle of the other end is chamfered by 2 multiplied by 30 degrees, so that the blank installation is convenient.
The machining size and precision of the blank 5 are as follows:
the thickness of the convex process ring is as follows: 6 mm;
outer diameter of the convex process ring: phi 562mm
Flatness of two sides of the convex process ring: 0.1mm
Wall thickness tolerance: 0.2 mm;
diameter tolerance: 0.3 mm.
2. Stress relieving treatment
According to the relevant standard specification of the aluminum alloy heat treatment, the blank 5 is subjected to heat treatment by adopting the following heat treatment system so as to reduce the strength of the blank 5 and meet the spinning requirement:
and (3) heat treatment equipment: the temperature control precision of the aluminum alloy heat treatment furnace is not more than +/-5 mm;
a heating mode: heating along with the furnace;
and (3) heat preservation temperature: 320 ℃;
and (3) heat preservation time: 1.5 h;
a cooling mode: cooling the mixture to 260 ℃ along with the furnace, and discharging the mixture out of the furnace.
3. Spinning track design
Designing a spinning track as shown in fig. 9, designing a forming mode of a spinning section 501, a positioning section 502, an inner reinforcing rib section 503, a skin and inner reinforcing rib transition section 504, a skin section 505 and an outer reinforcing rib section 506, designing the thinning rate and the rolling reduction of each section of spinning, completing the design of the spinning track, and determining the forming process. The specific process is as follows:
(1) the screwing-in section 501 is formed in an internal spinning mode, namely a traction mechanism is not moved, a spinning wheel moves towards the direction of a main shaft, the screwing-in point of the screwing-in section is in a stepped die and is 10mm away from the outer reinforcing rib section part 32 in the stepped die to be close to one side line of the main shaft, the track is 15mm long, the screw-in starting point screw-down amount is-0.5 mm, and the screwing-in terminal point reaches the slope of the screw-down amount of the positioning section 502;
(2) the positioning section 502 is formed in an internal spinning mode, the length of the positioning section is 30mm, the pressing amount of the positioning section is consistent with that of the first section of the product, namely the pressing amount of the inner reinforcing rib section 503, tension spinning is started after the positioning section 502 is spun, namely the axial position of the spinning wheel is fixed, and the traction mechanism 9 pulls the blank 5 to move according to a set speed in the direction opposite to the main shaft;
(3) the inner reinforcing rib section 503 is spun on the outer straight line section 31 in the stepped die, a straight line track is adopted, the rolling reduction is determined according to the thickness of a product and the spinning rebound amount, wherein the spinning rebound amount is determined to be 0.15mm through test and search, the rolling reduction amount is 1.95mm, and the length of the inner reinforcing rib section 503 is calculated according to the volume invariance principle;
(4) the skin section and the transition section 504 of the inner reinforcing rib are spun on the outer straight line section part 31 in the step die, a slope track is adopted, sharp points on two sides of the inner reinforcing rib 503 are naturally formed, and the rolling reduction of the slope section is consistent with that of the inner reinforcing rib section 503;
(5) the skin section 505 is spun in an outer straight line section part 31 in a stepped die, a straight line track is adopted, the rolling reduction is determined according to the thickness of a product and the spinning rebound quantity, the spinning rebound quantity is determined to be 0.2mm through test and search, the rolling reduction quantity is 4.5mm, and the length of the skin section 505 is calculated according to the volume invariance principle by the product;
(6) the outer reinforcing rib section 32 in the stepped die is spun, a traction mechanism 9 and a spinning wheel arm 6 are adopted to match movement tracks during spinning, namely after the spinning of a section of the skin section in front of the outer reinforcing rib 506 is finished, the spinning wheel 403 is radially retracted to a safe position, the traction mechanism 9 pulls the blank 5 to axially move along the direction opposite to the main shaft until the outer reinforcing rib is close to one end face of the convex process ring and is in the die and 5-10mm away from the end face of the die, the spinning wheel arm 6 moves to the starting point in the step (1), the spinning is carried out in the mode of the step (1), the outer reinforcing rib section positioning section is spun according to the mode of the step (2), and the pressing amount of the outer reinforcing rib section positioning section is consistent with that of the outer reinforcing rib section; then, carrying out tension spinning on the outer reinforced rib section, wherein the rolling reduction is 1.95 mm; and (3) after the outer reinforcing rib section is spun, axially stopping the traction mechanism 9, adopting an inner spinning mode, carrying out inner spinning from the spinning wheel arm 6 to the tension spinning starting point in the step (2) according to the rolling reduction of the skin section behind the outer reinforcing rib section, namely 4.5mm, and then carrying out tension spinning to finish spinning of each section behind.
4. Spinning
And (3) mounting the blank 5 obtained by the stress removing treatment according to the step (2) on spinning equipment, and performing composite spinning according to the spinning track determined in the step (3).
The spinning equipment is as shown in figure 4, and comprises a spindle box 1, a die transmission cylinder 2, a spinning wheel mechanism, a traction mechanism 9, a material pressing ring 10 and a numerically-controlled machine tool body 11, wherein the die transmission cylinder 2 is installed on the spindle of the numerically-controlled machine tool, a stepped die 3 is installed at the front end of an inner cavity of the die transmission cylinder 2, and the spinning wheel mechanism and the traction mechanism 9 are installed on the numerically-controlled machine tool body 11.
As shown in fig. 6, the drawing mechanism 9 includes a drawing mechanism rotor 901, a drawing mechanism rotor bearing 902, a drawing mechanism seat 903, a drawing mechanism axial feed screw 904, and a drawing mechanism axial feed driving motor 905, the drawing mechanism rotor 901 is installed in the drawing mechanism seat 903 through the drawing mechanism rotor bearing 902, the drawing mechanism seat 903 is installed on a guide rail of the numerically-controlled machine tool body 11, the blank 5 is installed on the drawing mechanism rotor 901 through a material pressing ring 10, and the drawing mechanism seat 903 realizes axial movement through the drawing mechanism axial feed screw 904 and the drawing mechanism axial feed driving motor 905.
The spinning wheel mechanism is shown in fig. 5 and 6 and comprises a spinning wheel head mechanism 4, a spinning wheel radial feed screw 12, a spinning wheel radial feed driving motor 13, a spinning wheel arm 6, a spinning arm seat 7, an axial feed screw 14, a feed box 8 and an axial feed driving motor 15, wherein the feed box 8 is fixed at the tail end of a machine body 11 of the numerical control machine tool, the axial feed driving motor 15 is installed in the feed box, and the center line of the feed box coincides with the center line of a machine tool spindle; the swing arm seat 7 is arranged on a guide rail of a numerical control machine tool body 11, the central line of the swing arm seat is superposed with the central line of a machine tool main shaft, and the swing arm seat 7 is connected with the feeding box 8 through an axial feeding screw 14 and can be driven by numerical control programming to enable the swing arm seat 7 to do axial feeding motion with accurately controlled speed and position; the rotary wheel arm 6 is fixed on the rotary arm seat 7 through a screw, the central line of the rotary wheel arm is superposed with the central line of the machine tool spindle, the rotary wheel arm is divided into a plurality of sections which are connected by bolts, the interior of the rotary wheel arm is hollow, and is used for placing a rotary wheel radial feed driving motor 13 and can be detached and maintained at the section; a rotary wheel radial feed driving motor 13 is fixed at one end of the inner cavity of the rotary wheel arm 6 close to the rotary wheel head mechanism 4; one end of a rotary wheel radial feed screw 12 is fixedly connected with the rotary wheel head mechanism 4, and the other end of the rotary wheel radial feed screw is arranged in the inner cavity of the rotary wheel arm 6 through a rotary wheel radial feed driving motor 13 and can drive the rotary wheel radial feed screw 12 to move through numerical control programming.
The spinning wheel head mechanism 4 is composed of three groups of spinning wheel components, spinning wheel head main bodies 406 and wedges 401 which are uniformly distributed in the circumferential direction, each group of spinning wheel components comprises a supporting rolling body 402, a spinning wheel 403, a connecting rod 404 and a connecting rod shaft 405, the spinning wheel head main bodies 406 are fixedly connected with spinning wheel arms 6 through screws, the spinning wheels 403 are connected to the spinning wheel head main bodies 406 through the connecting rods 404 and the connecting rod shafts 405, and springs are connected between the adjacent connecting rods 404 and have the function of keeping the spinning wheels to be shrunk in a natural state; the rotary wheel radial feed screw 12 is connected with one end of the wedge 401. The connecting rod 404 has a three-rod structure, and is used to connect and support the rolling body 402 and the roller head body 406, and transmit the axial movement of the wedge 401 to the roller 403.
As shown in fig. 8, the wedge 401 has a triangular wedge structure with a regular triangle cross section, three vertexes are rounded, so as to effectively prevent motion interference between adjacent supporting rolling bodies 402, the wedge 401 is placed inside the spinning roller head main body 406 and between three connecting rods, and is connected with a servo motor placed inside a spinning arm through a radial feed screw 12 of the spinning roller, and the servo motor drives the screw to rotate, so as to drive the wedge 10 to move axially; when the wedge 401 moves axially, 3 inclined planes contact with the supporting rolling body 402 connected with the front end of the connecting rod 404 to realize radial movement of the spinning wheel 403, the axial movement amount of the wedge 401 and the radial feeding amount of the spinning wheel 403 can be subjected to mathematical calculation to form a certain proportional relation, and the proportional relation is reflected in numerical control program control, so that numerical control program control of radial feeding of the spinning wheel 403 is realized.
In the spinning process, the blank 5 is drawn by the drawing mechanism 9 to realize axial tension, and the spinning wheel 403 arranged on the spinning wheel arm 6 realizes internal spinning; the installation part of the blank 5 on the traction mechanism 9 adopts a bearing, so that the blank 5 can rotate along with the step die 3 under the action of the friction force of the contact between the blank 5 and the step die 3 after being installed, meanwhile, the traction mechanism 9 is hollow inside and used for the rotating wheel arm 6 to pass through, and two axial movements are realized on the same axis; the traction mechanism 9 is driven by a servo motor arranged on the feeding box 8 through a lead screw, so that the precise and programmable control of the axial position and the movement speed can be realized; the rotary wheel arm 6 is arranged on the rotary arm seat 7 and is driven by a servo motor arranged on the feeding box 8 through a lead screw, so that the accurate and programmable control of the axial position and the movement speed can be realized.
During operation, the blank 5 is pressed on the traction mechanism 9 through the material pressing ring 10 in a screwing mode, a spinning program is designed on the basis of a spinning track, the traction mechanism 9 is moved to a preset spinning starting position, and spinning is started. And after the spinning program is executed, detaching the workpiece.
The specific process is as follows:
(1) the blank 5 is hoisted between the traction mechanism 9 and the stepped die 3, the convex process ring is tightly pressed on the end surface of the traction mechanism 9 by the material pressing ring 10, the blank 5 is placed in the stepped die 3 until the axial central line of the blank 5 is flush with the end surface of the die, the axial position of the blank is adjusted and fixed by the material pressing ring 10, and radial and axial positioning is realized;
(2) and (3) programming a spinning program on the basis of the pressing track to automatically execute actions such as material ejection, pre-rotation, spinning along a preset track, stopping and the like, wherein basic process parameters are as follows:
main shaft rotating speed: 100 r/min;
the internal rotation feeding speed of the screwing section is as follows: 60 mm/min;
positioning section internal rotation feeding speed: 80 mm/min;
traction speed: 80 mm/min.
(3) Spinning is started by a spinning program;
(4) and after the execution is finished, the crane is used for tightly hanging the product, the material pressing ring 10 is disassembled, and the product is disassembled.
5. Machining
And aligning the product by taking the outer diameter as a reference, and then cutting off the allowance at two ends to ensure that the product meets the design requirement.
6. Thermal treatment
According to the relevant standard specification of the aluminum alloy heat treatment, the blank 5 is subjected to heat treatment by adopting the following heat treatment system so as to reduce the strength of the blank 5 and meet the spinning requirement:
and (3) heat treatment equipment: the temperature control precision of the aluminum alloy heat treatment furnace is not more than +/-5 mm;
a heating mode: heating along with the furnace;
and (3) heat preservation temperature: 320 ℃;
and (3) heat preservation time: 1.5 h;
a cooling mode: cooling the mixture to 260 ℃ along with the furnace, and discharging the mixture out of the furnace.
The invention has not been described in detail and is in part known to those of skill in the art.
Claims (9)
1. A method for forming a cylinder body with inner and outer ring reinforcing ribs by internal spinning is characterized by comprising the following steps:
firstly, processing a blank with a straight cylindrical structure and an outward convex process ring at one end;
secondly, performing stress relief treatment on the blank;
thirdly, determining a spinning track,
the spinning track comprises a spinning section, a positioning section, a skin and inner reinforcing rib transition section, an inner reinforcing rib section and an outer reinforcing rib section;
the fourth step, spinning,
a4.1, mounting the blank processed in the second step on spinning equipment,
the spinning equipment comprises a spindle box (1), a die transmission cylinder (2), a spinning wheel mechanism, a traction mechanism (9), a material pressing ring (10) and a numerical control machine tool body (11), wherein a blank (5) is installed on the traction mechanism (9) through the material pressing ring (10), a step die (3) is installed at the front end of an inner cavity of the die transmission cylinder (2), the traction mechanism (9) drives the blank to axially move into the step die (3), and the step die consists of an outer reinforcing rib section part and an outer straight line section part;
a4.2, processing a screwing-in section,
the spinning section adopts internal spinning on the outer straight line section part of the stepped die;
a4.3, processing a positioning section,
the positioning section adopts internal spinning on the outer straight line section part of the stepped die;
a4.4, processing a skin section and an inner reinforcing rib section,
the skin section and the inner reinforcing rib section are processed in an outer straight line section of the stepped die by adopting tension spinning, the tension spinning refers to that the spinning wheel mechanism is axially static, the traction mechanism pulls the blank to axially move along the direction opposite to the main shaft, and the spinning wheel mechanism adopts an internal spinning process to spin;
a4.5, processing a transition section of the skin and the internal reinforcing ribs,
the transition section of the skin and the inner reinforcing rib is processed by tension spinning at the outer straight line section of the stepped die, and the transition section of the skin and the inner reinforcing rib adopts a slope track;
a4.6, processing an outer reinforcing rib section, wherein the outer reinforcing rib section consists of an outer reinforcing rib screwing-in section, an outer reinforcing rib positioning section, an outer reinforcing rib main body section and an outer reinforcing rib rear positioning section;
a4.7, repeating the steps A4.2-A4.6 according to the structure of the final product of the cylinder with the internal and external ring reinforcing ribs until the whole cylinder with the internal and external ring reinforcing ribs is formed;
and fifthly, machining and heat treating the cylinder body which is formed by spinning in the fourth step and is provided with the inner and outer ring reinforcing ribs.
2. The method for internal spin forming of a cylinder with inner and outer ring reinforcing ribs according to claim 1, characterized in that: the blank structure in the first step is realized through the following steps:
a1.1, determining the thickness t1 of the blank,
the method comprises the steps of determining the distribution of the thinning rate of an outer reinforcing rib section during spinning and the thinning rates of a skin section and an inner reinforcing rib section, wherein the thinning rate of the outer reinforcing rib section during spinning is more than 12%, and the distribution principle of the thinning rates of the skin section and the inner reinforcing rib section is that the thinning rate of the skin section does not exceed the limiting thinning rate, and the thinning rate of the inner reinforcing rib section improves the thinning rate of the skin section and reduces the thinning rate of the reinforcing rib section while ensuring sufficient diameter expansion and mold sticking;
a1.2, determining the theoretical length L of the blank,
according to the final product structure of the cylinder with the inner and outer ring reinforcing ribs and the blank thickness t1 determined in the step A1.1, the theoretical length of the blank is obtained according to the principle that the spinning volume is unchanged, a mounting and positioning allowance is reserved at one end of an outer convex process ring of the blank, and a process allowance is reserved at the other end of the outer convex process ring of the blank;
a1.3, using the formula
Determining the outer diameter PhiD of the blank, wherein PhiD1The outer diameter of the final product of the cylinder body with the inner and outer ring reinforcing ribs is the spinning expansion diameter,
is the gap between the blank and the outer straight line section of the stepped die.
3. The method for internal spin forming of a cylinder with inner and outer ring reinforcing ribs according to claim 1, characterized in that: the spinning wheel mechanism in the step A4.1 comprises a spinning wheel head mechanism (4), a spinning wheel radial feeding structure, a spinning wheel arm (6), a spinning arm seat (7) and an axial feeding structure, a traction mechanism (9) comprises a traction mechanism rotating body (901), a traction mechanism rotating body bearing (902), a traction mechanism seat (903) and a traction mechanism axial feeding structure, a mold transmission cylinder (2) is installed on a main shaft of the numerical control machine tool, a step mold (3) is installed at the front end of an inner cavity of the mold transmission cylinder (2), the traction mechanism rotating body (901) is installed in the traction mechanism seat (903) through the traction mechanism rotating body bearing (902), the traction mechanism seat (903) is installed on a guide rail of a machine tool body (11), a blank (5) is installed on the traction mechanism rotating body (901) through a material pressing ring (10), and the traction mechanism seat (903) realizes axial movement through the traction mechanism axial feeding structure, the rear end of the rotary wheel arm (6) is fixedly connected with the rotary arm seat (7), the front end of the rotary wheel arm is fixedly connected with the rotary wheel head mechanism (4), the rotary wheel radial feeding structure is installed in the inner cavity of the rotary wheel arm (6), the rotary wheel head mechanism (4) is connected with the rotary wheel radial feeding structure, and the rotary arm seat (7) is installed on a guide rail of a numerically-controlled machine tool body (11) and is connected with the axial feeding structure.
4. The internal spin forming method of a cylinder with inner and outer ring reinforcing ribs according to claim 3, characterized in that: the spinning roller head mechanism (4) is composed of a spinning roller head main body (406), a wedge iron (401) and three groups of spinning roller assemblies which are uniformly distributed in the circumferential direction, each group of spinning roller assembly comprises a supporting rolling body (402), a spinning roller (403), a connecting rod (404) and a connecting rod shaft (405), the spinning roller head main body (406) is fixedly connected with the front end of a spinning roller arm (6), the wedge iron (401) is of a triangular wedge-shaped structure in cross section, one end of the connecting rod (404) is connected with the supporting rolling body (402), the other end of the connecting rod (404) is connected onto the spinning roller head main body (406) through the connecting rod shaft (405), the spinning roller (403) is installed in the middle of the connecting rod (404), the supporting rolling body (402) is pressed on an inclined plane of the wedge iron (401), and the rear end of the wedge iron.
5. The internal spin forming method of a cylinder with inner and outer ring reinforcing ribs according to claim 4, characterized in that: the cross section of the wedge iron (401) is in a regular triangle shape, and three vertexes are rounded.
6. The internal spin forming method of a cylinder with inner and outer ring reinforcing ribs according to claim 3, characterized in that: the adjacent connecting rods (404) in the rotary wheel head mechanism (4) are connected through springs.
7. The internal spin forming method of a cylinder with inner and outer ring reinforcing ribs according to claim 3, characterized in that: the axial feeding structure comprises an axial feeding lead screw (14) and an axial feeding driving motor (15).
8. The internal spin forming method of a cylinder with inner and outer ring reinforcing ribs according to claim 3, characterized in that: the traction mechanism axial feeding structure comprises a traction mechanism axial feeding lead screw (904) and a traction mechanism axial feeding driving motor (905).
9. The internal spin forming method of a cylinder with inner and outer ring reinforcing ribs according to claim 3, characterized in that: the rotary wheel radial feeding structure comprises a rotary wheel radial feeding lead screw (12) and a rotary wheel radial feeding driving motor (13).
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| JP4139061B2 (en) * | 2000-10-23 | 2008-08-27 | 株式会社リコー | Roller core metal processing method and electrophotographic fixing roller core metal processing method |
| DE102005057945A1 (en) * | 2005-12-05 | 2007-06-21 | Reichhardt, Hans H. | Production of pipe sections and tubular workpieces formed with a protrusion in the cylindrical inner contour comprises deforming in only one clamp with only one counter roller spinning step |
| CN102078895B (en) * | 2010-11-11 | 2012-08-01 | 西北工业大学 | Method for forming large complex thin-wall shell with circumferential inner ribs |
| US9038428B2 (en) * | 2011-09-02 | 2015-05-26 | Victaulic Company | Spin forming method |
| CN104858286B (en) * | 2015-05-15 | 2017-03-08 | 航天特种材料及工艺技术研究所 | A kind of spinning machine |
| CN104858285B (en) * | 2015-05-15 | 2017-03-29 | 航天特种材料及工艺技术研究所 | A kind of spin-on process |
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