CN112339217A - Variable-thickness blade metal edge covering forming and connecting integrated device and method - Google Patents
Variable-thickness blade metal edge covering forming and connecting integrated device and method Download PDFInfo
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- CN112339217A CN112339217A CN202011087432.2A CN202011087432A CN112339217A CN 112339217 A CN112339217 A CN 112339217A CN 202011087432 A CN202011087432 A CN 202011087432A CN 112339217 A CN112339217 A CN 112339217A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14467—Joining articles or parts of a single article
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C2045/14213—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure deforming by gas or fluid pressure in the mould cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14467—Joining articles or parts of a single article
- B29C2045/1454—Joining articles or parts of a single article injecting between inserts not being in contact with each other
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- Mechanical Engineering (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Abstract
The invention discloses a variable-thickness blade metal edge-covering forming and connecting integrated device and a variable-thickness blade metal edge-covering forming and connecting integrated method, wherein the variable-thickness blade metal edge-covering forming and connecting integrated device comprises an upper die, a blank holder and a lower die, wherein the blank holder is positioned between the upper die and the lower die; a forming cavity of the metal wrapping edge can be formed between the upper die and the lower die; an upper die cavity gas channel and a glue injection channel are arranged in the upper die, a radial gas channel, a lower die cavity gas channel and a plurality of contact thermocouples are arranged in the lower die, the upper die cavity gas channel, the radial gas channel and the lower die cavity gas channel are respectively communicated with a pressure controller through pipelines, the pressure controller is communicated with a high-pressure gas cylinder, the glue injection channel is communicated with a glue injection pump, and the glue injection pump is communicated with a glue storage tank; the upper die is also provided with a plurality of ultrasonic vibration probes. The forming and connecting integrated device and the forming and connecting integrated method for the variable-thickness blade metal wrapping edge improve the forming quality and efficiency of the blade metal wrapping edge.
Description
Technical Field
The invention relates to the technical field of material forming, in particular to a forming and connecting integrated device and method for variable-thickness blade metal wrapping edges.
Background
At present, casting or machining is mostly adopted for preparing blade edge-covering metal, but the problems of insufficient pouring, poor casting quality and low size precision of a thin-wall part of a blade edge-covering can occur in the casting process, and the problems of low material utilization rate, broken metal streamline and poor service performance of machining are solved. The common method for wrapping the edges of the blades is to use plastic forming such as stamping or rolling and glue joint, but the manufacturing steps are complex, the forming efficiency is low, and the problem of geometric precision distortion is caused by glue joint after forming; compared with stamping and rolling, the air pressure forming has better forming efficiency, but the common air pressure forming mostly applies pressure on one side, the deformation behavior of the plate cannot be flexibly regulated and controlled, and a low-pressure area or even a dead area may exist in the method, so that the wrinkling and cracking defects occur, and the forming effect is lower than expected. In addition, the defects of underfilling, gaps, performance inequality and the like are easy to occur in the conventional curing process of the carbon fiber cloth resin. Therefore, how to improve the forming quality and efficiency of the metal blade edge wrapping becomes a technical problem to be solved in the field.
Disclosure of Invention
The invention aims to provide a variable-thickness blade metal edge-covering forming and connecting integrated device and a variable-thickness blade metal edge-covering forming and connecting integrated method, which are used for solving the problems in the prior art and improving the forming quality and efficiency of blade metal edge-covering.
In order to achieve the purpose, the invention provides the following scheme:
the invention provides a variable-thickness blade metal-clad forming and connecting integrated device which comprises an upper die, a blank holder and a lower die, wherein the blank holder is positioned between the upper die and the lower die; a forming cavity of the metal wrapping edge can be formed between the upper die and the lower die; an upper die cavity gas channel and a glue injection channel are arranged in the upper die, a radial gas channel, a lower die cavity gas channel and a plurality of contact thermocouples are arranged in the lower die, the upper die cavity gas channel, the radial gas channel and the lower die cavity gas channel are respectively communicated with a pressure controller through pipelines, the pressure controller is communicated with a high-pressure gas cylinder, the glue injection channel is communicated with a glue injection pump, and the glue injection pump is communicated with a glue storage tank; the upper die is also provided with a plurality of ultrasonic vibration probes.
Preferably, an upper die sealing ring is arranged between the blank holder and the upper die, the blank holder is connected with the lower die through a lower die sealing ring, and the initial metal plate is clamped between the blank holder and the lower die.
The invention also provides a forming and connecting integrated method of the variable-thickness blade metal wrapping edge, and the forming and connecting integrated device based on the variable-thickness blade metal wrapping edge comprises the following steps:
(1) carrying out pretreatment on an initial metal plate, including grinding and polishing, oil removal, rust removal and anodic oxidation, and then placing the initial metal plate between a blank holder and a lower die;
(2) arranging an upper die cavity gas channel and a glue injection channel in the variable-thickness blade to be edged, and arranging a vibration probe on the top surface of the variable-thickness blade to be edged so as to use the variable-thickness blade to be edged as an upper die in air pressure forming;
(3) a radial gas channel, a lower die cavity gas channel and a contact type thermocouple are arranged in the lower die;
(4) electrifying the contact type thermocouple to heat the lower die, and heating the initial metal plate by using the lower die;
(5) introducing high-pressure gas into the upper die cavity gas channel, the radial gas channel and the lower die cavity gas channel through a pressure controller, respectively extruding the initial metal sheet by the high-pressure gas from the upper die cavity gas channel, the radial gas channel and the lower die cavity gas channel, simultaneously feeding the upper die downwards, and starting a glue injection pump to inject glue into a gap between the upper die and the initial metal sheet through the glue injection channel;
(6) when the initial metal plate material is subjected to plastic deformation in the step (5), the ultrasonic vibration probe is started to apply ultrasonic vibration around the initial metal plate material to assist the deformation of the initial metal plate material;
(7) after the upper die is fed to a set position, adjusting the pressure difference between the gas channel of the upper die cavity and the gas channel of the lower die cavity and the pressure of high-pressure gas in the radial gas channel, so that the deformed metal plate gradually realizes die attaching and bonding;
(8) and carrying out heat preservation and pressure maintaining treatment on the deformed metal plate, opening the mold after the heat preservation and pressure maintaining treatment is finished, taking out the upper mold and the deformed metal plate, and carrying out air cooling on the upper mold and the deformed metal plate.
Preferably, in the step (1), after the top surface of the initial metal plate is provided with the plurality of transverse grooves and the plurality of vertical grooves, the initial metal plate is placed between the blank holder and the lower die, and the transverse grooves are intersected with the vertical grooves.
Compared with the prior art, the invention has the following technical effects:
the forming and connecting integrated device and the forming and connecting integrated method for the variable-thickness blade metal wrapping edge improve the forming quality and efficiency of the blade metal wrapping edge. The forming and connecting integrated device and the forming and connecting integrated method for the variable-thickness blade metal wrapping edge take a fiber composite material blade to be wrapped as an upper die, and a metal plate material of the pre-wrapping edge is arranged on the lower die; the method comprises the steps of heating a metal plate with a pre-wrapped edge, injecting glue, pressurizing three surfaces and assisting ultrasonic vibration, and meanwhile, realizing ultrasonic-assisted air pressure forming and connection of the wrapped edge of the variable-thickness blade to obtain the blade with a good wrapped edge. By adopting the forming and connecting integrated method of the variable-thickness blade metal wrapping edge, the air pressure forming and connecting process of the fiber composite material blade metal wrapping edge can be integrated, the processing efficiency is obviously improved, and the forming and connecting integrated method is improved by about 60 percent compared with the step-by-step process of forming firstly and then connecting; the ultrasonic vibration is added in the forming process, so that the forming limit of the metal plate can be effectively improved, the deformation resistance of the metal plate is reduced, the forming force is reduced, meanwhile, the ultrasonic vibration promotes the refinement of tissue grains to improve the strength of the plate, and the uniform distribution of glue solution can also be promoted, so that the interface strength and the forming quality are improved; the three-side gas pressure forming is adopted, rigid contact of a die is avoided, meanwhile, the adjustable freedom degree is high, the required deformation effect can be realized more accurately, excessive thinning during plastic deformation of metal plates can be effectively reduced, the quality of the edge covering surface is better, and the strength is higher.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a schematic structural view of a blade after edge covering;
FIG. 2 is a schematic structural diagram of a forming and connecting integrated device for metal wrapping of variable-thickness blades according to the invention;
FIG. 3 is a schematic structural diagram of a forming and connecting integrated device for metal wrapping of variable-thickness blades in the forming process;
FIG. 4 is a schematic structural diagram of the forming and connecting integrated device for metal wrapping of variable-thickness blades of the invention after forming;
FIG. 5 is a schematic diagram of the temperature and pressure of the forming and connecting integrated device for the variable thickness blade metal edge covering in the air pressure forming process;
wherein: 1. metal wrapping; 2. a blade base body; 3. an upper die; 4. a blank holder; 5. a lower die; 6. ultrasonically vibrating the probe; 7. an upper mold cavity gas channel; 8. a glue injection channel; 9. an upper die sealing ring; 10. a lower die sealing ring; 11. starting a metal plate; 12. a contact thermocouple; 13. a pressure controller; 14. a radial gas passage; 15. a lower mold cavity gas channel; 16. a high pressure gas cylinder; 17. a glue injection pump; 18. a glue storage tank; 19. metal wrapping in the forming process; 20. and (4) forming the finished metal edge.
Detailed Description
The invention aims to provide a variable-thickness blade metal edge-covering forming and connecting integrated device and a variable-thickness blade metal edge-covering forming and connecting integrated method, which are used for solving the problems in the prior art and improving the forming quality and efficiency of blade metal edge-covering.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
As shown in fig. 1 to 5: the embodiment provides a variable-thickness blade metal-clad forming and connecting integrated device which comprises an upper die 3, a blank holder 4 and a lower die 5, wherein the blank holder 4 is positioned between the upper die 3 and the lower die 5, an upper die sealing ring 9 is arranged between the blank holder 4 and the upper die 3, the blank holder 4 is connected with the lower die 5 through a lower die sealing ring 10, and an initial metal plate 11 is clamped between the blank holder 4 and the lower die 5; after the initial metal plate 11 is attached to the upper surface of the edge of the lower die 5, the blank holder 4 extrudes the initial metal plate 11 and is fixed with the raised edge of the lower die 5 through the lower die sealing ring 10 on the side edge, so that a closed space is provided for the subsequent action of radial air pressure. The lower die 5 is of a variable axis type designed according to the shape of the blade. The variable-thickness blade is a fiber composite material substrate, is directly used as an upper die 3 for air pressure forming, and is provided with an injection channel and an air pressure channel at non-key positions.
A forming cavity of the metal wrapping edge 1 can be formed between the upper die 3 and the lower die 5; an upper die cavity gas channel 7 and a glue injection channel 8 are arranged in the upper die 3, a radial gas channel 14, a lower die cavity gas channel 10 and a plurality of contact thermocouples 12 are arranged in the lower die 5, the upper die cavity gas channel 7, the radial gas channel 14 and the lower die cavity gas channel 10 are respectively communicated with a pressure controller 13 through pipelines, the pressure controller 13 is communicated with a high-pressure gas cylinder 16, the glue injection channel 8 is communicated with a glue injection pump 17, and the glue injection pump 17 is communicated with a glue storage tank 18; the upper die 3 is also provided with a plurality of ultrasonic vibration probes 6.
In the forming and connecting integrated device for the variable-thickness blade metal wrapping edge, a blade base body 2 made of fiber composite materials to be wrapped is used as an upper die 3, and a metal plate material to be wrapped is arranged on a lower die 5; the method comprises the steps of heating a metal plate with a pre-wrapped edge, injecting glue, pressurizing three surfaces and assisting ultrasonic vibration, and meanwhile, realizing ultrasonic-assisted air pressure forming and connection of the wrapped edge of the variable-thickness blade to obtain the blade with a good wrapped edge.
The embodiment also provides a forming and connecting integrated method of the variable-thickness blade metal wrapping edge, and the forming and connecting integrated device based on the variable-thickness blade metal wrapping edge comprises the following steps:
(1) the initial metal plate 11 is pretreated, including grinding and polishing, oil removal, rust removal and anodic oxidation, and is a variable thickness material, and the closer to the center, the greater the thickness.
Arranging a plurality of transverse grooves and a plurality of vertical grooves on the top surface of an initial metal plate material 11, wherein any transverse groove is crossed with any vertical groove, forming a cross-shaped groove on the top surface of the initial metal plate material 11, and then placing the initial metal plate material 11 between the blank holder 4 and the lower die 5;
in this embodiment, fine crisscross slotting is performed on the connecting portions of the initial metal plate 11 and the blades; the thickness of the thinner part of the initial metal plate 11 is preferably 8 mm-12 mm, and more preferably 9 mm-11 mm; the thickness of the thickest part is preferably 30mm to 45mm, and more preferably 35mm to 40 mm; the initial metal plate 11 has the grooving depth of 2 mm-6 mm, and the preferable depth is 3 mm-5 mm;
(2) arranging an upper die cavity gas channel 7 and a glue injection channel 8 in the variable-thickness blade to be edged, and arranging a vibration probe on the top surface of the variable-thickness blade to be edged so as to use the variable-thickness blade to be edged as an upper die 3 in air pressure forming;
(3) a radial gas channel 14, a lower die cavity gas channel 10 and a contact thermocouple 12 are arranged in the lower die 5;
(4) electrifying the contact thermocouple 12 to heat the lower die 5, and heating the initial metal plate 11 to 70-90 ℃ by using the lower die 5;
(5) high-pressure gas is introduced into the upper die cavity gas channel 7, the radial gas channel 14 and the lower die cavity gas channel 10 through the pressure controller 13, the high-pressure gas coming out of the upper die cavity gas channel 7, the radial gas channel 14 and the lower die cavity gas channel 10 respectively extrudes the initial metal plate 11, and the time of the pressurizing process and the temperature rising process of the initial metal plate 11 is equal, preferably 15-45 min, more preferably 20-40 min, and more preferably 25-35 min.
Simultaneously, feeding the upper die 3 downwards, and starting a glue injection pump 17 to inject glue into a gap between the upper die 3 and the initial metal plate 11 through a glue injection channel 8;
after the upper die and the lower die are closed, the temperature is continuously raised at a basic temperature of 70-90 ℃, the target temperature is 120-140 ℃, preferably 125-135 ℃, the deformed metal plate is pressurized on two or three sides, the pressure applied to the edge of the plate is unchanged, the pressure applied to the lower surface is higher than that of the upper surface, the metal plate is enabled to be attached to the blade of the upper die 3, after the upper die and the lower die are closed, the temperature rise time and the pressurization time of the initial plate are the same, preferably 10-20 min, and further preferably 10-15 min. In the process of two-stage three-side pressurization, the edge of the metal plate has an anti-expansion effect, and the metal plate is gradually attached to the surface of the blade and connected until an ideal edge covering shape is formed. Meanwhile, the metal plate is subjected to heat treatment at 120-140 ℃, so that the mechanical property of the blade edge covering is effectively improved. Therefore, in the secondary pressurizing process, the variable-thickness blade wrapping edge completes the connection and heat treatment processes while being subjected to air pressure forming, the integration of air pressure forming and connection is finally realized, and the production efficiency is greatly improved.
The radial pressure applied to the edge of the initial metal plate 11 is 5MPa to 15MPa, preferably 6MPa to 14MPa, and further preferably 7MPa to 13 MPa; the pressure applied to the upper surface of the initial metal plate 11 is higher than the lower surface, and is 15MPa to 20MPa, preferably 16MPa to 19MPa, and more preferably 17MPa to 18 MPa; the pressure applied to the lower surface of the initial metal blank 11 is 10 to 15MPa, preferably 11 to 14MPa, and more preferably 12 to 13 MPa. And the three-sided pressurization process is a process of gradually increasing the pressure from 0 to the target pressure. The pressure applied to the lower surface of the initial sheet metal material 11 is preferably higher than the pressure applied to the upper surface of the initial sheet metal material 11, and the pressure difference is preferably 0 to 15MPa, more preferably 2 to 13MPa, and still more preferably 5 to 10 MPa. The pressure applied to the lower surface of the initial metal plate 11 is controlled to be higher than the upper surface of the initial metal plate, so that the metal plate can be better attached to the blade of the upper die 3, and the connection between the metal plate and the blade is promoted.
The high-pressure gas is preferably nitrogen, in the embodiment, when the sheet material is subjected to plastic deformation, the gas is introduced into the gas channel at the edge of the sheet material, and the gas is introduced into the gas channels at the upper surface and the lower surface of the forming die, so that the pressure reaches the target pressure, the problems of poor surface quality and scratches of the metal sheet material caused by the fact that the forming die is directly contacted with the surface of the sheet material in the traditional method and the forming die is pressurized are solved, meanwhile, the flange is pushed to move towards the cavity of the die when the upper die 3 moves downwards, the excessive thinning phenomenon during the sheet material plastic deformation is effectively eliminated, and the edge covering quality is improved.
(6) When the initial metal plate 11 is plastically deformed in the step (5), the ultrasonic vibration probe 6 should be turned on to apply ultrasonic vibration around the initial metal plate 11 to assist the deformation of the initial metal plate 11, such as a metal covering 19 in the forming process shown in fig. 3;
(7) after the upper die 3 is fed to a set position, the pressure difference between the upper die cavity gas channel 7 and the lower die cavity gas channel 10 and the pressure of high-pressure gas in the radial gas channel 14 are adjusted, so that the deformed metal plate is gradually adhered to the die and bonded, and finally the deformed metal plate is connected with the upper die 3;
(8) as shown in fig. 4, the formed metal wrapping 20 is formed, the deformed metal plate is subjected to heat preservation and pressure maintaining treatment, the pressure maintaining time is preferably 50min to 70min, and more preferably 55min to 65min, the pressure inside the air pressure forming die is reduced at 120 ℃ to 140 ℃ until the edge pressure and the upper and lower surfaces of the plate are reduced to 0MPa, and the pressure reducing treatment time is preferably 8min to 12min, and more preferably 10 min. After the pressure reduction is finished, the heat preservation treatment is continuously carried out on the blade wrapping edges, and the temperature of the heat preservation treatment is preferably 120-150 ℃, and is further preferably 120-140 ℃; the heat preservation time is preferably 60min to 120min, and more preferably 80min to 100 min. The embodiment carries out heat preservation treatment under the above conditions, so that metal can be subjected to aging treatment, and meanwhile, the glue solution can better realize the connection effect, thereby being beneficial to improving the quality of edge covering. And after the heat preservation and pressure maintaining treatment is finished, opening the die to take out the upper die 3 and the deformed metal plate, and performing air cooling on the upper die 3 and the deformed metal plate so as to realize the forming and connection of the metal edge 1 of the variable-thickness blade.
In the forming and connecting integrated process, the pressure and temperature schematic diagram of the blade metal wrapping edge 1 is shown in FIG. 4, wherein T1 is 70-90 ℃ and T2 is 120-140 ℃ in FIG. 4; the gas pressure P1 is 7MPa to 13MPa, P2 is 13MPa to 17MPa, P3 is 12MPa to 13MPa, P4 is 17MPa to 18MPa, and P5 is 22MPa to 23 MPa; the time t1 is 25-35 min, the time t2-t1 is 10-15 min, the time t3-t2 is 55-65 min, the time t4-t3 is 10min, and the time t5-t4 is 80-100 min.
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
Example one
In the embodiment, the metal plate is made of solid solution aluminum alloy, and the composite material blade with variable thickness is made of thermoplastic (polyimide) carbon fiber composite material; carrying out conventional surface treatment such as grinding and polishing, oil removal, rust removal, activation and the like on the aluminum plate with the edge covered, and carrying out slotting treatment on the upper surface of the plate, wherein the thickness of a thin part of the plate is 9mm, the thickness of a thick part of the plate is 35mm, and the slotting depth is 3 mm; placing the prepared plate on the upper surface of a lower die 5, and restraining and fixing the longitudinal degree of freedom of the plate through a blank holder 4, meanwhile, sealing the blank holder 4 and a flange of the lower die 5 through a sealing ring, restraining the composite blade of the upper die 3 through the sealing ring, and forming a sealing environment in which gas can be introduced into the whole forming cavity; after the upper die 3 and the plate are arranged, the lower die 5 is used for heating the aluminum plate to 80 ℃ through resistance heating, glue is injected on the surface of the aluminum plate through the glue injection channel 8 of the upper die 3, meanwhile, the upper surface, the lower surface and the radial gas pressure are applied on the aluminum plate through the gas channels of the upper die 5, the lower die 5 and the side edge, when the time is 30min, the pressure of the cavity of the upper die 3 rises to 18MPa, the pressure of the cavity of the lower die 5 rises to 13MPa, and the radial pressure rises to 10 MPa. At the moment, the sheet material is gradually subjected to plastic deformation, and the upper die 3 is gradually fed downwards; when the sheet material is plastically deformed, ultrasonic vibration is applied to the periphery of the sheet material by using an ultrasonic probe; and after the upper die 3 is fed to the target position, continuously heating the plate, simultaneously increasing the radial pressure, keeping the pressure of the cavity of the upper die 3 unchanged, increasing the pressure of the cavity of the lower die 5, increasing the temperature to 130 ℃ when the total time is 40min, respectively increasing the radial pressure and the pressure of the cavity of the lower die 5 to 14MPa and 23MPa, and gradually attaching the aluminum plate to the upper blade die 3 to obtain the final required edge covering shape. Continuously carrying out heat preservation and pressure maintaining treatment on the aluminum plate, wherein during the heat preservation and pressure maintaining treatment, the aluminum plate is subjected to heat treatment, and the glue solution flows under the action of ultrasound and is uniformly filled between the aluminum plate and the blades; and when the total time reaches 100min, keeping the temperature of the die unchanged, closing the air pump to gradually release pressure, releasing the pressure for 10min until the pressure on three surfaces is reduced to 0, performing heat preservation treatment on the formed aluminum plate at the temperature of 130 ℃ and under the pressure of 0, wherein the heat preservation time is 90min, closing the heating device after the treatment is finished, and opening the die to take out the part to obtain the final blade edge wrapping part.
The forming and connecting integrated method for the variable-thickness blade metal wrapping edge realizes integration of air pressure forming and connecting processes of the thermoplastic fiber composite material blade aluminum alloy wrapping edge, obviously improves processing efficiency, and improves 50% compared with a step-by-step process of forming first and then connecting; in the forming process of the variable-thickness blade aluminum alloy wrapping edge, ultrasonic vibration assistance is added, the forming limit of an aluminum plate can be effectively improved, the deformation resistance of the aluminum plate is reduced, the forming force is reduced, meanwhile, the ultrasonic vibration promotes the refinement of tissue grains to improve the strength of the plate, and the uniform distribution of glue solution can also be promoted, so that the interface strength and the forming quality are improved; adopt trilateral gas pressure shaping, avoid mould rigid contact, adjustable degree of freedom is high simultaneously, the required deformation effect of realization that can be more accurate, excessive attenuate when also can effectively reducing aluminum plate plastic deformation, the quality on bordure surface is better, and intensity is higher.
Example two
In the embodiment, the metal plate is made of solid solution aluminum alloy, and the composite material blade with variable thickness is made of thermosetting (epoxy resin) carbon fiber composite material; carrying out conventional surface treatment such as grinding and polishing, oil removal, rust removal, activation and the like on the aluminum plate with the edge covered, and carrying out grooving treatment on the upper surface of the plate, wherein the thickness of a thin part of the plate is 10mm, the thickness of a thick part of the plate is 36mm, and the grooving depth is 4 mm; placing the prepared plate on the upper surface of a lower die 5, and restraining and fixing the longitudinal degree of freedom of the plate through a blank holder 4, meanwhile, sealing the blank holder 4 and a flange of the lower die 5 through a sealing ring, restraining the composite blade of the upper die 3 through the sealing ring, and forming a sealing environment in which gas can be introduced into the whole forming cavity; after the upper die 3 and the plate are arranged, the lower die 5 is used for heating the aluminum plate to 75 ℃ through resistance heating, glue is injected on the surface of the aluminum plate through the glue injection channel 8 of the upper die 3, meanwhile, the upper surface, the lower surface and the radial gas pressure are applied on the aluminum plate through the gas channels of the upper die 5, the lower die 5 and the side edge, when the time is up to 35min, the pressure of the cavity of the upper die 3 rises to 17MPa, the pressure of the cavity of the lower die 5 rises to 12MPa, and the radial pressure rises to 7 MPa. At the moment, the sheet material is gradually subjected to plastic deformation, and the upper die 3 is gradually fed downwards; when the sheet material is plastically deformed, ultrasonic vibration is applied to the periphery of the sheet material by using an ultrasonic probe; and after the upper die 3 is fed to the target position, continuously heating the plate, simultaneously increasing the radial pressure, keeping the pressure of the cavity of the upper die 3 unchanged, increasing the pressure of the cavity of the lower die 5, increasing the temperature to 125 ℃ when the total time is 45min, respectively increasing the radial pressure and the pressure of the cavity of the lower die 5 to 13MPa and 22MPa, and gradually attaching the aluminum plate to the upper blade die 3 to obtain the final required edge covering shape. Continuously carrying out heat preservation and pressure maintaining treatment on the aluminum plate, wherein during the heat preservation and pressure maintaining treatment, the aluminum plate is subjected to heat treatment, and the glue solution flows under the action of ultrasound and is uniformly filled between the aluminum plate and the blades; and when the total time reaches 100min, keeping the temperature of the die unchanged, closing the air pump to gradually release pressure, releasing the pressure for 10min until the pressure on three surfaces is reduced to 0, performing heat preservation treatment on the formed aluminum plate at 125 ℃ and under the pressure of 0, wherein the heat preservation time is 80min, closing the heating device after the treatment is finished, and opening the die to take out the part to obtain the final blade edge wrapping part.
The forming and connecting integrated method for the variable-thickness blade metal wrapping edge realizes integration of air pressure forming and connecting processes of the thermosetting fiber composite material blade aluminum alloy wrapping edge, obviously improves processing efficiency, improves 58% compared with a step-by-step process of forming first and then connecting, adds ultrasonic vibration assistance in the forming process of the variable-thickness blade aluminum alloy wrapping edge, can effectively improve the forming limit of an aluminum plate, reduces the deformation resistance of the aluminum plate and the forming force, simultaneously promotes tissue crystal grain refinement by ultrasonic vibration to improve the strength of the plate, and can also promote uniform distribution of glue solution so as to improve interface strength and forming quality; adopt trilateral gas pressure shaping, avoid mould rigid contact, adjustable degree of freedom is high simultaneously, the required deformation effect of realization that can be more accurate, excessive attenuate when also can effectively reducing aluminum plate plastic deformation, the quality on bordure surface is better, and intensity is higher.
EXAMPLE III
In the embodiment, the metal plate is made of solid-solution titanium alloy, and the composite material blade with variable thickness is made of thermoplastic (polyimide) carbon fiber composite material; carrying out conventional surface treatment such as grinding and polishing, oil removal, rust removal, activation and the like on the titanium plate with the edge, and carrying out grooving treatment on the upper surface of the plate, wherein the thickness of a thin part of the plate is 10mm, the thickness of a thick part of the plate is 38mm, and the grooving depth is 4 mm; placing the prepared plate on the upper surface of a lower die 5, and restraining and fixing the longitudinal degree of freedom of the plate through a blank holder 4, meanwhile, sealing the blank holder 4 and a flange of the lower die 5 through a sealing ring, restraining the composite blade of the upper die 3 through the sealing ring, and forming a sealing environment in which gas can be introduced into the whole forming cavity; after the upper die 3 and the plate are arranged, the titanium plate is heated to 85 ℃ by using the lower die 5 through resistance heating, glue is injected on the surface of the titanium plate through the glue injection channel 8 of the upper die 3, meanwhile, the upper surface, the lower surface and the radial gas pressure are applied on the titanium plate through the gas channels of the upper die 5, the lower die 5 and the side edges, when the time is 25min, the pressure of the cavity of the upper die 3 rises to 18MPa, the pressure of the cavity of the lower die 5 rises to 13MPa, and the radial pressure rises to 12 MPa. At the moment, the sheet material is gradually subjected to plastic deformation, and the upper die 3 is gradually fed downwards; when the sheet material is plastically deformed, ultrasonic vibration is applied to the periphery of the sheet material by using an ultrasonic probe; and after the upper die 3 is fed to the target position, continuously heating the plate, simultaneously increasing the radial pressure, keeping the pressure of the cavity of the upper die 3 unchanged, increasing the pressure of the cavity of the lower die 5, increasing the temperature to 135 ℃ when the total time is 35min, respectively increasing the radial pressure and the pressure of the cavity of the lower die 5 to 17MPa and 23MPa, and gradually attaching the titanium plate to the upper blade die 3 to obtain the final required edge covering shape. Continuously carrying out heat preservation and pressure maintaining treatment on the titanium plate, wherein the titanium plate is subjected to heat treatment during the period, and the glue solution flows under the action of ultrasound and is uniformly filled between the titanium plate and the blade; and when the total time reaches 90min, keeping the temperature of the die unchanged, closing the air pump to gradually release pressure, releasing the pressure for 10min until the pressure on three surfaces is reduced to 0, performing heat preservation treatment on the formed titanium plate at 135 ℃ under the pressure of 0, wherein the heat preservation time is 80min, closing the heating device after the treatment is finished, and opening the die to take out the part to obtain the final blade edge wrapping part.
The forming and connecting integrated method for the variable-thickness blade metal wrapping edge realizes the integration of air pressure forming and connecting processes of the thermoplastic fiber composite material blade titanium alloy wrapping edge, obviously improves the processing efficiency, improves 60 percent compared with the step-by-step process of forming before connecting, adds ultrasonic vibration assistance in the forming process of the variable-thickness blade titanium alloy wrapping edge, can effectively improve the forming limit of a titanium plate, reduces the deformation resistance of the titanium plate and the forming force, simultaneously promotes the refinement of tissue crystal grains by ultrasonic vibration to improve the strength of a plate material, and can also promote the uniform distribution of glue solution so as to improve the interface strength and the forming quality; the three-side gas pressure forming is adopted, the rigid contact of a die is avoided, the adjustable freedom degree is high, the required deformation effect can be realized more accurately, the excessive thinning during the plastic deformation of the titanium plate can be effectively reduced, the quality of the edge covering surface is better, and the strength is higher.
In the description of the present invention, it should be noted that the terms "top", "bottom", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, which are only for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.
The principle and the implementation mode of the present invention are explained by applying specific examples in the present specification, and the above descriptions of the examples are only used to help understanding the method and the core idea of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (4)
1. The utility model provides a become shape of thickness blade metal bordure and connect integrated device which characterized in that: the device comprises an upper die, a blank holder and a lower die, wherein the blank holder is positioned between the upper die and the lower die; a forming cavity of the metal wrapping edge can be formed between the upper die and the lower die; an upper die cavity gas channel and a glue injection channel are arranged in the upper die, a radial gas channel, a lower die cavity gas channel and a plurality of contact thermocouples are arranged in the lower die, the upper die cavity gas channel, the radial gas channel and the lower die cavity gas channel are respectively communicated with a pressure controller through pipelines, the pressure controller is communicated with a high-pressure gas cylinder, the glue injection channel is communicated with a glue injection pump, and the glue injection pump is communicated with a glue storage tank; the upper die is also provided with a plurality of ultrasonic vibration probes.
2. The forming and connecting integrated device for the metal covering edge of the variable-thickness blade as claimed in claim 1, wherein: an upper die sealing ring is arranged between the blank holder and the upper die, the blank holder is connected with the lower die through a lower die sealing ring, and an initial metal plate is clamped between the blank holder and the lower die.
3. A variable-thickness blade metal-clad forming and connecting integrated method is based on the variable-thickness blade metal-clad forming and connecting integrated device of claim 1 or 2, and is characterized by comprising the following steps of:
(1) carrying out pretreatment on an initial metal plate, including grinding and polishing, oil removal, rust removal and anodic oxidation, and then placing the initial metal plate between a blank holder and a lower die;
(2) arranging an upper die cavity gas channel and a glue injection channel in the variable-thickness blade to be edged, and arranging a vibration probe on the top surface of the variable-thickness blade to be edged so as to use the variable-thickness blade to be edged as an upper die in air pressure forming;
(3) a radial gas channel, a lower die cavity gas channel and a contact type thermocouple are arranged in the lower die;
(4) electrifying the contact type thermocouple to heat the lower die, and heating the initial metal plate by using the lower die;
(5) introducing high-pressure gas into the upper die cavity gas channel, the radial gas channel and the lower die cavity gas channel through a pressure controller, respectively extruding the initial metal sheet by the high-pressure gas from the upper die cavity gas channel, the radial gas channel and the lower die cavity gas channel, simultaneously feeding the upper die downwards, and starting a glue injection pump to inject glue into a gap between the upper die and the initial metal sheet through the glue injection channel;
(6) when the initial metal plate material is subjected to plastic deformation in the step (5), the ultrasonic vibration probe is started to apply ultrasonic vibration around the initial metal plate material to assist the deformation of the initial metal plate material;
(7) after the upper die is fed to a set position, adjusting the pressure difference between the gas channel of the upper die cavity and the gas channel of the lower die cavity and the pressure of high-pressure gas in the radial gas channel, so that the deformed metal plate gradually realizes die attaching and bonding;
(8) and carrying out heat preservation and pressure maintaining treatment on the deformed metal plate, opening the mold after the heat preservation and pressure maintaining treatment is finished, taking out the upper mold and the deformed metal plate, and carrying out air cooling on the upper mold and the deformed metal plate.
4. The forming and connecting integrated method for the metal covering edge of the variable-thickness blade as claimed in claim 3, wherein the forming and connecting integrated method comprises the following steps: in the step (1), after a plurality of transverse grooves and a plurality of vertical grooves are required to be arranged on the top surface of the initial metal plate, the initial metal plate is placed between the blank holder and the lower die, and the transverse grooves are intersected with the vertical grooves.
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