CN114042789B - Flexible gradual flanging forming optimization method for plate follow-up robot - Google Patents

Flexible gradual flanging forming optimization method for plate follow-up robot Download PDF

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CN114042789B
CN114042789B CN202111462574.7A CN202111462574A CN114042789B CN 114042789 B CN114042789 B CN 114042789B CN 202111462574 A CN202111462574 A CN 202111462574A CN 114042789 B CN114042789 B CN 114042789B
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forming
flanging
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plate
roller
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CN114042789A (en
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程旋
赵亦希
陈伟
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Shanghai Jiaotong University
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D19/00—Flanging or other edge treatment, e.g. of tubes
    • B21D19/02—Flanging or other edge treatment, e.g. of tubes by continuously-acting tools moving along the edge
    • B21D19/04—Flanging or other edge treatment, e.g. of tubes by continuously-acting tools moving along the edge shaped as rollers
    • B21D19/043—Flanging or other edge treatment, e.g. of tubes by continuously-acting tools moving along the edge shaped as rollers for flanging edges of plates
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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  • Mechanical Engineering (AREA)
  • Numerical Control (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)

Abstract

A flexible gradual flanging forming optimization method for a plate follow-up robot is characterized in that a flanging angle of each pass is determined according to characteristics of a target flanging part and introduced with a correction coefficient; setting the distance between the lower surface of the plate to be formed and the circle center according to the length of the roller and determining the initial position of the roller; determining the initial coordinate of the roller of each pass according to the flanging angle and the radius of the roller of each pass by taking the lower plane of the plate to be formed as a reference surface and the circle center of the plate to be formed as an original point; finally, calculating according to the equipment attributes to obtain the plate follow-up angular velocities under different forming tracks; and carrying out finite element iterative calculation based on the forming precision judgment basis, and repeatedly modifying the correction coefficient until the forming precision meets the requirement. The invention can quickly match the plate follow-up speed and the forming roller speed of the robot, can determine the initial position of the forming track of the next pass without stopping the machine, realizes the continuous flanging forming, effectively improves the forming production rhythm, leads the forming beat to be more compact, and improves the forming efficiency and the forming quality.

Description

Flexible gradual flanging forming optimization method for plate follow-up robot
Technical Field
The invention relates to a technology in the field of sheet metal manufacturing, in particular to a flexible gradual flanging forming optimization method for a sheet follow-up robot.
Background
The existing sheet metal flanging part for aerospace is flanged and formed by adopting a manual hammering mode or a robot guide roller mode, and the forming mode adopting the manual hammering mode has high noise and low forming efficiency; when the robot guide roller is adopted for flanging and forming, the flanging and forming force exerted on the plate by the forming roller is not uniform in the forming process, so that the forming quality and consistency are difficult to ensure. Therefore, a new sheet metal flanging process needs to be developed to meet the requirement of constantly accelerated production rhythm and solve the manufacturing problem of the sheet metal flanging structural member at present.
Disclosure of Invention
The invention provides a plate follow-up type robot flexible gradual flanging forming optimization method, aiming at the problems that the cooperation of a workbench and a forming roller in the existing flexible flanging forming technology is not coordinated, the machine needs to be stopped to determine the initial position of the forming track of the next pass after each pass is formed, and the production rhythm and the forming quality are influenced.
The invention is realized by the following technical scheme:
the invention relates to a flexible gradual flanging forming optimization method for a plate follow-up robot, which is characterized in that according to the characteristics of a target flanging piece and the introduction of a correction coefficient, the flanging angle of each pass is determined; setting the distance between the lower surface of the plate to be formed and the circle center according to the length of the roller and determining the initial position of the roller; determining the initial coordinate of the roller of each pass according to the flanging angle and the radius of the roller of each pass by taking the lower plane of the plate to be formed as a reference surface and the circle center of the plate to be formed as an original point; finally, calculating according to the equipment attributes to obtain the plate follow-up angular velocities under different forming tracks; and carrying out finite element iterative calculation based on the forming precision judgment basis, and repeatedly modifying the correction coefficient until the forming precision meets the requirement.
The device attributes include: the sheet metal robot has the advantages of moving speed, angle adjusting time and flexible gradual flanging workbench rotating angle.
When the simulation result does not meet the requirement, repeatedly calculating after modifying the correction coefficient of the flanging angle of each pass; and when the requirements are met, corresponding process parameters are saved for controlling execution, and the optimized flexible flanging forming is realized.
The forming track refers to a track path when the plate to be formed is turned over at different angles.
The forming precision judgment basis is that the error between the flanging opening angle and the flanging length of the flanging piece calculated by iterative calculation and the ideal flanging piece is less than 1 percent.
Technical effects
Compared with the prior art, the rapid forming track of the flanging piece with different characteristics is obtained by repeatedly modifying the correction coefficient, the initial position of the forming track of the next pass can be determined without stopping the machine, and the continuous flanging forming is realized. Compared with the traditional method that the machine needs to be stopped to determine the initial position of the forming track of the next pass after each pass of flanging forming, and the forming of qualified parts needs to take several hours, the method can quickly determine the coordination relation between the rotation speed of the flexible gradual flanging workbench and the moving speed of a robot, can determine the forming track of each pass without stopping, can realize the part forming only in tens of minutes, effectively improves the forming production rhythm, and enables the forming rhythm to be more compact.
Drawings
FIG. 1 is a flow chart of a flexible gradual flanging forming simulation method of a plate follow-up robot;
FIG. 2 is a schematic view of an initial position of the embodiment;
FIG. 3 is a dimensional view of the target turned-up member of example 1;
FIG. 4 is a dimension chart of the original plate of example 1;
FIG. 5 is a comparison graph of the opening angle of the flange when the correction coefficient k is adjusted a plurality of times in example 1;
FIG. 6 is a comparison graph of the cuff length when the correction coefficient k is adjusted a plurality of times in example 1;
FIG. 7 is a dimension chart of the objective burring of example 2;
FIG. 8 is a dimension chart of the original plate of example 2;
FIG. 9 is a comparison graph of the opening angle of the flange when the correction coefficient k is adjusted a plurality of times in example 2;
FIG. 10 is a comparison graph of the cuff length when the correction coefficient k is adjusted a plurality of times in example 2;
in the figure: 1 to-be-formed plate, 2 pressing mechanisms, 3 flexible gradual flanging workbench, 4 forming rollers, 5 embodiment 1 target flanging parts and 6 embodiment 2 target flanging parts.
Detailed Description
Example 1
Fig. 2 is a schematic view of an initial position of an original slab according to an embodiment. Fig. 3 and 4 are graphs of the target hemmer size and the original slab size of example 1, respectively. Example 1 a 5a06 aluminum alloy was used as a target turned-up member having a thickness d of 2mm, a turned-up opening angle θ of 120 °, an arc opening angle Φ of 90 °, and a sheet inner diameter R 0 1460mm, the length L of the plate material is 70mm, and the length L of the flanging is 30 mm. Therefore, the movement speed v of the flanging robot is set to be 100mm/s, and the angle adjustment time t of the robot is set to be 0 0.8s and the radius r is selected w 40mm and 50mm in length h, determining that the initial forming position of each roller is arranged at the position of axial symmetry of the plate to be formed,the rotating mechanism drives the flexible gradual flanging workbench to rotate, so that flanging forming is realized.
The specific steps of the embodiment include:
step 1) setting 6-pass flanging forming according to the flanging opening angle theta of 120 degrees, wherein angles of each pass are uniformly distributed, and a correction coefficient k is introduced, so that the initial flanging angle of each pass is as follows: β ═ k (180 ° - α)/n ═ 1 × (180 ° -120 °)/6 ═ 10 °, where k has an initial value of 1.
Step 2) in order to prevent the forming roller from interfering with a die when adjusting the angle, setting the distance H between the lower surface of the plate to be formed and the center of the circle to be 160mm according to the length H of the forming roller to be 50mm, and establishing a Cartesian coordinate system by taking the lower plane of the plate to be formed as a reference plane and the center of the circle of the plate to be formed as an origin;
step 3) based on the established Cartesian coordinate system, according to the flanging angle beta and the roller radius r of each pass w And calculating to obtain the initial coordinates of the roller in each pass as follows: the first pass X coordinate is
Figure BDA0003389195160000031
The Y coordinate being Y 1 0, Z coordinate is Z 1 -160; the X coordinate of the second pass is
Figure BDA0003389195160000032
Figure BDA0003389195160000033
The Y coordinate being Y 2 0, Z coordinate is Z 2 -160; the X coordinate of the third pass is
Figure BDA0003389195160000034
Figure BDA0003389195160000035
The Y coordinate being Y 3 0, Z coordinate is Z 3 -160; the fourth pass X coordinate is
Figure BDA0003389195160000036
Figure BDA0003389195160000037
The Y coordinate being Y 4 0, Z coordinate is Z 4 -160; the fifth pass X coordinate is
Figure BDA0003389195160000038
The Y coordinate being Y 5 0, Z coordinate is Z 5 -160; the X coordinate of the sixth pass is
Figure BDA0003389195160000039
Y coordinate is Y 6 0, Z coordinate is Z 6 ＝-160。
Step 4) because the initial forming position of the roller wheel of each pass is arranged at the axial symmetry position of the plate to be formed, the analysis can know the rotation angle of the flexible gradual flanging workbench during the adjustment of the forming roller wheel
Figure BDA00033891951600000310
Based on the obtained initial coordinates of the roller in each pass in the forming process, the robot angle adjusting time t is adjusted according to the movement speed v of the robot 0 And calculating to obtain the following angular velocity of each pass of the plate: first pass
Figure BDA00033891951600000311
Second pass
Figure BDA00033891951600000312
Figure BDA00033891951600000313
The third pass
Figure BDA00033891951600000314
Figure BDA00033891951600000315
The fourth pass
Figure BDA00033891951600000316
The fifth pass
Figure BDA00033891951600000317
Figure BDA00033891951600000318
The sixth pass
Figure BDA00033891951600000319
Figure BDA00033891951600000320
Step 5) carrying out finite element iterative calculation, and judging the calculated flanging opening angle theta of the flanging piece 1 And the length l of the flange 1 Whether the error from the ideal flanging piece is less than 1 percent or not. Wherein, turn-ups open angle error does:
Figure BDA00033891951600000321
the error of the flanging length is as follows:
Figure BDA00033891951600000322
Figure BDA00033891951600000323
step 6), when the forming precision does not meet the requirement, modifying the correction coefficient k, and recalculating the parameters, in this embodiment, when the correction coefficient k is equal to 1.09, the forming precision meets the requirement, and the iteration is ended;
and 7) storing corresponding process parameters, and executing actual flexible flanging forming.
Example 2
Fig. 2 is a schematic diagram showing an initial position of an original slab of the embodiment, and fig. 7 and 8 are graphs showing a target flanging member size and an original slab size of the embodiment 2, respectively. Example 2 the target hemming member used LY12 aluminum alloy, the thickness d of the target hemming member was 3mm, the hemming opening angle θ was 110 °, the arc opening angle Φ was 90 °, and the sheet inner diameter R 0 1070mm, the length L of the plate is 55mm, and the length L of the flanging is 25 mm. Therefore, the movement speed v of the flanging robot is set to be 120mm/s, and the angle adjustment time t of the robot is set to be 0 Is 1s, and the radius r is selected w Forming rollers with a length h of 40mm of 36mm, determining each channelThe secondary roller initial forming positions are sequentially located at two ends of a plate to be formed, and the rotating mechanism drives the flexible gradual flanging workbench to rotate, so that flanging forming is realized.
The specific steps of the embodiment include:
step 1) setting 7-pass flanging forming according to the flanging opening angle theta of 110 degrees, wherein angles of each pass are uniformly distributed, and a correction coefficient k is introduced, so that the initial flanging angle of each pass is as follows:
Figure BDA0003389195160000041
where k is initially 1.
Step 2) in order to prevent the forming roller from interfering with a die when adjusting the angle, setting the distance H between the lower surface of the sheet to be formed and the center of a circle to be 130mm according to the length H of the forming roller to be 40mm, and establishing a Cartesian coordinate system by taking the center of the circle at the end part of the forming roller as an origin and an axial plane passing through the center of the circle as a reference plane;
step 3) based on the established Cartesian coordinate system, according to the flanging angle beta and the roller radius r of each pass w And calculating to obtain the initial coordinates of the roller in each pass as follows: the first pass X coordinate is
Figure BDA0003389195160000042
Figure BDA0003389195160000043
The coordinates are
Figure BDA0003389195160000044
Z coordinate is Z 1 -130; the X coordinate of the second pass is
Figure BDA0003389195160000045
Y coordinate is
Figure BDA0003389195160000046
Z coordinate is Z 2 -130; the X coordinate of the third pass is
Figure BDA0003389195160000047
Y coordinate is
Figure BDA0003389195160000048
Figure BDA0003389195160000049
Z coordinate is Z 3 -130; the fourth pass X coordinate is
Figure BDA00033891951600000410
Y coordinate is
Figure BDA00033891951600000411
Figure BDA00033891951600000412
Z coordinate is Z 4 -130; the fifth pass X coordinate is
Figure BDA00033891951600000413
Figure BDA00033891951600000414
Y coordinate is
Figure BDA00033891951600000415
Figure BDA00033891951600000416
Z coordinate is Z 5 -130; the X coordinate of the sixth pass is
Figure BDA00033891951600000417
Figure BDA00033891951600000418
Y coordinate is
Figure BDA00033891951600000419
Figure BDA00033891951600000420
Z coordinate is Z 6 -130. The seventh pass has the X coordinate of
Figure BDA00033891951600000421
Figure BDA0003389195160000051
Y coordinate is
Figure BDA0003389195160000052
Figure BDA0003389195160000053
Z coordinate is Z 7 ＝-130。
Step 4) because the initial forming position of the roller wheel of each pass is arranged at the axial symmetry position of the plate to be formed, the analysis can know the rotation angle of the flexible gradual flanging workbench during the adjustment of the forming roller wheel
Figure BDA0003389195160000054
Based on the obtained initial coordinates of the roller in each pass in the forming process, the robot angle adjusting time t is adjusted according to the movement speed v of the robot 0 And calculating to obtain the following angular velocity of each pass of the plate: first pass
Figure BDA0003389195160000055
Second pass
Figure BDA0003389195160000056
Figure BDA0003389195160000057
The third pass
Figure BDA0003389195160000058
Figure BDA0003389195160000059
The fourth pass
Figure BDA00033891951600000510
The fifth pass
Figure BDA00033891951600000511
Figure BDA00033891951600000512
The sixth pass
Figure BDA00033891951600000513
Figure BDA00033891951600000514
The seventh pass
Figure BDA00033891951600000515
And 5) carrying out finite element iterative calculation, and judging whether the error between the calculated flanging opening angle and the flanging length of the flanging piece and the error between the ideal flanging piece are less than 1%. Wherein, turn-ups open angle error does:
Figure BDA00033891951600000516
the error of the flanging length is as follows:
Figure BDA00033891951600000517
Figure BDA00033891951600000518
step 6), when the forming precision does not meet the requirement, modifying the correction coefficient k, and recalculating the parameters, in this embodiment, when the correction coefficient k is 1.08, the forming precision meets the requirement, and the iteration is ended;
and 7) storing corresponding process parameters, and executing actual flexible flanging forming.
Through specific experiments, the initial position of the forming track of the next pass can be determined without stopping, and the flanging part formed by the forming track obtained by the method of the embodiment has the flanging opening angle and the flanging length which have errors smaller than 1% with the ideal flanging part, the deviation between the actual profile and the theoretical profile of the flanging part is smaller than or equal to 0.5mm/m, the surface is flat, and the obvious defects of collapse and the like are avoided.
Compared with the prior art that the initial position of the forming track of the next pass is determined by stopping the machine after each pass of forming of the flanging, and the forming of qualified parts takes 10 hours, the initial position of the forming track of the next pass can be determined without stopping the machine after the parameters are calculated by adjusting the correction coefficient k according to the resilience amount of the parts, so that the time required by forming the parts is only 0.3 hour under the condition of realizing continuous flanging, and the forming efficiency is greatly improved; compared with the prior art, the embodiment can design different forming tracks aiming at different parts, and the parts have smooth surfaces and no obvious defects such as collapse.
The foregoing embodiments may be modified in many different ways by those skilled in the art without departing from the spirit and scope of the invention, which is defined by the appended claims and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

Claims (1)

1. A flexible gradual flanging forming optimization method for a plate follow-up robot is characterized in that a flanging angle of each pass is determined according to the characteristics of a target flanging piece and by introducing a correction coefficient; setting the distance between the lower surface of the plate to be formed and the circle center of the roller according to the length of the roller and determining the initial position of the roller; determining the initial coordinate of each roller in each pass according to the flanging angle and the radius of the roller in each pass by taking the lower surface of the plate to be formed as a reference surface and the circle center of the plate to be formed as an original point; finally, calculating according to the equipment attributes to obtain the plate follow-up angular velocities under different forming tracks; based on the forming precision judgment basis, carrying out finite element iterative calculation, and repeatedly modifying the correction coefficient until the forming precision meets the requirement;
the device attributes include: the sheet metal robot has the advantages that the movement speed, the angle adjusting time and the rotation angle of the flexible gradual flanging workbench are increased;
the forming track refers to a track path when the plate to be formed is turned over at different angles;
the plate follow-up robot flexible gradual flanging forming optimization method specifically comprises the following steps:
step 1) setting n times of flanging forming according to the flanging opening angle, uniformly distributing the angle of each time, introducing a correction coefficient k, and setting the flanging angle beta of each time to be k (180-theta)/n at the beginning, wherein: theta is a flanging opening angle, beta is a flanging angle of each pass, n is the total track number, n is a value range of 6 or 7, and an initial value of k is 1;
step 2) establishing a Cartesian coordinate system by taking the lower surface of the plate to be formed as a reference surface and the circle center of the plate to be formed as an original point;
step 3) based on the established Cartesian coordinate system, according to the flanging angle beta and the roller radius r of each pass w And calculating to obtain the initial coordinates of the roller in each pass as follows: the X coordinate of the mth pass is
Figure FDA0003707506010000011
Figure FDA0003707506010000012
Wherein: r 0 Is the inner diameter of the plate, L is the length of the plate, L is the length of the flanging, r w To shape the roller radius;
step 4) because the initial forming position of the roller wheel of each pass is arranged at the axial symmetry position of the plate to be formed, the analysis can know the rotation angle of the flexible gradual flanging workbench during the adjustment of the forming roller wheel
Figure FDA0003707506010000013
Based on the obtained initial coordinates of the roller in each pass in the forming process, the robot angle adjusting time t is adjusted according to the movement speed v of the robot 0 And calculating the following angular speed of each pass of the plate according to the distance H between the lower surface of the plate to be formed and the circle center of the forming roller:
first pass
Figure FDA0003707506010000014
The m th pass
Figure FDA0003707506010000015
Figure FDA0003707506010000016
Wherein: n is more than or equal to m and more than or equal to 2;
step 5) finite element iterative computation and judgment are carried outCutting off the calculated opening angle theta of the flange 1 And the length l of the flange 1 Whether the error with an ideal flanging piece is less than 1 percent or not; wherein, turn-ups open angle error does:
Figure FDA0003707506010000017
the error of the flanging length is as follows:
Figure FDA0003707506010000018
Figure FDA0003707506010000019
step 6), when the forming precision does not meet the requirement, modifying the correction coefficient k, recalculating the parameters until the forming precision meets the requirement, and ending the iteration;
and 7) storing corresponding process parameters, and executing actual flexible flanging forming.
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DE102005004602A1 (en) * 2005-02-01 2006-08-10 Bayerische Motoren Werke Ag Device for edging the edge of a sheet component useful for edging automobile sheet components has rolling device with two rollers with space between them
EP2647448B1 (en) * 2010-11-29 2019-06-19 Toyota Jidosha Kabushiki Kaisha Roller hemming device
DE102016211571A1 (en) * 2016-06-28 2017-12-28 Audi Ag Rollfalzvorrichtung and method for folding an edge portion of a sheet metal part
WO2020243191A1 (en) * 2019-05-31 2020-12-03 Milwaukee Electric Toll Corporation Tubing expansion tools and systems and methods for leak detection
CN113714362B (en) * 2021-09-02 2022-08-09 上海交通大学 Multi-pass rolling type plate flexible flanging forming method
CN113714361B (en) * 2021-09-02 2022-09-30 上海交通大学 Flexible gradual flanging forming method based on robot
CN113714359B (en) * 2021-09-02 2022-07-22 上海交通大学 Multi-pass robot flexible flanging full-mold forming method

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