Background
Most parts on the aeroengine work in a high-temperature and high-pressure environment, so that the requirements on the strength and the rigidity of the parts are higher, the thinning rate and the appearance quality control of sheet metal part parts are more strict, and the specific technical requirements are directly given when the parts are designed. For sheet metal parts with thin wall thickness and complex structure on aero-engines, the round angle of part structures is small due to the limitation of structures and spaces, the molding difficulty is high, and the wall thickness is more difficult to ensure.
In the traditional sheet metal forming method, a hole flanging process is largely used for parts with higher inner hole heights, the hole flanging process is simpler, but the hole opening is extremely easy to crack, the rejection rate is high, the thinning rate is high, the highest thinning rate is up to 50% according to some forming simulation results, the highest thinning rate in field processing actual measurement is up to 45%, and the hole flanging position has obvious turnover steps.
Fig. 7 and 8 of the specification show a conventional sheet metal forming process flow, specifically:
firstly, deep drawing a middle circular convex hull, and simultaneously bending and forming an outer ring structure;
secondly, reversely drawing to form an inner ring structure and a part of height;
thirdly, cutting a hole in the center;
fourth, the inner hole is formed by flanging.
In the above process method, the round angle of the outer ring is small in the first step, the material is difficult to flow in, the center is a concave large round angle, the thinning is serious, according to the simulation analysis, as shown in fig. 5, the thinning rate of the center after the first step molding is 23%, the height of the inner hole is molded in the second step, because the middle part of the part is bent, the round angle is small, the thinning of the inner ring structure of the part is aggravated, the cylindrical straight-wall part is most serious in the round angle, the round angle in the second step is in the effective area of the part after the hole is turned over in the fourth step, and according to the on-site processing condition, the deep step is left in the inner hole after the round angle is turned over, and the round angle is difficult to eliminate.
The inner hole of the sheet metal part is required to be brazed with a corresponding part, the gap between the inner hole and the corresponding part needs to be controlled between 0.02 mm and 0.08mm, the requirements on the surface quality and the perpendicularity of the inner hole are extremely high, the control on the thinning rate after forming is very strict, and the requirement cannot be met by adopting a traditional forming mode.
The patent with publication number CN114160700A discloses an integral forming method and a forming die for an annular lip of an aeroengine, the drawing forming difficulty of the inner side wall of the annular lip can be reduced by reducing the depth of the inner side wall of the annular lip, and meanwhile, the material deformation is close to an equivalent double-drawing bulging state through a circular bottom supplementing surface. The deformation of the inner side wall and the complementary surface can be increased under the action of larger forming force, the deformation is uniform, the thinning rate is low, and the inflow of flange edge materials is reduced. The annular lip is also a thin-walled piece, but the forming process is just like the traditional sheet metal forming process, namely, the annular side wall and the annular groove are firstly drawn downwards reversely, and then the circular bottom is drawn reversely. Obviously, the effect of low thinning rate achieved by the technical scheme is limited.
The patent publication No. CN112170648B discloses a double-layer cylindrical part forward and reverse drawing forming die and method. The die adopts a male die with smaller diameter to carry out forward drawing to form an inner circle, then adopts a convex ring with larger inner diameter to carry out reverse drawing to form an outer circle, and the male die and the back pressure punch descend along with the convex ring when carrying out reverse drawing to form the outer circle. In the deep drawing process, the thickness of the plate wrapping the male die part is basically kept unchanged under the action of the back pressure punch and the inward and outward pressure of the inner cavity of the male die, so that the thinning of the plate is effectively restrained, and the wrinkling of the plate is avoided. However, the fillet in the patent is formed by adopting a convex ring to press downwards, and when the convex mold ascends to punch the plate, stress concentration is easily generated at the fillet to break.
Disclosure of Invention
The application aims to overcome the defects of the prior art and provide a low-thinning-rate reverse drawing forming method for a sheet metal part, which is particularly suitable for small-fillet and deep drawing bending composite forming sheet metal parts.
The aim of the application is achieved by the following technical scheme:
a sheet metal part low reduction rate reverse drawing forming method, the forming method comprising the following steps:
s1, deep drawing a sheet metal part plate to form a first cylinder part, wherein the first cylinder part is used as a sheet metal part outer ring, a first round corner and a flange edge are arranged at an opening of the first cylinder part, and the final process allowance is ensured by the deep drawing height of the deep drawing first cylinder part;
s2, removing the first round corner and the flange edge in the step S1;
s3, reversely drawing the cylinder bottom of the first cylinder part in the S1 to form a second cylinder part, wherein a first transition surface is formed between the second cylinder part and the cylinder bottom of the first cylinder part;
s4, reversely drawing the whole second cylinder part in the S3 to form a third cylinder part, wherein a second transition surface is formed between the third cylinder part and the cylinder bottom of the first cylinder part.
Further, in the step S3, the first transition surface is a round angle surface, and the radius of the round angle surface is 8-10 times of the thickness of the sheet metal part.
Further, in the step S1, the radius of the first round angle is 5-8 times of the thickness of the sheet metal part.
Further, a limiting block and a positioning ring are further arranged in a die adopted by the S3 step of reverse drawing, the positioning ring is arranged on a lower die of the die, the limiting block is arranged on an upper die of the die, the positioning ring is provided with a bent inner wall, the bent inner wall is attached to the outer surfaces of the cylinder bottom and the cylinder wall of the first cylinder part, and the limiting block is contacted with the positioning ring when the upper die and the lower die are clamped so as to ensure a clamping gap.
Further, the die closing gap meets the gap with the thickness of 1 to 1.1 times of the material thickness.
Further, a guide post is arranged on the positioning ring.
Further, the first transition surface is an inclined surface, and the first transition surface and the second transition surface are consistent in angle.
Still further, the first transition surface length is less than the second transition surface length, and the second barrel diameter is greater than the third barrel diameter.
Further, the length of the reverse drawing profile cross-section line in the step S4 is larger than that in the step S3.
Further, the corner of the bottom of the third barrel part is composed of a second round corner, a third round corner and a slope inclined plane connected with the second round corner and the third round corner, the third round corner is connected with the bottom of the third barrel part, the second round corner is connected with the side wall of the third barrel part, and the radius of the third round corner is larger than that of the second round corner.
Compared with the prior art, the application has the following beneficial effects:
the forming method comprises the steps of carrying out repeated reverse drawing on the plate, cutting off the most thinned round corners at the opening of the first cylinder part after the first drawing, and ensuring that the material at the straight wall is easier to flow in, wherein the first cylinder part is not thinned; the first transition surface between the second cylinder part and the first cylinder part is a large round angle or a large inclined surface during the second drawing, the forming of the first transition surface depends on the material thinning at the center of the second cylinder part and the material inflow supplement at the outer ring straight wall of the first cylinder part, and the limiting block and the positioning ring are arranged for limiting, so that the inflow of the outer ring straight wall material can be accelerated, and the thinning rate of the second cylinder part is effectively controlled; the third reverse drawing converts the second cylinder part into a third cylinder part and a second transition surface, and the thinning mainly occurs at the bottom fillet of the third cylinder part, so that the effective profile thinning rate of the part is not affected; the length drawing is performed by the third reverse drawing, so that the bent parts of the third barrel part cannot be piled up, and the profile quality of the part is ensured;
through practical processing, the thinning rate of the part can be reduced from 45% to 20%, the final wall thickness of the molding can be well ensured, and the molding qualification rate and the surface quality are greatly improved.
Detailed Description
In order to clearly illustrate the technical characteristics of the present solution, the following detailed description will explain the present solution by means of specific embodiments and with reference to the accompanying drawings.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application, however, the present application may be practiced in other ways than those described herein, and therefore the scope of the present application is not limited to the specific embodiments disclosed below.
In addition, in the description of the present application, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc. indicate orientations or positional relationships based on the drawings, are merely for convenience in describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present application. Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature. In the description of the present application, the meaning of "a plurality" is two or more, unless explicitly defined otherwise.
In the present application, unless explicitly specified and limited otherwise, the terms "mounted," "connected," "secured," and the like are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally formed; the device can be mechanically connected, electrically connected and communicated; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the above terms in the present application can be understood by those of ordinary skill in the art according to the specific circumstances.
In the present application, unless expressly stated or limited otherwise, a first feature "up" or "down" a second feature may be the first and second features in direct contact, or the first and second features in indirect contact via an intervening medium. In the description of the present specification, a description referring to terms "one embodiment," "some embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present application. In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
Example 1
The low reduction rate reverse drawing forming method of the rear sealing ring of the secondary guide on the aeroengine is provided, the sheet material for forming the part is high-temperature alloy GH3536, the thickness of the sheet material is 0.8mm, as shown in fig. 1, the finally formed part is provided with an inner hole 1, the wall thickness design requirement is not less than 0.6, the reduction rate is higher by adopting the traditional drawing process, steps are generated at the inner hole, and the appearance of the part is poor.
As shown in fig. 2 and 3, the molding method of the present embodiment includes the following steps:
s1, deep drawing a plate material to form a first cylinder part 21, wherein the first cylinder part 21 is used as a part outer ring, a first round corner 22 and a flange edge 23 are arranged at an opening of the first cylinder part, and the radius of the first round corner 22 is 5-8 times of the thickness of a sheet metal part; the corner of the bottom of the first barrel part 21 is a second round corner 24, the second round corner 24 is formed by drawing in the step, so that materials can flow more easily in the drawing process, and according to simulation results, the thinning is at most 4% at the second round corner 24 during drawing, and the rest parts are not thinned; wherein the stretching height of the first barrel 21 is proper, and the final process is ensured to have a margin;
s2, removing the first round corners 22 and the flange edges 23 formed in the S1, wherein the left straight wall materials are easier to flow in the subsequent drawing process;
s3, as shown in FIG. 4, performing reverse drawing (reverse drawing is opposite to the previous drawing direction) on the bottom of the first barrel portion 21 in S1 to form a second barrel portion 31, wherein the reverse drawing forms a first transition surface 32 between the second barrel portion 31 and the bottom of the first barrel portion 21; in the process of forming the second barrel 31, the material is mainly thinned by the material at the center and the material at the straight wall of the outer ring flows into and is supplemented, and according to the simulation result of the process step, the thinning rate of the thinnest part of the material is 16%.
S4, as shown in FIG. 5, the whole second cylinder 31 in S3 is subjected to reverse drawing again (the drawing direction is opposite to that in S3) to form a third cylinder 41, the inner hole profile of the part is formed, and a second transition surface 42 is formed between the third cylinder 41 and the bottom of the first cylinder 21. And then shaping the second round angle 24, wherein the shaping process does not increase the thinning of materials, and turning and removing the bottom of the third cylinder 41 including the corner together to form the part inner hole 1.
In the step S4, when the inner hole profile is formed, the cylinder bottom of the third cylinder part 41 can be added with a small-gradient inclined plane 43 so as to reduce the drawing height; specifically, the corner of the bottom of the third barrel part is composed of a second round corner 44, a third round corner 45 and the small-gradient inclined plane 43, the small-gradient inclined plane connects the two round corners, wherein the third round corner 45 is connected with the bottom of the third barrel part, the second round corner 44 is connected with the side wall of the third barrel part, and the radius of the third round corner 45 is larger than that of the second round corner 44, so that the effect of guiding the large round corner of the bottom of the third barrel part can be realized, and the drawing height can be reduced; the small slope of the slope is designed to be 10 ° in this embodiment.
In the step S3 of the forming method, in order to accelerate the inflow of the straight wall material of the outer ring and control the thinning as much as possible, a limit can be added in the forming mold in the step, so that the forming mold has a certain mold clamping gap. As shown in fig. 4, the molding die 51 for molding the second cylindrical portion 31 is provided on the lower die of the die, a positioning ring 52 is provided around the outer periphery of the die 51, the positioning ring 52 has a bent inner wall 521, the bent inner wall 521 is attached to the outer surface of the cylindrical bottom and cylindrical wall of the first cylindrical portion 21, the upper die of the die is provided with a stopper 53 which can be contacted with the upper surface of the positioning ring 52 when the die is clamped, and the clamping gap of the die is kept at 1 to 1.1 times the thickness gap when the stopper 53 and the positioning ring 52 are in a clamped state.
Since the positioning ring 52 is jacked up in the early stage of the step S3 to put in the part, the positioning ring 52 is required to be guided to ensure that the inner and outer structures of the part are concentric, specifically, the lower die base 54 is fixedly provided with the guide post 55, and the positioning ring 52 is provided with the through hole for the guide post 55 to penetrate through, so that no offset occurs in the jacking and resetting processes of the positioning ring 52.
In the embodiment S3, the first transition surface 32 is an inclined surface, the angles of the first transition surface 32 and the second transition surface 42 are consistent, i.e. the forming angle of the first transition surface 32 is consistent with the final forming angle of the part, but the length of the first transition surface 32 needs to be smaller than the length of the second transition surface 42, the diameter of the second barrel 31 needs to be larger than the diameter of the third barrel 41, and a space is left for reversely deep drawing the third barrel.
The length of the section line of the reverse drawing profile in the step S4 is required to be larger than that of the section line of the reverse drawing profile in the step S3, and the step of thinning mainly occurs at the corner 43 of the bottom of the third barrel portion, and the corner is finally turned and removed, so that the effective profile thinning rate is not affected. The length drawing in the step S4 can avoid the stacking phenomenon between the second transition surface 42 of the part and the wall of the third barrel portion 41 as shown in fig. 6, thereby avoiding the problem of out-of-tolerance of the profile of the part.
It should be noted that: the parts are lubricated on both sides during the forming process, such as castor oil, to increase lubrication.
The process of S3 molding using the mold shown in fig. 4 is as follows: after the mold is clamped, the mold is opened, the first ejector rod 56 pushes the positioning ring 52 up to the level of the part supporting surface and the upper surface of the die 51, the part A is placed in the positioning ring 52, the upper mold block 57 is pressed down, the limiting block 53 and the positioning ring 52 are blocked, the part is pressed and kept in a gap, the upper mold is continuously pressed down, the die contacts the material at the center of the part, the molded surface is pulled upwards, the bottom of the positioning ring 52 is blocked, and the molding is finished.
The process of S4 molding using the mold shown in fig. 5 is as follows: after the die is clamped, the die is opened, the second ejector rod 61 pushes the second positioning ring 62 up until the surface of the part is not interfered with the punch block 63, the part is placed on the second positioning ring 62, the first upper die pressing block 64 and the second upper die pressing block 65 are pressed down, the first upper die pressing block 64 is pressed down with the second positioning ring 62, the second round angle 24 is shaped, the second upper die pressing block 65 is lower than the first upper die pressing block 64 under the action of a spring, the first upper die pressing block 64 and the second upper die pressing block 65 are continuously pressed down, the punch block 63 contacts the material at the center of the part, the third cylinder part 41 is drawn upwards, the second upper die pressing block 65 extends out and keeps contact with the material all the time, no wrinkling is stacked between the second transition surface 42 and the cylinder wall of the third cylinder part 41, the bottom of the second positioning ring 62 is blocked, and the forming is finished.
The forming method of the embodiment is used for forming the part, the highest thinning rate is 17% in forming simulation, the highest thinning rate is 20% in field processing actual measurement, the surface quality of an inner hole of the part is good, the thinning rate of an effective area of the part is within 15%, the wall thickness is 0.68, the wall thickness meets the requirements of a design drawing, and the surface quality of the part is remarkably improved.
Example 2
This embodiment differs from embodiment 1 in that: and S3, the first transition surface is a round angle surface, and the radius of the round angle surface is designed to be 8-10 times of the thickness of the sheet metal part.
Example 3
This embodiment differs from embodiment 1 in that: and S4, when the inner hole molded surface is molded, designing a small-gradient inclined plane at the corner of the bottom of the third cylinder part to be 20 degrees.
Example 4
This embodiment differs from embodiment 1 in that: and S4, when the inner hole molded surface is molded, designing a small-gradient inclined plane at the corner of the bottom of the third cylinder part to be 30 degrees.
It is apparent that the above examples are only examples for clearly illustrating the technical solution of the present application, and are not limiting of the embodiments of the present application. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. Any modification, equivalent replacement, improvement, etc. which come within the spirit and principles of the application are desired to be protected by the following claims.