氮气弹簧快换机构设计

介绍了一种氮气弹簧快换机构,阐述了机构的结构特点及动作原理,可实现弹簧快换及自动锁死功能,有效降低了模具的风险系数,提升了模具品质。     

大型锻造压机模座紧固及快换机构的研制

大型锻造压机的模座体积大、重量大,难以锁紧及更换,传统的方法是人工操作插销式锁紧,不仅劳动强度大,而且锁紧不可靠。针对这种情况,结合我单位多年来锻压方面的研发优势,研制开发了一种模座紧固及快换机构。该机构结构简单,操作方便,自动化程度高,大大减轻了操作工人的劳动强度。     

一种全自动模板快换装置的设计方案及应用

公开了一种全自动模板快换装置,包括紧靠造型机一侧安装的模板输送机构和安装于模板输送机构上方的快换机构.采用自动换模以及智能人机交互的设计理念,具有结构紧凑、空间利用率高、效率高、生产成本低等特点.     

汽车顶盖天窗成形快换模设计

通过对汽车顶盖零件特点分析,设计了顶盖天窗成形快换模,根据生产需要,模具可成形有天窗的汽车顶盖和无天窗的汽车顶盖2种制件,着重介绍了模具快换结构的工作过程与设计制造要点。该快换结构功能可靠,降低了模具制造成本,可为类似零件的模具设计提供参考。     

快换模芯转子压铸模设计

通过对转子铸件的分析,设计了一种快换模芯式模具结构。模具成型零件可快速更换,并采用液压缸压斜楔锁紧模芯机构实现转子的系列化生产,达到了降低成本,提高效率,改善性能的目的。     

快换凸模在汽车冲孔模中的应用

简述了快换凸模的作用,介绍了汽车冲孔模用到的3种快换凸模的结构、特点及其使用场合。对模具设计人员合理应用快换凸模有借鉴作用。     

结晶器浸入式水口快换装置在连铸生产中的应用

浇注铁素体不锈钢板坯时，对浸入式水口的渣线和侧孔的侵蚀非常大。如果采用结晶器浸人式水口快换装置，可以提高生产效率及经济效益。     

大直缝埋弧焊管生产中对中机构在钢管举升中的应用

通过对传统的钢管升降旋转辊的分析,提出了一种利用对中机构完成钢管升降的改型结构设计应用,实现钢管从输送辊到旋转辊的换道.     

卡车车架纵梁滚压成形线浅析

由于用户需求的多样化,卡车车架尤其是车架纵梁表现为多品种、小批量生产特点。为实现卡车车架纵梁制造的高效率、高精度,卡车车架U形等截面纵梁采用滚压制造工艺。本文通过对滚压工艺可加工零件形状、设备结构形式、产品转换时设备调整方便性、生产效率、加工产品的质量保证等方面进行对比分析,结合卡车车架纵梁的形状特点,总结各种滚压设备结构的优点和不足,合理选择卡车车架纵梁滚压成形设备。     

轮辋滚型工艺研究

轮辋流通型工艺分二道滚型及三道滚型，二道滚型轮辋圆角减薄量接近20％，三道滚型轮辋圆角减薄量在8%-10%，轮辋圆角减薄量研究对于减轻车轮重量，实现车轮轻量化具有重要意义。     

滚压成形工艺设计及应用

讨论了滚压成形工艺的设计要点。通过一个具体实例，分析了滚压成形工艺的设计方法。     

无内胎车轮轮辋滚形时的变形分析

无内胎车轮对轮辋尺寸精度和圆角减薄量要求较高，其质量好坏取决于轮辋生产设备的精度及模具设计的合理性，轮辋滚形模具设计的关键在于保证尺寸精度的同时控制各圆角减薄量。按照本文给出的各道滚形变形量确定方法设计的模具，不仅生产出的轮辋尺寸精度高，圆角减薄量小，而且对各种型号的车轮通用性好，具有较大的现实意义。     

无内胎车轮轮辋滚形工艺

介绍了无内胎车轮轮辋的成形工艺,在此基础上设计了轮辋滚形加工模具。     

Prediction and inline compensation of springback in roll forming of high and ultra-high strength steels

With the rising interest in lightweight construction, the usage of high and ultra-high strength steels has increased remarkably during the last years. Unfortunately, these steel grades show more springback than mild steels do, which leads in consequence to lower dimensional accuracy. To improve the bended part’s geometry considerable trial-and-error work is necessary since the influence of different bending-parameters (e.g. the bending radius, sheet thickness, yield strength, Young’s modulus, the material’s strain hardening coefficient, …) on the amount of springback is still unknown. The aim of the paper at hand is therefore the investigation of springback for different parameter combinations. Furthermore, an online calibration system for occurring springback during roll forming is presented to compensate springback independent of material or process parameters.     

Study on the continuous roll forming process of swept surface sheet metal part

Continuous roll forming (CRF) is an effective process to manufacture swept surface parts of sheet metal. The forming tool in CRF is a pair of small-diameter bendable forming rolls, a swept surface is formed continuously after the rotating rolls sweep out the whole sheet metal blank. The two bent rolls and the non-uniformly distributed roll gap along the rolls’ length make the sheet metal bent in longitudinal and transverse directions simultaneously, the cross-section curve of the formed swept surface is controlled by the curved profile of the forming rolls and the spine curve is controlled by the differential elongations of sheet metal generated by roll gap. In this paper, a necessary condition for the formation of a swept surface is proposed and analyzed, the parametric equations of the formed surface in CRF are derived and the method to determine the roll gap for forming a given swept surface is presented. The numerical simulations and analyses on the CRF processes demonstrate the validity of the presented theoretical models. The experimental and measured results show that the formed surfaces are in good agreement with the desired surfaces, and swept surface parts with good forming precision can be obtained by CRF process.     

Investigation of a new incremental counter forming in flexible roll forming to manufacture accurate profiles with variable cross-sections

A roll-formed profile with variable cross-sections fabricated by flexible roll forming has a shape error, such as warping, because of geometrical deviations in transitional zones of the profile between the initial metal strip and the roll-formed profile. To reduce the shape error, a new process called incremental counter forming (ICF) is proposed. Our investigation of the ICF process shows that the longitudinal strain distribution at the flange of the roll-formed profile can be controlled by combinations of forming parameters of the ICF process. As the forming parameters increase the longitudinal strain distribution in the concave zone, the shape error decreases. However, when the longitudinal strain distribution in the straight zone reaches a critical limit, the additional longitudinal strain works as an excessive longitudinal strain to worsen the shape error. An analytical model, which describes the longitudinal strain at the flange during roll forming, is adopted to reveal that the increase of the longitudinal strain is induced by increasing derivatives of a bending angle, which is controlled by the forming parameters of the ICF process. Finally, the FE simulation has been carried out to compare with the experimental results, which show that the ICF process is effective for reducing the shape error of the profile with variable cross-sections in flexible roll forming.     

双直立锁边板的辊弯成形数值模拟与工艺研究

本文利用有限元软件ABAQUS对双直立锁边板的辊弯成形过程进行数值模拟,并对成形结果进行了分析,得到了成形后锁边板的等效应力分布情况,而后又对边部纵向应变、弯角处厚度、沿宽度方向横向应变等进行了深入分析,得到了锁边板成形过程中的规律,并通过将横向应变最大值与理论值对比验证了模型的有效性.最后通过正交试验研究了板厚、道次间距、下辊半径、成形速度对锁边板回弹的影响规律,结果显示板厚对锁边板回弹的敏感性较大且不易受到其他因素的干扰,其他三个因素对回弹的影响相对要小一些,为进一步对锁边板工艺参数的优化提供了依据.     

Three-dimensional sheet metal continuous forming process based on flexible roll bending: Principle and experiments

To effectively manufacture three-dimensional sheet metal parts with various curvatures produced in small batch quantities, continuous sheet metal forming, a new flexible forming technology is being developed. This process employs an upper flexible roll and two lower flexible rolls as a forming tool, and the shape of a flexible roll can be changed in vertical direction. With the rotation of flexible rolls, the sheet metal is bent in longitudinal and transverse directions simultaneously and is formed continuously. In the present study, the three-dimensional surface of formed part is described by sweep surface based on the characteristic of the forming process and the arc-length parametric equation for describing continuous forming part is developed. The three-roll bending deformation of sheet metal in longitudinal direction is analyzed and the longitudinal curvature equation of the formed part is derived. The shape of flexible roll axis controlled at a number of points is represented by the cubic spline curve and the transverse curvature of the formed part after springback is then calculated piecewise. Typically experiments for forming concave shape surface and saddle-type surface have been performed, the experiment results are measured and analyzed by a binocular stereo vision measurement system, it is demonstrated that the formed surfaces are in good agreement with the desired shapes and the presented equations are useful for the continuous forming process design.