CN113607632A - A test device that is used for welding board hydroforming performance and shaping law - Google Patents
A test device that is used for welding board hydroforming performance and shaping law Download PDFInfo
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- CN113607632A CN113607632A CN202110738732.0A CN202110738732A CN113607632A CN 113607632 A CN113607632 A CN 113607632A CN 202110738732 A CN202110738732 A CN 202110738732A CN 113607632 A CN113607632 A CN 113607632A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N19/00—Investigating materials by mechanical methods
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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
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/021—Deforming sheet bodies
- B21D26/025—Means for controlling the clamping or opening of the moulds
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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
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/021—Deforming sheet bodies
- B21D26/027—Means for controlling fluid parameters, e.g. pressure or temperature
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Abstract
本发明涉及一种用于拼焊板充液成形性能及成形规律的试验装置，属于拼焊板特种成形工艺技术领域。本发明装置采用分块压边圈设计，每块压边圈上配置一个液压缸，每个液压缸分别给压边圈施加压边力，控制压边力大小，每个分块压边圈的压边力独立控制和调整，可灵活控制焊缝两侧板料上的压边力大小，同时满足不同尺寸的拼焊板的压紧要求，既控制焊缝移动，又防止起皱，通过变化压边力能够满足不同压边力对成形规律影响的研究，同时，利用试验装置，分别调节左侧的主动径向液压力和左侧的主动径向液压力的大小，固定某一侧主动径向液压力，变换另一侧主动径向液压力的大小，能够获得不同主动径向液压力对拼焊板成形性能和成形规律的影响。
The invention relates to a test device for the liquid-filled forming performance and forming law of tailor-welded blanks, and belongs to the technical field of tailor-welded blank special forming technology. The device of the invention adopts the design of the segmented blank holder, and each segment is equipped with a hydraulic cylinder. The blank holder force is independently controlled and adjusted, which can flexibly control the blank holder force on the sheets on both sides of the weld, and at the same time meet the pressing requirements of tailor-welded blanks of different sizes, which not only controls the movement of the weld, but also prevents wrinkling. The blank holder force can satisfy the research on the influence of different blank holder forces on the forming law. At the same time, the active radial hydraulic pressure on the left side and the active radial hydraulic pressure on the left side are adjusted respectively by using the test device, and the active radial pressure on one side is fixed. To hydraulic pressure, changing the magnitude of the active radial hydraulic pressure on the other side can obtain the influence of different active radial hydraulic pressure on the forming performance and forming law of tailor-welded blanks.
Description
Technical Field
The invention relates to a testing device for hydro-forming performance and forming rule of a tailor-welded blank, belonging to the technical field of special forming process of tailor-welded blanks.
Background
With the further development of science and technology and the continuous progress of society, the structural lightweight plays an increasingly important role in improving the resource utilization rate, reducing energy consumption and improving the service performance of parts, and becomes one of the development trends of the current manufacturing industry, and two approaches, namely materials and structures, are mainly used for realizing the structural lightweight. The structural approach means that a variable-thickness plate or a variable-section equal-strength member is adopted to replace an equal-thickness plate and an equal-section member, so that the material can be saved, the weight can be reduced, and the strength and the rigidity of the material can be fully utilized, for example, a tailor-welded plate technology is adopted. The tailor-welded blank is a technical method for connecting two or more plates with different thicknesses, properties or surface coatings by welding technology and then forming. The split welding plate can fully play the role of materials, greatly reduces resource waste and becomes one of important ways of structure lightweight.
The butt-welded plate hydro-forming technology is the comprehensive application of the butt-welded plate forming technology and the hydro-forming technology, has the double advantages of the two advanced forming technologies, can greatly improve the forming performance, inherits the characteristic of hydro-forming flexibility, forms precise, complex and variable-thickness and hollow variable-section structural parts, is an important means for realizing light-weight forming of parts at present and in the future, meets the trend of social development, and has great significance for the research of the parts.
At present, the traditional stamping forming research of the tailor-welded blank is more at home and abroad, the research on the hydro-forming technology of the tailor-welded blank is less, and the forming rule and the deformation mechanism of the tailor-welded blank are different in different test methods. The mechanical property of the tailor-welded blank is not consistent with the required deformation condition, so that the tailor-welded blank is easy to deform unevenly to generate large-amplitude weld movement, and is easy to break to cause product rejection in the forming process, so that the hydro-forming property and the forming rule of the tailor-welded blank need to be further researched, the plastic deformation characteristic of hydro-forming of the tailor-welded blank is known, the hydro-forming rule and the deformation mechanism of the tailor-welded blank are mastered, the core problem of the technology is discussed, and a foundation is laid for guiding and controlling the application of hydro-forming of the tailor-welded blank.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the invention overcomes the defects of the prior art, discloses a test device for researching the hydro-forming performance and the forming rule of a tailor-welded blank, provides a test device and a test method for the hydro-forming performance and the forming rule of the tailor-welded blank, which are simple to operate and easy to realize, and can obtain the hydro-forming performance and the forming rule of the tailor-welded blank by utilizing the test device and the test method.
In order to achieve the purpose, the invention adopts the following technical scheme:
a testing device for hydro-forming performance and forming rule of a tailor-welded blank comprises a base, a glass plate, an O-shaped rubber sealing ring D, a cushion block, a concave die sleeve, an O-shaped rubber sealing ring A, an independent hydraulic system source III, an O-shaped rubber sealing ring B, a cushion plate, a left blank holder, a hydraulic cylinder III, an O-shaped rubber sealing ring C, a baffle, a hydraulic cylinder II, a hydraulic cylinder I, a right blank holder, an independent hydraulic system source I, an independent hydraulic system source II, a vacuum pump system and a forming rule measuring system;
a sealing groove is formed above the base and used for placing an O-shaped rubber sealing ring D, and the glass plate and the cushion block are sealed on the base;
the right side surface of the cushion block is provided with a vacuum pump system interface combined with a vacuum pump system and a liquid outlet channel of high-pressure liquid;
a sealing groove is formed above the cushion block and used for placing an O-shaped rubber sealing ring A, and the concave die sleeve is sealed on the cushion block;
a liquid filling interface combined with the independent hydraulic system source III and a liquid inlet channel of high-pressure liquid are formed in the left side of the female die sleeve, active radial high-pressure liquid generated by the independent hydraulic system source III enters a liquid filling chamber on the left side of the tailor-welded blank through the liquid inlet channel, and active radial pressure of the liquid is applied to the periphery of the left side of the tailor-welded blank;
a liquid filling interface combined with the independent hydraulic system source II and a liquid inlet channel of high-pressure liquid are formed in the right side of the female die sleeve, active radial high-pressure liquid generated by the independent hydraulic system source II enters the liquid filling chamber on the left side of the tailor-welded blank through the liquid inlet channel, and active radial pressure of the liquid is applied to the periphery of the right side of the tailor-welded blank;
a base plate is added between the thin plate of the tailor-welded blank and the left blank holder;
the left blank holder and the right blank holder form a circular ring, an O-shaped sealing ring groove is formed in the outer side of the baffle and used for mounting an O-shaped rubber sealing ring C, and the upper portion of the baffle is connected with the hydraulic cylinder II and used for controlling the position of the baffle;
a liquid filling interface combined with the independent hydraulic system source I and a liquid inlet channel of high-pressure liquid are formed in the right side of the right blank holder;
and a forming rule measuring system is arranged in the center of the base and below the glass plate with high light transmittance.
The left blank holder is of a semicircular ring structure, an O-shaped sealing ring groove is formed in the circular ring and used for installing an O-shaped rubber sealing ring C and used for sealing with a baffle, the O-shaped sealing ring groove is formed in the outer side of the circular ring, an O-shaped rubber sealing ring B is installed and used for sealing active radial high-pressure liquid generated by an independent hydraulic system source III, the lower side of the left blank holder is directly installed above a base plate, the upper side of the left blank holder is directly connected with a hydraulic cylinder III, and the hydraulic cylinder III is used for controlling the size of blank holding force loaded to the left blank holder.
The right blank holder is of a semicircular ring structure, an O-shaped seal ring groove is formed in the outer side of the right blank holder, an O-shaped rubber seal ring B is installed and used for sealing active radial high-pressure liquid generated by an independent hydraulic system source II, the lower portion of the right blank holder is directly installed above the tailor-welded blank, the upper portion of the right blank holder is connected with a hydraulic cylinder I, and the hydraulic cylinder I is used for controlling the blank holder force loaded on the right blank holder.
The right side of the cushion block is provided with a liquid outlet interface combined with the vacuum pump system and a liquid outlet channel of high-pressure liquid, and a sealing gasket and a conical surface combined seal are adopted between the joints of the liquid outlet interface and the liquid outlet interface.
The forming rule measuring system comprises a laser range finder, a binocular vision system, an LED charging light source, a data transmission cable, a data acquisition system and a computer system, wherein data of the vacuum pump system is transmitted to the data acquisition system through the data transmission cable;
the acquisition of deformation data in the hydraulic bulging process of the tailor-welded blank by the forming rule measuring system is realized by acquiring deformation images of the tailor-welded blank by a binocular vision system.
The binocular vision system is a non-contact optical measurement system, the three-dimensional geometry and each point relative displacement of the surface of the tailor-welded blank in the liquid-filling forming process are obtained by adopting a digital image processing technology, the liquid-filling forming process of the tailor-welded blank is dynamically monitored, real-time welding seam movement rule data of the tailor-welded blank and strain data used for calculating the forming rule of the tailor-welded blank are obtained, the data are uploaded to a data acquisition system in real time through a transmission cable, meanwhile, data of radial hydraulic pressure of an independent hydraulic system source I, data of liquid-filling forming force of an independent hydraulic system source II and data of radial hydraulic pressure of an independent hydraulic system source III are uploaded to the data acquisition system in real time through the transmission cable, a laser range finder measures displacement in the expanding forming process of the tailor-welded blank in real time, and data of the laser range finder are also uploaded to the data acquisition system in real time through the transmission cable. The glass sheet is required to have a visible light transmittance of greater than 90%.
The left side of the female die sleeve is provided with a liquid filling interface combined with the independent hydraulic system source III and a liquid inlet channel of high-pressure liquid, and a sealing gasket and a conical surface are adopted for combined sealing between the liquid filling interface and a joint of the liquid inlet channel III.
The tailor-welded blank comprises a thin plate, a thick plate and a welding line, the tailor-welded blank is placed on the female die sleeve, the welding line is placed in the center, a base plate is added between the thin plate and the left blank holder to ensure the equal thickness of the blank holder flange, the base plate is a semicircular base plate, and the thickness of the base plate is (t)h-tb) And mm, printing grids on the tailor-welded blank.
The difference in thickness between the thin plate and the thick plate by the thickness ratio etatTo quantify, the plate thickness ratio is equal to the ratio of the thickness of the thick plate to the thickness of the thin plate:
ηt＝th/tb
in the formula: t is tb-sheet thickness, th-thickness of the thick plate, the thickness ratio of the plates being in the range ηtGreater than or equal to 1, thickness ratio etatThe larger the difference, the larger the difference in plate thickness of the differential thickness tailor-welded blank is;
weld position pass chord height ratio etadQuantitative representation is performed, which is equal to the ratio of the chord height of the thin plate in the bulging area of the tailor-welded blank to the diameter of the bulging area:
ηd＝Db/D0
in the formula: dbSheet chord height, D0The diameter of the bulging area of the tailor-welded blank and the chord height ratio of the tailor-welded blank are within the range of 0 to etadLess than or equal to 1, when etadWhen 1, the tailor welded blank is completely thin, and when ηdWhen the chord height ratio is 0, the tailor-welded blank is completely a thick plate, and the proportion of the thin plate in the tailor-welded blank is reduced as the chord height ratio is reduced.
Compared with the prior art, the invention has the beneficial effects that:
1. the device adopts the design of the blocking blank holders, each blank holder is provided with one hydraulic cylinder, each hydraulic cylinder respectively applies blank holder force to the blank holder to control the size of the blank holder force, the blank holder force of each blocking blank holder is independently controlled and adjusted, the size of the blank holder force on the sheet materials at two sides of the welding line can be flexibly controlled, meanwhile, the pressing requirements of tailor welded blanks with different sizes (plate thickness ratio and chord height ratio) are met, the movement of welding seams is controlled, the wrinkling is prevented, the research on the influence of different edge pressing forces on the forming rule can be met by changing the edge pressing force, meanwhile, the testing device is utilized to respectively adjust the magnitude of the left active radial hydraulic pressure and the magnitude of the left active radial hydraulic pressure, fix the active radial hydraulic pressure on one side and change the magnitude of the active radial hydraulic pressure on the other side, so that the research on the influence of different active radial hydraulic pressures on the forming performance and forming rule of the tailor-welded blank can be obtained;
2. the test device adopts a modularized, combined, detachable and replaceable structure. The test device can replace different blank holders and backing plates in different forms according to different experimental conditions, meet the requirements of tailor-welded blanks with different plate thickness ratios and different position welding lines, does not need to replace a die, can realize the study on the forming performance and forming rule of the tailor-welded blanks with different plate thickness ratios and different position welding lines, and greatly saves the cost;
3. the testing device adopts a binocular vision system and a laser range finder to solve the three-dimensional information of a tested sample by obtaining a deformation image shot by a camera in the process of liquid-filling forming of the tailor-welded blank through image preprocessing, feature extraction, three-dimensional matching, time sequence matching, three-dimensional reconstruction and other work, so that the three-dimensional tracking of the sample on the time sequence is realized, and the strain measurement in the process of liquid-filling forming of the tailor-welded blank is completed.
4. The testing device adopts the data acquisition system which takes the computer as a control core and is based on the singlechip and the computer bus interface, can realize the real-time and high-precision acquisition of deformation data in the liquid filling and forming process of the tailor-welded blank, and simultaneously timely transmits the measurement results of the pressure, the bulging height and the like of the hydraulic cylinder to the data acquisition system, thereby ensuring the accurate unification of each measurement data on the time sequence and ensuring the accuracy of each measurement data.
5. The experimental method is simple and convenient to operate, low in experimental cost and high in experimental efficiency. When the test device and the test method for researching the hydro-forming performance and the forming rule of the tailor-welded blank are used for testing, the required operation steps are few, the operation is easy, each tailor-welded blank generally only needs to be tested for 1-3 times, the test result is stable, the repeated test is avoided, and the test cost is low.
Drawings
FIG. 1 is a schematic diagram showing main parameters of a tailor-welded blank;
FIG. 2 is a schematic view of a testing apparatus for studying hydro-forming performance and forming rule of a tailor-welded blank according to the present invention;
FIG. 3 is a flow chart of a hydro-forming performance and forming test process for studying tailor welded blanks according to the present invention;
FIG. 4 is a schematic view of a grid of tailor welded blanks;
fig. 5 shows the effect of sheet thickness ratio on the limit bulging height (η d 0.5);
FIG. 6 is a graph of the effect of weld location on ultimate bulging height (η t ═ 1.5);
FIG. 7 is a rule of influence of plate thickness difference on movement of a weld joint of a tailor-welded blank;
FIG. 8 is a rule showing the influence of the difference in sheet thickness on the maximum movement of the weld.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
The invention discloses a test device for researching hydro-forming performance and forming rule of a tailor-welded blank, and relates to the tailor-welded blank, wherein the tailor-welded blank is a blank which is formed by connecting two or more than two plates with different thicknesses, performances or surface coatings by a welding technology, mainly comprises a thin plate, a thick plate and a welding line, and the main parameter schematic diagram is shown in figure 1;
the plate thickness difference of the thin plate and the thick plate and the weld joint position of the tailor-welded blank are two basic physical quantities for representing the forming of the tailor-welded blank. The plate thickness difference is the most important characteristic of the difference thick tailor-welded plate from the equal-thickness tailor-welded plate, and the position of a welding seam is closely related to the stress and strain state of the tailor-welded plate in the hydraulic bulging process and is one of main parameters influencing the plastic deformation characteristic of the difference thick tailor-welded plate.
FIG. 1 is a schematic diagram showing main parameters of a tailor-welded blank. As can be seen from the figure, the difference in thickness between the thin plate and the thick plate can be determined by the thickness ratio etatTo quantify the description. The plate thickness ratio is equal to the ratio of the thickness of the thick plate to the thickness of the thin plate:
ηt＝th/tb
in the formula: t is tb-sheet thickness, th-thickness of the slab. Taking plate thickness ratioValue range of etatNot less than 1. Thickness ratio ηtThe larger the difference, the larger the difference in plate thickness of the differential thickness tailor-welded blank. The initial position of the welding seam (the position of the welding seam for short) directly determines the proportion of the thin plate and the thick plate in the plate blank, and is an important factor influencing the hydraulic forming of the poor thick tailor-welded blank. Chordal height of the plank (D) as the weld position changesh) And chord height of the sheet (D)b) And the chord height (D) of the thin plate is changed under the premise that the total forming diameter is not changedb) The ratio of the forming diameter of the tailor welded blank is changed correspondingly, and the position of the welding line can pass through the chord height ratio etadQuantitative representation is provided, which is equal to the ratio of the chord height of the thin plate in the bulging area of the tailor-welded blank to the diameter of the bulging area:
ηd＝Db/D0
in the formula: dbSheet chord height, D0-tailor welded blank bulging area diameter. The chord height ratio is within the range of 0-etadLess than or equal to 1. When etadWhen 1, the tailor welded blank is completely a thin plate. When eta isdWhen the value is 0, the tailor welded blank is completely thick. As the chord height ratio is reduced, the proportion of the thin plate in the tailor-welded blank is reduced. The hydro-forming performance and the forming rule of the tailor-welded blank are different for different plate thickness ratios and different weld positions, so that the hydro-forming performance and the forming rule of the tailor-welded blank can be obtained by using the test device and the test method.
The utility model provides a research tailor-welded blank hydroforming performance and test device of shaping law, this test device adopts the design of piecemeal blank holder, every blank holder configuration has a pneumatic cylinder, every pneumatic cylinder exerts the blank holder power respectively for the blank holder, control blank holder power size, the blank holder power independent control and the adjustment of every piecemeal blank holder, can control the blank holder power size on the welding seam both sides sheet material in a flexible way, satisfy the compress tightly requirement of the tailor-welded blank of different sizes (board thickness ratio and chord height ratio) simultaneously, both control the welding seam and remove, prevent wrinkling again, can satisfy the research of different blank holder powers to shaping law influence through changing the blank holder power, test device adopts the modularization, combination formula, can dismantle, the structure of change formula. The test device can replace different blank holders and backing plates in different forms according to different experimental conditions, meet the requirements of tailor-welded blanks with different plate thickness ratios and different position welding lines, does not need to replace a die, can realize the study on the forming performance and forming rule of the tailor-welded blanks with different plate thickness ratios and different position welding lines, and greatly saves the cost; which is shown in figure 2.
The utility model provides a test device of research tailor-welded blank hydroforming performance and shaping law, the whole equipment adopts modularization, combination formula, can dismantle, the structure of change formula, and the module can be adjusted and change according to the different thick tailor-welded blank of different plate thickness ratios. The device comprises a base 35, a glass plate 34 with high light transmittance, an O-shaped rubber sealing ring D (33), a cushion block 32, a concave die sleeve 31, an O-shaped rubber sealing ring A30, an independent hydraulic system source III29, a liquid filling interface III28, a liquid inlet channel III27, an O-shaped rubber sealing ring B26, a base plate 25, a left blank holder 24, a hydraulic cylinder III23, an O-shaped rubber sealing ring C22, a baffle 21, a hydraulic cylinder II20, a tailor-welded blank 19, a hydraulic cylinder I18, a liquid inlet channel I17, a right blank holder 15, a liquid filling interface I14, an independent hydraulic system source I13, a liquid inlet channel II12, a liquid filling interface II11, an independent hydraulic system source II10, a liquid outlet channel 9, a liquid outlet channel interface 8, a vacuum pump system 7, a computer system 6, a data acquisition system 5, a connecting cable 4, an LED charging light source 3, a binocular vision system 2 and a laser range finder 1;
a sealing groove is formed above the base 35, after an O-shaped rubber sealing ring D (33) is placed in the sealing groove, the high-light-transmittance glass plate 34 and the cushion block 32 are sequentially placed on the base 35 for sealing, and liquid is filled in the forming process for sealing. The high transmittance glass sheet 34 requires a visible light transmittance of greater than 90% to facilitate the recording of the forming process by the video device through the high transmittance glass sheet 34.
The right side surface of the cushion block 32 is provided with a vacuum pump system interface 8 combined with the vacuum pump system 7 and a liquid outlet channel 9 of high-pressure liquid, when the tailor-welded blank 19 is burst, the liquid and gas flowing out can be rapidly pumped out through the liquid outlet channel 9 by the vacuum pump system 7, and a sealing gasket and a conical surface composite seal are adopted between the interface 8 and the joint of the vacuum pump system 7.
A sealing groove is formed above the cushion block 32, an O-shaped rubber sealing ring is placed in the sealing groove, and after the O-shaped rubber sealing ring A30 is placed in the sealing groove, the concave die sleeve 31 is placed on the cushion block 32 for sealing liquid filling in the forming process.
The left side of the female die sleeve 31 is provided with a liquid filling interface III28 combined with an independent hydraulic system source III29 and a liquid inlet channel III27 of high-pressure liquid, a sealing gasket and a conical surface combined seal are adopted between joints of the liquid filling interface III28 and the liquid inlet channel III27, active radial high-pressure liquid generated by the independent hydraulic system source III29 enters a liquid filling chamber on the left side of the tailor-welded blank through an independent hydraulic control system, active radial pressure of the liquid is applied to the periphery of the left side of the tailor-welded blank, the active radial pressure is independently controlled and adjusted through an independent hydraulic cylinder, and the size of the active radial hydraulic pressure on the left side is independently controlled, so that the material flow of a flange area on the thin and thick side of the tailor-welded blank is controlled, the forming of the tailor-welded blank is further controlled, and the plastic deformation characteristic of the tailor-welded blank is further controlled;
the right side of the female die sleeve 31 is provided with a liquid filling interface 11 combined with an independent hydraulic system source II10 and a liquid inlet channel 12 of high-pressure liquid, a sealing gasket and a conical surface combined seal are adopted between joints of the liquid filling interface 11 and the liquid inlet channel 12, active radial high-pressure liquid generated by the independent hydraulic system source II10 enters a liquid filling chamber on the left side of the tailor-welded blank through the control of an independent hydraulic control system, active radial pressure of the liquid is applied to the periphery of the right side of the tailor-welded blank, the active radial pressure is independently controlled and adjusted through an independent hydraulic cylinder, the material flow of a flange area on the thin and thick side of the tailor-welded blank is controlled through independently controlling the size of the active radial hydraulic pressure on the right side, and the forming of the tailor-welded blank is controlled, so that the plastic deformation characteristic of the tailor-welded blank is controlled;
the tailor-welded blank 17 is composed of a thin plate 17-I, a thick plate 17-III and a welding line 17-II, the tailor-welded blank 17 is placed on a concave die sleeve 31, the welding line 17-II of the welding line is placed in the center, a backing plate 25 is added between the thin plate and a left blank holder 24 to ensure the equal thickness of the blank holder flange, the backing plate 25 is a semicircular backing plate, the shape of the backing plate 25 is shown in figure 3, and the thickness is (t)h-tb) mm on tailor welded blanksPrinting a grid as shown in fig. 4;
the left blank holder 24 is of a semicircular ring structure, an O-shaped sealing ring groove is formed in the inner portion of the circular ring and used for installing an O-shaped rubber sealing ring C22 and used for sealing between the O-shaped rubber sealing ring C22 and the baffle 21, the O-shaped sealing ring groove is formed in the outer side of the circular ring and used for installing an O-shaped rubber sealing ring B26 and used for sealing active radial high-pressure liquid generated by an independent hydraulic system source III27, the lower portion of the left blank holder 24 is directly installed above a base plate 25 above a thin plate 17-I side of the tailor-welded blank 17, the upper portion of the left blank holder 24 is directly connected with a hydraulic cylinder III23, and the hydraulic cylinder III23 can directly control the size of blank holding force loaded on the left blank holder 24.
The right blank holder 15 is of a semicircular ring structure, a sealing surface is arranged inside the circular ring, the sealing is performed between the right blank holder 15 and a rubber sealing ring C22 which is installed on the side surface of the baffle 21, an O-shaped sealing ring groove is formed in the outer side of the circular ring, an O-shaped rubber sealing ring B26 is installed for sealing active radial high-pressure liquid generated by an independent hydraulic system source II10, the lower side of the right blank holder 15 is directly installed above the thick plate 17-III side of the tailor-welded blank 17, the upper side of the right blank holder 15 is directly connected with a hydraulic cylinder I18, and the hydraulic cylinder I18 can directly control the blank holder force loaded on the right blank holder 15.
The ring has been constituteed to left blank holder 24 and right blank holder 15, and open the side of semicircle ring has the seal groove for the sealed in gap between left blank holder 24 and the right blank holder 15, and open in the baffle 21 outside has O shape sealing washer slot, and installation O shape rubber seal C22 back, then in installing the inner chamber of the ring that left blank holder 24 and right blank holder 15 are constituteed, the baffle 21 top is direct to be connected with pneumatic cylinder II20 for the position at control baffle 21 place.
The right side of the right blank holder 15 is provided with a liquid filling interface I14 combined with an independent hydraulic system source I13 and a liquid inlet channel I16 of high-pressure liquid, a sealing gasket and a conical surface are adopted between joints of the liquid filling interface I14 and the liquid inlet channel I16 for composite sealing, the bulging high-pressure liquid generated by the independent hydraulic system source I13 enters a high-pressure liquid filling chamber formed by the left blank holder 24, the right blank holder 15, the baffle 21 and the tailor-welded blank 17 through the liquid filling interface I14 and the liquid inlet channel I16 under the control of an independent hydraulic control system, then the pressure of the high-pressure liquid is directly applied to the upper part of the tailor-welded blank 17 in the high-pressure liquid filling chamber, the pressure is independently controlled and adjusted through the independent hydraulic system source I13, the size of the high-pressure can be controlled, so that the forming of the tailor-welded blank 17 is controlled, and the plastic deformation characteristic of the tailor-welded blank is further controlled;
the right side of the cushion block 32 is provided with a liquid outlet port 8 combined with the vacuum pump system 7 and a liquid outlet channel 9 of high-pressure liquid, and a sealing gasket and a conical surface composite seal are adopted between the liquid outlet port 8 and a joint of the liquid outlet port 8. Data from the vacuum pump system is transmitted to a data acquisition system 5 via a data transmission cable 4. The forming rule measuring system is installed in the center of the base 35 and below the glass plate 34 with high light transmittance, and mainly comprises a laser range finder 1, a binocular vision system 2, an LED charging light source 3, a data transmission cable 4, a data acquisition system 5 and a computer system 6. The data acquisition system 5 is designed based on a single chip microcomputer and a computer bus interface by taking a computer as a control core. The circuit adopts a high-resolution AD conversion chip to design a digital-to-analog conversion circuit, and a digital filtering method is used for filtering the acquired force signal, so that the acquisition system has higher reliability and integration level and is used for finishing the acquisition of the force signal data in real time and with high precision.
The acquisition of deformation data of the tailor-welded blank 17 in the process of hydraulic bulging by the measuring system is realized by the acquisition of deformation images of the tailor-welded blank 17 by the binocular vision system 2. The binocular vision system 2 is a non-contact optical measurement system, acquires the three-dimensional geometry and the relative displacement of each point of the surface of the tailor-welded blank in the hydro-forming process by adopting a digital image processing technology, realizes the dynamic monitoring of the hydro-forming process of the tailor-welded blank 17, acquires the real-time weld joint movement rule data of the tailor-welded blank 17 and the strain data for calculating the forming rule of the tailor-welded blank 7, and uploads the data to the data acquisition system 5 in real time through the transmission cable 4, meanwhile, the data of the radial hydraulic pressure of the independent hydraulic system source I13, the data of the liquid filling forming force of the independent hydraulic system source II10 and the data of the radial hydraulic pressure of the independent hydraulic system source III29 are uploaded to the data acquisition system 5 in real time through the transmission cable 4, on the other hand, the laser range finder 1 can measure the displacement of the tailor-welded blank in the bulging process in real time, the non-contact and quick measurement of the bulging height is realized, and the data of the laser range finder 1 is also uploaded to the data acquisition system 5 in real time through the transmission cable 4. The stress and the strain obtained by final calculation can be accurately unified on the time sequence, and the accuracy of the movement rule and the forming rule of the welding line is ensured.
The invention also provides a test device and a test method for researching the hydro-forming performance and the forming rule of the tailor-welded blank by using the device, which are used for researching the hydro-forming performance and the forming rule of the tailor-welded blank, and the test process mainly comprises the following steps:
step one, preparing a differential thickness tailor-welded blank sample, preparing the differential thickness tailor-welded blank, wherein the prepared tailor-welded blank is made of materials such as steel, aluminum alloy, magnesium alloy, titanium alloy and the like, and the preparation steps of the differential thickness tailor-welded blank are described in detail as follows:
1.1, firstly, blanking a sheet metal of a sheet material through a plate shearing machine, and then chemically cleaning the sheet material by using a chemical oil removal and alkali cleaning method to obtain a rectangular thin sheet and a rectangular thick sheet, wherein the thickness of the thin sheet and the thickness of the thick sheet are between 0.3mm and 5 mm;
1.2, welding rectangular thin plates and thick plates by using welding equipment to obtain splicing welding plates 19 with different specifications and thicknesses, wherein the welding equipment selects welding methods such as argon tungsten-arc welding, laser welding, electron beams and the like according to the welding characteristics of materials;
1.3, cutting the differential thickness tailor-welded blank into a circular blank in a linear cutting mode according to the size of the test device;
the requirements of the manufactured round blank are as follows: 1) the edge of the manufactured round blank is ensured to have no cracks; 2) preparing samples with different sizes and shapes, wherein each type of sample is not less than 3, performing three experiments in each experiment under the same condition, and taking the average value of the three experiments as the final experiment result. The experimental steps are as follows:
and step two, making grids in the surface area of the round blank to be measured, wherein the grid making mode can be performed by adopting a mode of manual paint spraying and laser ablation. The shape of the mesh is shown in fig. 4. The grids manufactured on the surface of the circular blank are randomly distributed, the contrast between grid lines and the original surface of the plate is obvious, the manufacturing range of the grids is larger than the measured deformation area, the sample is degreased and cleaned by alcohol, and is numbered and marked by a marking machine or a laser carving machine, and corresponding records are made.
And step three, calibrating the measured instrument before the experiment to ensure the correctness of the measured data.
And 3.1, calibrating the sensor and the laser range finder before the experiment to obtain the proportional relation between the load size corresponding to the tensile force output analog quantity and the digital quantity.
3.2, after the double cameras and the light source device are fixed, performing off-line calibration on the binocular vision system to determine respective internal parameters of the double cameras and external parameters between the double cameras for subsequent three-dimensional reconstruction and strain calculation;
step four, installing a testing device, placing the differential thickness tailor-welded blank into the testing device, and describing the installation steps in detail as follows:
4.1 installing an O-shaped rubber sealing ring D (33) on a base 35, then placing a glass plate 34 with high light transmittance on the base 35, then installing a cushion block 32 on the base 35, installing an O-shaped rubber sealing ring A30 in a sealing groove of the cushion block 32, installing a concave die sleeve 31 on the cushion block 32, connecting an independent hydraulic system source II10 and an independent hydraulic system source III29 with the concave die sleeve 31 by using a high-pressure adapter coupling after the installation to form a radial pressure generation source II and a radial pressure generation source III, then connecting the independent hydraulic system source II10 and the independent hydraulic system source III with a data acquisition system 5 through a data cable 4, and uploading pressure data of a hydraulic cylinder to the data acquisition system 5 in real time;
4.2 placing the tailored blank 17 manufactured in the first step on the female die sleeve 31, wherein the side of the tailored blank 17 with the stepped surface faces upwards, the thin plate side 17-I is placed on the left side of the female die sleeve 31, and a backing plate 25 is added between the thin plate and the left blank holder 24 to ensure the equal thickness and the equal clearance of the blank holder flange, the shape of the backing plate 25 is shown in figure 3, and the thickness is (t)h-tb)mm；
4.3 install LED charging light source 3, binocular vision system 2 and laser range finder 1 respectively on test platform, the signal output part of binocular vision system 2 and laser range finder 1 links to each other with data acquisition system 5 respectively, and data synchronization acquisition system 5 is connected to in the computer system 6. The vacuum pump system 7 is also connected with the data acquisition system 5 through a cable, and the data of the system can be uploaded to the data acquisition system 5 in real time.
4.4 placing the part which is finished by the installation in the step 4.2 on the forming rule measuring system formed in the step 4.3, and placing the forming rule measuring system at the center of the base 35 below the glass plate 34 with high light transmittance.
4.5, mounting the left blank holder 24 on a hydraulic cylinder III23 and mounting the right blank holder 15 on a hydraulic cylinder II20, adjusting the positions, mounting an O-shaped rubber seal ring B26 in a sealing groove of the left blank holder 24 and the right blank holder 15, connecting an independent hydraulic system source I13 with the right blank holder 15 by using a high-pressure adapter after the mounting is finished to form a liquid pressure charging source I, connecting the liquid pressure charging source I with the data acquisition system 5 through a data cable 4, and uploading pressure data of the hydraulic cylinders to the data acquisition system 5 in real time;
4.6 installing the O-ring rubber C22 into the sealing groove of the baffle 21 to form a baffle assembly, then installing the baffle assembly into the ring formed by the left clamping ring 24 and the right clamping ring 15, and finally connecting the baffle assembly to the hydraulic cylinder I18. The hydraulic cylinder I18, the hydraulic cylinder II20 and the hydraulic cylinder III23 independently control the hydraulic pressure and are connected with the data acquisition system 5 through the data cable 4, and the hydraulic cylinder pressure data are uploaded to the data acquisition system 5 in real time. Meanwhile, the independent hydraulic system source I13, the independent hydraulic system source II10 and the independent hydraulic system source III29 are respectively connected with the data acquisition system 5 through data cables 4, and the pressure data of the hydraulic cylinder are uploaded to the data acquisition system 5 in real time.
Step five, forming test, wherein the forming test steps are described in detail below;
5.1 in the test, the plate thickness ratio eta is takentChord height ratio etadFor variable parameters, the influence rule of the plate thickness difference and the weld joint position of the tailor-welded blank on the cracking pressure, the limit bulging height and the weld joint movement of the tailor-welded blank is researched. When the influence of the thickness difference of the plates on the forming of the tailor-welded blank is researched, the chord height ratio of the tailor-welded blank is required to be set as etadIs a constant value; when the influence of the position of a welding seam on the forming of the tailor-welded blank is researched, the plate thickness ratio eta of the tailor-welded blank needs to be settIs a constant value.
5.2 in the experiment process, firstly controlling a hydraulic cylinder I18, a hydraulic cylinder II20 and a hydraulic cylinder III23, and simultaneously controlling a left blank holder 24, a right blank holder 15 and a baffle 21 to move upwards, then placing the differential thickness tailor-welded blank 17 manufactured in the step I on a female die sleeve 31, wherein one surface of the differential thickness tailor-welded blank 17 with a step surface is upward, a thin plate side 17-I is placed on the left side of the female die sleeve 31, adding a cushion plate 25 between the thin plate and the left blank holder 24 to ensure the equal thickness and the equal clearance of the blank holder flange, the shape of the cushion plate 25 is shown in figure 3, and the thickness is (t)h-tb)mm
5.3 controlling a hydraulic cylinder I18, a hydraulic cylinder II20 and a hydraulic cylinder III23 to control a left blank holder 24, a right blank holder 15 and a baffle 21 to move downwards for die assembly, then increasing the blank holding force of the hydraulic cylinder I18 and the hydraulic cylinder III23, ensuring that no flow occurs in the bulging process, and ensuring that the blank holding force of the hydraulic cylinder I18 and the hydraulic cylinder III23 keeps unchanged in the liquid filling forming process;
5.4 controlling the independent hydraulic system source II10 and the independent hydraulic system source III29 so as to control the generation sources II and III of the radial pressure to be in a fixed value, and according to the test condition, changing the sizes of different radial pressures II and III to obtain the influence of different radial pressures on the hydro-forming rule of the differential thickness tailor-welded blank.
5.5 according to the curve of the preset liquid filling pressure, the independent hydraulic system source I13 is controlled so as to control the liquid filling pressure, liquid is slowly filled into the female die sleeve 31, in order to ensure the comparability of the test result, the time, the frequency and the deformation rate of each liquid filling are as stable as possible, and the curve of the actual liquid filling pressure and the actual time is consistent with the curve of the preset liquid filling pressure. The forming degree of the differential thick tailor-welded blank is continuously increased along with the continuous operation of the liquid filling time, the differential thick tailor-welded blank is broken when the forming reaches the forming limit, a liquid filling pressure generating source I is connected with the data acquisition system 5 through the data cable 4 in the forming process, the pressure data of the hydraulic cylinder is uploaded to the data acquisition system 5 in real time, and when the differential thick tailor-welded blank is broken, the forming pressure reaches the top peak and then is reduced, and the cracking pressure value is the peak value of the forming pressure. In the experimental process, the bulging height of the differential thick tailor-welded blank of the laser range finder 1 is transmitted to the data acquisition system 5 in real time, the vacuum pump system 7 of the device needs to be started while filling liquid, gas and liquid in a cavity formed by the female die sleeve 31, the cushion block 32, the glass plate 34 with high light transmittance and the differential thick tailor-welded blank 17 are removed in real time, and data information is uploaded to the data acquisition system in real time. After the forming is finished, controlling a hydraulic cylinder I18, a hydraulic cylinder II20 and a hydraulic cylinder III23, controlling the left blank holder 24, the right blank holder 15 and the baffle 21 to move upwards, and after the left blank holder, the right blank holder 15 and the baffle 21 are moved to a safety position, closing the equipment to take out a formed sample;
sixthly, by utilizing the modularized, combined, detachable and replaceable structure of the test device, the blank holder and the base plate in different forms are replaced according to different experimental conditions, then the tailor-welded blank with different plate thickness ratios and different position welding lines is replaced, and the step 5.1-5.5 is repeated to obtain the study on the forming performance and the forming rule of the tailor-welded blank with different plate thickness ratios and different position welding lines;
seventhly, controlling a hydraulic cylinder I18 and a hydraulic cylinder III23 by using a test device, respectively adjusting the blank holder force exerted on the left blank holder 24 and the right blank holder 15, fixing the blank holder force on one side, changing the blank holder force on the other side, repeating the steps of 5.1-5.5, and obtaining the research on the influence of different blank holder forces on the forming performance and the forming rule of the tailor-welded blank;
step eight, controlling an independent hydraulic system source II10 and an independent hydraulic system source III29 by using a test device, respectively adjusting the left active radial hydraulic pressure and the left active radial hydraulic pressure, fixing the active radial hydraulic pressure on one side, changing the active radial hydraulic pressure on the other side, repeating the step 5.1-5.5, and obtaining the research on the influence of different active radial hydraulic pressures on the forming performance and the forming rule of the tailor-welded blank;
nine steps, data processing after forming test
After the forming test is finished, the data processing software on the computer system 6 processes the data acquired by the data acquisition system in the forming process, and then the data is exported and processed to finally obtain the weld joint moving rule and the forming rule curve of the differential thickness tailor-welded blank.
Examples
The plate thickness ratio eta is respectively taken in the testtChord height ratio etadFor variable parameters, the influence rule of the plate thickness difference and the weld joint position of the tailor-welded blank on the cracking pressure, the limit bulging height and the weld joint movement of the tailor-welded blank is researched. As shown in Table 1, the plate thickness ratio was defined as eta in five casest＝3:1.5＝2.0、ηt＝3:1.8＝1.67、ηt＝3:2＝1.5、ηt3:2.3 ═ 1.3 and ηtThe welding position is equal to 3:2.5 and equal to 1.2, and the welding positions are equal to etad＝0.18、ηd＝0.32、ηd＝0.5、ηd0.68 and ηd0.82. When the influence of the thickness difference of the plates on the forming of the tailor-welded blank is researched, the chord height ratio of the tailor-welded blank is required to be set as etadThe welding seam is positioned in the center of the tailor welded blank, namely the welding seam is a fixed value of 0.5; when the influence of the position of a welding seam on the forming of the tailor-welded blank is researched, the plate thickness ratio eta of the tailor-welded blank needs to be settThe fixed value is 1.5, and the detailed study scheme is shown in table 2.
5.1 in the test, the plate thickness ratio eta is takentChord height ratio etadFor variable parameters, the influence rule of the plate thickness difference and the weld joint position of the tailor-welded blank on the cracking pressure, the limit bulging height and the weld joint movement of the tailor-welded blank is researched. When the influence of the thickness difference of the plates on the forming of the tailor-welded blank is researched, the chord height ratio of the tailor-welded blank is required to be set as etadThe welding seam is positioned in the center of the tailor welded blank, namely the welding seam is a fixed value of 0.5; when the influence of the position of a welding seam on the forming of the tailor-welded blank is researched, the plate thickness ratio eta of the tailor-welded blank needs to be settThe fixed value is 1.5, and the detailed study scheme is shown in table 2.
TABLE 1 tailor-welded blank hydraulic bulging influence parameter table
TABLE 2 study protocol
The tailor-welded blank in the experiment is formed by welding in an argon arc welding mode, a welding seam is polished after welding is finished, then a round blank with the same diameter of phi 220mm is cut in a laser cutting mode, three experiments are carried out on each sample under the same condition, and the average value of the three samples is taken as the final experiment result.
In order to study the influence rule of the plate thickness difference on the limit bulging height of the different-thickness tailor-welded blank in detail, the influence rule of the different plate thickness difference with the welding seam position as the center on the limit bulging height is analyzed. Fig. 5 shows the variation trend of the maximum bulging height of the tailor welded blank with the thickness ratio of the tailor welded blank, and fig. 6 shows the influence of the position of the weld joint on the maximum bulging height (η t is 1.5);
the difference thickness tailor welded blank (eta) of different plate thickness ratio from the welding seam located at the center of the tailor welded blankt＝2.0、ηt＝1.67、ηt＝1.5、ηt1.3 and ηtResults of the hydroforming test 1.2), it can be seen from the figure that the results of the bulging of the different thickness tailor welded blanks of different plate thickness ratios are not the same, with the most obvious being the difference in the bulging height of the tailor welded blanks.
When the plate thickness ratio etatWhen the ratio is 3: 2: 1.5, the splicing welding plate (eta) at different welding seam positionsd＝0.18、ηd＝0.32、ηd＝0.5、ηd0.68 and ηd0.82), the forming results of the tailor welded blanks at different weld positions are different, wherein the most obvious is the different ultimate bulging heights of the tailor welded blanks.
In order to research the influence rule of the thickness difference on the movement of the welding seam, the thickness ratio (eta) of the welding seam to different plates in the center of the tailor-welded platet＝2.0、ηt＝1.67、ηt＝1.5、ηt1.3 and ηt1.2) is subjected to finite element simulation, and the moving rule of the welding seam when the bulging height of the tailor-welded blank is 15mm is analyzed. FIG. 7 shows the law of the effect of different plate thickness ratios on the movement of the hydraulic bulging weld of the tailor-welded blank with different thickness, and FIG. 8 shows the plate thickness ratio on the difference thicknessThe law is influenced by the maximum movement of the welding seam of the tailor-welded blank.
The invention has not been described in detail in part of the common general knowledge of those skilled in the art. The specific embodiments described are merely illustrative of the spirit of the invention. Various modifications or additions may be made to the described embodiments or alternatives may be employed by those skilled in the art without departing from the spirit or ambit of the invention as defined in the appended claims.
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