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液压机成形技术在行业应用优势和优点

液压机成形技术在行业应用优势和优点

作者:admin    来源:未知    发布时间:2020-07-11 23:30    浏览量:

液压机成形技术优势

与传统的冲压工艺相比,液压成形工艺在减轻重量、减少零件数量和模具数量、提高刚度与强度、降低生产成本等方面具有明显的技术和经济优势,在工业领域尤其是汽车工业中得到了越来越多的应用。

在汽车工业及航空、航天等领域,减轻结构质量以节约运行中的能量是人们长期追求的目标,也是先进制造技术发展的趋势之一。液压成形(hydroforming)就是为实现结构轻量化的一种先进制造技术。

液压成形也被称为“内高压成形”,它的基本原理是以管材作为坯料,在管材内部施加超高压液体同时,对管坯的两端施加轴向推力,进行补料。在两种外力的共同作用下,管坯材料发生塑性变形,并最终与模具型腔内壁贴合,得到形状与精度均符合技术要求的中空零件。

液压机成形技术优点

对于空心变截面结构件,传统的制造工艺是先冲压成形两个半片,然后再焊接成整体,而液压成形则可以一次整体成形沿构件截面有变化的空心结构件。与冲压焊接工艺相比,液压成形技术和工艺有以下主要优点:

1. 减轻质量,节约材料。对于汽车发动机托架、散热器支架等典型零件,液压成形件比冲压件减轻20%~40%;对于空心阶梯轴类零件,可以减轻40%~50%的重量。

2.减少零件和模具数量,降低模具费用。液压成形件通常只需要1套模具,而冲压件大多需要多套模具。液压成形的发动机托架零件由6个减少到1个,散热器支架零件由17个减少到10个。

3. 可减少后续机械加工和组装的焊接量。以散热器支架为例,散热面积增加43%,焊点由174个减少到20个,工序由13道减少到6道,生产率提高66%。

4. 提高强度与刚度,尤其是疲劳强度,如液压成形的散热器支架,其刚度在垂直方向可提高39%,水平方向可提高50%。

5. 降低生产成本。根据对已应用液压成形零件的统计分析,液压成形件的生产成本比冲压件平均降低15%~20%,模具费用降低20%~30%。

 

 

Advantages of forming technology of hydraulic press

Compared with the traditional stamping process, hydroforming technology has obvious technical and economic advantages in reducing weight, reducing the number of parts and dies, improving stiffness and strength, reducing production costs and so on. It has been applied more and more in the industrial field, especially in the automobile industry.

In the automotive industry, aviation, aerospace and other fields, reducing structural mass to save energy in operation is a long-term goal pursued by people, and is also one of the development trends of advanced manufacturing technology. Hydroforming is an advanced manufacturing technology for lightweight structure.

Hydroforming is also known as "internal high pressure forming". Its basic principle is that the tube is used as the blank, and the ultra-high pressure liquid is applied inside the tube. At the same time, the axial thrust is applied to both ends of the tube blank to supplement the material. Under the joint action of the two external forces, the tube blank material plastic deformation, and finally fit with the inner wall of the mold cavity, so as to obtain the hollow parts whose shape and precision meet the technical requirements.

Advantages of hydraulic press forming technology

For the hollow variable cross-section structural parts, the traditional manufacturing process is to form two half pieces first, and then weld them into a whole, while hydroforming can form the hollow structural parts with changes along the cross-section of the components at one time. Compared with stamping welding process, hydroforming technology and process have the following main advantages:

1. Reduce weight and save materials. For typical parts such as engine bracket and radiator bracket, the weight of hydroforming parts is 20% - 40% less than that of stamping parts, and the weight of hollow stepped shaft parts can be reduced by 40% - 50%.

2. Reduce the number of parts and molds and reduce the cost of molds. Hydroforming parts usually only need one set of dies, while most stamping parts need more than one set of dies. The number of engine bracket parts reduced from 6 to 1, and the number of radiator bracket parts decreased from 17 to 10.

3. It can reduce the welding amount of subsequent machining and assembly. Taking the radiator bracket as an example, the heat dissipation area increased by 43%, the number of solder joints decreased from 174 to 20, the process decreased from 13 to 6, and the productivity increased by 66%.

4. Improve the strength and stiffness, especially the fatigue strength. For example, the stiffness of the hydroforming radiator bracket can be increased by 39% in the vertical direction and 50% in the horizontal direction.

5. Reduce production cost. According to the statistical analysis of applied hydroforming parts, the production cost of hydroforming parts is reduced by 15% ~ 20% and the die cost is reduced by 20% ~ 30%.

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