Hydraulic press forming technology and common faults
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Hydraulic press forming technology and common faults

Views: 38     Author: Site Editor     Publish Time: 2020-11-18      Origin: Site

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Hydraulic press forming technology

Preponderance.

Compared with the traditional stamping technology, hydraulic forming technology has obvious technical and economic advantages in reducing weight, reducing the number of parts and molds, improving stiffness and strength, and reducing production cost, etc. It has been applied more and more in the industrial field, especially in the automobile industry.


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


Hydraulic forming is also known as "internal high-pressure forming", its basic principle is to take the pipe as the blank, apply the ultra-high pressure liquid inside the pipe, at the same time, apply axial thrust to both ends of the pipe blank, for filling. Under the joint action of two kinds of external forces, the tube billet material has plastic deformation, and finally fits with the inner wall of the mold cavity, and the hollow part whose shape and precision meet the technical requirements is obtained.


Advantages

For the hollow variable section structure, the traditional manufacturing process is to press and form two half pieces, and then weld them into a whole, while the hydraulic forming can form the hollow structure with changes along the section of the member as a whole. Compared with the stamping and welding process, hydraulic forming technology and process have the following main advantages:

1. Reduce quality and save material. For typical parts such as automobile engine bracket and radiator bracket, hydraulic forming parts can be reduced by 20% ~ 40% compared with stamping parts. For hollow step shaft parts, the weight can be reduced by 40% ~ 50%.

2. Reduce the number of parts and molds, reduce the cost of molds. Hydraulic forming parts usually need only one set of die, while stamping parts mostly need more than one set of die. The number of hydraulic forming engine bracket parts was reduced from 6 to 1, and radiator bracket parts were reduced from 17 to 10.

3. Reduces the amount of welding in subsequent machining and assembly. Take the radiator bracket as an example, the heat dissipation area increases by 43%, the number of welding spots decreases from 174 to 20, the number of working procedures decreases from 13 to 6, and the productivity increases by 66%.

4. Increase strength and stiffness, especially fatigue strength, such as hydraulic forming radiator bracket, its stiffness can be increased by 39% in the vertical direction and 50% in the horizontal direction.

5. Reduce production costs. According to the statistical analysis of the applied hydraulic forming parts, the production cost of hydraulic forming parts is reduced by 15% ~ 20% on average compared with the stamping parts, and the mold cost is reduced by 20% ~ 30%.


Common faults

During the operation of the metal extrusion hydraulic press, some bolts would fall off and fall into the hydraulic cylinder, causing severe scratches on the plunger wall. After the occurrence of problems, traditional methods can not achieve on-site repair, can only be dismantled and shipped to the manufacturer for repair welding processing of scrap replacement. Because there is no replacement of spare parts, the time of re-production of spare parts or returning to the factory for maintenance cannot be controlled, and the long time of shutdown causes serious economic losses to the enterprise, and meanwhile, high processing or repair costs have to be paid. In order to meet the requirements of continuous production, it is necessary to find a convenient, quick, simple, and effective means of maintenance to solve the equipment problem, to minimize the enterprise's downtime and maintenance costs. The polymer composite material can be used for field repair.


Operation steps:

1. Use the oxygen-acetylene flame to bake the scratched part (to control the temperature and avoid surface annealing), and bake the oil on the perennially permeated metal surface until no sparks splash.

2. The scratched part shall be treated with the surface of the Angle grinder, and the grinding depth shall be more than 1 mm, and the groove shall be ground out along the outer wall of the cylinder, preferably dovetail groove. The drill holes at both ends of the scratches are deepened to change the stress condition.

3. Use absorbent cotton dipped in acetone or anhydrous ethanol to clean the surface.

4. Apply uniform repair material to the scratched surface; The first layer should be thin, evenly, and completely cover the scratch surface to ensure the best adhesion between the material and the metal surface. After applying the material to the whole repair area, press it repeatedly to ensure that the material is filled and reaches the required thickness, making it slightly higher than the surface of the cylinder wall.

5. It takes 24 hours for the material to fully achieve all properties at 24℃. In order to save time, the temperature can be increased by a halogen tungsten lamp. For every 11℃ increase in temperature, the curing time will be reduced by half, and the best curing temperature is 70℃.

6. After the material is cured, use a fine grindstone or scraper to repair and level the material that is higher than the outer wall surface of the cylinder and finish the construction.

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