一、內高壓成行發展史

德國於20世紀70年代末開始內高壓液力成形基礎研究，並於90年代初開始在工業生產中採用內高壓成形技術製造汽車輕體構件，90年代中國開始引進這項技術，進入21世紀開始充分應用於市場產品當中，並得到快速發展，可控水壓逐年快速遞增：2000-2006年水80MPa，2006-2010年水壓120MPa,2010-2013年水壓160MPa，2013-2015年水壓200MPa,2015-2017年水壓240MPa，2017-2019年水壓300MPa,2020-2023年水壓400MPa。

Germany started basic research on internal high pressure hydroforming at the end of 1970s,: water 80MPa,: 120MPa in 2006-2010, 160MPa in 2010-2013, 200MPa in 2013-2015, 240MPa in 2015-2017, 300MPa in 2017-2019 and 400MPa in 2020-2023.

 

二、成形原理

內高壓成形原理是通過內部加壓和軸向加力補料，將管坯壓入模具型腔使其成形，成形時內壓和軸向進給按事先給定的匹配關係，由計算機精確控制。

The principle of internal high pressure forming is to press the tube billet into the mold cavity by internal pressure and axial force feed, which is precisely controlled by computer according to the given matching relationship during forming.

 

三、工藝介紹

其成形工藝過程可以分爲三個階段，如圖1所示。初始充填階段（圖1a）模具閉合後，將管的兩端用水準衝頭密封，使管坯內充滿液體，並排出氣體，實現管端衝頭密封；成形階段（圖1b），對管內液體加壓脹形的同時，兩端的衝頭按照設定的載入曲線向內推進補料，在內壓和軸向補料的聯合作用下使管坯基本貼靠模具，這時除了過渡區圓角以外的大部分區域已經成形；整形階段（圖1c），提高壓力使過渡區圓角完全貼靠模具而成形爲所需的工件。

(Figure 1a) when the die is closed, both ends of the pipe are sealed with a horizontal punch, which fills the billet with liquid and discharges gas to achieve the end punch seal; during the forming stage (Figure 1b)At the same time, when the liquid in the pipe is pressurized and bulged, the punches at both ends push the filler inward according to the set loading curve, and under the combined action of internal pressure and axial filler,, most areas except the fillets in the transition zone have been formed; at the shaping stage (Figure 1c), increasing the pressure makes the fillets in the transition zone fully adhere to the die and become the required workpiece.

1. 充填階段

2. 成形階段

c. 整形階段

C. Plastic stage 

圖1 變徑管件內高壓成形工藝過程

Fig.1 High pressure forming process for variable diameter tube

成形過程中涉及主要工藝參數/The main process parameters are involved in the forming process：

初始屈服壓力Ps：管材開始發生塑性變形時所需要的內壓；

開裂壓力Pb：貼模前內壓應小於開裂壓力；

整形壓力（成形壓力）Pc：用於成形截面過渡圓角，並保證尺寸精度；

軸向進給力Fa：實現軸向補料；

合模力Fc：使模具閉合不產生縫隙；

補料量△l：減少成形區壁厚減薄，並提高膨脹率。

Initial yield pressure Ps: The internal pressure required for the tube to begin plastic deformation;

Cracking pressure Pb: The internal pressure before bonding should be less than the cracking pressure;

Reshaping Pressure (Forming Pressure) Pc: Used to shape transition rounded corners of cross sections and ensure dimension accuracy;

Axial feed force Fa: to achieve axial filling;

Mould closing force Fc: Make the mould close without creating gaps;

Feed amount Delta l: reduce the thickness of the forming area and thin the wall, and increase the expansion rate.

 

四、設備特點/Characteristics of the equipment

1.採用自來水作爲加工成形介質

2.加工成型件量身定製，批量生產，產能提高10-50倍

3.伺服技術爲企業節電30-70%

4.伺服同步精度小於0.05mm

5.軸向進給精度0.03mm

6.液壓系統液壓油升溫降幅60%

7.密封件使用壽命延長2倍

8.提高原件材料利用率超過80%

9.內高壓水壓400Mpa.100萬次無故障

10.可搭載工業機器人的數控系統。

10-50 times through customized processing and mass production

30-70% electricity for enterprises

0.05mm

0.03mm

60%

2 times

80%

價格僅供參考，具體價格根據定製不同產生變化