MULTI-WARM FORMING DEVICE AND THE FORMING METHOD THEREOF

Abstract

A multi-warm forming device and the forming method are disclosed. A multi-warm forming device according to one or a plurality of exemplary embodiments of the present invention may include: a lower mold die that is disposed on a bolster for a process and in which a mold mounting portion having at least one space portion is formed at a center thereof; a lower mold that is disposed at an upper surface of a mold mounting portion of the lower mold die, in which a plurality of gas supply passages formed therein in a vertical direction are connected to a gas supply device of an outside through a gas supply line, and a lower forming surface is formed at an upper surface thereof; an upper mold that is mounted on a slider of an upper portion to be able to be moved up and down corresponding to the lower mold at an upper portion of the lower mold die, in which an upper forming surface is formed at a lower surface corresponding to the lower mold, an upper mold face surface is formed at a circumference of the upper forming surface, and a plurality of heating cartridges are mounted inside along the upper forming surface and the upper mold face surface; and a blank holder of which the mold mounting portion is inserted into a penetration hole that is formed corresponding to the mold mounting portion, is able to be moved in a vertical direction by a guide post and a cushion spring that are mounted within the lower mold die, and in which a plurality of heating cartridges are mounted along a holder face surface that restrains a material together with the upper mold face surface at an early stage of a forming process.

Claims

1. A multi-warm forming device, comprising: a lower mold die that is disposed on a bolster for a process and in which a mold mounting portion having at least one space portion is formed at a center thereof; a lower mold that is disposed at an upper surface of a mold mounting portion of the lower mold die, in which a plurality of gas supply passages formed therein in a vertical direction are connected to a gas supply device of an outside through a gas supply line, and a lower forming surface is formed at an upper surface thereof; an upper mold that is mounted on a slider of an upper portion to be able to be moved up and down corresponding to the lower mold at an upper portion of the lower mold die, in which an upper forming surface is formed at a lower surface corresponding to the lower mold, an upper mold face surface is formed at a circumference of the upper forming surface, and a plurality of heating cartridges are mounted inside along the upper forming surface and the upper mold face surface; and a blank holder of which the mold mounting portion is inserted into a penetration hole that is formed corresponding to the mold mounting portion, is able to be moved in a vertical direction by a guide post and a cushion spring that are mounted within the lower mold die, and in which a plurality of heating cartridges are mounted along a holder face surface that restrains a material together with the upper mold face surface at an early stage of a forming process.

2. The multi-warm forming device of claim 1, wherein the material is applied as a super-plasticity material.

3. The multi-warm forming device of claim 2, wherein an aluminum alloy plate is applied as the super-plasticity material.

4. The multi-warm forming device of claim 1, further comprising an insulating case that is respectively mounted on an outside surface of the upper mold and the blank holder to preserve heat energy of the mold.

5. The multi-warm forming device of claim 4, wherein the insulating case is made of a micro-porosity panel that is assembled on each outside surface of the upper mold and the blank holder.

6. The multi-warm forming device of claim 1, wherein a plurality of key grooves are formed corresponding to an upper surface of a mold mounting portion of the lower mold die and a lower surface of a lower mold that is mounted thereon, and a restraining key that is inserted into the key groove fixes the lower mold on the lower mold die.

7. The multi-warm forming device of claim 6, wherein an upper surface of a mold mounting portion of the lower mold die is formed as a flat mold mounting surface.

8. The multi-warm forming device of claim 1, wherein the gas supply line that is connected to an outside gas supply device is connected to the gas supply passage through a space portion of the mold mounting portion.

9. The multi-warm forming device of claim 1, wherein the gas supply line is disposed to penetrate a central portion of a heating unit that is configured inside a space portion of the mold mounting portion.

10. The multi-warm forming device of claim 9, wherein the heating unit includes a heater housing in which a penetration hole is formed at a center thereof and is disposed in a space portion of the mold mounting portion, and a heating coil that is wound in the heater housing.

11. The multi-warm forming device of claim 9, wherein an outside of the heating unit is covered by a heat insulating material inside a space portion of the mold mounting portion.

12. The multi-warm forming device of claim 1, wherein the lower forming surface is formed as an unfinished product shape surface to be able to form a material to a maximum forming depth.

13. The multi-warm forming device of claim 1, wherein the upper forming surface is formed as a complete product shape to be able to form a material to a final complete shape.

14. A multi-warm forming method, comprising: a material supply step in which a plate made of a super-plasticity material is loaded on a blank holder that is mounted on a lower mold die through a guide post and a cushion spring corresponding to a circumference of a lower mold, wherein the lower mold is mounted on the lower mold die; a material heating step in which the plate is heated to a warm forming temperature through a heating cartridge configured inside the upper mold and the blank holder by moving an upper mold that is disposed at an upper portion of the lower mold to be operated by a slider downwards and by holding the edge of the plate together with the blank holder; a warm forming step that combines the upper mold and the lower mold through the operation of the slider at the warm forming temperature to deform the plate to a maximum forming depth through plastic deformation; and a blow-forming step in which the heating cartridge further heats the plate to a super plasticity temperature in a condition that the plate is already warm-formed to a maximum forming depth, a gas is supplied through a gas supply passage that is formed inside the lower mold, and the plate is formed to a final shape of a product along an upper forming surface of the upper mold by a gas pressure in a condition that the upper mold is combined with the lower mold.

15. The multi-warm forming method of claim 14, wherein an aluminum alloy plate is applied as the super-plasticity material.

16. The multi-warm forming method of claim 14, wherein an insulating case that is made of a micro-porosity panel is mounted on an outside surface of the upper mold and the blank holder to preserve heat energy of a mold therein.

17. The multi-warm forming method of claim 14, wherein the gas supply passage is connected to a gas supply device and receives a high pressure gas through a gas supply line.

18. The multi-warm forming method of claim 17, wherein the gas supply line is covered by a heating unit that is configured inside the lower mold die and supplies a high temperature gas to the gas supply passage.

19. The multi-warm forming method of claim 14, wherein a lower forming surface of the lower mold is formed as an unfinished product shape surface to be able to form a material to a maximum forming depth.

20. The multi-warm forming method of claim 14, wherein an upper forming surface of the upper mold is formed as a complete product shape to be able to form a material to a final complete shape.

21. The multi-warm forming method of claim 14, wherein the warm forming temperature is set to a value below an annealing temperature that lowers a dislocation density inside a material having a super-plasticity characteristic.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] FIG. 1 is a partial exploded perspective view of a multi-warm forming device according to an exemplary embodiment of the present invention.

[0039] FIG. 2 is an exploded perspective view of a mold that is applied to a multi-warm forming device according to an exemplary embodiment of the present invention.

[0040] FIG. 3 is a cross-sectional view of a multi-warm forming device according to an exemplary embodiment of the present invention.

[0041] FIG. 4 is a process block diagram showing steps of a multi-warm forming device according to an exemplary embodiment of the present invention.

[0042] FIG. 5 to FIG. 8 show an operational state of a multi-warm forming device according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0043] Hereinafter, an exemplary embodiment of the present invention will be described with reference to accompanying drawings. Further, the sizes and thicknesses of the configurations shown in the drawings are selectively provided for convenience of description, and the present invention is not limited to those shown in the drawings, and to clearly describe the present invention, parts that are irrelevant to the description will be omitted.

[0044] FIG. 1 is a partial exploded perspective view of a multi-warm forming device according to an exemplary embodiment of the present invention, FIG. 2 is an exploded perspective view of a mold that is applied to a multi-warm forming device according to an exemplary embodiment of the present invention, and FIG. 3 is a cross-sectional view of a multi-warm forming device according to an exemplary embodiment of the present invention.

[0045] Referring to FIG. 1 to FIG. 3, a multi-warm forming device and the forming method thereof according to an exemplary embodiment of the present invention forms an aluminum alloy sheet having super-plasticity to a maximum forming depth in a warm forming condition and then performs blow-forming to a final shape of a product.

[0046] Here, the super-plasticity material shows extreme ductility without local shrinkage when the material is deformed under a specific temperature condition, and the material can be an aluminum alloy sheet in an exemplary embodiment of the present invention.

[0047] That is, a multi-warm forming device and a forming method thereof according to an exemplary embodiment of the present invention perform warm forming that forms a material to a maximum forming depth through pressurized plastic deformation below an annealing temperature that lowers dislocation density within a material having a super-plasticity characteristic and then performs blow-forming that forms a material to a final product shape at a super-plasticity temperature of an aluminum alloy sheet such that a product can be produced by one mold set to have a deep forming depth and a complicated shape.

[0048] A multi-warm forming device according to an exemplary embodiment for realizing a technical characteristic of the present invention includes a lower mold die 1, a lower mold 3, an upper mold 5, and a blank holder 7.

[0049] The lower mold die 1 is mounted on a bolster (not shown) for a process, and a mold mounting portion 9 having two inside space portions (SP) is formed at a center thereof.

[0050] The lower mold 3 is mounted on an upper surface of a mold mounting portion 9 of the lower mold die 1, two gas supply passages L1 are formed inside in the vertical direction, and a lower forming surface 3a is formed on an upper surface thereof. Further, the gas supply passage L1 is connected to a gas supply device 11 that is disposed at an outside to supply a high pressure forming gas through a gas supply line L2.

[0051] Here, the lower forming surface 3a has an unfinished shape surface to form a material only to a maximum forming depth.

[0052] An upper surface of a mold mounting portion 9 of the lower mold die 1 is fixed to a lower surface of the lower mold 3 that is mounted thereto by key mounting, a key groove (KG) is formed at three points on an upper surface of a mold mounting portion 9 of the lower mold die 1 and a lower surface of a lower mold 3, and a holding key (K) is inserted into each key groove (KG) to fix a location of the lower mold 3 on the lower mold die 1.

[0053] An upper surface of a molding mounting portion 9 of the lower mold die 1 is formed as a flat mold mounting surface (F) such that a lower surface of the lower mold 3 is seated thereon.

[0054] Also, the gas supply line L2 that is connected to an outside gas supply device 11 is connected to two gas supply passages L1 through two space portions (SP) of the mold mounting portion 9. In this case, the gas supply line L2 is disposed to be covered by a heating unit (HU) inside two space portions (SP) of the mold mounting portion 9. That is, the heating unit (HU) is configured inside two space portions (SP) of the mold mounting portion 9, and the gas supply line L2 penetrates the center portion thereof to be disposed therein.

[0055] The heating unit (HU) includes a heater housing (HH) and a heating coil (HO), a penetration hole H1 that the gas supply line L2 penetrates is formed at a central portion of the heater housing (HH) that is disposed in a space portion

[0056] (SP) of the mold mounting portion 9, and the heating coil (HO) is wound in the heater housing (HH) and heats a forming gas of the gas supply line L2 to a predetermined high temperature by a power controller.

[0057] A heat insulating material (HP) is configured in two space portions (SP) of the mold mounting portion 9 and covers an outside of the heating unit (HU) so as to insulate the heating unit (HU).

[0058] The upper mold 5 is mounted on a slider (not shown) of an upper portion to move up and down corresponding to the lower mold 3 at an upper portion of the lower mold die 1. An upper forming surface 5a is formed at a lower surface of the upper mold 5 corresponding to the lower mold 3, and an upper mold face surface 5b is formed along a circumference of the upper forming surface 5a.

[0059] A plurality of heating cartridges 13 are mounted inside the upper forming surface 5a and the upper mold face surface 5b to be able to heat the upper mold 5 to a predetermined temperature.

[0060] The upper forming surface 5a is formed with a final product shape so as to form a final shape of a product.

[0061] The blank holder 7 is disposed to move in a vertical direction through a guide post 21 and a cushion spring 17 within the lower mold die 1 in a condition that the mold mounting portion 9 is inserted into a penetration hole H2 that is formed corresponding to the mold mounting portion 9.

[0062] In the blank holder 7, a plurality of heating cartridges 15 are formed inside a holder face surface 7a that holds a material together with the upper mold face surface 5b at an early stage of a forming process, and are configured to heat the blank holder 7 to a predetermined temperature.

[0063] An insulating case 19 is mounted on each outside surface of the upper mold 5 and the blank holder 7 to conserve heat energy inside the mold, and the insulating case 19 that is assembled on each outside surface of the upper mold 5 and the blank holder 7 can be a fine-porosity insulating sheet. FIG. 4 is a process block diagram showing steps of a multi-warm forming device according to an exemplary embodiment of the present invention, and FIG. 5 to FIG. 8 show an operational state of a multi-warm forming device according to an exemplary embodiment of the present invention.

[0064] Hereinafter, referring to FIG. 4 to FIG. 7, a forming method using a multi-warm forming device according to an exemplary embodiment of the present invention will be described in stages.

[0065] Referring to FIG. 4, a forming method using a multi-warm forming device according to an exemplary embodiment of the present invention performs a material supply step S1, a material heating step S2, a warm forming step S3, and a blow-forming step S4.

[0066] Firstly, as shown in FIG. 5, a material supply step S1 loads an aluminum alloy sheet (P) on a blank holder 7 that is mounted on the lower mold die 1 through a guide post 21 and a cushion spring 17 corresponding to a lower mold 3 that is mounted on the lower mold die 1 and a circumference of the lower mold 3.

[0067] Subsequently, as shown in FIG. 6, a material heating step S2 heats the aluminum alloy sheet (P) to a warm-forming temperature through a heating cartridge 13 disposed inside the upper mold 5 and the blank holder 7, wherein an upper mold 5 is firstly lowered by a slider (not shown) at an upper portion of the lower mold 3 and the upper mold 5 holds an edge of the aluminum alloy sheet (P) together with the blank holder 7.

[0068] Here, an edge of the aluminum alloy sheet (P) is held by an upper mold face surface 5b and a holder face surface 7a between the upper mold 5 and the blank holder 7, and the warm forming temperature set to a value below an annealing temperature that lowers dislocation density within an aluminum alloy sheet (P) having a super-plasticity characteristic.

[0069] Then, the warm forming step S3 is performed, and as shown in FIG. 7, the warm forming step S3 combines the upper mold 5 with the lower mold 3 through an operation of the slider (not shown) at the warm forming temperature, wherein the aluminum alloy sheet (P) is formed to a maximum forming depth by plastic deformation that is caused by pressurization.

[0070] The aluminum alloy sheet (P) is plastically deformed to a maximum forming depth by a warm forming process to have a first forming shape.

[0071] In this condition, the blow-forming step S4 is performed, as shown in FIG. 8, and the blow-forming step S4 uses the heating cartridges 13 and 15 to further heat the aluminum alloy sheet (P) that is formed to a maximum forming depth to a super-plasticity temperature, in a condition in which the upper mold 5 is combined with the lower mold 3, supplies a high pressure forming gas through a gas supply passage L1 that is formed inside the lower mold 3, and inflates the aluminum alloy sheet (P) through gas pressure along the upper forming surface 5a of the upper mold 5 such that the aluminum alloy sheet (P) is formed to a final shape of a complicated product.

[0072] At this time, the forming gas is supplied through a gas supply line L2 from an outside gas supply device 11, is heated to a high temperature while passing a heating unit (HU), and is supplied through a gas supply line L2 to the inside the lower mold 3.

[0073] In processes according to the forming method of the multi-warm forming device, the heat energy inside the upper mold 5 and the lower mold 3 is conserved by the insulating case 19 that is made of an insulating plate member having fine porosity and is mounted on each outside surface of the upper mold 5 and the blank holder 7 such that the heat loss is minimized to perform the processes.

[0074] As described above, a multi-warm forming device and a forming method thereof according to an exemplary embodiment of the present invention perform warm forming that forms a material to a maximum forming depth through pressurized plastic deformation below an annealing temperature that lowers dislocation density within an aluminum alloy sheet (P) having a super-plasticity characteristic and then heats an aluminum alloy sheet to a super-plasticity temperature to perform blow-forming that forms a material to a final product shape such that a product can be produced to have a deep forming depth and a complicated shape, and therefore it is not necessary to prepare a separate mold.

[0075] Further, in a multi-warm forming device and a forming method thereof according to an exemplary embodiment of the present invention, the number of components is reduced and the cost can be saved through a minimized number of processes when a product of which a forming depth is deep and a shape is complicated is formed, and therefore there is a merit in terms of cost, and complicated parts in the product are formed through blow-forming in which a gas pressure enlarges the material through non-contact with a mold and thus there is a merit of minimizing the defect rate compared with a conventional die casting method.

[0076] While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

DESCRIPTION OF SYMBOLS

[0077] 1: lower mold die

[0078] 3: lower mold

[0079] 5: upper mold

[0080] 7: blank holder

[0081] 9: mold mounting portion

[0082] 11: gas supply device

[0083] 13, 15: heating cartridge

[0084] 17: cushion spring

[0085] 19: insulating case

[0086] 21: guide post

[0087] HU: heating unit

[0088] SP: space portion

[0089] L1: gas supply passage

[0090] L2: gas supply line

[0091] H1, H2: penetration hole

[0092] 3a: lower forming surface

[0093] 5a: upper forming surface

[0094] 5b: upper mold face surface

[0095] 7a: holder face surface