CN111872300A - Progressive loading precision forming die device and process method for complex components of ultra-long grid high-rib wallboard - Google Patents
Progressive loading precision forming die device and process method for complex components of ultra-long grid high-rib wallboard Download PDFInfo
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- CN111872300A CN111872300A CN202010449399.7A CN202010449399A CN111872300A CN 111872300 A CN111872300 A CN 111872300A CN 202010449399 A CN202010449399 A CN 202010449399A CN 111872300 A CN111872300 A CN 111872300A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
- B21J13/02—Dies or mountings therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
- B21J5/025—Closed die forging
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K29/00—Arrangements for heating or cooling during processing
Abstract
The invention discloses a progressive loading precision forming die device and a process method for a complex component of an ultra-long grid high-rib wallboard, which relate to the technical field of hot working and comprise an upper die and a lower die, wherein a punch is arranged on the upper die; the lower die comprises an insert, a die core and a die holder, wherein the upper surface of the die holder is provided with an installation groove, the die core is slidably installed in the installation groove, and the insert is installed on the upper surface of the die core. According to the invention, through the horizontal sliding of the die core on the die holder, the local progressive loading of the forge piece on the single-action press is realized, the size of the die is reduced, and the folding defect caused by the integral loading is avoided.
Description
Technical Field
The invention relates to the technical field of hot working, in particular to a progressive loading precision forming die device and a process method for a complex component of an ultra-long grid high-rib wallboard.
Background
With the increasing requirements on high performance and light weight of carrying equipment and vehicles, the adoption of light high-strength materials (such as aluminum alloy, titanium alloy, high-performance steel and the like) and light-weight structures (such as high-rib thin-web structures and overall ultra-long complex structures) becomes an effective way for improving the reliability and reducing the weight of the carrying equipment and the vehicles.
If a traditional integral forging forming method is adopted for complex components such as ultra-long (the length is more than 1 meter) grid high-rib wallboards, long-shaft connecting rods or crankshafts, a large-tonnage die forging press is required, so that the forming load of a forging piece is overlarge, and the service life of a die is shortened. The isothermal local loading is adopted, so that the limit of a workbench and tonnage of forming equipment is broken through, the forming and manufacturing can be carried out on small and medium-sized equipment, the equipment investment and the maintenance cost are reduced, the temperature transfer between a die and a blank is avoided, the deformation of a forging piece is more uniform, and the structure performance after forming is more ideal.
The traditional local loading isothermal forming die device and the process method mainly utilize a plurality of combined upper dies for local loading, the upper die is divided into a step pressing plate and a plurality of inserts for forming a web by the JPH05293581A patent, the step pressing plate is dragged in the forming process to cause the height difference between the inserts, so that the web area of a forged piece is formed and an unformed area is pressed, the boundary area between the insert and the insert of the upper die structure must be selected near a forged piece rib, otherwise, a blank flows into the insert due to a gap between the insert and the insert to generate burrs, and the size of the upper die is limited by the size of the forged piece.
The patent of CN106134318B adopts a combined die of an inner die and an outer die, the forming process is mainly divided into two steps, the first step is to use a part of the die to form part of the web feature of the forging, the second step is to assemble the part of the die into an integral die and then integrally load the die, thus although the forming load is reduced, the size of the upper die is not reduced, and when the second step is integrally loaded, because the formed area is not restricted by the die, the metal in the unformed area flows to the formed area to generate folding.
For the curved rib plate, if the former die device is adopted, the bending step is required to be added to position on the lower die; the CN109894563A patent requires multiple loading of multiple stages of upper molds to form a local area.
Therefore, it is desirable to provide a new mold device and a new process method for local progressive loading precision forming of complex components of ultra-long mesh high-rib wall panels, so as to solve the above problems in the prior art.
Disclosure of Invention
The invention aims to provide a progressive loading precision forming die device and a process method for a complex component of an ultralong grid high-rib wallboard, which are used for solving the problems in the prior art, reducing the forming load of the component and forming the complex component of the ultralong grid high-rib wallboard.
In order to achieve the purpose, the invention provides the following scheme: the invention provides a progressive loading precision forming die device for a complex component of an overlong grid high-rib wallboard, which comprises an upper die and a lower die, wherein a punch is arranged on the upper die; the lower die comprises an insert, a die core and a die holder, wherein the upper surface of the die holder is provided with an installation groove, the die core is slidably installed in the installation groove, and the insert is installed on the upper surface of the die core.
Preferably, the insert and the die core are matched through a trapezoidal inclined surface; a wedge-shaped groove is processed at the joint of the upper surface of the mold core and the bottom of the insert, and a wedge iron is driven into the wedge-shaped groove; the angle of the inclined plane of the wedge iron is 10-30 degrees.
Preferably, the mold core is provided with scale marks in the length direction.
Preferably, the length of the punch is equal to the maximum local forming length of the forging in the forging pass; the length of the insert, the die core and the die holder is the same and is greater than that of the punch.
Preferably, the die holder further comprises a first pressing plate and a second pressing plate, the first pressing plate and the second pressing plate are respectively fixed at two ends of the die holder through pressing bolts, and the two ends of the die holder are correspondingly provided with pressing bolt holes; the lower surface of the first pressing plate is provided with a guide groove for positioning the blank.
Preferably, the width of the mounting groove is larger than that of the mold core, a puller bolt hole is formed in one side of the mold base, and a puller bolt is mounted in the puller bolt hole to fix the mold core.
Preferably, one end of the mold core is provided with a pull rod threaded hole, and a pull rod is installed in the pull rod threaded hole and used for pulling the mold core to horizontally move on the mold base.
The invention also discloses a gradual loading precision forming method of the complex component of the overlong grid high-rib wallboard, which comprises the following steps:
step (1): installing an upper die and a die holder, installing a die core with an insert on the die holder, enabling end surfaces on two sides of the die core and end surfaces on two sides of the die holder to be on a plane, and tightly pushing the die core in the die holder; after the installation is finished, heating the die to a specific temperature by using a heating pipe, and placing the blank, the first pressing plate and the second pressing plate in a heating furnace to be heated to the specific temperature;
step (2): after the blank and the die are heated, firstly installing a pull rod in a pull rod threaded hole on a die core, then taking a first pressing plate out of the heating furnace, positioning the position of the first pressing plate by utilizing a pressing bolt hole at one end of a die holder, and lapping a guide groove of the first pressing plate on the die core for positioning the initial blank;
taking out a blank from the heating furnace, placing the blank on the die core, plugging the blank into a guide groove of the first pressing plate, loosening the puller bolts, determining the numerical value of the scale mark on the die core corresponding to the tail end of the die holder according to the designed loading sequence of the grid high-rib wallboard component and the length of the first-pass forming, pulling the pull rod to pull the die core to the scale mark corresponding to the tail end of the die holder, and screwing the puller bolts at the two ends to fix the position of the die core on the die holder;
after the die core is fixed, a second pressing plate is arranged on a pressing bolt hole at the other end of the die holder, and a nut on the pressing bolt is screwed down so as to press the blank, so that the blank in an unformed area is prevented from warping due to local loading in the forming process;
after the installation is finished, the upper die descends, local characteristics of the forge piece are formed, the forging die returns to the initial position, and the nut and the puller bolt are loosened;
and (3): determining scales on the mold core corresponding to the tail end of the mold base according to the designed loading sequence of the grid high-rib wallboard component and the second-pass forming length, so that the mold core is pulled to a scale line corresponding to the side face of the mold base, tightening the jacking bolts at two ends to fix the mold core at the set position of the mold base, tightening nuts on the compression bolts, descending the upper mold after the installation is finished, returning to the initial position after local characteristics of a forge piece are molded, and loosening the nuts and the jacking bolts;
when all the characteristics of the forge piece cannot be formed through the two-pass local loading process step, continuing the third or more-pass loading process step until the forge piece meets all the characteristic requirements;
and (4): aiming at slight warping of a part of area of the forge piece caused by local loading, local finishing is carried out on the forge piece, the number of the locally finished passes is consistent with that of the locally loaded passes, each pass of the local finishing is that a mold core is horizontally pulled to a scale mark position of a corresponding pass local loading step, then a jacking bolt is screwed down according to the sequence of each previous pass local loading, a nut on a compression bolt is screwed down, then local characteristic finishing of the forge piece is carried out by descending an upper mold, the upper mold returns to an initial position after finishing, the nut and the jacking bolt are loosened, and the process of the local finishing is gradually finished until all the locally finished passes are finished;
and (5): and (3) unloading the first pressing plate and the second pressing plate, and driving the wedge iron into the wedge-shaped groove, so that the insert is slightly lifted relative to the mold core, and the forging demoulding effect is achieved.
Preferably, in the step (2), the heating temperature of the blank and the die is 400-450 ℃; in the steps (2) to (4), the descending speed of the upper die is 0.5mm/s to 3 mm/s.
Preferably, the first and second liquid crystal materials are,
the width of the blank is:
the width of the blank of the complex component of the straight-face overlong grid high-rib wallboard is the width of the forge piece plus delta B;
the width of the curved surface overlength grid high-rib wallboard complex component blank is as follows:
B＝Rα+ΔB
wherein: b is the width of the curved surface overlength grid high-rib wallboard complex component blank, the unit is mm, R is the curved surface radius, the unit is mm, alpha is the curved surface corresponding central angle, the unit is rad, and the value range of delta B is 10-30 mm;
the length of the blank is as follows:
L＝l(1-Δ)
wherein: l is the blank length in mm, L is the projection length of the component in mm, and the value range of delta is 0.04-0.06;
the thickness of the blank is as follows:
wherein: h is the thickness of the blank in mm and V1Is the volume of the forged piece in mm3，V2Is the product of flash tank body, and the unit is mm3，k3The filling coefficient is in a value range of 0.2-0.5;
the number of local loads is:
wherein: t is1Is the maximum tonnage of the equipment, and the unit is T, T2The tonnage required for integral forming is given in t, M is the local loading frequency]To get the integer down, k1The value of k is an equipment coefficient and ranges from 0.5 to 0.9 according to the stability of the equipment2Taking a positive integer as a pass coefficient;
the local progressive loading sequence is a sequence of sequentially loading from one end to the other end or a sequence of sequentially loading from the middle to the two ends;
the overlapping size of the two loading areas is 1/3-1/2 of the length of the rib spacing, and in order to ensure that the rib part at the edge part of the local loading area is well filled, the length of the local loading area needs to cross the rib part at the edge part of the loading area and cross 1/5-1/2 of the distance of the rib spacing.
Compared with the prior art, the invention has the following technical effects:
the die core sliding structure is adopted in the invention, the size of the upper die is not restricted by the size of a forged piece, but the forming method can be designed according to the maximum local forming length allowed by the tonnage of the existing equipment, compared with the traditional local loading device, the die core sliding structure breaks through the limitation of the size and the tonnage of a workbench of the forging equipment, saves die materials, reduces forging cost, avoids the generation of folding defects, and enables the local forging process to be flexibly modified according to the tonnage of the equipment.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a front view of a progressive loading precision forming die structure for a complex component of an ultralong grid high-rib wallboard;
FIG. 2 is a schematic view of a curved surface mesh rib sheet forging;
FIG. 3 is a left side view of a progressive loading precision forming die structure for a complex component of an ultra-long grid high-rib wallboard of the present invention;
FIG. 4 is a schematic view of the process of forming the complex component of the ultra-long grid high-rib wallboard by multi-pass gradual local loading according to the present invention;
FIG. 5 is a left side view of the upper die of the present invention;
FIG. 6 is a top view of the mold core and mold base combination of the present invention;
FIG. 7 is a schematic view of a first platen of the present invention;
FIG. 8 is a schematic view of a second platen of the present invention;
FIG. 9 is a schematic view of the wedge of the present invention;
FIG. 10 is a schematic view of a drawbar according to the present invention;
in the drawing, 1 is an upper die, 2 is a compression bolt, 3 is a first pressing plate, 4 is a blank, 5 is an insert, 6 is a die core, 7 is a die holder, 8 is a pull rod threaded hole, 9 is a wedge-shaped groove, 10 is a pressing plate threaded hole, 11 is a puller bolt, 12 is a second pressing plate, 13 is a wedge, and 14 is a pull rod.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
The invention discloses a progressive loading precision forming die device for a complex component of an overlong grid high-rib wallboard, which comprises an upper die 1, a first pressing plate 3, a second pressing plate 12, a pull rod 14, an insert 5, a die core 6, a die holder 7 and a wedge 13, wherein a lower die consists of the insert 5, the die core 6 and the die holder 7.
Specifically, the insert 5 and the die core 6 are matched by utilizing a trapezoidal inclined surface to form a die structure capable of moving together, the insert type die structure is to reduce the demolding force of a grid high-rib wall plate forge piece and prevent the forge piece from deforming during demolding, a wedge-shaped groove is processed on the die core 6, the insert 5 is slightly lifted by driving a wedge 13 into the wedge-shaped groove, the forge piece can be separated from the die core 6 to achieve the demolding effect, and the angle of the wedge inclined surface is 10-30 degrees.
Specifically, the length N of the punch of the upper die 1 is equal to the local forming length of the largest forge piece in a forging pass, the length of the insert 5, the length of the die core 6 and the length of the die holder 7 are the same, the length X of the insert is the total length of the forge piece plus the length of the flash, and N is less than X.
Further, a first pressing plate 3 and a second pressing plate 12 are positioned on two sides of the punch of the upper die 1, and the first pressing plate 3 and the second pressing plate 12 are positioned through pressing bolt holes in the die holder 7 and are respectively installed on the four pressing plate bolts 2; the guide groove of the first pressing plate 3 is lapped on the upper surface of the blank 4 and is used for positioning the initial position of the blank on the mold core 6, and the blank is pressed by screwing the screw caps on the first pressing plate 3 and the second pressing plate 12, so that the two ends of the blank are prevented from being upwarped in the local loading process.
Furthermore, scale marks are arranged in the length direction of the die core 6, and the local forming length of each pass of the forge piece is converted into the numerical value of the corresponding die core scale mark on the side surface of the die holder.
Furthermore, a gap with a distance L is reserved on one side of the die core 6 and one side of the die holder 7, so that the die core 6 with the insert 5 can horizontally slide on the die holder 7 conveniently, and the distance L is 1-5 mm; and a tight-jacking threaded hole is punched in the side surface of one end of the die holder 7, and a tight-jacking bolt 11 is screwed into the tight-jacking threaded hole to enable the die core 6 to be tightly attached to the end surface of the die holder groove on the gapless side.
Two threaded tie rod holes are provided at one end of the mold core 6, and two tie rods 14 are mounted in the threaded holes for pulling the mold core 6 to move horizontally on the mold base 7.
Example one
As shown in figures 1-10, a large-scale grid rib plate aluminum alloy member is taken as an example, the shape of the large-scale grid rib plate aluminum alloy member is shown in figure 2, the material of a part is 5A06 aluminum alloy, the length of the member is 1100mm, the arc radius of a curved surface is 180mm, the central angle is 60 degrees, 12 grids are provided, the length of each grid is 170mm, the width is 75mm, the thickness is 4mm, the height of a rib is 10mm, and the width of the rib is 10 mm.
The progressive loading precision forming die device for the complex component of the overlong grid high-rib wallboard comprises a press plate bolt 2, an insert 5, a die core 6, a die holder 7, an upper die 1, a first press plate 3, a second press plate 12, a wedge 13 and a pull rod 14, and the specific forming process is shown in fig. 3 and 4.
Firstly, the size of the blank, the specific times of local loading and the sequence of the local loading, the loading length and the loading area position are determined.
Determining the size of the blank: according to the geometrical characteristics of the complex components of the overlong grid high-rib wallboard, a rolled plate blank can be used as a blank, the blank width of the complex components of the straight-face overlong grid high-rib wallboard is the width of a forge piece plus delta B, the blank width is ensured to be slightly larger than the unfolding width of a curved-face component for the curved-face overlong grid high-rib wallboard component, and the blank width B of the curved-face overlong grid high-rib wallboard component is determined by adopting a formula (1):
B＝Rα+ΔB (1)
in the formula: b is the width (mm) of the curved surface overlong grid high-rib wallboard component blank, R is the curved surface radius (mm), alpha is the curved surface corresponding central angle (rad), and the value range of delta B is 10-30 mm;
in the embodiment, the width of the blank is slightly larger than the width of the component, which is beneficial to quickly forming bridge opening resistance in the pressing process, forcing more blanks to flow into the cavity and fill the rib part to improve the material utilization rate, and in order to ensure that the blanks are stably placed, the width of the blank is slightly wider than delta B, so that the blanks can be lapped on a flat bridge opening; the value range of the delta B is set to be 10-30 mm, the upper limit of the delta B is selected to be 30mm, and the width of the blank is not allowed to exceed the bridge opening.
The billet will flow to some extent during loading, so the length of the billet should be slightly shorter than the length of the member, and the length L of the billet is determined by the formula (2):
L＝l(1-Δ) (2)
in the formula: l is the blank length (mm), L is the projection length (mm) of the component, and the value range of delta is 0.04-0.06;
the blank can extend to the free end in the loading process, certain flow can occur in the length direction, so that the length of the blank can be slightly shorter than the projection length of the forge piece, and the reduction ratio delta is set to be 0.04-0.06.
According to the design rule of the forging, the blank volume simultaneously considers the forging volume and the volume of the flash groove, the thickness H of the blank is determined by adopting a formula (3), and the blank is optimized according to the standard series;
in the formula: h is blank thickness (mm), V1Is the volume (mm) of the forging3)，V2Is the volume (mm) of the flash tank3)，k3The filling coefficient is in a value range of 0.2-0.5;
the design rule of the forge piece is that the blank volume is equal to the forge piece volume plus the flash volume of the forge piece, and the flash volume of the forge piece is estimated by the flash tank volume of 0.2-0.5 in the actual production.
Determining the specific times of local loading: maximum tonnage T of existing equipment1And the maximum tonnage T required by forming the complex component of the ultra-long grid high-rib wallboard2Determining the specific number M of local loading by adopting a formula (4):
in the formula: t is1Is the maximum tonnage (T) of the equipment2The required tonnage (t) for the integral forming]To get the integer down, k1The value of k is an equipment coefficient and ranges from 0.5 to 0.9 according to the stability of the equipment2Taking a positive integer as a pass coefficient;
according to the design of equipment, the maximum tonnage is used, great loss is generated on the equipment, meanwhile, some old equipment can generate unstable conditions under the condition of full tonnage loading, therefore, the proper tonnage loading is recommended to be selected according to the actual condition of the equipment, and the coefficient k is given1Represents;
for example, the whole loading tonnage is 8000T, the maximum tonnage of 3000T is allowed to be locally loaded, and the loading is dividedAnd the lower integer is 2, the forming can be completed by at least 3 times, and more times can be used for completing the forming from the process point of view, so that the positive integer k is added after the lower integer is rounded2。
Determining the loading sequence: if the loading times are determined to be M according to the step 2, considering the symmetry of the complex components of the overlong grid high rib wallboard, the loading times coexist in M! And 2 loading sequences. The loading sequence easy to operate comprises three types, wherein one type is that the loading is carried out from one end to the other end in sequence, the other type is that the loading is carried out from two ends to the middle in sequence, and the third type is that the loading is carried out from the middle to two ends in sequence; from a metal flow perspective, the second loading sequence results in a continuous build up of metal toward the middle causing the slab to buckle, which may occur during loading in the middle area. In this embodiment, the first or third type loading order is used as the preferred loading order.
Determining the size of an overlapping area and the loading length: to ensure the formation of the interface region between the two passes, the two loading regions overlap by a dimension 1/3-1/2 of the rib pitch length. In order to ensure good filling of the edge portion rib of the local loading zone, the length of the local loading zone needs to cross the edge portion rib of the loading zone and cross 1/5-1/2 with the distance of the rib spacing, so that the rib positioned in the edge area can obtain good filling effect, and the blank around the next locally formed rib is sufficient. The loading length should be selected in combination with the above considerations.
In the embodiment, according to the characteristics of a grid rib structure and the tonnage of a press, a flat plate material with the length of 1050mm, the width of 200mm and the thickness of 10mm is determined to be adopted, a local loading pass is designed to be 3 passes, the local loading length of the first pass is 410mm, the local loading length of the second pass is 440mm, the local loading length of the third pass is 410mm, a transition overlapping area with the length of 80mm is reserved between the passes, the loading sequence is from left to right, the punch length N of an upper die 1 is designed according to the maximum local forming length of a forge piece in the forging pass and is the same as the local loading length of the second pass, so that N is 440mm, the length of a die 7, the length of a die core 6 and the length of an insert 5 are the same, the design also needs to consider the flash and the bearing capacity according to the overall length of the forge piece, 1150mm is marked on the die core, and the position of a scale mark line 0 on the die core is arranged on, the clearance L between the die core 6 and the die holder 7 is 3mm, and the wedge inclined angle is 15 degrees.
The local progressive loading precision forming method for the complex component of the overlong grid high-rib wallboard in the embodiment comprises the following specific steps:
step 1: installing an upper die and a die holder, matching an insert 5 with a die core 6 through a trapezoidal inclined plane to enable the end surfaces of two sides of the two components to be basically on the same plane, then installing the die core 6 with the insert 5 on the die holder 7 to enable the end surfaces of two sides of the die core 6 and the end surfaces of two sides of the die holder 7 to be basically on the same plane, fixing the die core in the die holder through a puller bolt 11, heating the upper die and the lower die to 435 ℃ by using a heating pipe after the installation is finished, and heating the blank 4, the first pressing plate 3 and the second pressing plate 12 in a heating furnace to 435 ℃.
Step two: after the blank 4 and the die are heated, firstly two pull rods 14 are arranged in two pull rod threaded holes 8 at one end of a die core 6, a first pressing plate 3 with a guide groove is taken out, the position of the first pressing plate 3 is positioned by four bolt holes 10 at one end of the die base, the guide groove is lapped on the die core and is used for positioning an initial blank, the blank 4 is taken out from a heating furnace and is placed on the die core and is inserted into the guide groove of the first pressing plate 3, a jacking bolt is loosened, the corresponding scale mark of the tail end of the die base 7 when the die core 6 is pulled to the tail end of the die base 7 is determined to be 215mm according to the length of the first-time forming, the pull rods 14 are pulled, at the moment, as shown in figure 6, the die core 6 exceeds one end of the die base 7, the jacking bolt 11 is screwed, after the die core is fixed, a second pressing plate 12 is arranged on four bolts 2 at the other end of the die base 7, nuts on the pressing plate bolts 2 are screwed, so, after the installation is finished, the upper die descends at 1mm/s until the upper die and the lower die abut against each other, then the upper die returns to the initial position, and then eight nuts and jacking bolts are loosened.
Step three: according to the length of the second-pass forming, the two ends of the die holder are determined to be aligned with the two ends of the die core, the jacking bolt 11 is screwed to fix the die core, the nut on the pressing plate bolt 2 is screwed after the die core is fixed, the upper die descends at 1mm/s after the installation is finished until the upper die returns to the initial position after the upper die and the lower die are abutted, and then the eight nuts and the jacking bolt are loosened;
step four: according to the length of the third forming, which is 410mm, determining that the scale mark corresponding to the end, pulled to the die holder 7, of the die core 6 is 215mm, the position of the scale mark 215mm at the moment is different from that in the step 2 and is positioned at the other side of the scale mark 0, the die core 6 exceeds one end of the die holder 7 at the moment, screwing the jacking bolt 11 to fix the die core, screwing the nut on the pressing plate bolt 2 after the die core is fixed, then descending the upper die at 1mm/s until the upper die and the lower die are abutted, then returning the upper die to the initial position, and then loosening the eight nuts and the jacking bolt;
step five: performing local finishing on the forge piece, performing first-pass finishing, pulling the mold core 6 back to the position of the scale mark locally loaded at the first pass, screwing the jacking bolt 11 to fix the mold core, screwing the nut on the pressure plate bolt 2 after the mold core is fixed, descending the lower mold at 1mm/s after the installation is finished until the upper mold returns to the initial position after the upper mold and the lower mold are closed, and then loosening the eight nuts and the jacking bolt;
step six: second pass finishing, namely pulling out the mold core 6 to a second pass local loading position, screwing the jacking bolt 11 to fix the mold core, screwing the nut on the pressure plate bolt 2 after the mold core is fixed, descending the upper mold at 1mm/s after the installation is finished until the upper mold returns to the initial position after the upper mold and the lower mold are abutted, and then loosening the eight nuts and the jacking bolt;
step seven: and (3) performing third finishing, namely pulling out the mold core 6 to a third local loading position, screwing the jacking bolt 11 to fix the mold core, screwing the nut on the pressing plate bolt 2 after the mold core is fixed, descending the lower mold at 1mm/s after the installation is finished until the upper mold returns to the initial position after the upper mold and the lower mold are abutted, and then loosening the eight nuts and the jacking bolt.
Step eight: and (3) unloading the two pressing plates, respectively driving the two wedges 13 into the wedge-shaped grooves 9 at the two ends of the insert 5, slightly lifting the insert 5 relative to the mold core 6, separating the forge piece from the mold core 6, and then taking out the forge piece. The forged piece has good rib filling and no folding defect through the detection surface.
The invention makes the lower die into a die structure capable of sliding back and forth and adopts a process method of partial overlapping loading, the upper die can vertically move up and down relative to the lower die, and the local rib and web characteristics of the forge piece are formed by horizontally moving the die core of the lower die, thereby realizing the local gradual loading. If the former die device is adopted, the bending step must be added to position the curved rib plate on the lower die, but the loading area can be adjusted by adopting the device of the invention, so that the curved rib plate component can be formed by adopting a flat plate blank.
According to the invention, each pass of loading area is formed for one time, the problem of upwarping of an unloaded area in a local loading process is solved by using the pressing plate, a blank is positioned on the die, and the position of the lower die in dragging is fixed by tightening the bolt.
The principle and the implementation mode of the invention are explained by applying a specific example of a complex component of an ultra-long grid high-rib wallboard, and the description of the embodiment is only used for helping to understand the method and the core idea of the invention; meanwhile, for those skilled in the art, according to the idea of the present invention, the specific implementation and the application range may be changed, for example, the invention is applied to a long shaft type connecting rod or a crankshaft and other complex components. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (10)
1. A progressive loading precision forming die device for a complex component of an overlong grid high-rib wallboard comprises an upper die and a lower die, wherein a punch is arranged on the upper die; the method is characterized in that: the lower die comprises an insert, a die core and a die holder, wherein the upper surface of the die holder is provided with an installation groove, the die core is slidably installed in the installation groove, and the insert is installed on the upper surface of the die core.
2. The progressive loading precision forming die device for the complex component of the overlong grid high-rib wallboard according to claim 1, characterized in that: the insert and the mold core are matched through a trapezoidal inclined surface; a wedge-shaped groove is processed at the joint of the upper surface of the mold core and the bottom of the insert, and a wedge iron is driven into the wedge-shaped groove; the angle of the inclined plane of the wedge iron is 10-30 degrees.
3. The progressive loading precision forming die device for the complex component of the overlong grid high-rib wallboard according to claim 2, characterized in that: and scale marks are arranged in the length direction of the mold core.
4. The progressive loading precision forming die device for the complex component of the overlong grid high-rib wallboard according to claim 1, characterized in that: the length of the punch is equal to the local forming length of the largest forging in the forging pass; the length of the insert, the die core and the die holder is the same and is greater than that of the punch.
5. The progressive loading precision forming die device for the complex component of the overlong grid high-rib wallboard according to claim 1, characterized in that: the die holder is characterized by further comprising a first pressing plate and a second pressing plate, wherein the first pressing plate and the second pressing plate are fixed at two ends of the die holder through pressing bolts respectively, and pressing bolt holes are correspondingly formed in two ends of the die holder; the lower surface of the first pressing plate is provided with a guide groove for positioning the blank.
6. The progressive loading precision forming die device for the complex component of the overlong grid high-rib wallboard according to claim 1, characterized in that: the width of the mounting groove is larger than that of the mold core, a tightening bolt hole is formed in one side of the mold base, and a tightening bolt is mounted in the tightening bolt hole and used for fixing the mold core.
7. The progressive loading precision forming die device for the complex component of the overlong grid high-rib wallboard according to claim 1, characterized in that: and a pull rod threaded hole is formed in one end of the mold core, and a pull rod is installed in the pull rod threaded hole and used for pulling the mold core to horizontally move on the mold base.
8. A gradual loading precision forming method for a complex component of an overlong grid high-rib wallboard is characterized by comprising the following steps: the method comprises the following steps:
step (1): installing an upper die and a die holder, installing a die core with an insert on the die holder, enabling end surfaces on two sides of the die core and end surfaces on two sides of the die holder to be on a plane, and tightly pushing the die core in the die holder; after the installation is finished, heating the die to a specific temperature by using a heating pipe, and placing the blank, the first pressing plate and the second pressing plate in a heating furnace to be heated to the specific temperature;
step (2): after the blank and the die are heated, firstly installing a pull rod in a pull rod threaded hole on a die core, then taking a first pressing plate out of the heating furnace, positioning the position of the first pressing plate by utilizing a pressing bolt hole at one end of a die holder, and lapping a guide groove of the first pressing plate on the die core for positioning the initial blank;
taking out a blank from the heating furnace, placing the blank on the die core, plugging the blank into a guide groove of the first pressing plate, loosening the puller bolts, determining the numerical value of the scale mark on the die core corresponding to the tail end of the die holder according to the designed loading sequence of the grid high-rib wallboard component and the length of the first-pass forming, pulling the pull rod to pull the die core to the scale mark corresponding to the tail end of the die holder, and screwing the puller bolts at the two ends to fix the position of the die core on the die holder;
after the die core is fixed, a second pressing plate is arranged on a pressing bolt hole at the other end of the die holder, and a nut on the pressing bolt is screwed down so as to press the blank, so that the blank in an unformed area is prevented from warping due to local loading in the forming process;
after the installation is finished, the upper die descends, local characteristics of the forge piece are formed, the forging die returns to the initial position, and the nut and the puller bolt are loosened;
and (3): determining scales on the mold core corresponding to the tail end of the mold base according to the designed loading sequence of the grid high-rib wallboard component and the second-pass forming length, so that the mold core is pulled to a scale line corresponding to the side face of the mold base, tightening the jacking bolts at two ends to fix the mold core at the set position of the mold base, tightening nuts on the compression bolts, descending the upper mold after the installation is finished, returning to the initial position after local characteristics of a forge piece are molded, and loosening the nuts and the jacking bolts;
when all the characteristics of the forge piece cannot be formed through the two-pass local loading process step, continuing the third or more-pass loading process step until the forge piece meets all the characteristic requirements;
and (4): aiming at slight warping of a part of area of the forge piece caused by local loading, local finishing is carried out on the forge piece, the number of the locally finished passes is consistent with that of the locally loaded passes, each pass of the local finishing is that a mold core is horizontally pulled to a scale mark position of a corresponding pass local loading step, then a jacking bolt is screwed down according to the sequence of each previous pass local loading, a nut on a compression bolt is screwed down, then local characteristic finishing of the forge piece is carried out by descending an upper mold, the upper mold returns to an initial position after finishing, the nut and the jacking bolt are loosened, and the process of the local finishing is gradually finished until all the locally finished passes are finished;
and (5): and (3) unloading the first pressing plate and the second pressing plate, and driving the wedge iron into the wedge-shaped groove, so that the insert is slightly lifted relative to the mold core, and the forging demoulding effect is achieved.
9. The progressive loading precision forming method of the complex component of the overlong grid high-rib wallboard according to claim 8, characterized in that: in the step (2), the heating temperature of the blank and the die is 400-450 ℃; in the steps (2) to (4), the descending speed of the upper die is 0.5mm/s to 3 mm/s.
10. The progressive loading precision forming method of the complex component of the overlong grid high-rib wallboard according to claim 8, characterized in that:
the width of the blank is:
the width of the blank of the complex component of the straight-face overlong grid high-rib wallboard is the width of the forge piece plus delta B;
the width of the curved surface overlength grid high-rib wallboard complex component blank is as follows:
B＝Rα+ΔB
wherein: b is the width of the curved surface overlength grid high-rib wallboard complex component blank, the unit is mm, R is the curved surface radius, the unit is mm, alpha is the curved surface corresponding central angle, the unit is rad, and the value range of delta B is 10-30 mm;
the length of the blank is as follows:
L＝l(1-Δ)
wherein: l is the blank length in mm, L is the projection length of the component in mm, and the value range of delta is 0.04-0.06;
the thickness of the blank is as follows:
wherein: h is the thickness of the blank in mm and V1Is the volume of the forged piece in mm3，V2Is the product of flash tank body, and the unit is mm3，k3The filling coefficient is in a value range of 0.2-0.5;
the number of local loads is:
wherein: t is1Is the maximum tonnage of the equipment, and the unit is T, T2The tonnage required for integral forming is given in t, M is the local loading frequency]To get the integer down, k1The value of k is an equipment coefficient and ranges from 0.5 to 0.9 according to the stability of the equipment2Taking a positive integer as a pass coefficient;
the local progressive loading sequence is a sequence of sequentially loading from one end to the other end or a sequence of sequentially loading from the middle to the two ends;
the overlapping size of the two loading areas is 1/3-1/2 of the length of the rib spacing, and in order to ensure that the rib part at the edge part of the local loading area is well filled, the length of the local loading area needs to cross the rib part at the edge part of the loading area and cross 1/5-1/2 of the distance of the rib spacing.
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| CN114799004A (en) * | 2022-04-28 | 2022-07-29 | 中国第二重型机械集团德阳万航模锻有限责任公司 | Forming method of thin web forging |
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