Manufacturing method for forge welding shaft bridge
Technical Field
The invention relates to the technical field of vehicles, in particular to a manufacturing method for a forge welding axle bridge.
Background
Generally speaking, a forge welding axle bridge can be composed of three parts, namely a two-side axle head and a middle axle body, wherein the axle head can be made of carbon steel through forging, heat treatment and machining; the shaft body can adopt heterogeneous H-shaped steel, and the H-shaped structure meeting the requirements is formed by re-welding after cutting off materials from the web part; finally, the shaft heads and the shaft bodies on the two sides can be welded into a shaft bridge.
Typically, the existing shaft products are usually integrally forged and processed into a final delivery state, and the existing shaft products are cylindrical and centrosymmetric, the circumferential rotating centrifugal force is small during processing, and the influence of the shape characteristics of the products on the processing precision is small. However, the forge welding axle head is formed by welding a multi-step cylindrical part at the end part and a square head part at one end, and the deformation caused by welding and the deviation of the gravity center of the square head part and the central line of the cylindrical part are far away, so that the eccentric swing is serious in the axle machining process. The axle head of the axle comprises three cylindrical surfaces and a conical surface, the dimensional tolerance of the three cylindrical surfaces is small, the conical surface needs to detect the size of two positions away from the axle shoulder, and the tolerance is small. And the runout of the cylinders and the conical surfaces at the two ends of the shaft head is required to be less than 0.02 mm.
Accordingly, there is a need in the art for a method of manufacturing a forge welded axle bridge that eliminates or at least alleviates all or some of the above-mentioned deficiencies of the prior art.
Disclosure of Invention
Aiming at the technical problems in the prior art, the invention aims to provide a manufacturing method for a forge welding axle, which can reasonably design axle head forging, heat treatment and processing technologies and cutting and welding of axle body deformed steel, so that the performance and the size of an axle head and an axle body before welding can meet the welding requirement while the material utilization rate and the production efficiency are improved, and the machining process of the axle is integrally optimized.
It is emphasized that, unless otherwise indicated, the terms used herein correspond to the ordinary meanings of the various technical and scientific terms in the art, and the meanings of the technical terms defined in the various technical dictionaries, textbooks, etc.
To this end, according to an embodiment of the invention, a manufacturing method for a forge welded axle bridge is provided, wherein the manufacturing method comprises:
optimally designing the integral manufacturing process of the forge welding shaft bridge;
optimally designing a shaft head manufacturing procedure;
optimally designing a welding procedure;
and optimally designing the machining process of the axle bridge.
Further, the optimization design of the integral manufacturing process of the forge welding shaft bridge can comprise the following steps:
the shaft head of the forge welding shaft bridge is manufactured by forging, heat treating and machining carbon steel billets in sequence;
manufacturing a shaft body of the forge welding shaft bridge by using dissimilar H-shaped steel, wherein the dissimilar H-shaped steel is formed by welding two T-shaped steel plates;
and then, welding the manufactured shaft body and the shaft heads positioned at the two ends of the shaft body together.
Further, the optimized design of the shaft head manufacturing process can comprise the following steps:
the shaft head consists of a shaft end shaft neck and a square head part, wherein the shaft head is forged by adopting a two-in-one free co-forging process.
Further, the optimized design of the shaft head manufacturing process can further comprise the following steps:
performing finish machining on the shaft head after heat treatment;
inclined planes and arc surfaces on two sides of the shaft head are directly processed to be in a finished product state;
the welding area is directly processed and formed in a linear cutting mode.
Further, the welding process optimization design may include:
when the shaft body is manufactured, alloy steel is selected as the steel plate for welding.
Furthermore, the alloy steel can be H-shaped steel with proper specification.
Further, the welding procedure optimization design may further include:
after the standard specification of the H-shaped steel is inspected to be qualified, each H-shaped steel is cut into two parts along the center of a web plate;
after the H-shaped steel is cut off, grooves are processed on the section steel parts at the upper end and the lower end, and then the section steel parts at the upper end and the lower end are welded into finished H-shaped steel.
Further, the welding procedure optimization design may further include:
after the forge welding shaft bridge is welded, performing post-welding stress relief treatment on the forge welding shaft bridge;
before and after the stress relief treatment, visual inspection, radiographic inspection, magnetic detection and ultra detection are respectively carried out on the welding seam.
Further, the axle bridge machining process optimization design can comprise two stages which are sequentially carried out, namely an axle bridge semi-finishing process and an axle bridge finishing process, wherein the axle bridge semi-finishing process comprises the following steps which are sequentially carried out:
milling the side face of the axle bridge → finely milling the bottom face of the axle bridge → finely milling the two side faces of the axle bridge → finely milling the upper planes of the axle heads at the two ends of the axle bridge → finely milling the inner open of the axle bridge → processing the threaded hole → assembling and adjusting the fixed plate and the counterweight block → turning the cylindrical part of the axle head → boring the end hole of the axle → vibrating destressing → the end hole of the axle of the finished axle → semi-finely turning the cylindrical part of the axle head → standing destressing;
the axle bridge finishing process may comprise the steps in the following order:
the column and the arc of the axle head of the finish turning axle → the groove between the column and the square head of the axle head of the finish turning axle → each column of the axle head of the finish turning unilateral → the conical surface of the axle head of the finish turning opposite side → each column of the axle head of the finish turning opposite side.
Further, the axle bridge machining process optimization design may further include:
at least one thin gasket is selectively clamped between the axle bridge balancing weight and the fixing plate so as to adjust the upper part of the axle bridge to distribute the heavy end rotating moment;
and after balancing by balancing weight and adjusting balance, performing grinding processing on the forge welding shaft bridge.
The manufacturing method for the forge welding shaft bridge provided by the embodiment of the invention has the following beneficial effects:
firstly, the processing technology designed by the invention reasonably designs the forging, heat treatment and processing technologies of the shaft head and the cutting and welding of the shaft body deformed steel, so that the performance and the size of the shaft head and the shaft body before welding can meet the welding requirement while the material utilization rate and the production efficiency are improved, and the machining process of the shaft bridge is integrally optimized.
Furthermore, the invention can reasonably scribe after welding, and carry out boring-milling and turning-grinding processing; meanwhile, stress relief treatment can be carried out in multiple links in the processing and manufacturing process; in the turning and grinding process, a special choke plug and a special balancing weight can be arranged; the taper surface of the shaft head can be designed and manufactured with a special detection device and the like so as to ensure that the sizes and form and position tolerances of all parts of the cylindrical surface and the conical surface detection part of the forge welding shaft bridge meet the requirements, and all parts of a final product meet the requirements of drawings and technology.
Drawings
The accompanying drawings, which are included to provide a further understanding of embodiments of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 schematically illustrates a flow chart of a method of manufacturing a forge welded axle bridge in accordance with one embodiment of the present invention;
FIG. 2 schematically illustrates a schematic view of a forge welded axle bridge manufactured using the manufacturing method for a forge welded axle bridge of FIG. 1;
FIG. 3 schematically illustrates a schematic view of a stub shaft of the forge welded axle bridge of FIG. 2;
FIG. 4 schematically shows a schematic view of an H-section steel for the axle body of the forge welded axle bridge of FIG. 2.
Description of the element reference numerals
100: forge welding the axle bridge; 110: a shaft body; 120: a shaft head; 121: a shaft end journal; 122: a square head part.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the specific embodiments of the present invention and the accompanying drawings. It is to be understood that the described embodiments are merely a few embodiments of the invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present invention without making any creative effort, shall fall within the protection scope of the present invention.
The technical scheme provided by the embodiment of the invention is explained in detail in the following with the accompanying drawings.
Referring to FIG. 1, a method of manufacturing a forge welded axle bridge according to an embodiment of the present invention is shown, wherein the method of manufacturing comprises:
optimally designing the integral manufacturing process of the forge welding shaft bridge;
optimally designing a shaft head manufacturing procedure;
optimally designing a welding procedure;
and optimally designing the machining process of the axle bridge.
Aiming at the characteristics of complex structure and higher precision requirement of a forge welding shaft bridge, in order to meet the drawing and technical requirements, the general design idea of the invention is as follows:
1) optimally designing the integral manufacturing process of the forge welding shaft bridge;
2) optimally designing a shaft head manufacturing procedure;
3) optimally designing a welding procedure;
4) and (3) optimizing and designing the machining process of the high-precision axle bridge machine.
The above design method is described in detail below with reference to the accompanying drawings.
1) Designing the process of the integral manufacturing method of the forge welding shaft bridge.
As shown in FIG. 2, the forge welded axle bridge 100 is complex in construction and may be generally comprised of three sections, an axle body 110 at the center and axle heads 120 at the ends of the axle body 110. Wherein, the spindle head 120 can be made of carbon steel billet by forging, heat treatment and machining in sequence; the shaft body 110 can be made of heterogeneous H-shaped steel which is formed by welding an upper T-shaped steel plate and a lower T-shaped steel plate; finally, the two end stub shafts 120 and the axle body 110 may be welded together to ultimately form the forge welded axle bridge 100.
2) The shaft head manufacturing method is designed in process.
The stub shaft 120 may be comprised of a shaft end journal 121 and a square head portion 122. When the shaft head 120 is forged, a two-in-one free co-forging process can be adopted, and fig. 3 shows a co-forging schematic view of the shaft head 120.
The stub shaft 120 may be finish machined after heat treatment. After finish machining, the square head part 122 of the shaft head 120 can be left with allowance on one side; inclined planes and arc surfaces on two sides of the shaft head 120 can be directly processed to be in a finished product state, so that the defect that the inclined planes on the side of the square head part 122 are difficult to bore and mill after the shaft bridge is welded is overcome; the outer diameter of the cylindrical part of the shaft head 120 and the shaft end can be left with allowance; the welding area can be directly processed and formed by adopting a linear cutting mode.
3) And (5) optimally designing a welding process.
As described above, after the finish machining of the spindle head 120, the inclined planes and the arc surfaces on the two sides of the spindle head 120 can be directly machined to be in a finished product state, so that the defect that the inclined planes on the side of the square head part 122 are difficult to bore and mill after the axle bridge is welded is eliminated; further, the welding area can be directly processed and formed in a wire cutting mode.
When the shaft body 110 is manufactured, the steel plate for welding may be alloy steel, and H-shaped steel of a suitable specification may be selected according to relevant standards, as shown in fig. 4; and, various dimensional and performance tests can be further performed.
After the standard specification of the H-shaped steel is inspected to be qualified, each H-shaped steel can be cut into two parts along the center of the web plate; after the sections are cut off, grooves are processed on the section steel parts at the upper end and the lower end, and then the sections are welded in a splicing mode to form finished H-shaped steel meeting the use requirements of the forge welding shaft bridge. Before welding, strict welding process evaluation is required, and a special welding method is adopted. After the forge welding shaft bridge is welded, post-welding stress relief treatment can be carried out on the forge welding shaft bridge, so that residual internal stress is eliminated; before and after the stress relief treatment, visual inspection, radiographic inspection, magnetic inspection, hypersonic inspection and the like can be respectively carried out on the welding seam according to relevant standards.
4) And (5) optimally designing the machining process of the high-precision axle bridge.
The high-precision axle bridge machining method can comprise two stages which are sequentially carried out, namely an axle bridge semi-finishing process and an axle bridge finishing process.
In the first stage, the axle bridge semi-finishing process flow can be carried out in the following sequence:
milling the side face of the axle bridge → finely milling the bottom face of the axle bridge → finely milling the two side faces of the axle bridge → finely milling the upper plane of the axle head at the two ends of the axle bridge → finely milling the inner open of the axle bridge → processing the threaded hole → assembling and adjusting the fixed plate and the counterweight block → turning the cylindrical part of the axle head → boring the end hole of the axle → vibrating destressing → the end hole of the axle of the finished axle → semi-finishing axle head column → standing destressing.
During finish milling, the bottom surface of the axle bridge can be used as a reference surface. The cylindrical portion may be used as a reference when turning the stub shaft.
After the axle bridge is semi-finished, all parts of the axle bridge can be ensured to reach a final state, the internal stress of the axle bridge is eliminated by adopting a vibration and standing method, the rotating centrifugal rotating torque is eliminated by adopting a counterweight mode, and a good processing foundation is provided for high-precision finish machining.
In the second stage, the axle bridge finish machining process flow can be carried out in the following sequence:
the column and the arc of the axle head of the finish turning axle → the groove between the column and the square head of the axle head of the finish turning axle → each column of the axle head of the finish turning unilateral → the conical surface of the axle head of the finish turning opposite side → each column of the axle head of the finish turning opposite side.
After finish machining, the sizes of the cylindrical and conical parts of the shaft heads at the two ends of the shaft bridge can meet the technical requirements of required sizes, form and position tolerances, roughness and the like, so that the final qualified product can be obtained.
The forge welding axle bridge is an eccentric axle, the final machining tolerance of each shaft neck of the axle head 120 is less than or equal to 0.025mm, although the centrifugal force of the axle after rotation is offset by using the counter weight, the axle head and the axle body of each forge welding axle bridge cannot be completely consistent in machining, the counter weight is only calculated and assembled according to theory, and the roundness of the cylindrical part of the axle after the forge welding axle bridge is ground can be out of tolerance. At least one thin gasket can be selectively clamped between the axle bridge balancing weight and the fixing plate so as to increase or reduce the weight end rotating moment distributed on the upper part of the forge welding axle bridge, and the forge welding axle bridge can be adjusted to be in a state of minimum centrifugal force. Finally, the rotation of the axle can be stopped at any position after the axle is rotated.
Through balancing weight and adjusting balance piece by piece, finally the forge welding shaft bridge can be processed by grinding, and the roundness and the jumping of each part of the shaft end journal 121 and the square head part 122 can meet the requirements of drawings and technologies.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.
Finally, it should be noted that: the above examples are only for illustrating the technical solutions of the present invention, and not for limiting the same; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.