CN113118353A - Surface-strengthened inner-step shaft inner hole precision forming process - Google Patents
Surface-strengthened inner-step shaft inner hole precision forming process Download PDFInfo
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- CN113118353A CN113118353A CN202110428148.5A CN202110428148A CN113118353A CN 113118353 A CN113118353 A CN 113118353A CN 202110428148 A CN202110428148 A CN 202110428148A CN 113118353 A CN113118353 A CN 113118353A
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- mandrel
- blank
- lubricant
- inner hole
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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
- B21J5/002—Hybrid process, e.g. forging following casting
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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
- B21J3/00—Lubricating during forging or pressing
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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
Abstract
A precise forming process for an inner hole of a surface-strengthened inner step shaft comprises the steps of firstly designing a blank, and then pumping a lubricant into an inner area formed by a main lubricant filling channel and a sub lubricant channel of a core shaft; assembling the mandrel and the blank, installing a rotary forging machine through an installation hole in the rear part of the mandrel, forging the mandrel and the blank together by the high frequency of a forging die, and forming a large inner hole by rotary forging; then adjusting the positions of the mandrel and the blank, starting rotary swaging from the bulge of the blank, and forming a small inner hole by rotary swaging; replacing and using the strengthening die, assembling the rotary swaging machine, reducing the rotating speed of a motor of the rotary swaging machine so as to reduce the impact energy of the die, forging the whole surface of the blank subjected to the inner hole rotary swaging, and adding uniform compressive stress to the surface of the blank so as to realize the surface secondary strengthening effect similar to shot blasting impact; finally, the workpiece is pumped away; the invention can not only ensure the formation of the inner hole, but also effectively strengthen the surface of the shaft and improve the fatigue strength.
Description
Technical Field
The invention relates to the technical field of machining, in particular to a precise forming process of an inner hole of a surface-strengthened inner step shaft.
Background
Thin-wall slender shaft parts, particularly parts with step inner holes, occupy important positions in small and medium-sized aircraft engines, bear bending and torsion alternating stress, and the working safety and reliability of the engines are influenced by the processing quality of the parts.
The inner hole of the step shaft in the thin-wall slender shaft is complex in shape and high in precision requirement, and a blind hole which is difficult to machine exists. The current processing technology is as follows: blank-drill small hole-deep hole drill large hole-external surface finish machining, or blank-drill small hole-drill large hole from one side-drill large hole from the other side-external surface finish machining.
The rotary forging technology is a rotary forming process for precise forming and processing of pipes, bars or wires, two, four or eight same forging dies are uniformly distributed in the peripheral circumferential direction of a blank, the blank is subjected to high-frequency short-stroke rapid forging and simultaneously does circumferential rotary motion around the blank, and the blank is subjected to radial vertical forging to generate local uniform necking according to the mold line. The rotary forging technology can be well applied to the forming machining of the inner hole of the inner step shaft.
The traditional deep hole drill is adopted for processing and manufacturing, the period is long, the efficiency is low, the rejection rate is high, and the large holes are respectively processed from two sides, so that the problems of poor coaxiality, poor straightness and the like are easy to occur. In the conventional rotary swaging process using a tube as a blank, a spindle having a large step change in an inner hole or a requirement for an outer diameter may be damaged or fail to be formed.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a surface-strengthened inner-step shaft inner hole precision forming process, which not only can ensure the inner hole forming, but also can effectively strengthen the surface of a shaft and improve the fatigue strength.
In order to achieve the purpose, the invention is realized by the following technical scheme:
a surface strengthening inner step shaft inner hole precise forming process comprises the following steps:
1) designing a blank: the design length of the blank 1 is L, the inner diameter and the outer diameter are respectively R1 and R2, the length of a projection of the blank is W, and the height of the projection is h 2; the radius difference of the mandrel step is h1, and the length of the mandrel step is L1; design reference proportion W of blank 1 is L1, (h2-h 1): 6-7): 9-10): 1
2) Taking down the lubricant plug 3 of the mandrel, pumping lubricant into the lubricant main runner 4 of the mandrel, filling the pumped lubricant into an inner area formed by the lubricant main runner 4 and the lubricant sub-runner 5, and filling the lubricant plug 3 after the pumping is finished;
3) and (3) rotary swaging to form a large inner hole: the mandrel and the blank 1 are assembled, a rotary forging machine is arranged through a mounting hole 9 in the rear of the mandrel, the mandrel and the blank 1 are subjected to high-frequency forging by a forging die, the diameter of the blank 1 shrinks and deforms, the mandrel is tightly wrapped, and the machining precision of a large inner hole is ensured through the mandrel;
4) and (3) forming a small inner hole by rotary swaging: adjusting the positions of the mandrel and the blank 1, starting rotary swaging from the bulge of the blank 1, contracting and deforming the pipe diameter at the bulge of the blank 1 again, tightly wrapping the mandrel, and ensuring the machining precision of the small inner hole through the mandrel; after the forming is finished, the outer surface of the blank 1 has no protrusion;
5) surface secondary strengthening: replacing and using the strengthening die 6, assembling the rotary swaging machine, reducing the rotating speed of a motor of the rotary swaging machine so as to reduce the impact energy of the die, forging the whole surface of the blank 1 subjected to the inner hole rotary swaging, and adding uniform compressive stress on the surface of the blank 1 to realize the surface secondary strengthening effect similar to shot blasting impact;
6) extracting the mandrel: and finishing the secondary strengthening processing of the surface, drawing away the workpiece, and processing the next blank 1.
The mandrel is divided into an integral mandrel 2-1 and a split mandrel 2-2; the lubricant main runner 4 along the axial direction is arranged in the integral mandrel 2-1, the lubricant main runner 4 branches from the lubricant main runner 4 at different positions of the lubricant main runner 4 along the radial direction to form lubricant sub-runners 5, the lubricant sub-runners 5 penetrate from the outer surface of the integral mandrel 2-1 to the lubricant main runner 4 along the radial direction, runner holes are exposed on the outer surface of the integral mandrel 2-1, and the sectional area of the lubricant main runner 4 and the sectional area of the lubricant sub-runners 5 meet the following formula:
Smaster and slave＝N·SIs divided into
Wherein S isMaster and slaveThe sectional area of the main flow passage 4 of the lubricant; sIs divided intoThe sectional area of the single lubricant branch channel 5; n is the total number of the lubricant sub-runners 5;
the split core shaft 2-2 is suitable for the condition that the core can not be pulled after the rotary swaging processing of the integral core shaft 2-1, the split core shaft 2-2 comprises a straight section core shaft 7 and a step section core shaft 8, the straight section core shaft 7 and the step section core shaft 8 are connected through threads, and the diameter of the step section core shaft 8 is the same as the design size of the large and small inner holes of a workpiece; a lubricant main runner 4 and a lubricant sub-runner 5 are also designed in the straight section mandrel 7 and the step section mandrel 8; the rear parts of the integral mandrel 2-1 and the split mandrel 2-2 are provided with mounting holes 9.
The four rows of lubricant runners 5 are uniformly distributed along the circumferential direction of the mandrel, are densely distributed at positions difficult to demould along the axis of the mandrel, and are sparsely distributed at positions easy to demould.
The surface of the strengthening die 6 is designed with a spherical bulge 10.
3-5 spherical protrusions 10 are distributed on the single arc surface of the strengthening die 6, the radius of each spherical protrusion 10 is not more than 4mm, and the closest distance d from the edge of the die is more than 20 mm; along the circumferential direction of the single circular arc, the included angle of two adjacent spherical protrusions 10 is 30 degrees.
The invention has the following advantages:
1. the processing efficiency is improved. The inner hole of the inner step shaft is formed by rotary swaging and reducing, and compared with a deep hole drill, the processing time is greatly shortened.
2. Improve the coaxiality and the straightness of the inner hole. The mandrel is adopted to form the inner hole by rotary swaging, so that drilling at two ends is avoided, the coaxiality of inner hole steps is ensured, and the wall thickness precision is improved.
3. Through the blank design, the problems of workpiece defects, mandrel damage and the like caused by overlarge deformation in the rotary swaging process are effectively avoided.
4. The mandrel with the lubricant flow channel inside is beneficial to fully covering the surface of the mandrel with lubricant, so that the mandrel and the blank are easily separated, the complicated process of manually coating the lubricant is avoided, the damage to the surface quality of the inner surface of the thin-wall slender shaft blank and the change of residual stress in the core pulling process are reduced, and the precision and the mechanical property of the processed blank are improved to a certain extent.
5. The surface secondary strengthening is carried out by utilizing the strengthening die, so that the surface compressive stress is effectively applied, and the fatigue resistance of the whole shaft is improved.
6. The mechanical structure of the rotary forging machine ensures the simultaneity of the movement of the die, the radial acting force of the shaft is balanced, and the influence on the dimensional precision of the shaft caused by the strengthening of common shot blasting is avoided.
Drawings
Figure 1 is an isometric view of a monolithic mandrel of the present invention.
Figure 2 is an isometric view of a split mandrel of the present invention.
Figure 3 is a cross-sectional view of the present invention illustrating the assembly of the blank with the mandrel as it is swaged with a one-piece mandrel.
FIG. 4 is a schematic view of the present invention using a solid mandrel to swage a large internal bore.
FIG. 5 is a schematic view of the present invention using a solid mandrel to swage a small internal bore.
Figure 6 is a cross-sectional view of a design blank assembled with a mandrel during swaging with a split mandrel of the present invention.
FIG. 7 is a schematic view of the present invention using a split mandrel to swage a large inner bore.
FIG. 8 is a schematic view of the present invention using a split mandrel to swage a small bore.
Fig. 9 is a cross-sectional view of the integral or split mandrel of the present invention in the radial direction.
FIG. 10 is a schematic view of a consolidation die of the present invention.
Detailed Description
The technical solutions of the present invention are further described below with reference to the drawings and examples, but the scope of the claims is not limited thereto.
Referring to fig. 1, 2, 3 and 6, the mandrel is divided into an integral mandrel 2-1 and a split mandrel 2-2; a lubricant main runner 4 along the axial direction is arranged in the integral mandrel 2-1, lubricant sub-runners 5 are arranged at different positions of the lubricant main runner 4 in a branching manner from the lubricant main runner 4 along the radial direction, the lubricant sub-runners 5 penetrate from the outer surface of the integral mandrel 2-1 to the lubricant main runner 4 along the radial direction, runner holes are exposed on the outer surface of the integral mandrel 2-1, four rows of lubricant sub-runners 5 are uniformly distributed along the circumferential direction, and are densely arranged at positions difficult to demold along the axial line and sparsely arranged at positions easy to demold; the sectional area of the main lubricant flow passage 4 and the sectional area of the sub lubricant flow passage 5 satisfy the following formula:
Smaster and slave＝N·SIs divided into
Wherein S isMaster and slaveThe sectional area of the main flow passage 4 of the lubricant; sIs divided intoThe sectional area of the single lubricant branch channel 5; n is the total number of the lubricant sub-runners 5;
the split core shaft 2-2 is suitable for the condition that the core can not be pulled after the integral core shaft 2-1 is swaged, the split core shaft 2-2 comprises a straight section core shaft 7 and a step section core shaft 8, and the straight section core shaft 7 and the step section core shaft 8 are connected through threads; a lubricant main runner 4 and a lubricant sub-runner 5 are also designed in the straight section mandrel 7 and the step section mandrel 8; the diameter of the mandrel 8 in the stage is the same as the design size of the large and small inner holes of the workpiece; the rear parts of the integral mandrel 2-1 and the split mandrel 2-2 are provided with mounting holes 9.
1) designing a blank: referring to fig. 3, the design length of the blank 1 is L, the inner diameter and the outer diameter are respectively R1 and R2, the length of the protruding part of the blank is W, and the height of the protruding part is h 2; the step radius difference h1 of the integral mandrel 2-1 and the step length L1 of the integral mandrel 2-1; the design reference proportion W of the blank 1 is L1, (h2-h1) is (6-7): 9-10): 1, and the more detailed size design of the blank 1 needs to be obtained according to finite element simulation and experimental experience results;
2) taking down the lubricant plug 3 of the integral mandrel 2-1, pumping lubricant into the lubricant main flow passage 4 of the integral mandrel 2-1, filling the pumped lubricant into an inner area formed by the lubricant main flow passage 4 and the lubricant sub-flow passage 5, and filling the lubricant plug 3 after the pumping is finished to prevent the lubricant from leaking;
3) and (3) rotary swaging to form a large inner hole: the integral mandrel 2-1 and the blank 1 are assembled, a rotary forging machine is arranged through a mounting hole 9 in the rear of the integral mandrel 2-1, the integral mandrel 2-1 and the blank 1 are subjected to high-frequency forging by a forging die, the pipe diameter of the blank 1 is shrunk and deformed, the integral mandrel 2-1 is tightly wrapped, and the machining precision of a large inner hole is ensured through the integral mandrel 2-1, as shown in figure 4;
4) and (3) forming a small inner hole by rotary swaging: adjusting the positions of the integral mandrel 2-1 and the blank 1, starting rotary swaging from the bulge of the blank 1, contracting and deforming the pipe diameter at the bulge of the blank 1 again, tightly wrapping the integral mandrel 2-1, and ensuring the machining precision of the small inner hole through the integral mandrel 2-1, as shown in fig. 5; after the forming is finished, the outer surface of the blank 1 has no protrusion;
5) surface secondary strengthening: replacing and using the strengthening die 6, assembling the rotary swaging machine, reducing the rotating speed of a motor of the rotary swaging machine so as to reduce the impact energy of the die, forging the whole surface of the blank 1 subjected to the inner hole rotary swaging, and adding uniform compressive stress on the surface of the blank 1 to realize the surface secondary strengthening effect similar to shot blasting impact;
6) extracting the integral mandrel 2-1: and (5) finishing the surface strengthening processing, directly drawing away the workpiece, and installing the next blank 1 for further processing.
1) designing a blank: referring to fig. 6, the design length of the blank 1 is L, the inner diameter and the outer diameter are respectively R1 and R2, the length of the protruding part of the blank is W, and the height of the protruding part is h 2; the radius difference of the steps of the split mandrel 2-2 is h1, and the step length of the split mandrel 2-2 is L1; the design reference proportion W of the blank 1 is L1, (h2-h1) is (6-7): 9-10): 1, and the more detailed size design of the blank 1 needs to be obtained according to finite element simulation and experimental experience results;
2) taking down the lubricant plug 3 of the split core shaft 2-2, pumping lubricant into the lubricant main flow passage 4 of the split core shaft 2-2, filling the pumped lubricant into an inner area formed by the lubricant main flow passage 4 and the lubricant sub-flow passage 5, and filling the lubricant plug 3 after the pumping is finished to prevent the lubricant from leaking;
3) and (3) rotary swaging to form a large inner hole: the split core shaft 2-2 and the blank 1 are assembled, a rotary forging machine is installed through a mounting hole 9 in the rear portion of the split core shaft 2-2, the split core shaft 2-2 and the blank 1 are subjected to high-frequency forging by a forging die, the pipe diameter of the blank 1 shrinks and deforms, the split core shaft 2-2 is tightly wrapped, and the precision of processing a large inner hole is guaranteed through the split core shaft 2-2, as shown in fig. 7;
4) and (3) forming a small inner hole by rotary swaging: adjusting the positions of the split core shaft 2-2 and the blank 1, starting rotary swaging from the bulge of the blank 1, contracting and deforming the pipe diameter of the bulge of the blank 1 again, tightly wrapping the split core shaft 2-2, and ensuring the machining precision of the small inner hole through the split core shaft 2-2, as shown in fig. 8; after the forming is finished, the outer surface of the blank 1 has no protrusion;
5) surface secondary strengthening: replacing and using the strengthening die 6, assembling the rotary swaging machine, reducing the rotating speed of a motor of the rotary swaging machine so as to reduce the impact energy of the die, forging the whole surface of the blank 1 subjected to the inner hole rotary swaging, and adding uniform compressive stress on the surface of the blank 1 to realize the surface secondary strengthening effect similar to shot blasting impact;
6) extracting the mandrel 2: and (3) finishing surface strengthening processing, namely unscrewing the connecting threads, separating the straight section mandrel 7 from the step section mandrel 8, drawing away the step section mandrel 8, then drawing away the workpiece, and installing the next blank 1 for continuous processing.
Referring to fig. 9, the mandrel of embodiments 1 and 2 is cut in a radial section, and a main lubricant flow channel 4 is formed in the center, and four sub lubricant flow channels 5 are formed by dividing the main lubricant flow channel 4 to the outside at an angle of 90 ° with each other.
Referring to fig. 10, the surface of the strengthening die 6 in examples 1 and 2 is designed with spherical protrusions 10, since the surface of the blank 1 is formed, a double-arc design is not needed, 3-5 spherical protrusions 10 are distributed on a single arc surface, the radius of each spherical protrusion 10 is not more than 4mm, and the closest distance d to the edge of the die is more than 20 mm; along the circumferential direction of the single circular arc, the included angle of two adjacent spherical protrusions 10 is 30 degrees.
Claims (5)
1. A surface strengthening inner step shaft inner hole precision forming process is characterized by comprising the following steps:
1) designing a blank: the design length of the blank (1) is L, the inner diameter and the outer diameter are respectively R1 and R2, the length of a projection of the blank is W, and the height of the projection is h 2; the radius difference of the mandrel step is h1, and the length of the mandrel step is L1; the design reference proportion W of the blank (1) is L1, (h2-h 1): 6-7), (9-10): 1
2) Taking down a lubricant plug (3) of the mandrel, pumping lubricant into a lubricant main flow passage (4) of the mandrel, filling the pumped lubricant into an inner area formed by the lubricant main flow passage (4) and a lubricant sub-flow passage (5), and filling the lubricant plug (3) after the pumping is finished;
3) and (3) rotary swaging to form a large inner hole: the mandrel and the blank (1) are assembled, a rotary forging machine is arranged through a mounting hole (9) in the rear of the mandrel, the mandrel and the blank (1) are forged by a forging die at high frequency, the pipe diameter of the blank (1) shrinks and deforms, the mandrel is tightly wrapped, and the machining precision of a large inner hole is ensured through the mandrel;
4) and (3) forming a small inner hole by rotary swaging: adjusting the positions of the mandrel and the blank (1), starting rotary swaging from the bulge of the blank (1), contracting and deforming the pipe diameter at the bulge of the blank (1) again, tightly wrapping the mandrel, and ensuring the processing precision of the small inner hole through the mandrel; after the forming is finished, the outer surface of the blank (1) does not have a bulge any more;
5) surface secondary strengthening: replacing and using the strengthening die (6), assembling the upper rotary swaging machine, reducing the rotating speed of a motor of the rotary swaging machine so as to reduce the impact energy of the die, forging the whole surface of the blank (1) subjected to the inner hole rotary swaging, and adding uniform compressive stress on the surface of the blank (1) to realize the surface secondary strengthening effect similar to shot blasting impact;
6) extracting the mandrel: and (5) finishing the secondary strengthening processing of the surface, drawing away the workpiece, and processing the next blank (1).
2. The process of claim 1, wherein the precision forming of the inner bore of the surface-strengthened inner-step shaft comprises the following steps: the mandrel is divided into an integral mandrel (2-1) and a split mandrel (2-2); the lubricant main runner (4) along the axis direction is arranged in the integral mandrel (2-1), the lubricant main runner (4) is branched from the lubricant main runner (4) at different positions of the lubricant main runner (4) along the radial direction to form lubricant sub-runners (5), the lubricant sub-runners (5) penetrate through the lubricant main runner (4) from the outer surface of the integral mandrel (2-1) in the radial direction, runner holes are exposed on the outer surface of the integral mandrel (2-1), and the sectional area of the lubricant main runner (4) and the sectional area of the lubricant sub-runners (5) meet the following formula:
Smaster and slave＝N·SIs divided into
Wherein S isMaster and slaveThe sectional area of the main flow passage (4) of the lubricant; sIs divided intoThe cross section area of the single lubricant shunt passage (5); n is the total number of the lubricant sub-runners (5);
the split core shaft (2-2) is suitable for the condition that the core can not be pulled after the integral core shaft (2-1) is swaged, the split core shaft (2-2) comprises a straight section core shaft (7) and a step section core shaft (8), the straight section core shaft (7) and the step section core shaft (8) are connected through threads, and the diameter of the step section core shaft (8) is the same as the design size of the large and small inner holes of a workpiece; a main runner (4) and a lubricant sub-runner (5) are also designed in the straight section mandrel (7) and the step section mandrel (8); the rear parts of the integral mandrel (2-1) and the split mandrel (2-2) are provided with mounting holes (9).
3. The process of claim 2, wherein the precision forming of the inner bore of the surface-strengthened inner-step shaft comprises the following steps: the four rows of lubricant runners (5) are uniformly distributed along the circumferential direction of the mandrel, are densely distributed at positions difficult to demould along the axis of the mandrel, and are sparsely distributed at positions easy to demould.
4. The process of claim 1, wherein the precision forming of the inner bore of the surface-strengthened inner-step shaft comprises the following steps: the surface of the strengthening die (6) is designed with a spherical bulge (10).
5. The process of claim 4, wherein the precision forming of the inner bore of the surface-strengthened inner-step shaft comprises the following steps: 3-5 spherical protrusions (10) are distributed on the single arc surface of the strengthening die (6), the radius of each spherical protrusion (10) is not more than 4mm, and the closest distance d from the spherical protrusion to the edge of the die is more than 20 mm; along the circumferential direction of the single circular arc, the included angle of two adjacent spherical bulges (10) is 30 degrees.
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| CN202110428148.5A CN113118353B (en) | 2021-04-21 | 2021-04-21 | Surface-strengthened inner-step shaft inner hole precision forming process |
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| CN104148518A (en) * | 2014-07-07 | 2014-11-19 | 西安交通大学 | Material gathering technology and device applied to flange on head of super-long pipe and based on servo rotation of single-end die |
| CN104723045A (en) * | 2015-03-24 | 2015-06-24 | 西安交通大学 | Machining process and tool for shaft with inner step hole with large depth-diameter ratio |
| JP2020168654A (en) * | 2019-04-05 | 2020-10-15 | Thk株式会社 | Hollow shaft member and rolling device |
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2021
- 2021-04-21 CN CN202110428148.5A patent/CN113118353B/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| KR20050029091A (en) * | 2003-10-31 | 2005-03-24 | 주식회사 성진파스너 | Method and apparatus for manufacturing inner tube |
| CN101068636A (en) * | 2004-10-25 | 2007-11-07 | V&M德国有限公司 | Method for production of a seamless hot-finished steel tube and device for carrying out said method |
| US20070062241A1 (en) * | 2005-08-25 | 2007-03-22 | James Main | Unitary rear axle housing and method for manufacturing same |
| CN103302461A (en) * | 2013-06-25 | 2013-09-18 | 陈靖忠 | Manufacturing method and manufacturing equipment of integral petroleum heavy weight drill pipe |
| CN104148518A (en) * | 2014-07-07 | 2014-11-19 | 西安交通大学 | Material gathering technology and device applied to flange on head of super-long pipe and based on servo rotation of single-end die |
| CN104723045A (en) * | 2015-03-24 | 2015-06-24 | 西安交通大学 | Machining process and tool for shaft with inner step hole with large depth-diameter ratio |
| JP2020168654A (en) * | 2019-04-05 | 2020-10-15 | Thk株式会社 | Hollow shaft member and rolling device |
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