CN115255132A - Single sheet forming method of EGR housing - Google Patents
Single sheet forming method of EGR housing Download PDFInfo
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- CN115255132A CN115255132A CN202210954830.2A CN202210954830A CN115255132A CN 115255132 A CN115255132 A CN 115255132A CN 202210954830 A CN202210954830 A CN 202210954830A CN 115255132 A CN115255132 A CN 115255132A
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- 238000000034 method Methods 0.000 title claims abstract description 40
- 239000000463 material Substances 0.000 claims abstract description 35
- 238000000465 moulding Methods 0.000 claims abstract description 30
- 238000007493 shaping process Methods 0.000 claims abstract description 21
- 238000003466 welding Methods 0.000 claims abstract description 20
- 238000012545 processing Methods 0.000 claims abstract description 12
- 238000005452 bending Methods 0.000 claims abstract description 7
- 210000001503 joint Anatomy 0.000 claims abstract description 4
- 238000005520 cutting process Methods 0.000 claims description 9
- 239000002699 waste material Substances 0.000 claims description 7
- 238000004519 manufacturing process Methods 0.000 abstract description 14
- 238000012797 qualification Methods 0.000 abstract description 8
- 230000009286 beneficial effect Effects 0.000 abstract description 4
- 238000004080 punching Methods 0.000 description 16
- 239000007788 liquid Substances 0.000 description 7
- 238000000137 annealing Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 239000000428 dust Substances 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 238000005096 rolling process Methods 0.000 description 4
- 238000007127 saponification reaction Methods 0.000 description 4
- 239000007789 gas Substances 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000003028 elevating effect Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/02—Bending sheet metal along straight lines, e.g. to form simple curves on press brakes without making use of clamping means
- B21D5/0209—Tools therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D7/00—Bending rods, profiles, or tubes
- B21D7/06—Bending rods, profiles, or tubes in press brakes or between rams and anvils or abutments; Pliers with forming dies
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
The invention discloses a method for forming an EGR shell by a single sheet, which comprises the following steps of S01: blanking; processing the materials into material sheets by adopting a blanking die; step S02: one-step molding; bending the material sheet into a concave structure by adopting a first forming die, and forming a first external profile on the concave structure; step S03: secondary molding; adopting a second forming die to extrude and butt the opening end inwards to form a tubular body, and simultaneously forming a second external contour, wherein the first external contour and the second external contour form the integral external contour of the EGR shell; step S04: welding; welding the butt joint in the step S03; step S05: and (5) shaping. The invention has the beneficial effects that: the method can be realized by adopting conventional equipment without adopting special equipment, thereby greatly reducing the equipment investment, having high material utilization rate, improving the qualification rate and reducing the production cost.
Description
Technical Field
The invention relates to a forming technology of pipe parts, in particular to a forming method of an EGR shell.
Background
An EGR system (exhaust gas recirculation system) is a system for reducing nitrogen oxides in automobile exhaust emissions, and is a product which must be adopted for automobile exhaust emissions to reach the euro IV and V standards. The EGR cooler is a emerging environmental protection product, is used for the cooling of backward flow exhaust gas to install in car EGR system, and the principle and the effect of cooler: during the combustion process of the automobile, high temperature of about 500-600 degrees is generated, the exhaust gas can flow back only after being cooled, otherwise, the emission effect cannot be achieved, and the process is finished in an EGR cooler. A typical EGR cooler comprises a hollow housing.
The common forming process of the metal shell comprises internal high-pressure forming, and specifically comprises the following steps: a. lower fixed process length pipe (can sort multiple products); b. placing the pipe material into an inner high-pressure die, starting special forming equipment, and enabling a device sliding block to move downwards until an upper die and a lower die are closed; c. injecting high-pressure liquid into the pipe material, and forming by the pressure of the liquid inside, wherein the shape of the product is ensured by a mould; d. after the molding is finished, the equipment slide block moves upwards, and a product is taken out; e. by adopting the cutting process, the utility model has the advantages that, cut into the desired product.
Such as patents publication number: cn201811587034.X, name: the patent document of the EGR shell opening flanging hole forming process comprises the following steps: (1) Preparing an EGR preformed shell by using a pipe hydraulic bulging process; (2) Manufacturing a reference bottom hole of the flange at the end to be processed of the preformed shell by using a punching die, and flanging the reference bottom hole to obtain a preformed flange; (3) Carrying out high-frequency annealing treatment on the preformed flange, and then shaping the preformed flange to obtain the straight arm caliber size precision of the flange preliminarily; (4) And (4) rolling the inner wall of the preformed flange processed in the step (3) to enable the inner wall to generate plastic deformation until the size of the straight arm of the flange reaches the design precision. The punching die in the step (2) comprises a first upper die plate, a first lower die plate, a pressure plate I, a punch and a die insert which are matched with each other; the to-be-processed end of the preforming shell is arranged between the first upper template and the first lower template, the to-be-processed end is fixed by the pressure plate I, the female die insert is padded on the inner side of the to-be-processed end, and the punch and the female die insert descend to be matched with each other to form a reference bottom hole at the to-be-processed end; the hole flanging die in the step (2) comprises a second upper die plate and a second lower die plate which are matched with each other, a hole flanging male die and a hole flanging female die which are matched with each other, and a pressure plate II; the hole flanging male die penetrates out of the reference bottom hole of the end to be machined and is inserted into the hole flanging female die so as to complete hole flanging of the reference bottom hole; the high-frequency annealing parameter in the step (3) is the annealing temperature of 1050 ℃ and the annealing time of 8-10 s; the shaping die in the step (3) comprises a third upper die plate and a third lower die plate, the third upper die plate is provided with a shaping male die and a limiting plate, the third lower die plate is provided with a second limiting column for limiting the position of the end to be machined, a core rod I for supporting the end to be machined is further arranged between the third upper die plate and the third lower die plate, and the core rod I is fixed to the third upper die plate and the third lower die plate through a vertical plate; the limiting plate is provided with a through hole for the shaping male die to pass through and extrude the flange straight arm; the rolling die in the step (4) comprises a pressing plate, is arranged at a rolling part of the pressing plate and supports a core rod II at the end to be machined; the rolling part can extend into the flange to roll the inner side wall of the straight arm of the flange.
The internal high pressure forming process also has the following disadvantages: a. special internal high-pressure forming equipment is needed, the equipment investment cost is high, the mould is complex, and the processing cost is high; b. the process has more waste materials and low material utilization rate; c. the auxiliary cutting process is multiple, the product thinning rate is high, the reject ratio is high, the production period is long, and the cost is high; d. the molding needs liquid, the production field is easy to be dirty and messy, and the appearance is influenced; and when the air temperature is low, the working environment of the staff is poor.
The information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms part of the prior art that is already known to a person skilled in the art.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: how to solve the problem that the prior internal high pressure forming method adopted by the EGR shell needs to adopt special internal high pressure forming equipment, so that the investment cost is high.
The invention solves the technical problems through the following technical means:
a method of forming an EGR housing from a single web, comprising the steps of,
step S01: blanking; processing the materials into material sheets by adopting a blanking die;
step S02: one-step molding; bending the material sheet into a concave structure by using a first forming die, and forming a first external contour on the concave structure;
step S03: secondary molding; adopting a second molding die to extrude and butt the opening end inwards to form a tubular body, and simultaneously molding a second external contour, wherein the first external contour and the second external contour form the external contour of the integral EGR shell;
step S04: welding; welding the butt joint in the step S03;
step S05: and (6) shaping.
The invention is formed twice, the concave structure is formed for the first time, and a first external contour is formed on three surfaces of the concave structure at the same time; forming the tubular body for the second time, and stamping a second outer contour on the other side surface, and finally forming a reducing pipe structure by the first outer contour and the second outer contour; structurally, a piece of material is molded, and only one welding line is formed; in the process, two-time forming is carried out, the matching of the two-time formed groove surfaces is ensured, then the precision of the pipe orifice is ensured through shaping, and the step of flaring is omitted; the invention is not only suitable for regular square pipes, but also suitable for special square pipes or round pipes, and has strong adaptability; meanwhile, the invention can be realized by adopting conventional equipment without adopting special equipment, thereby greatly reducing the equipment investment, and adopting equipment with the same model, being beneficial to automatic connection, reducing the labor cost, and approaching the area of a finished product during blanking, thereby greatly reducing the material waste of the product and having high material utilization rate; compared with the problem of high reject ratio of the internal high pressure forming technology, the invention improves the qualification rate, reduces the production period of products and reduces the production cost.
Preferably, in step S01, a punch press device and a blanking die are used to process the material sheet.
Preferably, in the step S02, a first forming mold is installed on the punching equipment or the oil press, the first forming mold includes a first female mold and a first male mold capable of moving up and down, an inner surface of the first female mold is a forming surface, an outer surface of the first male mold is a forming surface, and in the process of forming the first external contour, a chamfer is formed at a bending position of the concave structure.
Preferably, in step S02, a second forming mold is installed on the punching equipment or the oil press, the second forming mold includes a positioning assembly and a forming assembly that are vertically distributed in a crossed manner, an end portion of the positioning assembly extends into the concave structure to be internally supported, and the forming assembly relatively moves from the outside of the concave structure to the middle portion to bend and butt-joint an open end of the concave structure to the middle portion.
Preferably, the positioning assembly comprises a first upper die wedge block capable of moving up and down, a first lower die wedge block capable of moving horizontally and a core rod, the first upper die wedge blocks are symmetrically arranged, the first lower die wedge blocks are symmetrically arranged, the core rod is connected with the inner side of the first lower die wedge blocks, the first upper die wedge blocks are pushed to move relatively while descending, and the core rods on two sides extend into the concave structure to be supported relatively.
Preferably, the opposite sides of the two first upper die wedge blocks are inclined surfaces, the sides, close to the first upper die wedge blocks, of the two first lower die wedge blocks are inclined surfaces, and the outer contour of the core rod is matched with the inner contour of the concave structure.
Preferably, the molding assembly comprises a second upper die wedge block capable of moving up and down, a second lower die wedge block capable of moving horizontally, a cavity and a molding block, the second upper die wedge block is symmetrically arranged, the second lower die wedge block is symmetrically arranged, the cavity is connected with the inner side of the second lower die wedge block, and the molding block is connected with the inner side of the cavity.
Preferably, one side of the second upper die wedge block opposite to the second upper die wedge block is an inclined surface, one side of the second lower die wedge block close to the first upper die wedge block is an inclined surface, and the cavity is a bending piece.
Preferably, in step S04, the laser welding apparatus is clamped to perform the laser welding.
Preferably, in step S05, a punch press device or an oil press is used to place the welded tubular body into a shaping mold, so as to level the surface of the product; then, the rotary cutting device is replaced, the product is placed into a rotary cutting die, and waste materials at two ends are cut off; and then putting the two ends into a shaping die for shaping by using punch equipment or an oil press.
The processing process adopts punching machine equipment, and the characteristics of short beat of the punching machine are utilized, so that the processing working hours of the product are greatly reduced, the qualification rate is high, the production efficiency is improved, and the cost is reduced; the operating environment of the punch press is free of oil stain, dust, saponification liquid and the like, and the field environment is better.
The invention has the advantages that:
(1) The invention is formed twice, the concave structure is formed for the first time, and a first external contour is formed on three surfaces of the concave structure at the same time; forming the tubular body for the second time, and stamping a second outer contour on the other side surface, and finally forming a reducing pipe structure by the first outer contour and the second outer contour; structurally, a piece of material is molded, and only one welding line is formed; in the process, two-time forming is carried out, the surfaces of the grooves formed in two times are ensured to be matched, then the precision of a pipe orifice is ensured through shaping, and the step of flaring is omitted; the invention can be realized by adopting conventional equipment without adopting special equipment, thereby greatly reducing the equipment investment, and adopting equipment with the same model, being beneficial to automatic wiring, reducing the labor cost, and being close to the area of a finished product when blanking, thereby greatly reducing the material waste of the product and having high material utilization rate; compared with the problem of high reject ratio of the internal high pressure forming technology, the invention improves the qualification rate, reduces the production period of products and reduces the production cost;
(2) The processing process adopts punching machine equipment, and the characteristics of short beat of the punching machine are utilized, so that the processing working hours of the product are greatly reduced, the qualification rate is high, the production efficiency is improved, and the cost is reduced; the operating environment of the punch press is free of oil stain, dust, saponification liquid and the like, and the field environment is good;
(3) The invention is not only suitable for regular square pipes, but also suitable for special square pipes or round pipes, and has strong adaptability.
Drawings
FIG. 1 is a schematic structural diagram of an EGR housing formed from a single sheet of material according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a punching apparatus used in step S02 according to an embodiment of the present invention;
FIG. 3 is a schematic structural view of a first molding die in the embodiment of the present invention;
FIG. 4 is a schematic structural diagram of a punching apparatus used in step S03 according to an embodiment of the present invention;
FIG. 5 is a plan view of a second molding die in the embodiment of the present invention;
FIG. 6 is a schematic structural view of a second molding die in the embodiment of the present invention;
FIG. 7 is a schematic structural view of a second molding die in the embodiment of the present invention;
FIG. 8 is a schematic view showing the structure of a molding member of the second molding die according to the embodiment of the present invention;
FIG. 9 is a process flow diagram of an embodiment of the invention;
reference numbers in the figures:
1. a first molding die; 11. a first female die; 12. a first male die; 13. a first positioning pin;
2. a second molding die; 21. a positioning assembly; 211. a first upper die wedge block; 212. a first lower die wedge; 213. a core rod; 22. a molding assembly; 221. a second upper die wedge block; 222. a second lower die wedge block; 223. a cavity; 224. forming a block;
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are some embodiments of the present invention, but not all 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.
The first embodiment is as follows:
the embodiment solves the technical problems by the following technical means:
as shown in FIG. 1, this embodiment is illustrated in the form of a square tube that includes four sides, each side having an inward groove therein and a top surface that includes a weld.
As shown in fig. 1-8, 9, a method of forming an EGR housing from a single web includes the steps of;
step S01: blanking; the blanking die is processed into the material sheet by adopting the punching equipment, and in the process shown in fig. 9, the material sheet is integrally square or rectangular, and an arc-shaped notch can be formed in the end part of the material sheet, so that the material sheet is convenient to position in the subsequent bending process.
Step S02: one-step molding; bending the material sheet into a concave structure by using a first forming die 1, and forming a first external profile on the concave structure;
as shown in fig. 2, specifically, a first forming mold 1 is installed on a punch press device or an oil press, the first forming mold 1 includes a first female mold 11, a first male mold 12 capable of moving up and down, and a first positioning pin 13, the first positioning pin 13 is connected to bottom surfaces of two ends of the first female mold 11, an inner surface of the first female mold 11 is a forming surface, an outer surface of the first male mold 12 is a forming surface, and in a process of forming a first external contour, a chamfer is formed at a bent portion of a concave structure, and in the forming process, the first positioning pin 13 can be positioned with arc-shaped notches at two ends of a material sheet.
As shown in fig. 2 and fig. 3, in the present embodiment, a 160 ton punching apparatus in the prior art is adopted, the first concave die 11 is fixed on a workbench of the punching apparatus, when the first concave die 11 is installed, an opening faces upward, the first concave die 11 is U-shaped, and has a forming surface corresponding to an external contour of a finished product, for example, a side surface of a finished square tube is recessed inward, and then an inner surface of the first concave die 11 protrudes inward, so as to form a recessed structure. The first female die 11 can be composed of three dies, the dies on two sides can be connected to a workbench through slide rail sliders, and the die at the bottom can be fixedly connected to the workbench or detachably connected to the workbench, so that the dies can be conveniently replaced; the moulds at the two sides are closed and locked towards the middle part, and form a U-shaped first female die 11 together with the mould at the bottom.
The first punch 12 may be installed at a punch end of the punch apparatus, the punch end may perform an elevating motion by being operated by a hydraulic or pneumatic device, the first punch 12 has a forming surface corresponding to the concave structure, for example, a position where an inner surface of the first die 11 protrudes inward, and the first punch 12 is also recessed inward. Two ends of the first male die 12 are provided with avoidance grooves which are avoided from the first positioning pin 13. During one-step forming, the sheet is placed on the first female die 11, the punch end drives the first male die 12 to move downwards, and the flat sheet is punched into a concave structure.
When the die is punched to be in a concave structure, two sides of the bottom die of the first female die 11 are provided with upward extending structures and are in an arc shape, so that arc-shaped chamfers can be formed simultaneously; the radius of the bottom mold of the first concave mold 11 can be set according to the requirements of chamfering.
Step S03: secondary molding; adopting a second forming die 2 to extrude and butt the opening end inwards to form a tubular body, and simultaneously forming a second external contour, wherein the first external contour and the second external contour form the external contour of the integral EGR shell;
as shown in fig. 4-8, specifically, a second forming die 2 is installed on a punching device or an oil press, the second forming die 2 includes a positioning assembly 21 and a forming assembly 22 which are vertically distributed in a crossed manner, an end portion of the positioning assembly 21 extends into the concave structure for internal support, and the forming assembly 22 relatively moves from the outer portion to the middle portion of the concave structure to bend, butt-joint and form the open end of the concave structure toward the middle portion.
As shown in fig. 6, the positioning assembly 21 includes a first upper die wedge block 211 capable of moving up and down, a first lower die wedge block 212 capable of moving horizontally, and a core rod 213, wherein the first upper die wedge block 211 can move up and down by means of an air cylinder or a hydraulic cylinder, two first upper die wedge blocks 211 are symmetrically arranged and located on two sides of the concave structure in the length direction, respectively, the two first lower die wedge blocks 212 are also symmetrically arranged and located on two sides of the concave structure in the length direction, the bottom of the first lower die wedge block 212 can slide, the two first lower die wedge blocks 212 can move relatively, the two first upper die wedge blocks 211 are located on the outer sides of the two first lower die wedge blocks 212, the core rod 213 is connected to the inner side of the first lower die wedge block 212, and the two core rods 213 are located on the same horizontal line. The opposite sides of the two first upper die wedge blocks 211 are inclined surfaces, the sides of the two first lower die wedge blocks 212 close to the first upper die wedge blocks 211 are inclined surfaces, and the outer contour of the core rod 213 is matched with the inner contour of the concave structure, so that better support can be realized.
When the positioning assembly 21 is used, when the first upper die wedge block 211 descends through the air cylinder, the inclined surface of the first upper die wedge block 211 is in contact with the inclined surface of the first lower die wedge block 212, and the descending force of the first upper die wedge block 211 can be decomposed into a force pushing the first lower die wedge block 212 to move relatively through the inclined surface, so that the first upper die wedge blocks 211 on two sides descend simultaneously and push the first lower die wedge blocks 212 on two sides to move relatively simultaneously, and the core rods 213 on two sides are driven to move relatively to extend into the concave structure for supporting.
As shown in fig. 7 and 8, the molding assembly 22 includes a second upper mold wedge block 221 capable of moving up and down, a second lower mold wedge block 222 capable of moving horizontally, a cavity 223, and a molding block 224, the second upper mold wedge block 221 can move up and down by means of a cylinder or a hydraulic cylinder, the two second upper mold wedge blocks 221 are symmetrically arranged, and similarly, the second lower mold wedge blocks 222 are symmetrically arranged and located on two sides of the concave structure in the width direction; the bottoms of the second lower die wedge blocks 222 can slide, the two second lower die wedge blocks 222 can move relatively, and the two second upper die wedge blocks 221 are located on the outer sides of the two second lower die wedge blocks 222; the opposite sides of the two second upper die wedge blocks 221 are inclined surfaces, and the sides of the two second lower die wedge blocks 222 close to the first upper die wedge block 211 are inclined surfaces. The cavity 223 is connected to the inside of the second lower die wedge block 222, and the molding block 224 is connected to the inside of the cavity 223. The cavity 223 is of an inverted L-shaped structure, and the inner side surface of the forming block 224 can be formed with a groove structure.
When the forming assembly 22 is used, when the second upper die wedge block 221 descends through the cylinder, the inclined surface of the second upper die wedge block 221 contacts with the inclined surface of the second lower die wedge block 222, the descending force of the second upper die wedge block 221 can be decomposed into the force for pushing the second lower die wedge block 222 to move relatively through the inclined surface, therefore, the second upper die wedge blocks 221 on two sides descend simultaneously, the second lower die wedge blocks 222 on two sides are pushed to move relatively simultaneously, then the cavity 223 is driven to move relatively, the top of the concave structure is bent inwards by the cavity 223, and the forming block 224 forms a second external profile.
In practical use, the position of the forming block 224 needs to be controlled to ensure that the first outer profile of the one-step forming in step S02 matches the second outer profile of the two-step forming in step S03.
Step S04: welding; welding the butt joint in the step S03;
step S05: and (6) shaping.
The processing process adopts punching machine equipment, and the characteristics of short beat of the punching machine are utilized, so that the processing working hours of the product are greatly reduced, the qualification rate is high, the production efficiency is improved, and the cost is reduced; the operating environment of the punch press is free of oil stain, dust, saponification liquid and the like, and the field environment is better.
In the embodiment, the concave structure is formed for the first time through two-time forming, and the first external contour is formed on three surfaces of the concave structure at the same time; forming the tubular body for the second time, and stamping a second outer contour on the other side surface, and finally forming a reducing pipe structure by the first outer contour and the second outer contour; structurally, a piece of material is molded, and only one welding line is formed; in the process, two-time forming is carried out, the surfaces of the grooves formed in two times are ensured to be matched, then the precision of a pipe orifice is ensured through shaping, and the step of flaring is omitted; meanwhile, the invention can be realized by only adopting conventional equipment without adopting special equipment, thereby greatly reducing the equipment investment, and equipment with the same type can be adopted, thereby being beneficial to automatic wiring, reducing the labor cost, and approaching the area of a finished product during blanking, thereby greatly reducing the material waste of the product and having high material utilization rate; compared with the problem of high reject ratio of the internal high pressure forming technology, the invention improves the qualification rate, reduces the production period of products and reduces the production cost.
The embodiment is not only suitable for regular square pipes, but also suitable for special-shaped square pipes or round pipes, and has strong adaptability.
Example two:
in the present embodiment, on the basis of the first embodiment, the welding in step S04; and adopting 1500W special laser welding equipment to clamp and weld the tubular part. Before welding, can use 160 tons of punch press equipment, the side cut mould is neat with the welding seam sideline cutting, guarantees the welding seam parallel and level.
Step S05, shaping, namely, putting the welded tubular body into a shaping die by adopting punch equipment or an oil press, and leveling the surface of the product; then, the rotary cutting device is replaced, the product is placed into a rotary cutting die, and waste materials at two ends are cut off; and then putting the two ends into a shaping die for shaping by using punch equipment or an oil press.
The processing process mostly adopts punch equipment, and the characteristic of short beat of the punch is utilized, so that the processing working hour of the product is greatly reduced, the qualification rate is high, the production efficiency is improved, and the cost is reduced; the operating environment of the punch press is free of oil stain, dust, saponification liquid and the like, and the field environment is better.
The above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; 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.
Claims (10)
1. A method of forming an EGR housing from a single web of material comprising the steps of,
step S01: blanking; processing the materials into material sheets by adopting a blanking die;
step S02: one-step molding; the material sheet is bent into a concave structure by adopting a first forming die, simultaneously molding a first outer profile over the concave structure;
step S03: secondary molding; adopting a second molding die to extrude and butt the opening end inwards to form a tubular body, and simultaneously molding a second external contour, wherein the first external contour and the second external contour form the external contour of the integral EGR shell;
step S04: welding; welding the butt joint in the step S03;
step S05: and (5) shaping.
2. The method for forming an EGR housing from a single sheet according to claim 1, wherein in step S01, the blanking die is processed into the sheet by using a punch press device.
3. The method for forming the EGR housing from a single sheet according to claim 1, wherein in step S02, a first forming mold is installed on a punch press device or an oil press, the first forming mold comprises a first female mold and a first male mold capable of moving up and down, the inner surface of the first female mold is a forming surface, the outer surface of the first male mold is a forming surface, and a chamfer is formed at the bending part of the concave structure during the process of forming the first outer contour.
4. The method for forming the EGR housing from a single sheet according to claim 1, wherein in step S02, a second forming mold is installed on a punch press device or an oil press, the second forming mold comprises a positioning assembly and a forming assembly which are vertically distributed in a crossed manner, an end portion of the positioning assembly extends into the concave structure for internal supporting, and the forming assembly relatively moves from an outer portion to a middle portion of the concave structure to bend and butt an open end of the concave structure towards the middle portion.
5. The method for forming the EGR shell through the single sheet according to claim 4, wherein the positioning assembly comprises a first upper die wedge block capable of moving up and down, a first lower die wedge block capable of moving horizontally, and a core rod, wherein the first upper die wedge block is symmetrically arranged, the first lower die wedge block is symmetrically arranged, the core rod is connected with the inner side of the first lower die wedge block, the first upper die wedge block descends while pushing the first lower die wedge blocks at two sides to move relatively, and the core rods at two sides extend into the concave structure to support the relative movement.
6. The method for forming an EGR shell from a single sheet of material as claimed in claim 5, wherein the opposite side of the two first upper die wedge blocks is an inclined surface, the side of the two first lower die wedge blocks close to the first upper die wedge block is an inclined surface, and the outer contour of the core rod is adapted to the inner contour of the concave structure.
7. The method for forming the EGR shell from the single sheet according to claim 4, wherein the forming assembly comprises a second upper die wedge block capable of moving up and down, a second lower die wedge block capable of moving horizontally, a cavity and a forming block, the second upper die wedge block is arranged symmetrically, the second lower die wedge block is arranged symmetrically, the cavity is connected with the inner side of the second lower die wedge block, and the forming block is connected with the inner side of the cavity.
8. The method for forming an EGR housing from a single sheet of material as set forth in claim 7, wherein the opposite sides of the two second upper die wedge blocks are inclined surfaces, the side of the two second lower die wedge blocks adjacent to the first upper die wedge block is an inclined surface, and the cavity is a bent piece.
9. The method of forming an EGR housing from a single sheet of material as defined in claim 1 wherein in step S04, the laser welding is performed while clamping on a laser welding apparatus.
10. The method for forming the EGR housing from a single sheet according to claim 1, wherein in step S05, the welded tubular body is placed in a shaping mold by using a punch press device or an oil press, and the surface of the product is flattened; then, the rotary cutting device is replaced, the product is placed into a rotary cutting die, and waste materials at two ends are cut off; and then putting the two ends into a shaping die for shaping by using punch equipment or an oil press.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210954830.2A CN115255132A (en) | 2022-08-10 | 2022-08-10 | Single sheet forming method of EGR housing |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210954830.2A CN115255132A (en) | 2022-08-10 | 2022-08-10 | Single sheet forming method of EGR housing |
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| CN115255132A true CN115255132A (en) | 2022-11-01 |
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| CN202210954830.2A Pending CN115255132A (en) | 2022-08-10 | 2022-08-10 | Single sheet forming method of EGR housing |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116900142A (en) * | 2023-09-13 | 2023-10-20 | 常州震裕汽车部件有限公司 | Four post oil pressure moulds of lithium cell shell aluminum plate |
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2022
- 2022-08-10 CN CN202210954830.2A patent/CN115255132A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116900142A (en) * | 2023-09-13 | 2023-10-20 | 常州震裕汽车部件有限公司 | Four post oil pressure moulds of lithium cell shell aluminum plate |
| CN116900142B (en) * | 2023-09-13 | 2023-11-17 | 常州震裕汽车部件有限公司 | Four post oil pressure moulds of lithium cell shell aluminum plate |
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Effective date of registration: 20231227 Address after: 242399 No.15 Diaoyutai Road, Nanshan Park, Ningguo Economic and Technological Development Zone, Xuancheng City, Anhui Province Applicant after: BAOLONG (ANHUI) AUTO PARTS Co.,Ltd. Address before: No. 15, Diaoyutai Road, Ningguo Economic and Technological Development Zone, Xuancheng City, Anhui Province 242399 Applicant before: Anhui Longteng Automobile Technology Co.,Ltd. |