CN116803595A - Manufacturing method of high-pressure pump eccentric wheel - Google Patents
Manufacturing method of high-pressure pump eccentric wheel Download PDFInfo
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- CN116803595A CN116803595A CN202310939757.6A CN202310939757A CN116803595A CN 116803595 A CN116803595 A CN 116803595A CN 202310939757 A CN202310939757 A CN 202310939757A CN 116803595 A CN116803595 A CN 116803595A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 20
- 238000010273 cold forging Methods 0.000 claims abstract description 23
- 239000000463 material Substances 0.000 claims abstract description 21
- 238000000641 cold extrusion Methods 0.000 claims abstract description 5
- 238000000137 annealing Methods 0.000 claims abstract description 3
- 238000000034 method Methods 0.000 claims description 25
- 238000004080 punching Methods 0.000 claims description 16
- 238000001125 extrusion Methods 0.000 claims description 15
- 238000005242 forging Methods 0.000 claims description 12
- 239000011265 semifinished product Substances 0.000 claims description 10
- 239000000047 product Substances 0.000 claims description 6
- 239000002131 composite material Substances 0.000 claims description 4
- 238000007493 shaping process Methods 0.000 claims description 4
- 238000005461 lubrication Methods 0.000 claims description 3
- 238000007127 saponification reaction Methods 0.000 claims description 3
- 239000010960 cold rolled steel Substances 0.000 claims description 2
- 238000005336 cracking Methods 0.000 claims description 2
- 238000001035 drying Methods 0.000 claims description 2
- 238000000227 grinding Methods 0.000 claims description 2
- 238000005488 sandblasting Methods 0.000 claims description 2
- 238000007781 pre-processing Methods 0.000 claims 1
- 238000005516 engineering process Methods 0.000 abstract description 4
- 238000005422 blasting Methods 0.000 abstract description 2
- 230000003746 surface roughness Effects 0.000 abstract description 2
- 230000007547 defect Effects 0.000 description 8
- 239000002184 metal Substances 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 230000013011 mating Effects 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910000639 Spring steel Inorganic materials 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000003337 fertilizer Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/02—Making uncoated products
- B21C23/03—Making uncoated products by both direct and backward extrusion
-
- 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
- B21J1/04—Shaping in the rough solely by forging or pressing
-
- 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
-
- 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
- B21J5/008—Incremental forging
-
- 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
-
- 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
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/10—Piercing billets
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
Abstract
A high-pressure pump eccentric wheel is made up through sawing to obtain blank, annealing, softening, ball blasting to remove oxide skin, phosphating and saponifying, setting mould frame and mould on a crank-type cold forging pressure, and processing in correspondent steps. The invention adopts the advanced small-cutting-free cold extrusion technology, only four steps are needed for one-time feeding to finish the manufacture of the eccentric wheel, the material utilization rate is up to more than 95%, the product precision IT is 8-11, the surface roughness Ra is more than 10 mu m, and the mechanical property is excellent.
Description
Technical Field
The invention relates to a technology in the field of cold forging, in particular to a cold forging manufacturing method of a high-pressure pump eccentric wheel for a diesel engine.
Background
At present, the manufacturing method of the eccentric wheel adopts a machine tool special for cutting metal processing, which not only cuts off metal streamline of the part and worsens mechanical property of material, but also wastes a lot of materials. An accurate forming method of an eccentric water drop type end cover forge piece is disclosed in application number 202211176289.3 in the prior art. For the water drop type forge piece, eccentric materials are few, material distribution and flow are easy, a hot forging process which is convenient to form and not friendly to the environment is adopted, the produced forge piece has large fertilizer head and large lug, and the machining amount is large. The precision and quality of the cold forging product are different from those of the cold forging product.
Disclosure of Invention
Aiming at the fact that the existing forging technology is only suitable for forming conventional products and cannot be suitable for manufacturing eccentric wheels on high-pressure pumps, the invention provides a manufacturing method of the eccentric wheels of the high-pressure pumps, an advanced few-cutting-free cold forging technology is adopted, the eccentric wheel manufacturing is completed in one feeding step only by four working steps, the material utilization rate is up to more than 95%, the product precision IT8-11, the surface roughness Ra is 0.2-1.6, and the mechanical property is excellent.
The invention is realized by the following technical scheme:
the invention relates to a manufacturing method of a high-pressure pump eccentric wheel, which comprises the following steps:
step 1) blanking and pretreatment: blanking by a sawing machine to obtain a blank, and carrying out annealing softening, shot blasting, oxide scale removal, phosphating-saponification lubrication treatment on the blank;
step 2) arranging a die carrier and a die on a crank type cold forging pressure and carrying out corresponding processing steps, wherein the method specifically comprises the following steps:
2.1 Positive extrusion, specifically: the deformation degree is 37% -40%.
2.2 Cold forging the pre-upsetting flange, setting the dip angle between the lower plane of the pre-formed eccentric flange of the female die and the horizontal plane to be 0 degrees, and setting the dip angle beta between the end part of the male die and the horizontal plane to be 9-12 degrees.
2.3 A composite cold extrusion final forging flange, which comprises the following concrete steps: and (3) reversely extruding an inner hole of the upper cylinder corresponding to the first step, leaving a connecting skin with the thickness of 3-5mm in the middle, reversely extruding the eccentric flange with the deformation degree of 37-40 percent, and shaping the eccentric flange.
2.4 Punching, specifically: and (3) punching out the connecting skin generated by the composite cold extrusion to prepare the cold forging of the high-pressure pump eccentric wheel, wherein the cold forging comprises a hollow cylinder and a flange which is deviated from the center of the hollow cylinder.
Technical effects
The invention can manufacture the eccentric wheel with complete and smooth metal streamline and excellent performance by four working steps in one press by using a cold forging method, simultaneously saves more than 50 percent of materials, and saves 78.8g of materials per piece, and saves 158 tons of steel by year when 200 ten thousand automobiles are produced per year.
Drawings
FIG. 1 is a schematic illustration of a high pressure pump eccentric part made in accordance with the present invention;
FIG. 2 is a schematic illustration of a cold swaging process for eccentric parts;
in the figure: a is a blank, b, c and d are semi-finished products obtained after three steps in sequence, and e is a cold forging;
FIG. 3 is a schematic diagram of a four step mold assembly according to the present invention;
in the figure: a) a first step, b) a second step, c) a third step, d) a fourth step;
FIGS. 4 and 5 are partial enlarged schematic views of FIG. 3;
in the figure: 101-104 are male dies adopted in four working steps, 201-203 are lower ejector rods adopted in the first to third working steps, 304 are punching female dies adopted in the fourth working step, and 301-303 are cold forging female dies in the 1 st to 3 rd working steps; 3-5 are 3 layers of interference sleeves, 2 layers of interference sleeves and a female die in sequence; 304 is a punching female die; 6. 7, 8, respectively obtaining semi-finished products after 3 steps; 9 is a punched cold forging;
FIG. 6 is a schematic diagram of a folding defect formed in a coextrusion step;
in the figure: a) displacement of material from the horizontal surface of the mould, b) annular corrugations on the blank, c) folding defects;
FIG. 7 is a schematic illustration of shrinkage cavity (geometry of type I blank) occurring at a > 6;
in the figure: a) material flow velocity vector, b) shrinkage cavity, c) fold formation;
FIG. 8 is a schematic illustration of the occurrence of folding (geometry blank of type II) in the condition of alpha > 0;
FIG. 9 is a schematic illustration of folding in which co-extrusion occurs;
in the figure: a) Deformation starts; b) Mold level scrap; c) Folding occurs;
FIG. 10 is a schematic diagram of defect elimination during coextrusion;
in the figure: a) Starting to deform; b) Transferring material out of the eccentric flange horizontal plane; c) Without fold formation.
FIG. 11 is a graph showing measured process forces for each step in the example;
in the figure: a), b), c) correspond to the first, second and third steps in sequence.
Detailed Description
As shown in fig. 2, this embodiment relates to a method for manufacturing a high-pressure pump eccentric wheel, including:
step 1) blanking and blank pretreatment: as shown in fig. 2a, a phi 24mm No. 10 cold rolled steel is sawed into a phi 24 multiplied by 22.2 blank on a sawing machine, the blank is annealed and softened, then the oxide skin is removed by sand blasting, phosphating-saponification lubrication treatment is carried out, and natural drying is carried out.
Step 2) cold die forging treatment: as shown in fig. 2b to e and fig. 3 to 5, the 4MN crank type cold forging press (J87-400) is provided with a die carrier and a die and performs corresponding steps, specifically including:
2.1 Three layers of combined female dies 3, 4 and 5 in interference fit, a first male die 101, a first female die 301 and a first lower ejector rod 201 are arranged, forward extrusion is carried out on a blank shown in fig. 2a, the first male die 101 is used for pre-upsetting and flattening the end face of the blank and pushing the blank to descend for forward extrusion, the extrusion depth meets the condition that the upper end plane of the first lower ejector rod 201 and the lower plane of an eccentric flange are located on the same horizontal plane, and a semi-finished product shown in fig. 2b is obtained, so that the flange is upset by undeformed materials in the second process step.
The degree of deformation epsilon=39.1% by the forward extrusion;
in the combined female dies 3, 4 and 5, the matched conical surface of each layer of sleeve and the vertical inclination angle of the outer conical surface of the female die are 1 degrees 30', the matched conical surface of each layer of sleeve is ground on the same grinding machine, and the interference is 7-8 percent 0 The diameter of the inner hole is measured. And the press-in sequence of the combined female die adopts a room temperature press-in method. In addition to ensuring the interference, the finish of the mating surface is not lower than R a =0.4 μm and ensures that the contact area should not be less than 75% of the mating area.
In order to avoid the cracking of the pre-stress ring caused by overlarge pre-stress, the middle pre-stress ring is pressed into the outer layer ring, and finally the female die is pressed. And the disassembly sequence is opposite, the female die is pressed out firstly, and then the middle ring is pressed out.
2.2 Three layers of combined female dies 3, 4 and 5 in interference fit, a second male die 102, a second female die 302 and a second lower ejector rod 202 are arranged, and pre-upsetting is carried out on the semi-finished part 6 shown in fig. 2b to obtain a semi-finished part 7.
The material of the outer sleeve 3 in the combined female die is 40Cr, and the material is subjected to heat treatment of 42-46HRC; the middle sleeve 4 is made of spring steel 60Si2Mn and is subjected to heat treatment of 46-50HRC.
As shown in tables 1 and 2, the values of the angles of inclination to the lower and upper planes of the flange in the pre-upsetting flange step and the defects found during the swaging process are shown. Similar analysis, satisfactory cold forgings only occur with a change in the upper rake angle and a lower rake angle equal to zero, as shown in table 3.
Table 1 defects occurring in the second process step using the geometry of the first parison
Table 2 defects occurring in the second process step using the second type blank geometry
Table 3 using blank geometry in the second process step and α=0°
The treatment results show several significant drawbacks on the proposed mould. In the second step, a gap is formed almost over the entire eccentric transition contour as shown in fig. 6a and 6b, and shrinkage cavities are formed at the end of the swaging, as shown in fig. 6 c. If α >6 ° during flange formation, severe metal flow in the radial direction occurs as shown in fig. 7a, resulting in shrinkage cavity formation as shown in fig. 7b, and folding in the third step as shown in fig. 7 c.
Similar problems are observed for the second step of swaging the second parison geometry and forming the fold at a >0 deg. as shown in fig. 8. Observing the extrusion of the semi-finished product shown in fig. 2 c2, the eccentric flange horizontal surface material was transferred to the flange forming place after 2 steps to extrude the meat-deficiency, and further folded as shown in fig. 9a and 9b, as shown in fig. 9 c.
It can be concluded that the accumulation of larger flange material must be achieved by increasing the flange upper plane inclination angle beta, while the lower plane angle alpha should be equal to zero. Preferably, the parameter α is set to 0 ° and the parameter β is set to 9 ° to 12 ° in this embodiment, so that different defects existing at other angles are avoided, as shown in table 3 and fig. 10, and when the upper inclination angle β is increased to be equal to or larger than 9 °, the mold surface material is hardly formed with scraps and defects, as shown in fig. 10.
To sum up, in this embodiment, the inclination angle β=9° between the end of the second punch 102 and the horizontal plane is such that some material is preset on the eccentric flange, so as to ensure that the flange is full and defect-free in the next step.
The preformed eccentric flange lower plane of the second die 302 described in this embodiment is inclined at an angle α=0° to the horizontal.
2.3 Three layers of combined female dies 3, 4 and 5 in interference fit, a third male die 103, a third female die 303 and a third lower ejector rod 203 are arranged, the inner hole of the cylinder is reversely extruded, and the flange part is shaped.
The cross-sectional area of the third punch 103 is shown in fig. 1.
The degree of deformation epsilon=39% of the back extrusion; shaping the flange part.
As shown in fig. 3 and 4, a working belt h is provided on the top of the first lower ejector 201 1 For positively extruding the bore, the bottom of the third punch 103 is correspondingly provided with the same structureAnd a working belt for back-extruding the inner holes with the same size at the corresponding positions of the semi-finished product 7, wherein the diameter of the working belt is 0.2mm larger than that of a rod body connected with the working belt, namely Z=0.1 mm, so as to reduce metal flow friction force, and the plane of the male die end and the working belt adopt small circular arcs to be excessively large and are carefully polished.
2.4 Two layers of combined female dies 3, 10, a fourth male die 104 and a fourth female die 304 are arranged, and the semi-finished product part diagram (9) shown in fig. 2d is punched to punch out the continuous skin formed by the combined extrusion, so that a cold forging finished product is obtained, as shown in fig. 1.
Because the punching force of the process step is smaller, only two layers of combined female dies are needed.
The combined female die is made of cold die steel Cr12MoV, hot forging deformation reaches forging ratio=5, and heat treatment hardness is 58-62HRC.
The fourth male die 104 is of a cylindrical integral structure and is suitable for cold punching of smaller forgings. The male die is convenient to fasten, and is directly fastened on the male die holder through the nut. Accurate positioning and high punching precision.
The fourth die 304 adopts a round punching die structure, the clearance delta between the male die and the die is 0.15-0.2mm, and the punching die generally only plays a supporting role, and the die cavity plays a positioning role. The die cavity is designed according to the forge piece shown in fig. 1, so that the forge piece is convenient to take and place, a gap delta is reserved between the cold forge piece and the punching female die, the value delta=e/2+ (0.3-0.5) mm, and e is the positive tolerance of the forge piece at the position.
Through specific practical experiments, in the aspect that the inclination angle beta is changed from 9 degrees to 12 degrees to realize the influence on the die forging force and the material flow characteristics, the process can be completed on a 4MN cold forging press, and the die forging process is carried out as shown in fig. 11. The metal streamline of the prepared eccentric wheel extrusion piece is complete and smooth, the performance is excellent, and besides the mechanical property of the part is greatly improved, each piece saves more than 50% of metal. 78.8g of materials are saved for each piece, and the annual production of 200 ten thousand automobiles is counted, the annual steel is saved for 158 tons.
The foregoing embodiments may be partially modified in numerous ways by those skilled in the art without departing from the principles and spirit of the invention, the scope of which is defined in the claims and not by the foregoing embodiments, and all such implementations are within the scope of the invention.
Claims (8)
1. A method of manufacturing a high pressure pump eccentric comprising:
step 1) blanking and preprocessing;
step 2) arranging a die carrier and a die on a crank type cold forging pressure and carrying out corresponding processing steps, wherein the method specifically comprises the following steps:
2.1 Positive extrusion, specifically: the deformation degree is 37% -40%;
2.2 Cold forging, pre-upsetting the flange, setting the inclination angle between the lower plane of the pre-formed eccentric flange of the female die and the horizontal plane to be 0 degrees, and setting the inclination angle beta between the end part of the male die and the horizontal plane to be 9-12 degrees;
2.3 A composite cold extrusion final forging flange, which comprises the following concrete steps: back-extruding an inner hole of the upper cylinder corresponding to the first step, leaving a connecting skin with the thickness of 3-5mm in the middle, and shaping the eccentric flange with the back-extrusion deformation degree of 37-40%;
2.4 Punching, specifically: and (3) punching out the connecting skin generated by the composite cold extrusion to prepare the high-pressure pump eccentric wheel cold forging comprising a hollow cylinder and a flange which is deviated from the center of the hollow cylinder.
2. The method for manufacturing the high-pressure pump eccentric wheel according to claim 1, wherein the step 1 is specifically: sawing No. 10 cold-rolled steel with the diameter of 24mm into a blank with the diameter of 24 multiplied by 22.2 on a sawing machine, annealing and softening the blank, removing oxide skin by sand blasting, performing phosphating-saponification lubrication treatment, and naturally drying.
3. The method for manufacturing the high-pressure pump eccentric wheel according to claim 1, wherein the step 2.1 is specifically: the method comprises the steps of setting a combined female die, a first male die, a first female die and a first lower ejector rod which are in interference fit of three layers, forward extruding a blank, wherein the first male die is used for pre-upsetting and flattening the end face of the blank and pushing the blank to descend for forward extrusion, the extrusion depth meets the condition that the upper end plane of the first lower ejector rod and the lower plane of an eccentric flange are located on the same horizontal plane, and a semi-finished product is obtained, so that an undeformed material upsetting flange is formed in the second process step.
4. The method for manufacturing the eccentric wheel of the high-pressure pump according to claim 3, wherein in the combined female die, the matched conical surface of each layer of sleeve and the outer conical surface of the female die have an inclination angle of 1 DEG 30', the matched conical surface of each layer of sleeve is ground on the same grinding machine, and the interference is 7-8 percent 0 The diameter of the inner hole;
the press-in sequence of the combined female die adopts a room temperature press-in method, in order to avoid the cracking of the pre-stress ring caused by overlarge pre-stress, the middle pre-stress ring is pressed into the outer layer ring, and finally the female die is pressed in.
5. The method for manufacturing the high-pressure pump eccentric wheel according to claim 1, wherein the step 2.2 is specifically: setting a combined female die, a second male die, a second female die and a second lower ejector rod which are in interference fit of three layers, and pre-upsetting a flange on the semi-finished product to obtain the semi-finished product;
the step 2.3 specifically comprises the following steps: setting a three-layer interference fit combined female die, a third male die, a third female die and a third lower ejector rod, reversely extruding an inner hole of the cylinder and shaping a flange part;
the inclination angle beta=9 DEG between the end of the second male die and the horizontal plane.
6. The method for manufacturing the high-pressure pump eccentric wheel according to claim 1, wherein the step 2.4 is specifically: arranging a two-layer combined female die, a fourth male die and a fourth female die, punching the semi-finished product, and punching out a connecting skin formed by combined extrusion to obtain a cold forging finished product;
the fourth male die is of a cylindrical integral structure and is suitable for cold punching of smaller forgings;
the fourth female die adopts a round punching female die structure.
7. The method of manufacturing a high pressure pump eccentric as in claim 6, wherein the fourth punch and fourth die gap δ = 0.15-0.2mm.
8. The method of manufacturing a high pressure pump eccentric according to claim 6, wherein a gap delta is left between the cold forging and the fourth die, the value delta = e/2+ (0.3-0.5) mm, and e is the positive tolerance of the forging at the position.
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CN202310939757.6A CN116803595A (en) | 2023-07-28 | 2023-07-28 | Manufacturing method of high-pressure pump eccentric wheel |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN117900364A (en) * | 2024-03-20 | 2024-04-19 | 星泓智造装备有限公司 | Near-net-shape forging method for offshore wind power tower flange |
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- 2023-07-28 CN CN202310939757.6A patent/CN116803595A/en active Pending
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN117900364A (en) * | 2024-03-20 | 2024-04-19 | 星泓智造装备有限公司 | Near-net-shape forging method for offshore wind power tower flange |
CN117900364B (en) * | 2024-03-20 | 2024-05-10 | 星泓智造装备有限公司 | Near-net-shape forging method for offshore wind power tower flange |
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