JPH04361847A - System for manufacturing integral type crank shaft - Google Patents

Abstract

PURPOSE:To reduce heat loss in a heating furnace, to reduce the bending of a material to be forged, to improve the accuracy of a manufactured crank shaft, to restrain the number of the heating furnaces to the minimum, to prevent overcrowding of space in a plant and maintenance works, to consistently execute the forging work, to eliminate exchange of die, to shorten the waiting time of worker and to improve working efficiency. CONSTITUTION:A material 11 to be forged is wholly heated in a closed type heating furnace 12, and the wholly heated material 11 is carried to the position of a forging press 14, and by using the forging press 14 fitting the prescribed dies 14a, 14b, every time a part of the material 11 is formed to the prescribed shape, the material is shifted from one end side to the other end side in order, and also unforged part in the material 11 cooled naturally during forging is compensated in the temp. with an induction heating device 16, and after heating for short time, successively, the unforged part in the material 11 is formed into the prescribed shape in order by using the forging press 14.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] This invention relates to a system for manufacturing an integral crankshaft by sequentially forming a heated forged material into a predetermined shape using a forging press equipped with a predetermined mold. In particular, it relates to an integrated crankshaft manufacturing system in which the entire forged material is heated, and the unforged portion of the forged material that is allowed to cool during forging is temperature-compensated with an induction heating device and sequentially formed into a predetermined shape. be.

0002

[Prior Art] Conventionally, an integrated crankshaft is shown in Figs. 8 to 1.
It is generally manufactured by the method shown in 4. That is, about half of the material 11 to be forged is put into a batch type heating furnace 12 and the remaining part is heated while being taken out of the furnace. The material to be forged 1
The partially heated portion of No. 1 is forged one throw at a time using a forging press 14. In this case, the partially heated forged material 1
It is forged one throw at a time from the end of 1 to the center.

[0003] When the forging of the partially heated portion of the material 11 to be forged is completed, the remaining unheated portion (unforged portion) is forged in order to forge the remaining unheated portion (unforged portion).
is returned to the batch type heating furnace 12 and partially heated. After sufficiently partially heating the remaining part, it is pulled out from the heating furnace 12 again using the manipulator 15 and placed in a predetermined mold 1.
The forged material 11 is transported to the forging press 14 to which the forging materials 4a and 14b are attached, and the partially heated portions of the forged material 11 are forged one throw at a time by the forging press 14. In this case, the partially heated material 11 to be forged is forged one throw at a time from the center toward the ends. For this reason, it is necessary to change the molds 14a and 14b attached to the forging press 14, and the molds 14a and 14b are removed and installed in the opposite direction.

0004

However, the conventional integrated crankshaft manufacturing system described above has the following problems.

(1) The method of heating the material to be forged is partial heating, in which about half of the material to be forged is placed in the heating furnace and heated with the remainder taken out of the furnace. , the heating furnace door is ajar, and some of the heat inside the heating furnace escapes through the ajar door, resulting in large heat loss.

(2) Batch type heating furnaces are generally used, and the unheated portion of the forged material is grabbed by a manipulator, and the heated part of the forged material is heated when it is transported to the forging press location. Due to the weight of the part (red-hot part) and the bounding effect of the manipulator, small bends often occur locally, often making die forging impossible. Furthermore, in order to release the crankshaft from the mold once forging is completed for each throw, bending occurs when the crankshaft is lifted up by a crane using a hanging device such as a wire. Furthermore, it is necessary to position each forged material during the movement of the heating furnace and forging press.

(3) Normally, this type of stamped integral crankshaft is produced in lots of about 5 to 10 pieces, and 3 to 4 heating furnaces are permanently installed. Therefore, there is an inconvenience that the factory space and maintenance are congested.

(4) Since the material to be forged is divided into two parts and heated, the manipulator, the opening and closing of the heating furnace, the lubrication and cooling of other dies, and the change of dies require double work and waiting time for each press worker. There is an inconvenience that may occur.

[0009] This invention was devised in view of the above-mentioned problems and to solve the problems, and its purpose is to reduce the heat loss of the heating furnace and to reduce the heat loss of the material to be forged. This reduces bending and improves the accuracy of the finished crankshaft product. Minimizes the number of heating furnaces to save space and maintenance in the factory. It also allows forging operations to be carried out consistently and changes in molds to be made easier. To provide a manufacturing system for an integrated crankshaft, which can eliminate the need for an integrated crankshaft, reduce worker's waiting time, and improve work efficiency.

0010

[Means for Solving the Problems] In order to achieve the above objects, the present invention heats the entire forged material in a closed heating furnace, transports the entirely heated forged material to a forging press location, Each time a part of the material to be forged is formed into a predetermined shape using a forging press equipped with a predetermined die, the material to be forged is sequentially moved from one end to the other and allowed to cool during forging. This method involves temperature-compensating the unforged portion of the forged material using an induction heating device, heating it for a short time, and then sequentially forming the unforged portion of the forged material into a predetermined shape using a forging press. Here, in a preferred embodiment, each time a part of the material to be forged is formed into a predetermined shape, the material to be forged is released from a predetermined mold by mechanical force by knocking out by a mold release device built in the forging press. There is a way to mold it.

[0011]

[Operation] The present invention having the above structure operates as follows. In other words, by heating the entire material to be forged in a closed heating furnace, the heat inside the heating furnace is prevented from escaping, and the heat loss inside the heating furnace is reduced. Each time a portion of the material to be forged is formed into a predetermined shape using a forging press equipped with By heating the unforged part of the forged material that has been left to cool during forging with an induction heating device for a short time, it is possible to avoid reheating the forged material in the heating furnace. It works so that work can be done consistently.

0012

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be explained in more detail below based on embodiments shown in the drawings. Here, FIG. 1 is a plan view of the heating furnace, FIG. 2 is a side view of the material to be forged being transported, FIG. 3 is a side view of the material being set in a forging press, and FIG. Figure 5 is a side view of the forged material, Figure 5 is a side view of the half-forged workpiece, Figure 6 is a side view of the forged material being heated with an induction heating device, and Figure 7 is a side view of the completed integral crankshaft. be.

In FIG. 1, a closed type heating furnace 12 for heating the material 11 to be forged is, for example, one walking hearth type, and four to five materials 11 to be forged are placed in advance in the heating furnace 12. is loaded, and when one forged material 11 after heating is rolled out of the heating furnace 12, one cold forged material 11 is charged into the furnace. There is.

The to-be-forged material 11 is completely roasted in the heating furnace 12, and the door of the heating furnace 12 is closed to the forged material 1.
Since it is closed except for loading and unloading in step 1, heat loss is significantly reduced compared to conventional partial heating methods.

As shown in FIG. 2, the heated forged material 11 carried out from the heating furnace 12 is conveyed while being gripped by the automatic tongs 13 at approximately the center of its entire length, so that it is in a completely roasted state. Even if bending occurs, it is a large bend with a large radius of curvature and has little effect on forging.

The forged material 11 is conveyed by the automatic tongs 13 to the press center of the forging press 14, and is held horizontally by placing one end on a roller support and simultaneously gripping one end with the manipulator 15. The height of this roller support device can be easily adjusted to match the height of the clamping jaws 15a of the manipulator 15.

As shown in FIG. 3, another manipulator 15 is waiting on the opposite side of the forging press 14, so the clamping jaw 15a of the waiting manipulator 15 is covered via the rollers. Push in the forging material 11. Then, the forged material 11 is set at a predetermined position. At this time, the forged material 11 is supported by the manipulators 15 on both ends thereof, so that the bending becomes extremely small, and the waste material (excess material) of the integral crankshaft 17 as a whole can be reduced.

After the material 11 to be forged is set between the upper and lower molds 14a, 14b of the forging press 14, both manipulators 15, 15 are moved by their clamping jaws 15a, 15a.
each in a free state. Thereafter, the forging press 14 is driven, the press and the die-stamping device are operated, and the material to be forged 11 is forged by one throw between the upper and lower molds 14a and 14b.

When one throw of forging is completed, the punching device is also released, and as shown in FIG. 4, the crank (forged material 11 ) is pushed up, and the forged material 11 is released from the lower mold 14b by mechanical force. Then, by both manipulators 15, 15,
The crank (material 11 to be forged) is lifted up to the height at which it is pulled out from the mold, and the material 11 to be forged is pulled out to a predetermined position on the working side.

Forged material 11 pulled out to a predetermined position
is supported in height by a roller device, and the manipulator 15 on the opposite side is released. Further, the manipulator 15 on the working side moves backward and stops at a predetermined position. By repeating the die exchange and the like for forging the second throw, up to the third throw can be performed without raising the temperature of the material to be forged 11 (see FIG. 5).

However, at the fourth throw, since the unforged portion of the forged material 11 has cooled down due to cooling, it is necessary to perform temperature compensation. Temperature compensation of the unforged portion of the forged material 11 is performed by an induction heating device 16. The induction heating device 16 applies an electric current through the forged material 11 to be heated by induction, and heats the forged material 11 by using its resistance. The induction heating device 16 is comprised of a power distribution board, a transformer, a frequency converter, a matching device, an induction heating coil, a control panel, etc. The induction heating device 16 uses, for example, a high-medium-low frequency induction heating device. ing.

The induction heating device 16 is hollow inside and has a coil wound around its circumferential surface. When the induction heating device 16 is operated, the induction heating device 16 is guided to the free shaft end side of the material 11 to be forged. The heating coil advances, and the to-be-forged material 1 is applied to the coil.
1, and the second roller support device supports the forged material 11 through which the induction heating coil has passed. At the same time, the first support is released, the induction heating coil is set in a predetermined position, and heating begins (see FIG. 6).

Since the to-be-forged material 11 is originally entirely heated in the heating furnace 12, even though its surface is cold, its inside is sufficiently hot.Therefore, the cooled surface is heated by the induction heating device 16. As a result, the temperature is restored to the point where it can be forged in a short time, less than one-tenth of the time required before.

[0024] Then, wait until the unforged part of the material 11 to be forged reaches a temperature at which it can be forged, and then remove the coil.
The forging operations of 4th throw, 5th throw, and final throw are performed in sequence to manufacture the integral crankshaft 17 as shown in FIG. 7.

It should be noted that the present invention is not limited to the above embodiments, and it goes without saying that various modifications can be made without departing from the spirit of the invention.

[0026]

[Effects of the Invention] As is clear from the above description, according to the integrated crankshaft manufacturing system according to the present invention, the entire forged material is heated in a closed heating furnace. Unlike partial heating, in which about half of the material to be forged is heated inside the furnace and the rest is taken out of the furnace, the door of the heating furnace is left ajar, and part of the heat inside the furnace is absorbed through the half-open door. Therefore, the heat loss inside the heating furnace can be reduced.

Furthermore, the number of heating furnaces can be minimized to prevent congestion in the factory space and maintenance, and the forging work can be performed in a straight line between the forging press and the manipulator, making it easy to change molds. It can be made unnecessary. This reduces worker waiting time, increases work efficiency, and lowers manufacturing costs for integrated crankshafts.At the same time, congested work can be performed in a straight line, improving worker safety. Can be completely secured.

Further, as in the second aspect of the present invention, each time a part of the material to be forged is formed into a predetermined shape, a knockout is performed by a mold release device built in the forging press, and a predetermined mold is removed by mechanical force. When the material to be forged is released from the mold, it is possible to reduce the bending of the material to be forged, and it is possible to avoid a situation in which forging work cannot be performed thereafter, which is a very novel and beneficial effect. It is something that plays.

[Brief explanation of drawings]

FIG. 1 is a plan view of a heating furnace according to an embodiment of the present invention.

FIG. 2 is a side view of a forged material being transported according to an embodiment of the present invention.

FIG. 3 is a side view of the embodiment of the present invention when set in a forging press.

FIG. 4 is a side view of the forged material when it is released from the mold by knockout according to the embodiment of the present invention.

FIG. 5 is a side view of a half-forged workpiece according to an embodiment of the invention.

FIG. 6 is a side view of a forged material being heated by the induction heating apparatus according to the embodiment of the present invention.

FIG. 7 is a side view of a completed integral crankshaft according to an embodiment of the present invention.

FIG. 8 is a plan view of a heating furnace in a partially heated state in a conventional manufacturing method.

FIG. 9 is a side view when set in a forging press in a conventional manufacturing method.

FIG. 10 is a side view of a forged material when it is released from the mold by a hanging tool such as a wire in a conventional manufacturing method.

FIG. 11 is a side view of a half-forged workpiece according to a conventional manufacturing method.

FIG. 12 is a plan view of a heating furnace in a partially heated state in a conventional manufacturing method.

FIG. 13 is a side view of the forging press set in a conventional manufacturing method.

FIG. 14 is a side view of an integrated crankshaft produced by a conventional manufacturing method.

[Explanation of symbols]

11: Forged material 12: Heating furnace 13: Automatic tongs 14: Forging press 14a, 14b: Mold 15: Manipulator 15a: Clamping jaw 16: Induction heating device 17: Integrated crankshaft 18: Mold release device

Claims (2)

[Claims] Claim 1: The entire forged material is heated in a closed heating furnace, the heated entire forged material is transported to a forging press location, and the forged material is forged using a forging press equipped with a predetermined die. Each time a part is formed into a predetermined shape, the forged material is sequentially moved from one end to the other, and the unforged part of the forged material that is left to cool during forging is temperature compensated using an induction heating device. A manufacturing system for an integrated crankshaft, characterized in that, after heating for a short time, the unforged portion of the forged material is sequentially formed into a predetermined shape using a forging press. [Claim 2] A claim in which each time a part of the forged material is formed into a predetermined shape, the forged material is released from a predetermined mold by mechanical force by knockout by a mold release device built into the forging press. Item 1. The integrated crankshaft manufacturing system according to item 1.