SU1590157A1 - Method of producing ring-like articles - Google Patents

Abstract

The invention relates to the processing of metals by pressure, in particular, to methods for producing synchronizer rings, as well as other ring parts, mainly from non-ferrous metals. Rings are made by hot stamping from a previously obtained ring-shaped billet. The latter is obtained by heating a round bar stock, flexible, winding a heated bar stock onto a mandrel of an ellipse cross section when the formed coils are tilted to the plane of the larger axis of the ellipse section at an angle α depending on the diameters of the bar stock and the inner contour of the ring-shaped workpiece, and cutting the coils. clearance in the same plane. After removal from the mandrel, the ring-shaped billet is heated in a heating device with a protective atmosphere and stamped with pressure simultaneously carried out by welding in the butt zone, obtaining a forged block. The latter is cut in a trim stamp. Then the forging of the synchronizer ring is finally machined. 1 hp f-ly, 12 ill.

Description

The invention relates to the processing of metals by pressure, in particular, to methods for producing rings of a synchronizer, as well as other ring parts derived mainly from non-ferrous metals.

The aim of the invention is to improve the accuracy and reduce the consumption of metal during the bending of the synchronizer rings.

FIG. 1 shows the mandrel; in fig. 2 is a section A-A in FIG. one; in fig. 3 - coiled on a mandrel; in fig. 4 - mandrel with one turn of the spiral; in fig. 5 - ring-shaped billet after removal from the mandrel; in fig. 6 - ring-shaped billet with closed ends of its joint; in fig. 7 - scheme for calculation; in fig. 8 — stamp for hot stamping at the time of closing the ends of the ring-shaped billet; in fig. 9 — stamp at the end of the hot stamping process; in fig. 10 - fill pattern;

in fig. 11 - the same, side view; in fig. 12 is a view B in FIG. eleven.

The method is carried out as follows.

A round bar cross-section billet is heated and subjected to bending by winding it on a mandrel I of an elliptical cross-section 2 with a large a and a small b axis. Winding is carried out to obtain at least two formed turns, each turn 3 of helix 4 is located with a fixed inclination to the plane / 7, in which lies the major axis of the ellipse cross section 2 of the mandrel 1, and without forming a gap between adjacent turns of helix 4. Bending by winding is performed on the mandrel 1 of ellipse cross section 2, whose major axis is equal and the small axis is equal to b (), where d is the diameter of the inner contour

;about

sd

a radial, flexible ring-shaped preform I 5 with the closed ends 6 of its joint 7; D is the diameter of the cross section of the billet str; P is the angle of inclination of the joint 7 to the diametral plane 8 of the ring-shaped billet 5 with the closed ends 6 of its joint 7. When winding, the coils of the spiral 4 are placed at an angle a to the plane P, i.e. in the plane of the major axis a of the elliptical cross section 2 of the mandrel 1, at the same angle

D,. 5 d

a, -arcsinj + arc sin--.

 The resulting flexible helix 4 is then cut into separate turns when simultaneously trimming the ends of the helix 4, do not: remove the latter from the mandrel 1. In this case, cutting and trimming are carried out in the plane P of the major axis and with the aid of a saw, for example a circular one. For this, the plane of the saw is positioned in the plane P of the major axis a and the saw disk is moved along the longitudinal axis of the mandrel 1.

To fix the inclination of the first turn, a stop 9 is fixed on the mandrel 1, the reference plane of which is at an angle to the plane P of the major axis a.

In order to ensure a high-quality cut, the mandrel 1 has a longitudinal groove 10, left: sticking in the plane of the major axis a. ; Spiral cutting; w 4 is carried out at a crush, not propyl, equal to

(d-fD) jsma,

where a is the angle of inclination of turns formed during bending on the mandrel 1 to the plane P, i.e. to the plane in which the major axis a lies;

/ the length of the geometrical axis of one turn, the ends of which are m and n, before cutting the helix 4.

This length can be determined, for example, by the formula

, / oizi i 1 (- + ---) l + 2- + R4 + -l.

cosa

Where

.

a-} b + 2D / cosa

graphic or other methods.

Obtained by cutting spiral 4 ring-shaped blanks removed from the mandrel 1 and placed in a heating device with a protective atmosphere, if necessary, heating or thermostat. Then, an annular billet having a forging temperature is fed to the punching equipment, placed on the die 11 of the stamp installed on it, and hot stamping is performed with the joint pressure dried simultaneously by pressure welding of the die 12 and the outer 14, a bur (a stamp for cutting is not shown), as a result of which a stamped synchronizer ring (forging) 15 is obtained, which is to be finished by cutting. At the beginning of the punching process at the ring-shaped billet, the ends 6 of its joint 7 are closed by the action of the punch 12, and the inner contour of the ring-shaped billet laid on the matrix 11 becomes round with a diameter d. After the closure of the ends 6 occurs and the gap between them disappears, hot-cutting with simultaneous pressure welding takes place until a synchronized ring of the synchronizer 15 is produced to form

5 there is a slight oblo 13 and 14. The removal of the oblo is done in an edging stamp.

The magnitude of the large a and small b axes of the ellipse cross section 2 of the mandrel 1 is set from the following conditions of bending by winding. To maintain the cutting direction of the helix 4 along its longitudinal axis, as well as to coincide the cutting plane with the plane of the major axis a, which is technically most easily accomplished when jr simultaneously produces end 6 on the ring-shaped billet 5, which is optimal for welding pressure p, significantly greater than zero, it is necessary to wind the bar stock when bending; each turn of 3 30 helix 4 is inclined with a slope, the angle of which depends on the specified angle p. To obtain a ring-shaped billet 5 (with its ends closed 6) of a round shape, not oval, it is necessary to use a mandrel 1 ellipse-cross section 2, the larger axis of which is equal to the diameter d of the inner circumference of the ring-shaped billet 5 in - meiit closure of its bargaining 6 under the action of the punch 12. Choi this small axis b of the same cross section is determined by kg T, based on the values of d, D and p, i.e., taking article equal

40

b (d + D} sin -C

With the indicated values of d and D ps.: We can ring the billet 5 with closed

the ends 6 of its joint 7 has an internal contour, described by diameter d.

When determining the value of the angle a, the following conditions are used. It is taken into account that the angle p has an optimal value of 40-50 °, which provides the best pressure welding conditions. At smaller angles, especially those close to zero, the welding conditions become unfavorable, since the interface plane becomes parallel to the direction of the punching force or almost parallel. At angles greater than 50 °, the ends

The coil after cutting helix 4 is a thin elongated wedge section web. This shape of the ends leads to rapid cooling before stamping and, as a result, to a deterioration in the quality of the synchronizer rings. Further, after removal from the mandrel I of the ring-shaped billet 3, the planes of the ends b are located

at an angle (p-arcsmr-) to the median plane 8, if the ends are not closed. Under the action of the punch 2 during hot stamping, the angle at which the ends of the b are inclined to the diametral plane 8,

is reduced by the value of arcsin "and is a, -arcsin --- L + arcsin. POA- -DLO

In the process of hot stamping, the position of the pressure-welded joint 7 is optimal, i.e. the plane of the joint 7 is located at the optimum angle p to the diametric plane 8.

The thickness of the cut And in the process of cutting the spiral 4 is determined by taking into account the angle a, the diameters of and D, as well as the length of the geometrical axis L of one turn of the spiral 4 (before cutting). The value of /. exceeds the length of the geometric axis of the annular coil (the distance from the point m to the point n along the specified axis) and is to be determined (calculated) by any known method or calculation method. When tatschine propyl A L-n {d- -D) sina. the length of the geometrical axis of one turn after cutting becomes equal to the length of the geometrical axis. an annular billet 5 with docked ends 6 of its joint 7.

Thus, bending the coiled billet, the diameter D of the cross section of which is relative to the major axis, onto the mandrel 1 of the ellipse cross section 2, the axes of which are taken with regard to the optimum angle p, the diameters d to D, allows to obtain an annular billet 5 with given diameter d and angle p without deviating its shape from round and keeping the directivity of cutting the helix 4 along the longitudinal axis of this helix and the axis of the mandrel I, and not resorting to cutting the helix along the helix in the case of winding on the support a round section and the need to obtain an optimum angle p.

At the optimum angle p and the absence of deviations of the shape of the ring-shaped billet 5 from the circle, hot stamping and pressure welding make it possible to obtain stamped rings of synchro-synchronizers with minimal metal waste due to the high dimensional accuracy of the ring-shaped billet 5 and improved quality of their welded joint.

In addition, this is facilitated by heating in a heating device with a high-pressure atmosphere.

0

F,

As an option, when cutting the helix 4, the ring-shaped billet 5 is obtained with a gash that is thicker than the thickness ((i-f D) s /, 7, c: on

magnitude 5.O / cos p ... /) / cos p. In this case, the thickness of the ghropil A-f-.A. An annular billet with such a kerf is formed to flatten it by applying two opposing axial forces to it. To do this, it is placed between two dies 16 and 1 and squeeze the village-1 week. Then the JOHV cut with thickness A with a shape and a vacuum of such co-ring ozuazu billet 5 is placed in the gall 18 and pour

5 5 with the help of chute 19 (along arrow K) with a melt of material similar to that of a synchronizer according to CGCTP.BV. cooling the melt to crystallize its mineral and form a compound with the ring-shaped material.

 The melt is produced by melting waste, for example, in the form of flash in a known casting tooling. After crystallization of the melt in the zone of cutting with a tap area A of the ring-shaped billet 5, it is heated in the case of

5 ;; с: obkhodimost and subjected to a hot strain Example. For preparing a synchronizer ring of a heavy truck, the LMTSKA-58-2-2-1-i brass pipe is used as the starting material 0. After the pieces of the annular billet are cut, the last is machined to obtain a complete synchronizer stone. At the same time the coefficient of metal absorption is 0.33.

For the manufacture of the same ring, according to the predicted method, heated L-700-740 ° C with a prupoch diameter of 26 m. L. From the same brass bend by winding ii.g the elliptical cross section, whose major axis is G - 152 .v: .M, and the small axis, 85 mm, to produce a helix, consisting of more than two

turns (depending on C, trade

rod)., having turns to the plane of the major axis of the section at an angle. Then, the disk ailo made the helix a ;; o cut. ib longitudinal axis of the mandrel at rgspo. and. blades of the disk in the plane of the major axis of the section and the cut of the cut. - 052-f26) ls; "42 ° 45, where L 602 mm. Ots ode thickness spent on drink .6 mm.

Then, the obtained ring-shaped billet is subjected to hot stamping in a single-punch die at a temperature not lower than 650 ° C (if necessary, heating the ring-shaped billet is placed in a Hai-pe 15 protective device with a protective atmosphere) with simultaneously producing my pressure m of the joint before the forging of the synchronizer ring with the formation of the outer and the inner | -o oblo on the forging. Said scallop is then removed in the trimmed grill.

0

0

J

At present, the brass rings of the synchronizer of a heavy truck are manufactured by a cutting method, carried out in the following sequence: shredding the ring blanks from the pipe; mechanical machining on lathes.

The waste of metal in the form of chips is 68--75% depending on the size of the rings and the pipes used as the initial batch. For example, ring No. 15 17 70176, with a weight of 0.8 kg, was manufactured from a 195x130 mm tube. At the same time waste 2.4 kg.

The application of the proposed method makes it possible to reduce the metal consumption by increasing the dimensional accuracy used for hot stamping of the ring-shaped billet and to improve the quality of the synchronizer rings when using a bent billet.

Claims (2)

1. A method of manufacturing ring-shaped products, including heating a bar stock, bending it by winding an ellipse section over a mandrel, cutting vit-ov along a generatrix, removing it from a mandrel and welding BciTbiK, characterized in that, in order to improve accuracy and reduce metal consumption during bending synchronizer rings, the bar stock is wound up when the coils are tilted to the plane of a larger: th axis of the ellipse section of the mandrel under the mind a -arcsin, + arcsin, a + L) whether five cutting the coils along the generatrix is carried out in the plane of the major axis of the ellipse cross section of the mandrel with the formation of a gap equal to Ln (d -} - D) sina, where a is the angle of inclination of the turns of the helix to the plane of the large axis of the elliptical cross section of the mandrel; P is the angle of inclination of the joint to the diametral plane of the ring-shaped billet with the closed ends of its joint; D is the diameter of the bar bar cross section; d is the diameter of the inner contour of the ring-shaped billet with closed ends of its joint; L is the length of the geometric axis of one coil spiral to cut; and after removal from the mandrel, the ring-shaped workpiece is subjected to hot shtampovka with closed ends of its joint with simultaneous welding, carried out by pressure. five 2. A method according to claim 1, characterized in that prior to hot stamping, the ring-shaped billet is formed to make it flat by applying two opposing axial forces to it, the melt of the bar material is poured into the gap between the ends of its joint and cooled. crystallization, and when cutting the coils of the helix, the gap is increased by the value of 5D / cosp ... D / cosp. / 7 FIG. five F (R14g.5 d four -. S -Z / ig.b / J Fiyo.9 (. eleven Vidb pryuёrno TU5 x 18 Fig.P