WO2016026261A1

WO2016026261A1 - Integrated plate welded-joint-free vehicle wheel and forming method thereof

Info

Publication number: WO2016026261A1
Application number: PCT/CN2015/070163
Authority: WO
Inventors: 张兴元
Original assignee: 上海兴浦旋压车轮有限公司
Priority date: 2014-08-20
Filing date: 2015-01-06
Publication date: 2016-02-25
Also published as: EP3184185A1; CN104191900A; EP3184185A4; CN104191900B; JP2017530868A; US20170232498A1

Abstract

Disclosed is a forming method of an integrated plate welded-joint-free vehicle wheel, comprising: rolling, adopting at least two rolling wheels (4) which are symmetrically arranged in the circumferential direction of a rolling master form (3), conducting planar and synchronous rolling on a round material (1), and forming a vehicle wheel billet (5); preliminarily forming a rim and spokes, adopting a profiling die (7) and a profiling punch (6) to apply a force in the axial direction, and pressing the vehicle wheel billet to preliminarily form the rim and the spokes; conducting roll forming, positioning the vehicle wheel billet between a rolling punch (8) and a rolling die (9), the two moulds synchronously rotating around the axis, and at the same time using a side press roller (10, 11, 12) which rotates around its own axis to extrude in the radial direction of the billet; and conducting compression sizing, positioning the billet in the step of roll forming between a sizing punch (16) and a sizing die (17), and using a side sizing press mould (18) to conduct flattening, compression and finishing on the rolling billet at the same time, so as to manufacture an integrated plate welded-joint-free vehicle wheel. Further disclosed is a vehicle wheel manufactured with the forming method. With the forming method, vehicle wheels with unequal thickness can be cold rolled, and the deflection amount and run-out amount of the vehicle wheel are reduced, such that the accuracy grade of the vehicle wheel is increased.

Description

Integrated plate weldless wheel and forming method thereof

Technical field

The invention relates to a method for manufacturing an automobile accessory, in particular to a method for manufacturing a plate-free welded wheel.

Background technique

The existing method for manufacturing a plate wheel is to separately manufacture the rim and the spoke, and then synthesize and weld the manufactured rim and spoke to form a wheel. The specific process flow includes:

Production rim: R-1 unwinding; R-2 flattening; R-3 butt welding; R-4 circle round; R-5 butt welding; R-6 scraping slag; R-7 end cutting; R-8, 9, 10 three-step cold rolling forming; R-11 expansion sizing; R-12 punching door hole.

Production spokes: D-1 unwinding; D-2 flattening; D-3 lower material; D-4 multi-station molding; D-5 reverse stretching; D-6 punching; D-7 extrusion center hole and Screw hole.

The rim and the spoke are combined into a wheel: A-1 positioning raceway; A-2 pressure fitting rim spoke; A-3 synthetic welding.

It can be seen that the existing process for producing plate wheels is very complicated, and the above process does not include some auxiliary processes, and there are more than twenty steps, so the production efficiency is low. In addition, the plate wheels produced by this process are subject to complicated air tightness inspection, which further reduces production efficiency.

Further, as shown in Fig. 1, the plate wheel produced according to the above process has a weld bead 3 between the rim 1 and the spoke 2, and further has a rim butt weld 4, so that the overall strength and rigidity of the wheel are not very Well, fatigue fracture is likely to occur at the weld bead 3 and the rim weld seam 4.

Based on this, it is desirable to provide a sheet and wheel forming method which greatly improves wheel production efficiency and quality strength, and provides an integrated sheet non-welded wheel produced by the forming method.

Summary of the invention

The object of the present invention is to provide a method for forming a one-piece sheet weldless wheel, which is compared with The traditional wheel manufacturing method can greatly reduce the manufacturing process, thereby greatly improving the production efficiency, and can produce wheels with high strength, good rigidity and long service life; in addition, the method can also produce high-precision wheels, which are produced by the method. Out of the wheel, all the forces on the surface are equal in strength and different in thickness. In addition, the wheels produced by this method do not need to be welded, there is no weld, they will not leak, and airtightness detection is not required.

In order to achieve the above object, the present invention provides an integrated sheet weldless wheel forming method comprising the steps of:

(1) rolling: placing the round material in a pressing mold, the outer contour of the rolling master is circular, and adopting at least two rolling wheels symmetrically arranged along the circumferential direction of the pressing master. The plane is synchronously pressed in the rolling profile to press the round material into a wheel blank; the so-called plane rolling means that the rolling track of the rolling wheel is always in one plane, so-called synchronous 辗Pressure means that the rolling action of at least two rolling wheels is synchronized, so as to ensure the uniform quality of the pressed surface of the round material and ensure the surface of the round material is dense, so the more the rolling wheel, the rolling marks on the surface of the round material The denser the surface, the better the surface quality, but the number of rolling wheels needs to take into account economic costs and stress factors;

(2) Initial forming of the rim spoke: applying a pressure in the axial direction of the wheel blank by using a pressing punch and a pressing die to press the wheel blank out of the rim initial shape of the plate wheel;

(3) Roll type: Roll type: the wheel blank is positioned between the roll type punch and the roll type die and pressed, and the roll type punch and the roll type die are controlled to rotate synchronously around the axis thereof, and one or both are used. A plurality of side pressure rollers apply pressure to the initially formed rim profiling portion (i.e., the side wall portion of the wheel blank) in a radial direction of the wheel blank to further precisely shape the rim profiling portion by pressing, The side pressure roller also rotates around its own axis while applying pressure;

(4) Compression shaping: the blank passing through the rolling step is positioned between the shaping punch and the shaping die, and the shaping punch and the shaping die apply pressure in the axial direction of the wheel blank, and the shaping side pressing die is used. Pressure is applied to the rim priming portion of the blank in the radial direction of the entire circumference of the wheel blank to simultaneously flatten, compress and finish to form a one-piece sheet weldless wheel.

The rolling step in the method for forming a one-piece sheet weldless wheel according to the present invention is preferably a planar synchronous misalignment rolling. The so-called misalignment pressure means that the setting of each of the rolling wheels in the initial position is offset from each other, so that the rolling tracks of the rolling wheels on the surface of the round material do not coincide, so that the surface of the round material is more dense.

Further, the method for forming a one-piece sheet weldless wheel according to the present invention further comprises the steps of: stepping the lower round material and punching a positioning hole on the round material before the step (1), the positioning hole is used for the round material Stable placed in the rolling mold.

Further, the method for forming a one-piece sheet weldless wheel according to the present invention further comprises the step of: squeezing the center hole between the step (3) and the step (4).

Further, the method for forming a one-piece sheet weldless wheel according to the present invention further comprises the step of: pressing the screw hole between the step (3) and the step (4).

Further, the method for forming a one-piece sheet weldless wheel according to the present invention further comprises the step of: squeezing the air hole between the step (3) and the step (4).

Further, the integrated sheet non-weld wheel forming method of the present invention further comprises the step (5): punching the door hole on the integrated sheet non-weld wheel.

The above-mentioned punching positioning hole, pressing center hole, pressing screw hole, pressing air hole and punching door hole are not substantially different from the corresponding processes in the manufacturing process of the existing plate wheel, and therefore these steps will not be described in detail in this case.

Further, in the method for forming a one-piece sheet weldless wheel according to the present invention, the rolling action of at least two pressure rollers in the step (1) includes: feeding movement of at least two pressure rollers in a horizontal direction And the rotation of each rolling wheel.

Further, in the step (4) of the method for forming a one-piece sheet weldless wheel according to the present invention, three lateral pressure rollers are used to gradually divide into three stages in the radial direction of the wheel blank toward the initially formed rim type. Partially applying pressure to further precisely shape the rim profiling portion by pressing, the three side pressing rolls are evenly arranged along the circumferential direction of the wheel blank.

Accordingly, the present invention also provides an integrated sheet weldless wheel produced by the above-described integrated sheet non-weld wheel forming method.

Further, the material of the integrated sheet non-weld wheel of the present invention is carbon steel, aluminum, magnesium aluminum alloy or stainless steel.

The integrated sheet non-weld wheel forming method of the present invention is a production process completely different from the existing sheet wheel manufacturing method. As described in the background art of the present invention, the existing sheet wheel manufacturing method is to separately produce rims and The spokes are then welded together with the rim and the spokes to produce a welded plate wheel. The technical solution adopts an integrated molding process, which is completely different from the prior art, and is mainly embodied in:

(1) The rolling forming process is pioneered in the forming process of the one-piece sheet non-weld wheel. The rolling forming process is flat rolling forming, and the rolling wheel is only in the pressing mode except for the rotation. The horizontal plane feeds, while the pressing master applies a binding force to the material, and the material is deformed by the interaction force of the rolling wheel and the pressing master, so that both the upper surface and the lower surface of the material are deformed. The workpiece produced by the rolling process has a tighter structure, higher strength, lighter weight and lower material consumption. In addition, by adopting the rolling forming process, the workpiece is subjected to a large force, and deformation resistance is generated due to the restriction of the pressing of the pressing form on the workpiece during the forming process, and the workpiece blank is pressed, so that the deformation of the workpiece blank is more accurate. In addition, the press forming process can greatly improve the bending fatigue life of the workpiece produced by the same material. By adopting the rolling forming process, the forming method of the workpiece is limited by a large range, which is forced forming. Therefore, various progressively deformed geometric sections can be accurately formed according to the shape of the pressing cavity, and the axial and circumferential quality balance after molding. High dynamic balance. In addition, by using the rolling forming process, the wheels of equal strength can be pressed out (that is, the strengths of all the force receiving surfaces of the wheel are equal, meeting the strength requirement), and the wheels of the same strength are unequal thickness wheels, and the stress points of the wheels are The force can change the thickness of the material according to the demand. For example, the position of the small force can reduce the thickness of the material, thereby reducing the material, and the unequal thickness wheel can not be produced by the existing manufacturing method, only According to the method described in the technical solution, since the round material is first formed in the rolling master, the corresponding pressing mold can be designed according to the force requirement of the wheel. However, in the prior art, both the production of the rim and the production of the spokes are produced by the method of rolling stamping deformation. In the process of rolling deformation, the rolling master is open, and the material is not binding, and The rolling wheel is controlled to be displaced in the radial direction, which only changes the shape of the workpiece surface without changing the thickness of the workpiece.

(2) The composite pressing type (ie, the initial forming of the rim spoke) is adopted, so that the rim spoke initial type of the integrated plate wheel is directly pressed out from the blank.

(3) The rolling process is used to further complete the deformation of the rim, thereby further accurately forming the rim portion of the plate wheel directly from the rim initial shape of the integrated plate wheel, thereby completing the key steps of manufacturing the weld-free plate wheel. The type of process step is to gradually and slowly cold-roll, cold-extrude and bend-deform within the plastic deformation range of the material to form a high-strength rim section. It should be noted that, as with the rolling master, the technical solution does not limit the specific shapes of the rolling punch, the rolling die and the side pressing roller. The key point of the technical solution lies in the molding method, and the technology in the art. The personnel should be able to design the outer contour of the side pressure roller according to the actual product shape, size, etc., thereby forming a rim shape that meets the requirements.

(4) The compression shaping process is adopted to ensure the relative position and offset of the rim and the spoke, and to ensure the standard diameter and yaw requirements of the rim.

It can be seen that the production process of the integrated sheet non-weld wheel forming method of the present invention is far less than the existing method of manufacturing the plate wheel, and therefore the molding method according to the present invention can greatly improve the production efficiency.

In addition, since the integrated plate non-weld wheel forming method of the present invention adopts the rolling forming and rolling type process, the production process of the plate wheel is integrated, without the need for butt welding, thereby greatly improving the rigidity of the wheel. , strength and longevity. In addition, the butt welding step is omitted, and the equipment consumption and power consumption of the related butt welding equipment, the suction device, and the like are eliminated, and the pollution caused by welding, such as splashes and smoke, is avoided.

Similarly, the one-piece sheet weldless wheel manufactured by the integrated sheet non-weld wheel forming method of the present invention has no weld seam compared with the plate wheel synthesized by welding, and has better safety and does not need to be conventional. Air tightness test.

The integrated plate weldless wheel manufactured by the integrated sheet non-weld wheel forming method of the present invention can be used for a passenger car or a commercial vehicle.

DRAWINGS

Figure 1 shows the structure of an existing sheet metal wheel.

2 is a schematic flow chart of a method for forming a one-piece sheet weldless wheel according to an embodiment of the present invention.

Figures 3-14 show the steps of the flow shown in Figure 2, respectively.

Figure 15 is a view showing a vertical cold rolling machine used in the roll forming step of the one-piece sheet weldless wheel forming method of the present invention.

Figure 16 is a schematic view showing the structure of a one-piece plate weldless wheel according to the present invention.

detailed description

The integrated sheet non-weld wheel forming method of the present invention will be further described below based on the specific embodiments and the drawings, but the specific embodiments and related descriptions do not constitute an undue limitation on the technical solutions of the present invention.

FIG. 2 is a schematic flow chart showing the method for forming a one-piece sheet weldless wheel according to the present invention in one embodiment. Figures 3-14 show the steps, respectively. As shown in FIG. 2 to FIG. 14, this embodiment manufactures a one-piece sheet weldless wheel according to the following steps:

B-1: Lower round material 1 (Fig. 3).

B-2: Punch the center hole 2 on the round material 1 (Fig. 4).

B-3: The round material is placed in the rolling master 3 having a circular outer contour, and two rolling wheels 4 symmetrically arranged along the circumferential direction of the rolling master are used to press the rolling material in the rolling mold 3 The plane synchronous misalignment pressing is performed, and the round material is pressed into the wheel blank 5. As can be seen from the figure, in the present embodiment, the pressing master has two recessed cavities 31, so that the rolling is performed. The lower surface of the wheel blank has two projections. The rolling process can be completed by a rolling press, and the Chinese patent publication No. CN201744545U discloses a rolling press, but it should be understood that the implementation of the rolling process involved in the present invention should not be limited to the rolling machine. Press (Figure 5).

B-4: Pressing type (ie, initial forming of the rim spoke): applying a pressure to the axial direction of the wheel blank by the pressing punch 6 and the pressing die 7 to press the wheel blank out of the wheel rim of the plate wheel (Figure 6).

B-5, B-6, B-7: three-station composite roll type: the wheel blank is positioned between the roll-type punch 8 and the roll-type die 9, and the roll-type punch 8 and the roll-type die 9 are controlled. Rotating synchronously about its common axis, while applying pressure to the side wall of the wheel blank in the radial direction of the wheel blank by three

side pressure rollers

10, 11 and 12, three times to the initial part of the wheel rim on the wheel blank For further precision molding, the

side pressure rollers

10, 11 and 12 are also rotated about their own axes while applying pressure. In the present embodiment, the roller male die 8 and the rolling die 9 are all in contact with the wheel blank and Pressing, the

side pressure rollers

10, 11, 12 apply pressure to the wheel blank; in the present embodiment, the

side pressure rollers

10, 11, 12 complete the further precise forming of the rim in three steps, wherein the step B-5 The side pressure roller 10 performs cold rolling and extrusion of the rim deep groove R, which slowly pushes the material into the cavity and is extruded (Fig. 7); the side pressure roller 11 in the step B-6 cools the rim straight portion The bevel P is formed by rolling and forming, so that the shape of the rim portion initially conforms to the shape requirement of the rim (Fig. 8); the side pressure roller 12 in the step B-7 is completed. R Q rim edge molding (FIG. 9).

In the present embodiment, the rolling step is performed by a vertical cold rolling machine as shown in Fig. 15, but it should be understood that the vertical cold rolling machine is only a device capable of implementing the rolling step. This technical solution should not be limited to the roller type machine shown in FIG.

As shown in FIG. 15, the vertical cold rolling type in this embodiment includes a frame including an upper beam 51, a base 52, a base bracket 53, and six fixedly disposed on the upper beam 51 and the base 52. The column 54 and the six columns 54 are evenly arranged on the circumference centering on the axis of the vertical cold rolling machine. That is, the angle between the two adjacent columns 54 is 60°; the lower transmission assembly 55 is disposed on the base 52; the three sub-cylinder assemblies 56 are fixedly disposed on the upper beam 51, and the cylinder rods of the cylinder assembly 56 are sliding. Block 57 is fixedly coupled and slider 57 is fixedly coupled to upper ram assembly 58 such that cylinder assembly 56 can drive upper ram assembly 58 in the axial direction of the vertical cold rolling mill (i.e., vertical) a hydraulic motor that is coupled to the lower drive assembly 55 and the upper ram assembly 58 to drive the lower drive assembly 55 and the upper ram assembly 58 to rotate about their respective axes; three side roll assemblies 59 is uniformly arranged on the circumference centering on the axis of the vertical cold rolling machine, that is, the angle between the two adjacent side roll assemblies is 120°; the three side roll feed cylinders are respectively The side roll assemblies 59 are connected to drive the side roll assemblies 59 to feed in the radial direction of the circumference. The three side roll assemblies can be fed synchronously or separately; the side roll hydraulic motor, and the side rolls The assembly 59 is connected to drive the side roll assemblies to rotate about their respective axes, and the side roll hydraulic motor can control the three side rolls The assembly can be rotated synchronously, and the three side roll assemblies can also be controlled to rotate respectively; the roll type punch 510 is fixedly coupled to the upper head assembly 58; the roll type die 511 is fixedly coupled to the lower drive assembly 55. In addition, the vertical cold rolling machine further includes a control system not shown, the control system comprising: a displacement sensor corresponding to each side roller feeding mechanism for detecting a feeding position of the side roller assembly The servo valve is respectively connected with the hydraulic motor, the side roller feed cylinder and the side roller hydraulic motor; the control PLC is connected with the displacement sensor, each servo valve and the cylinder assembly to realize the rotation speed and the feed speed of each component. control. For the convenience of roll forming, the position of the side roll assembly of the vertical cold rolling machine is adjustable in the axial direction (ie, the vertical direction) of the vertical cold rolling machine, and the side passes through the side The roll assembly is connected to the side roll vertical position adjustment mechanism.

The rolling process using the above vertical cold rolling mill is:

(1) placing the wheel blank into the die 511;

(2) the control cylinder assembly 56 drives the upper ram assembly 58 to feed vertically downward along the axial direction of the vertical cold rolling mill until the rolling ram 510 presses the wheel blank;

(3) controlling the hydraulic motor to drive the lower transmission assembly 55 and the upper pressing head assembly 58 to rotate synchronously, thereby driving the rolling type punch 510, the rolling type concave die 511 and the wheel blank to synchronously rotate accordingly;

(4) The control side roll feed cylinder drive side roll assembly is fed in the radial direction of the circumference (horizontal feed) to apply a deformation force to the side wall of the wheel blank, and the side roll assembly is directed to the side wall of the wheel blank While applying the deformation force, the control side roll hydraulic motor drives the side roll assembly to rotate until the roll step is completed.

B-8: Squeeze the center hole 13 (Fig. 10).

B-9: Squeeze the screw hole 14 (Fig. 11).

B-10: Squeeze the air hole 15 (Fig. 12).

B-11: Compression shaping: the wheel blank is positioned between the shaping punch 16 and the shaping die 17, and the shaping punch 16 and the shaping die 17 apply pressure in the axial direction of the wheel blank, and the shaping side pressure is used. The die 18 applies pressure to the rim priming portion of the wheel blank in the radial direction of the wheel blank to form a plate weldless wheel (Fig. 13).

B-12: Exhaust valve hole 19 (Fig. 14).

Figure 16 shows the integrated plate weldless wheel made by the above steps. As can be seen from the figure, the shape of the welded plate of the integrated plate is the same as that of the existing plate without weld, but the spokes There is no weld at the transition to the rim, so its strength, rigidity and longevity are much higher than the existing plate wheels.

It is to be noted that the above description is only specific embodiments of the present invention, and it is obvious that the present invention is not limited to the above embodiments, and there are many similar variations. All modifications that are directly derived or associated by those of ordinary skill in the art are intended to be within the scope of the invention.

Claims

An integrated sheet non-weld wheel forming method, characterized in that it comprises the steps of:

(1) rolling: placing the round material in a pressing mold, the outer contour of the rolling master is circular, and adopting at least two rolling wheels symmetrically arranged along the circumferential direction of the pressing master. Performing plane synchronous rolling on the round material in the rolling master to press the round material into a wheel blank;

(2) Initial forming of the rim spoke: applying a pressure in the axial direction of the wheel blank by using a pressing punch and a pressing die to press the wheel blank out of the rim initial shape of the plate wheel;

(3) Roll type: the wheel blank is positioned between the rolling type punch and the rolling type die and pressed, and the rolling type punch and the rolling type die are controlled to rotate synchronously around the axis thereof, and the side pressure roller is used at the wheel. Applying pressure to the priming portion of the rim that is initially formed in the radial direction of the blank to further precisely shape the rim profiling portion by pressing, the side embossing roller also rotating about its own axis while applying pressure;

(4) Compression shaping: the blank passing through the rolling step is positioned between the shaping punch and the shaping die, and the shaping punch and the shaping die apply pressure in the axial direction of the wheel blank, and the shaping side pressing die is used. Pressure is applied to the rim priming portion of the blank in the radial direction of the entire circumference of the wheel blank to simultaneously flatten, compress and finish to form a one-piece sheet weldless wheel.
The method of forming a one-piece sheet weldless wheel according to claim 1, further comprising the steps of: stepping the lower round material and punching the positioning hole on the round material before the step (1).
The method of forming a one-piece sheet weldless wheel according to claim 1, further comprising the step of: squeezing the center hole between the step (3) and the step (4).
The method of forming a one-piece sheet weldless wheel according to claim 1, further comprising the step of: pressing the screw hole between the step (3) and the step (4).
The method of forming a one-piece sheet weldless wheel according to claim 1, further comprising the step of: squeezing the air hole between the step (3) and the step (4).
The method of forming a one-piece sheet weldless wheel according to claim 1, further comprising the step (5): punching the door opening on the one-piece sheet non-weld wheel.
The method of forming a one-piece sheet weldless wheel according to claim 1, wherein the rolling action of at least two of the pressure rollers in the step (1) comprises: feeding at least two pressure rollers in a horizontal direction The action, as well as the rotation of each rolling wheel.
The method of forming a one-piece sheet weldless wheel according to claim 1, wherein in the step (3), three side pressure rollers are used in the radial direction of the wheel blank toward the initial formed rim. The profile portion applies pressure to further precisely shape the rim profiling portion by pressing, the three side roller rollers being evenly arranged along the circumferential direction of the wheel blank.
An integrated sheet weldless wheel produced by the integrated sheet non-weld wheel forming method according to any one of claims 1-8.
The one-piece sheet weldless wheel according to claim 9, wherein the material is carbon steel, aluminum, magnesium aluminum alloy or stainless steel.