WO2023071376A1 - 用于锻造大型曲拐的组合砧模及工艺 - Google Patents

用于锻造大型曲拐的组合砧模及工艺 Download PDF

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Publication number
WO2023071376A1
WO2023071376A1 PCT/CN2022/110637 CN2022110637W WO2023071376A1 WO 2023071376 A1 WO2023071376 A1 WO 2023071376A1 CN 2022110637 W CN2022110637 W CN 2022110637W WO 2023071376 A1 WO2023071376 A1 WO 2023071376A1
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Prior art keywords
anvil
die
forging
billet
manipulator
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PCT/CN2022/110637
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English (en)
French (fr)
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张晖
张连华
陈习中
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中聚信海洋工程装备有限公司
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Priority claimed from CN202122607356.XU external-priority patent/CN216176308U/zh
Priority claimed from CN202111260932.6A external-priority patent/CN113926973B/zh
Application filed by 中聚信海洋工程装备有限公司 filed Critical 中聚信海洋工程装备有限公司
Publication of WO2023071376A1 publication Critical patent/WO2023071376A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • B21J13/02—Dies or mountings therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • B21J13/06—Hammers tups; Anvils; Anvil blocks
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/06—Making machine elements axles or shafts
    • B21K1/08—Making machine elements axles or shafts crankshafts

Definitions

  • the disclosure relates to the production of a crank throw forging billet, in particular to the setting and process of an anvil die for large crank throw forging, and belongs to the technical field of forging.
  • crankshaft is the main part of the mechanical transmission, and the crankshaft is an important part on the crankshaft. Because the crankshaft undertakes the conversion of mechanical rotation and reciprocating motion, the crankshaft of a large crankshaft bears large and complicated forces, so it must have sufficient rigidity, strength and Ability to withstand shock loads.
  • forged bell cranks are usually used. Common forging methods include: solid forging method, die forging method and bending forging method. The solid forging method is to forge the blank into a square and then machine it into shape. This method not only has a large machining allowance and high cost, but also often has loose defects on the inner wall of the crank throw.
  • the die forging method is to press the steel ingot into a square through chamfering and upsetting, and further press it in the forging die, and finally use a punch to split it into shape.
  • This method has a high pass rate, forming rate, and material utilization rate. machine, and different models require different molds, which is expensive.
  • the bending and forging method is to press the steel billet into a slab first, then bend it on the bending die frame, and forge and press it step by step. This method is good in forming, easy to operate, good in metal flow, and does not require high equipment, so bending forging is the most commonly used method. Methods. However, the relevant bending and forging methods require processes such as jaw pressing, upsetting, billet drawing, grooving, bending, and shape finishing.
  • Each process needs to replace the anvil die, especially the upper anvil of the forging machine that needs to be replaced many times, resulting in The forging machine cannot perform multi-process continuous forming operations.
  • the above-mentioned forging process requires multiple fires and repeated heating, consumes a lot of energy and raw materials, has low production efficiency, and high product cost.
  • the present disclosure proposes a combined anvil die and process for forging large crank throws.
  • a combined anvil die for forging large crank throws may include a forging machine and a manipulator, the forging machine may include an upper anvil, a lower anvil and an upper die, the upper anvil is connected At the lower end of the upper anvil of the forging machine, the manipulator can be set to at least include two manipulators, the lower anvil can include an anvil mold and a mobile workbench, the anvil mold can include a large flat anvil, a small flat anvil and a drain plate, and the small flat anvil and the upper anvil
  • the upper mold can include a forming mandrel and an upsetting plate, there is a through hole in the middle of the drain plate, the mobile workbench can include a longitudinal workbench and a transverse workbench, and the drain plate can be placed on the longitudinal workbench,
  • the large flat anvil and the small flat anvil can be set on the horizontal
  • a connecting seat may be provided on the transverse workbench, and the lower end of the large flat anvil or the small flat anvil or the double indentation die or the trapezoidal die or the concave die may be movably connected with the upper end of the connecting seat.
  • connection base can be provided with a positioning hole, and the lower end of the large flat anvil or small flat anvil or double indentation die or trapezoidal die or concave die can be inserted into the positioning hole.
  • the two die tips of the double indentation die can be arranged parallel and upward at the same height.
  • a process for forging a large crank throw includes the following steps:
  • Step 1 Billet upsetting: heat the steel billet with single or multiple bellcranks connected to the forging temperature, move the anvil vertically, the lower anvil is a small flat anvil, chamfer the billet, move the anvil vertically, and the lower anvil is a leaking plate , the billet after chamfering is placed vertically on the drain plate, the upsetting plate is placed between the billet and the upper anvil, the billet is upset and a process handle is made, the anvil is moved horizontally on the worktable, the lower anvil is a small flat anvil, and the billet is pulled out grow into a forging billet;
  • Step 2 drawing and pressing: heat the forging billet obtained in step 1 to the forging temperature for the second time, the lower anvil is a small flat anvil, and roll the forging billet to the set geometric shape;
  • Step 3 positioning indentation: move the anvil horizontally on the worktable, and the lower anvil is a double indentation die, and position the forging billet obtained in step 2 to forge double indentation in sections;
  • Step 4 Forging the boss: move the anvil horizontally on the worktable, and the lower anvil is a large flat anvil. Turn the forging blank obtained in step 3 by 180°, and roll the outer sides of the double indentation of the forging blank obtained in step 3 to the set size respectively.
  • the inner part of the double indentation is a boss;
  • Step 5 forging the trapezoidal groove: move the anvil across the worktable, the lower anvil is a trapezoidal mold, and forge the four sides of the forging blank boss made in step 4 to connect the trapezoidal groove;
  • Step 6 forging curved neck: move the anvil across the workbench, and the lower anvil is a concave die, and forge and press the inner part of the trapezoidal groove obtained in step 5 into a curved neck blank;
  • Step 7 Segmentation: cooling the forged billet obtained in step 5, and dividing it according to the set size to obtain a semi-finished forging of a single crank throw;
  • Step 8 Bending: Heat the semi-finished crankshaft forging to the set temperature for the third time, move the anvil horizontally, the lower anvil is a concave mold, and a manipulator holds the semi-finished crankshaft forging, and engages the curved neck in the concave mold. On the upper end of the shape die, the other manipulator holds the reverse bending die and buckles it upside down above the boss, and the upper anvil presses down on the reverse bending die, and the forging semi-finished product is bent into a "herringbone" shape;
  • Step 9 Pressing: move the anvil horizontally on the worktable, the lower anvil is a large flat anvil, one manipulator clamps the semi-finished boss of the forging, and the other manipulator clamps the forming mandrel and inserts it from the "herringbone”-shaped opening, and sticks it to the curved neck. Close, press down on the anvil, so that the two sides of the word " ⁇ " merge with the forming mandrel;
  • Step 10 final forging: two manipulators hold the forging semi-finished product obtained in step 8 and the forming mandrel and turn it over synchronously, and forge the four sides to the set geometric size;
  • Step 11 the finished forged billet is released from the mold.
  • the duplex indentation die can be a conjoined die with two die tips facing upwards, and the distance between the two die tips can be equal to the width of the root of the boss.
  • step 1 and step 2 are completed in one shot.
  • the upper anvil of the combined anvil mold is fixedly set as a flat anvil, the anvil mold and the upper mold are set as movable anvil molds that can be replaced at any time, and part of the anvil molds are placed on the workbench to move Replacement, part of the anvil mold is clamped and replaced by the manipulator to achieve rapid replacement, complete multiple complex forging processes within the forgeable temperature range of one fire time, and reduce the traditional 5-7 fire time crank throw forging billet process to 2-3 Fire times complete.
  • the disclosure has the characteristics of energy saving, consumption reduction, high quality and high efficiency.
  • 1 is the upper anvil
  • 2 is the upsetting plate
  • 3 is the right manipulator
  • 3' is the left manipulator
  • 4 is the longitudinal workbench
  • 4' is the horizontal workbench
  • 5 is the leakage plate
  • 6 is the billet
  • 6' 6" is forging blank
  • 6" is forging semi-finished product
  • 601 is process handle
  • 602 is indentation
  • 603 is boss
  • 604 is trapezoidal groove
  • 7 is small flat anvil
  • 8 is double indentation die
  • 9 is large flat anvil
  • 10 is Trapezoidal mould
  • 11 is concave mould
  • 12 is dividing surface
  • 13 is buckle bending mold
  • 14 is forming mandrel.
  • FIGS. 1 to 4 The combined anvil mold according to the exemplary embodiment of the present disclosure will be described below with reference to FIGS. 1 to 4 .
  • FIGS. 1 to 4 put leaky plate 5 on longitudinal workbench 4, move longitudinal workbench 4 to move anvil, lower anvil is leaky plate 5, steel billet 6 stands on leaky plate 5, upper anvil 1 presses down The workpiece is upset, and the craft handle is made at the same time.
  • small flat anvil 7, double indentation die 8, large flat anvil 9, trapezoidal die 10, concave die 11 are arranged on the horizontal workbench 4 ', and the movable horizontal workbench 4' moves the anvil, and the small flat anvil 7.
  • the double indentation die 8, the large flat anvil 9, the trapezoidal die 10, and the concave die 11 can be used as the lower anvil respectively, and the upper anvil 1 is respectively connected with the small flat anvil 7, the double indentation die 8, the large flat anvil 9, and the trapezoidal die 10 ,
  • the concave die 11 cooperates to perform various operations on the forging blank 6', and cooperates with the Xiaoping anvil 7 to pull out and press the forging blank 6', and cooperates with the double indentation die 8 to perform various operations on the forging blank.
  • 6' forging double marks cooperate with the large flat anvil 9, make the curved neck of the forging blank 6', cooperate with the trapezoidal die 10, forge the trapezoidal groove for the forging blank 6', cooperate with the concave die 11, and make the forging blank
  • the inner part of the 6' trapezoidal groove is forged into a curved neck blank.
  • the right manipulator 3 clamps the buckle bending die 13 between the forging blank 6' and the upper anvil 1, and at the same time replaces the lower anvil with a concave mold 11 to bend the two arms of the forging blank 6' Into two crank forging billets.
  • the left manipulator 3' clamps the forming mandrel 14 between the two cranks, the lower anvil is replaced with a large flat anvil 9, and the two crank arms are fitted to the forming mandrel 14 to make the forging blank 6' Crank forging billet.
  • one steel billet 6 can be used to produce three bellcrank forging semi-finished products 6 ′′, and accompanying drawings 5 to 25 show the process of making a single bellcrank forging semi-finished product 6 ′′ from a steel billet 6 .
  • the drain plate 5 is placed on the vertical workbench 4, and the vertical workbench 4 moves the anvil, so that the drain plate 5 is moved to the below of the upper anvil 1, and the heated steel billet 6 is erected, and the lower end is placed on
  • the right manipulator 3 clamps the upsetting plate 2 and places it on the upper end of the steel billet 6, and the upper anvil 1 presses down, as shown in Figure 6, the steel billet 6 is upset, and at the same time, a process handle is made in the through hole of the leakage plate 5 601.
  • the horizontal workbench 4' moves the anvil, the small flat anvil 7 is the lower anvil, and the upper anvil 1 presses the billet 6 into a forged billet 6' of a set size.
  • the horizontal worktable 4' moves the anvil, the double indentation die 8 is the lower anvil, and the indentation 602 is forged under the forging blank 6'.
  • the forging blank 6' is turned over 180°, the horizontal worktable 4' moves the anvil, the large flat anvil 9 is the lower anvil, the upper anvil 1 is rolled outward from the indentation 302, and the forging between the two indentations 602 Boss 603 is made.
  • the horizontal workbench 4' moves the anvil, the trapezoidal anvil 10 moves below the boss 603, and the forging blank 6' is turned over to forge the trapezoidal groove 604, and the bosses are forged into interconnected trapezoidal grooves 604 .
  • the lower anvil is set as a concave die 11, the forging blank 6' is turned over, and the inside of the trapezoidal groove 604 is forged into a curved neck.
  • the forging billet 6' is cooled and divided at the dividing plane 12 shown in Figure 13, and the single forging semi-finished product 6" after division is shown in Figure 16.
  • the horizontal workbench 4' moves the anvil, the concave die 11 is the lower anvil, and the heated single forging semi-finished product 6" is placed above the concave die 11, and the upper end of the concave die 11 fits the forging semi-finished product 6 ", the right manipulator 3 clamps the reverse buckle bending die 13, which is sleeved on the boss 603 of the forging semi-finished product 6", and the reverse buckle bending die 13 presses and bends the two arms of the forging semi-finished product 6 "to form In the "herringbone” shape shown in accompanying drawing 18, the right manipulator 3 moves out the reverse buckle bending die 13.
  • the horizontal workbench 4' moves the anvil, the large flat anvil 9 is the lower anvil, the right manipulator 3 clamps the boss 603 and places it on the large flat anvil 9, and the left manipulator 3' will form
  • the mandrel 14 is inserted into the curved neck from the "person" opening of the forging semi-finished product 6 ", and the upper anvil 1 and the large flat anvil 9 press the "man” character both sides with the forming mandrel 14.
  • the right manipulator 3 and the left manipulator 3' synchronously overturn the forging semi-finished product 6" and the forming mandrel 14, and finally forge the forging semi-finished product 6" from four sides as shown in accompanying drawings 23, 24, and 25. Finished forgings.
  • the disclosure provides a combined anvil die and process for forging a large crank throw.
  • the combined anvil die includes a forging machine and a manipulator, and the forging machine includes an upper anvil, a lower anvil and an upper die.
  • the upper anvil is connected to the lower end of the upper anvil of the forging machine and is fixedly set as a flat anvil;
  • the manipulator is set to include two manipulators;
  • the lower anvil includes an anvil die and vertical and horizontal worktables, and the anvil die includes a large flat anvil, a small flat anvil, and a double-combined pressing die , trapezoidal mold, concave mold and leakage plate, the leakage plate is placed on the longitudinal workbench, the anvil mold is set on the horizontal workbench,
  • the upper mold includes the forming core mold, the buckle bending mold and the upsetting plate, which are clamped by the manipulator hold.
  • the process of forging large crankshafts with the above-mentioned combined anvil die is divided into eleven working steps. Since the anvil die and the upper die are set as movable anvil dies that can be replaced at any time, some anvil dies are placed on the workbench to move and replace, and some anvil dies are moved by the manipulator. The clamping is replaced, so one fire can complete multiple forging steps, reducing the traditional forging process of 5-7 fires to 2-3 fires.
  • the disclosure has the characteristics of energy saving, consumption reduction, high quality and high efficiency.
  • the combined anvil die and process for forging large crank throws of the present disclosure are reproducible and can be applied in various industrial applications.
  • the combined anvil die and process for forging large crank throws disclosed in the present disclosure can be applied to the technical field of mechanical manufacturing.

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  • Mechanical Engineering (AREA)
  • Forging (AREA)

Abstract

提供一种锻造大型曲拐的组合砧模及工艺，组合砧模包括锻机和机械手（3，3'），锻机包括上砧（1）、下砧和上模。上砧（1）连接在锻机上砧座下端且固定设置为平砧；机械手（3，3'）设置为包括两只机械手（3，3'）；下砧包括砧模和纵、横向工作台（4，4'），砧模包括大平砧（9）、小平砧（7）、双联压痕模（8）、梯形模（10）、凹形模（11）和漏盘（5），漏盘（5）置于纵向工作台（4）上，砧模设置在横向工作台（4'）上，上模包括成型芯模（14）、反扣折弯模（13）和镦粗盘（2），其由机械手（3，3'）夹持。运用组合砧模锻造大型曲拐的工艺分为十一工步，由于砧模和上模设置为随时可以更换的活动砧模，部分砧模放置在工作台上移动更换，部分砧模由机械手夹持更换，因此一个火次可完成多个锻造工步，将传统5-7火次的锻件工艺缩减至2-3火次完成。

Description

用于锻造大型曲拐的组合砧模及工艺
相关申请的交叉引用
本申请要求于2021年10月28日提交中国国家知识产权局的申请号为202122607356.X、名称为“一种锻造大型曲拐的组合砧模”的中国专利申请、于2021年10月28日提交中国国家知识产权局的申请号为202111260932.6、名称为“一种锻造大型曲拐的组合砧模及工艺”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本公开涉及一种曲拐锻坯的制作，特别涉及大型曲拐锻造的砧模设置及工艺，属于锻造技术领域。
背景技术
曲轴是机械传动中的主要部件，曲拐是曲轴上的重要零件，因曲轴承担机械旋转运动和往复运动的变换，大型曲轴的曲拐受力大而复杂，因此要有足够的刚度、强度和承受冲击载荷的能力。为了满足上述性能要求，通常选用锻制曲拐，常见的锻造方法有：实型锻造法、模锻法和弯锻法。实型锻造法是将毛坯锻成一个方块，再机加工成型，这种方法不仅加工余量大、成本高，而且曲拐内侧壁常出现疏松缺陷。模锻法是通过倒棱、镦粗将钢锭压方块，并在锻模中进一步强压，最后用冲头劈开成型，这种方法合格率、成型率、材料利用率高，需要运用超大型锻机，且不同型号需不同模具，费用高。弯锻法是将钢坯先压成扁坯，然后在弯曲模架上弯曲，分步锻压成型，这种方法成型好，操作方便，金属流向好，对设备要求不高，所以弯锻是最常用的方法。然而相关的弯锻法需要压钳口、镦粗、拔坯、压槽、弯曲和精整外形等工序，每道工序都需要更换砧模，特别是需要多次更换锻机的上砧，造成锻机不能多工序连续成型操作。上述锻造工艺需要多火次反复加热，能源和原材料消耗多，生产效率低，产品成本高。
发明内容
为了减少曲拐锻坯的锻造火次和原材料损耗，本公开提出了一种锻造大型曲拐的组合砧模及工艺。
根据本公开的一些示例性实施方式，提供了一种锻造大型曲拐的组合砧模，该组合砧模可以包括锻机和机械手，锻机可以包括上砧、下砧和上模，上砧连接在锻机的上砧座的下端，机械手可以至少设置为包括两只机械手，下砧可以包括砧模和移动工作台，砧模可以包括大平砧、小平砧和漏盘，小平砧与上砧的砧面形状和面积相同，上模可以包括成型芯模和镦粗板，漏盘中间设有通孔，移动工作台可以包括纵向工作台和横向工作台，漏盘可以置于纵向工作台上，大平砧、小平砧可以设置在横向工作台上，成型芯模和镦粗板可以由机械手夹持，其中，上砧固定设置为平砧；上模还可以包括反扣折弯模；砧模还可以包括双联压痕模、梯形模和凹形模；双联压痕模、梯形模和凹形模可以设置在横向工作台上；反扣折弯模可以通过机械手夹持。
可选地，横向工作台上可以设置有连接座，大平砧或小平砧或双联压痕模或梯形模或凹形模的下端可以与连接座的上端活动连接。
可选地，连接座的上端可以设有定位孔，大平砧或小平砧或双联压痕模或梯形模或凹形模的下端可以插入定位孔。
可选地，双联压痕模的两只模尖可以平行向上等高设置。
根据本公开的一些示例性实施方式，还提供了一种锻造大型曲拐的工艺，该工艺包括以下步骤：
步骤1、钢坯镦粗：将单个或多个曲拐连体的钢坯加热至锻造温度，纵向工作台移砧，下砧为小平砧，钢坯倒棱，纵向工作台移砧，下砧为漏盘，倒棱后的钢坯竖直置于漏盘上，镦粗板置于钢坯与上砧之间，钢坯镦粗并制得工艺柄，横向工作台移砧，下砧为小平砧，将钢坯拔长成锻坯；
步骤2、拔长压方：将步骤1制得锻坯第二次加热至锻造温度，下砧为小平砧，将锻坯压延至设定的几何形状；
步骤3、定位压痕：横向工作台移砧，下砧为双联压痕模，将步骤2制得锻坯定位分段锻制双压痕；
步骤4、锻制凸台：横向工作台移砧，下砧为大平砧，将步骤3制得锻坯翻转180°，将步骤3制得锻坯的双压痕外侧分别压延至设定尺寸，双压痕内侧部分为凸台；
步骤5、锻制梯形槽：横向工作台移砧，下砧为梯形模，将步骤4制得锻坯凸台的四面锻制相连接的梯形槽；
步骤6、锻制曲颈部：横向工作台移砧，下砧为凹形模，将步骤5制得的梯形槽内部分锻压成曲颈坯；
步骤7、分割：将步骤5制得锻坯冷却，按设定尺寸分割，获得单个曲拐的锻件半成品；
步骤8、折弯：将曲拐锻件半成品第三次加热至设定温度，横向工作台移砧，下砧为凹形模，一只机械手夹持曲拐锻件半成品，将曲颈部啮合在凹形模上端，另一只机械手夹持反向折弯模倒扣在凸台上方，上砧下压反向折弯模，锻件半成品弯折成“人”字形；
步骤9、压合：横向工作台移砧，下砧为大平砧，一只机械手夹持锻件半成品凸台，另一只机械手夹持成型芯模从“人”字形开口插入，与曲颈部贴合，上砧下压，使“人”字两边与成型芯模并合；
步骤10、终锻：两只机械手分别夹持步骤8制得的锻件半成品和成型芯模同步翻转，锻制四面至设定几何尺寸；
步骤11、锻坯成品出模。
可选地，所述双联压痕模可以为两只模尖向上的连体模，且两模尖的间距可以与所述凸台 的根部宽度相等。
可选地，当步骤1中所述钢坯为单个曲拐锻坯时，步骤1和步骤2一火次完成。
根据本公开示例性施方式的组合砧模及工艺，组合砧模的上砧固定设置为平砧，砧模和上模设置为随时可以更换的活动砧模，部分砧模放置在工作台上移动更换，部分砧模由机械手夹持更换，实现快速更换，在一个火次可锻温度范围内完成多个复杂锻制工序，将传统5-7火次的曲拐锻坯工艺缩减至2-3火次完成。
本公开具有节能降耗、优质高效的特点。
附图说明
附图1为纵向工作台组合砧模示意图；
附图2为横向工作台组合砧模示意图；
附图3为机械手夹持反扣折弯模状态图；
附图4为机械手夹持成型芯模状态图；
附图5、6为钢坯镦粗工步过程示意图；
附图7为锻坯拔长压方工步过程示意图；
附图8为锻坯定位压痕工步过程示意图；
附图9为锻制凸台工步过程示意图；
附图10、11、12为锻制四面梯形槽工步过程示意图；
附图13为锻制曲颈工步过程示意图；
附图14为附图13中A-A截面的剖视结构示意图；
附图15为锻坯分割工步过程示意图；
附图16为曲拐锻件半成品结构示意图；
附图17、18为曲拐锻件半成品折弯工步示意图；
附图19为曲拐锻件半成品压合工步过程示意图；
附图20、21、22为曲拐锻件半成品终锻成型工步过程示意图；
附图23为曲拐锻件成品的主视结构示意图；
附图24为曲拐锻件成品的左视结构示意图，
附图25为曲拐锻件成品的俯视结构示意图。
附图中，1为上砧、2为镦粗盘、3为右机械手、3'为左机械手、4为纵向工作台、4'为横向工作台、5为漏盘、6为钢坯、6'为锻坯、6”为锻件半成品、601为工艺柄、602为压痕、603为凸台、604为梯形槽、7为小平砧、8为双联压痕模、9为大平砧、10为梯形模、11为凹形模、12为分割面、13为反扣折弯模、14为成型芯模。
具体实施方式
下面结合图1至图4对根据本公开的示例性实施方式的组合砧模进行描述。如附图1所示，将漏盘5放置在纵向工作台4上，移动纵向工作台4移砧，下砧为漏盘5，钢坯6立放在漏盘5上，上砧1下压将工件镦粗，并同时制得工艺柄。
如附图2所示，小平砧7、双联压痕模8、大平砧9、梯形模10、凹形模11设置在横向工作台4'上，移动横向工作台4'移砧，小平砧7、双联压痕模8、大平砧9、梯形模10、凹形模11可分别作为下砧，上砧1分别与小平砧7、双联压痕模8、大平砧9、梯形模10、凹形模11配合动作，可对锻坯6’进行各种不同的操作，与小平砧7配合，对锻坯6’进行拔长压方，与双联压痕模8配合，对锻坯6’锻制双痕，与大平砧9配合，对锻坯6’的曲颈部制作，与梯形模10配合，对锻坯6’锻制梯形槽，与凹形模11配合，将锻坯6’的梯形槽内部分锻制成曲颈坯。
如附图3所示，右机械手3将反扣折弯模13夹持至锻坯6’与上砧1之间，同时下砧更换成凹形模11，将锻坯6’两臂折弯成两曲柄锻坯。
如附图4所示，左机械手3’将成型芯模14夹持至两曲柄之间，下砧更换成大平砧9，两曲柄臂与成型芯模14贴合，将锻坯6’制成曲拐锻坯。
下面结合图5至图25对根据本公开的示例性实施方式的使用组合砧模对大型曲拐进行锻造的工艺进行描述。在示例性施方式中，一件钢坯6可制作三个曲拐锻件半成品6″，附图5到附图25所示的是钢坯6制成单个曲拐锻件半成品6″的过程。
如附图5所示，将漏盘5放置在纵向工作台4上，纵向工作台4移砧，使漏盘5移动到上砧1的下方，将加热后的钢坯6立置，下端放置在漏盘5上，右机械手3夹持镦粗盘2放置在钢坯6上端，上砧1下压，如附图6所示，钢坯6被镦粗，同时漏盘5通孔内制得工艺柄601。
如附图7所示，横向工作台4′移砧，小平砧7为下砧，上砧1将钢坯6压成设定尺寸的锻坯6′。
如附图8所示，横向工作台4′移砧，双联压痕模8为下砧，锻坯6′下方锻制出压痕602。
如附图9所示，将锻坯6′翻转180°，横向工作台4′移砧，大平砧9为下砧，上砧1自压痕302分别向外压延，两压痕602之间锻制出凸台603。
如附图10、11、12所示，横向工作台4′移砧，梯形砧10移至凸台603下方，翻转锻坯6′锻制梯形槽604，凸台锻成互相连接的梯形槽604。
如附图13、14所示，下砧设置为凹形模11，翻转锻坯6′，将梯形槽604内部锻制成曲颈。
在附图8至附图14中，锻坯6′由左机械手3′夹持移动或翻转。
如附图15所示，将锻坯6′冷却，在图13所示分割面12处分割，分割后的单个锻件半成品6〞如附图16所示。
如附图17所示，横向工作台4′移砧，凹形模11为下砧，加热后的单个锻件半成品6″放置在凹形模11上方，且凹形模11上端贴合锻件半成品6″的曲颈部，右机械手3夹持反扣折弯模 13，套置在锻件半成品6″的凸台603上，反扣折弯模13将锻件半成品6″的两臂下压折弯成附图18所示的“人”字形，右机械手3移出反扣折弯模13。
如附图19、20、21所示，横向工作台4′移砧，大平砧9为下砧，右机械手3夹持凸台603并将其放置在大平砧9上，左机械手3′将成型芯模14从锻件半成品6″的“人”字开口处插入至曲颈部，上砧1和大平砧9将“人”字两边与成型芯模14压合。
如附图22所示，右机械手3和左机械手3′同步翻转锻件半成品6″和成型芯模14，从四个侧面将锻件半成品6″终锻成如附图23、24、25所示的锻件成品。
工业实用性
本公开提供了用于锻造大型曲拐的组合砧模及工艺，组合砧模包括锻机和机械手，锻机包括上砧、下砧和上模。上砧连接在锻机上砧座下端且固定设置为平砧；机械手设置为包括两只机械手；下砧包括砧模和纵、横向工作台，砧模包括大平砧、小平砧、双联压形模、梯形模、凹形模和漏盘，漏盘置于纵向工作台上，砧模设置在横向工作台上，上模包括成型芯模、反扣折弯模和镦粗板，其由机械手夹持。运用上述组合砧模锻造大型曲拐的工艺分为十一工步，由于砧模和上模设置为随时可以更换的活动砧模，部分砧模放置在工作台上移动更换，部分砧模由机械手夹持更换，因此一个火次可完成多个锻造工步，将传统5-7火次的锻件工艺缩减至2-3火次完成。本公开具有节能降耗、优质高效的特点。
此外，可以理解的是，本公开的锻造大型曲拐的组合砧模及工艺是可以重现的，并且可以应用在多种工业应用中。例如，本公开的锻造大型曲拐的组合砧模及工艺可以应用于机械制造技术领域。

Claims (7)

  1. 一种用于锻造大型曲拐的组合砧模，包括锻机和机械手，所述锻机包括上砧、下砧和上模，所述上砧连接在所述锻机上砧座的下端，所述机械手至少包括两只机械手，所述下砧包括砧模和移动工作台，所述砧模包括大平砧、小平砧和漏盘，所述小平砧与上砧的砧面形状和面积相同，所述上模包括成型芯模和镦粗板，所述漏盘中间设有通孔，所述移动工作台包括纵向工作台和横向工作台，所述漏盘置于纵向工作台上，所述大平砧、小平砧设置在横向工作台上，所述成型芯模和镦粗板由机械手夹持，其特征在于：
    所述上模还设置反扣折弯模；
    所述砧模还设置双联压痕模、梯形模和凹形模；
    所述双联压痕模、梯形模和凹形模设置在所述横向工作台上；所述反扣折弯模通过所述机械手夹持。
  2. 根据权利要求1所述的用于锻造大型曲拐的组合砧模，其特征在于：所述横向工作台上设置连接座，所述大平砧或小平砧或双联压痕模或梯形模或凹形模的下端与所述连接座的上端活动连接。
  3. 根据权利要求2所述的用于锻造大型曲拐的组合砧模，其特征在于：所述连接座上端设有定位孔，所述大平砧或小平砧或双联压痕模或梯形模或凹形模的下端插入所述定位孔。
  4. 根据权利要求1或2所述的用于锻造大型曲拐的组合砧模，其特征在于：所述双联压痕模的两只模尖平行向上等高设置。
  5. 一种使用权利要求1所述组合砧模来锻造大型曲拐的工艺，包含以下步骤：
    步骤1、钢坯镦粗：将钢坯加热至锻造温度，纵向工作台移砧，下砧为小平砧，钢坯倒棱，纵向工作台移砧，下砧为漏盘，倒棱后的钢坯竖直置于漏盘上，镦粗板置于钢坯与上砧之间，钢坯镦粗并制得工艺柄，横向工作台移砧，下砧为小平砧，将钢坯拔长成锻坯；
    步骤2、拔长压方：将步骤1制得锻坯第二次加热至锻造温度，下砧为小平砧，将锻坯压延至设定的几何形状；
    步骤4、锻制凸台：横向工作台移砧，下砧为大平砧，将步骤3制得锻坯翻转180°，将步骤3制得锻坯的双压痕外侧分别压延至设定尺寸，双压痕内侧部分为凸台；
    步骤7、分割：将步骤5制得锻坯冷却，按设定尺寸分割，获得单个曲拐的锻件半成品；
    步骤9、压合：横向工作台移砧，下砧为大平砧，一只机械手夹持锻件半成品凸台，另一只机械手夹持成型芯模从“人”字形开口插入，与曲颈部贴合，上砧下压，使“人”字两边与成型芯模并合；
    步骤10、终锻：两只机械手分别夹持步骤8制得的锻件半成品和成型芯模同步翻转，锻制四面至设定几何尺寸；
    步骤11、锻坯成品出模，
    其特征在于：
    在所述步骤2与所述步骤4之间设步骤3，
    所述的步骤3为定位压痕：横向工作台移砧，下砧为双联压痕模，将步骤2制得锻坯定位分段锻制双压痕；
    在所述步骤4与所述步骤7之间设有步骤5和6，
    所述的步骤5为锻制梯形槽：横向工作台移砧，下砧为梯形模，将步骤4制得锻坯凸台的四面锻制相连接的梯形槽；
    所述的步骤6为锻制曲颈部：横向工作台移砧，下砧为凹形模，将步骤5制得的梯形槽内部分锻压成曲颈坯；
    在所述步骤7与所述步骤9之间设有步骤8，
    所述的步骤8为折弯：将曲拐锻件半成品第三次加热至设定温度，横向工作台移砧，下砧为凹形模，一只机械手夹持曲拐锻件半成品，将曲颈部啮合在凹形模上端，另一只机械手夹持反向折弯模倒扣在凸台上方，上砧下压反向折弯模，锻件半成品弯折成“人”字形。
  6. 根据权利要求5所述的锻造大型曲拐的工艺，其特征在于：所述双联压痕模为两只模尖向上的连体模，且两模尖间距与所述凸台的根部宽度相等。
  7. 根据权利要求5所述锻造大型曲拐的工艺，其特征在于：当步骤1中所述钢坯为单个曲拐钢坯时，步骤1和步骤2为一火次完成。
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