WO2023087849A1 - 一种汽车万向节内星轮的球道免铣加工方法 - Google Patents

一种汽车万向节内星轮的球道免铣加工方法 Download PDF

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WO2023087849A1
WO2023087849A1 PCT/CN2022/116680 CN2022116680W WO2023087849A1 WO 2023087849 A1 WO2023087849 A1 WO 2023087849A1 CN 2022116680 W CN2022116680 W CN 2022116680W WO 2023087849 A1 WO2023087849 A1 WO 2023087849A1
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Prior art keywords
forging
die
hole
blank
finishing
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PCT/CN2022/116680
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English (en)
French (fr)
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曾凡
吴兵
沈建龙
胡忆瑞
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上海纳铁福传动系统有限公司
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Publication of WO2023087849A1 publication Critical patent/WO2023087849A1/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
    • 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
    • B21J5/08—Upsetting
    • 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
    • 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
    • B21K1/28—Making machine elements wheels; discs

Definitions

  • the invention relates to the field of production and processing of automobile parts, in particular to a milling-free processing method for a raceway of an inner star wheel of an automobile universal joint.
  • the ball cage universal joint is a relatively common car transmission universal joint.
  • the ball cage universal joint mainly includes an outer star wheel, an inner star wheel, a ball cage, and a plurality of steel balls. There are several fairways on the outer peripheral side of the outer star wheel, and several fairways are set on the inner peripheral surface of the outer star wheel. In the window, and contact with the fairway of outer star wheel and the fairway of inner star wheel simultaneously.
  • closed forging is usually used when manufacturing an inner star wheel with several tracks on the outer periphery.
  • this manufacturing method has a large forming force and a large amount of mold deformation, resulting in relatively poor dimensional stability of the forging.
  • burrs on the parting surface there are obvious burrs on the parting surface, and the fine machining of the fairway surface must be completed through subsequent milling.
  • the object of the present invention is to provide a milling-free processing method for the ball track of the inner star wheel of the automobile universal joint. After forging, the size of the ball track on the surface of the forging can directly meet the product requirements.
  • the present invention provides a milling-free processing method for the inner star wheel of an automobile universal joint.
  • the milling-free processing method for the ball track includes the following steps in sequence:
  • Pre-upsetting pre-upsetting the blank downward, forming an inverted conical positioning groove at the center of the upper end surface of the blank to obtain a pre-upsetting blank
  • Pre-forging cold forging the pre-upsetting blank, cold forging an upper counterbore at the center of the upper part of the pre-upsetting blank, cold forging several upper ballways on the outer peripheral surface of the upper part of the pre-upsetting blank, A countersink is cold forged at the center of the lower part of the pre-upsetting blank, and several lower ballways are cold-forged on the outer peripheral surface of the lower part of the pre-heading blank, as well as the balls distributed between the adjacent two lower ballways.
  • the lower part of the size profile is obtained as a pre-forging; in the pre-forging, the lower end of the upper fairway is connected with the upper end of the lower fairway to form a pre-forging fairway, and the pre-forging has a continuous skin between the upper sink hole and the sink hole;
  • the split forging die includes a lower die with a fixed position, an upper die and a reaming mandrel capable of reciprocating up and down, the lower die is provided with a lower section of the ballway, and the upper die is provided with a star-shaped hole, and The upper part of the ballway is connected to the lower end of the star-shaped hole.
  • the reaming mandrel is used to be inserted into the inner hole of the blank.
  • the star-shaped hole penetrates upward through the upper mold. And a material distribution cavity is formed between the hole wall of the star-shaped hole;
  • the upper end of the final forging has a splitter block formed in the material splitting cavity, a shaft hole formed by a reaming mandrel, and a fairway formed in the lower section of the ballway and the upper section of the ballway;
  • Finishing finishing the fairway of the final forging, turning off the outer circle allowance and the diverter block of the final forging.
  • the downward pre-heading amount of the blank is 2-3 mm
  • the depth of the positioning groove is 1-2 mm
  • the taper of the positioning groove is 15°-20°.
  • the aperture d of the upper sinkhole and the sinkhole are both 0.25-0.45 times the maximum aperture D of the pre-forging, and the thickness of the continuous skin is 10-15mm.
  • the annealing temperature of the pre-forging is 650-750° C.
  • the annealing time is 5-6 hours.
  • the lower end of the reaming mandrel has a conical section, and the outer diameter of the conical section decreases gradually from top to bottom.
  • the width of the material distribution cavity is 2-8 mm.
  • step S7 sequentially includes the following sub-steps:
  • the cold finishing mold includes a fixed base, and several finishing dies distributed in the circumferential direction and radially movably mounted on the fixed base, and the inner end of each finishing die has a The finishing part for the abutting fit of the fairway, the outer peripheral surface of the finishing part is a fairway profile;
  • the milling-free processing method for the inner star wheel of the automobile universal joint involved in the present invention has the following beneficial effects:
  • pre-forging and final forging are used to forge the billet twice, especially the split forging is used for the pre-forging during the final forging, allowing the metal material of the pre-forging to flow to the split forging die during the process of forming several ballways on the outer periphery of the pre-forging
  • the forming force during forging can be greatly reduced, and the life of the die can be improved, especially the dimensional accuracy and dimensional stability of the final forging after final forging can be greatly improved
  • the split The burrs on the die surface and the size of the ball track after finishing the final forging can directly meet the product requirements, thereby eliminating the need for subsequent milling of the ball track, reducing the production cost of the inner star wheel of the automobile universal joint, and improving production efficiency.
  • Fig. 1 is the flowchart of the milling-free processing method for the inner star wheel of the automobile universal joint in the present application.
  • Fig. 2 is a structural schematic diagram of a pre-heading blank in the present application.
  • FIG. 3 is a half-sectional view of FIG. 2 .
  • Fig. 4 is a structural schematic diagram of the pre-forging in the present application.
  • FIG. 5 is a half-sectional view of FIG. 4 .
  • Fig. 6 is a structural schematic diagram of the pre-forging in the present application after the inner hole is punched.
  • FIG. 7 is a half-sectional view of FIG. 6 .
  • Fig. 8 is a schematic structural view of the final forging in this application.
  • Fig. 9 is a schematic diagram of the structure of the final forging after rough turning in the present application.
  • Fig. 10 is a schematic diagram of the relationship between the split forging die and the pre-forging in the present application.
  • FIG. 11 is a half-sectional view of FIG. 10 .
  • FIG. 12 is a top view of FIG. 10 .
  • Fig. 13 is a schematic structural view of the upper mold in Fig. 10 .
  • FIG. 14 is a half-sectional view of FIG. 13 .
  • Fig. 15 is a structural schematic diagram of the cold finishing mold in the present application.
  • This application provides a milling-free processing method for the inner star wheel of the automobile universal joint. Forging is carried out twice through pre-forging and final forging, especially during the final forging, the split forging is carried out through a split forging die, so that the final forging is cooled and finished.
  • the size of the fairway 143 of the final forging 14 obtained after trimming can directly meet the product requirements, and furthermore, there is no need to mill the fairway 143 in the future.
  • the ball lane milling-free processing method involved in the present application includes the following steps in sequence:
  • Step S1 blanking: Obtain a cylindrical blank 11, which is a solid cylinder.
  • Step S2 pre-upsetting: Pre-upsetting the blank 12 downwards by cold heading, and pre-piering the cylindrical blank 11 downward by 2-3mm, as shown in Figure 2 and Figure 3, upsetting at the center of the upper end surface of the blank 11
  • An inverted conical positioning groove 121 is formed to obtain the pre-heading blank 12 .
  • the inner diameter of the positioning groove 121 at the upper end of the pre-heading blank 12 gradually decreases from top to bottom; preferably, the depth of the positioning groove 121 is 1-2mm, and the taper of the positioning groove 121 is 15°-20°.
  • Step S3 pre-forging: at room temperature, pre-forging the pre-upsetting blank 12 by cold forging, as shown in Figure 4 and Figure 5, cold forging the upper counterbore at the center of the upper section of the pre-upsetting blank 12 131, cold forging several upper ballways 132 on the outer peripheral surface of the upper part of the pre-upsetting blank 12, cold forging a sink hole 133 at the center of the lower part of the pre-upsetting blank 12, Cold forging several lower ballways 134 and the lower section dimension profiles distributed between two adjacent lower ballways 134 to obtain the pre-forged part 13 .
  • the lower end of the upper ballway 132 is connected with the upper end of the lower ballway 134 to form a pre-forging ballway, and the pre-forging 13 has a continuous skin 135 between the upper sink hole 131 and the sink hole 133;
  • the size profile of the lower part of the part is produced, and the size profile of the upper part of the part is not forged, and the upper part of the part is a cylinder with a star-shaped cross section.
  • Step S4 punching the inner hole: using a punching machine to remove the continuous skin 135 at the center of the pre-forging 13, then the upper counterbore 131 and the lower counterbore 133 are connected to form the billet inner hole 136, as shown in Fig. 6 and Fig. 7 .
  • Step S5 pretreatment: performing annealing, shot blasting and lubrication on the pre-forging piece 13 in sequence.
  • Annealing refers to performing softening annealing on the pre-forging 13, the annealing temperature of the pre-forging 13 is 650-750° C., and the annealing time is 5-6 hours.
  • Shot blasting is carried out with a shot blasting machine.
  • Lubrication refers to performing phosphorus saponification treatment on the surface of the pre-forging 13 .
  • Step S6 final forging: performing split forging on the pre-forging 13 using a split forging die to obtain the final forging 14 .
  • the split forging die includes a fixed lower die, an upper die 20 and a reaming mandrel 30 that can reciprocate up and down, and the reciprocating movement of the upper die 20 and the reciprocating movement of the reaming mandrel 30
  • the up and down reciprocating movements are independent of each other.
  • Lower mold is not shown in the figure, offers the lower part of fairway type face in the lower mold, and the lower part of fairway type face is counterbore structure, opening upwards, and the lower part of fairway lower part type face is used for forming the lower half of fairway 143.
  • a star-shaped hole 21 is provided in the upper mold 20, and an upper part of the ballway face 22 connected to the lower end of the star-shaped hole 21, the upper part of the ballway face 22 is used to form the upper half of the ballway 143;
  • the star-shaped hole 21 penetrates the upper die 20 upwards, so that the upper end surface of the upper die 20 is not closed and is an open structure; the reaming mandrel 30 is used to insert into the inner hole 136 of the blank, and the reaming mandrel 30 is installed in the star-shaped hole 21
  • a material distribution chamber 40 is formed between the center and the hole wall of the star-shaped hole 21.
  • the material distribution chamber 40 is also located at the upper end of the surface hole 22 in the upper section of the ballway and penetrates up and down.
  • the material distribution chamber 40 is used for the pre-forging 13 when forging Its metal material flows in, thereby reducing the forging forming force.
  • the material distribution cavity 40 is an annular area, that is, the maximum outer diameter of the reaming mandrel 30 is smaller than the minimum inner diameter of the star-shaped hole 21; in this embodiment, the width of the material distribution cavity 40 is 2-8mm, that is, the expansion The maximum outer diameter of the mandrel 30 is 4-16 mm smaller than the minimum inner diameter of the star-shaped hole 21 .
  • the pre-forging 13 is placed in the face of the lower part of the ballway of the lower die, and the upper die 20 moves down to press the pre-forging 13; after that, the reaming mandrel 30 moves down to expand the inner hole 136 of the blank into a shaft hole 142 ; Under the joint action of the upper die 20 and the reaming mandrel 30, all the dimensions of the ballways 143 on the outer periphery of the part are forged to obtain the final forging 14.
  • the upper end of the final forging 14 has a splitter block 141 formed in the material splitter cavity 40, the thickness of the splitter block 141 is 2 to 8 mm, and the inner diameter of the splitter block 141 matches the outer diameter of the mandrel; the forged part There is a shaft hole 142 formed after reaming by the reaming mandrel 30 at the central position; the outer peripheral surface of the forging has several ballways 143 formed in the lower section of the ballway of the lower mold and the upper section of the ballway of the upper mold 20. .
  • the lower end of the reaming mandrel 30 has a conical section 31, the outer diameter of the conical section 31 gradually decreases from top to bottom, when the reaming mandrel 30 moves down, the conical section 31 With a better guiding effect, the reaming mandrel 30 can be smoothly entered into the upper end of the inner hole 136 of the blank.
  • Step S7 finishing: finishing the fairway 143 of the final forging 14 , turning off the outer circle allowance and the diverter block 141 of the final forging 14 to obtain a precision forging.
  • the step S7 includes the following sub-steps in turn:
  • the cold finishing mold comprises a fixed base 50, and several finishing molds 60 distributed in the circumferential direction and all radially movably installed on the fixed base 50, the number of finishing molds 60 is the same as that of the ball lane 143. Corresponding to the number; in the present embodiment, the number of finishing molds 60 and the number of ballways 143 are all six.
  • the inner end of each finishing die 60 has a finishing portion 61 for abutting against the ballway 143 of the final forging 14 , and the outer peripheral surface of the finishing portion 61 is a ballway profile 62 .
  • a hydraulic system is used to drive several finishing dies 60 to move radially to realize the radial opening and closing of several finishing dies 60; the driving force of the hydraulic system to drive the finishing dies 60 to move is 250-350 Bar.
  • the milling-free processing method for ballways in this application uses pre-forging and final forging to forge the blank 11 twice, especially the pre-forging 13 is split-forged during final forging, and a material distribution cavity 40 is added to the upper end surface of the pre-forging 13 , allowing the metal material of the pre-forging 13 to flow into the material distribution chamber 40 of the distribution forging die during the process of forming the outer circumference of the track 143 to form a distribution block 141, which can be removed by subsequent turning.
  • the forming force during forging can be greatly reduced, which helps to improve the life of the die, especially the dimensional accuracy and dimensional stability of the final forging 14 after final forging can be greatly improved, and the burrs at the parting surface can also be eliminated, and the final forging 14
  • the size of the ballway 143 after cold finishing can directly meet the product requirements, thereby eliminating the subsequent milling machining of the ballway 143, reducing the production cost of the inner star wheel of the automobile universal joint, and improving production efficiency.
  • Pre-upsetting use the cold heading method to pre-upset the blank 12 downwards, pre-pier the cylindrical blank 11 downward by 2mm, and upset an inverted conical positioning groove 121 at the center of the upper end surface of the blank 11, and position it The depth of the groove 121 is 1 mm, the taper of the positioning groove 121 is 18°, and the pre-heading blank 12 is obtained.
  • the pre-forging blank 12 is pre-forged by cold forging; in the pre-forging 13, the aperture d of the upper sink hole 131 and the sink hole 133 are both 20 mm, and the maximum aperture D of the pre-forging 13 is 58 mm.
  • the thickness of the middle connecting skin 135 is 12mm.
  • Final forging use a split forging die to carry out split forging on the pre-forging 13, press down on the upper die 20, and press down on the reaming mandrel 30 to obtain the final forging 14 with a splitter block 141 on the upper end, and six on the final forging 14 All the ballways 143 are formed, the inner diameter of the diverter block 141 is 20.1 mm, and the outer diameter of the diverter block 141 is 24 mm.
  • the splitter block 141 on the upper end of the final forging 14 is removed by rough turning, and at the same time, the outer spherical surface of the final forging 14 is rough turned, and part of the outer circle allowance of the final forging 14 is turned by turning.
  • the precision forging of the inner star wheel of the automobile universal joint is accurate in size and meets the requirements.
  • the forming force is reduced by more than 50%, and the life of the die is improved; at the same time, the burr at the parting surface is eliminated, and the size of the precision forging is eliminated.
  • the precision reaches 0.03mm, the ballway profile is completely free of milling, and the economy is greatly improved.
  • the present invention effectively overcomes various shortcomings in the prior art and has high industrial application value.

Abstract

一种汽车万向节内星轮的球道免铣加工方法，包括以下步骤：下料；预镦粗；预锻；冲内孔；预处理；终锻：使用分流锻造模具对预锻件（13）进行分流锻造；分流锻造模具包括下模、上模（20）和扩孔芯棒（30），下模中开设球道下段型面孔，上模中开设有星形孔（21）和球道上段型面孔（22），扩孔芯棒穿设在星形孔中、并与星形孔的孔壁之间形成有材料分流腔（40）；终锻件（14）的上端具有在材料分流腔内成形的分流块（141）、以及在球道下段型面孔和球道上段型面孔内成形的球道（143）；精加工：精整终锻件球道，车削掉终锻件的外圆余量和分流块。本方法在终锻时对预锻件采用分流锻造，能够降低锻造时的成形力，提高终锻后终锻件的尺寸精度和尺寸稳定性，由此省去后续对球道的铣削机加工，降低成本。

Description

一种汽车万向节内星轮的球道免铣加工方法 技术领域
本发明涉及汽车零部件生产加工领域，特别是涉及一种汽车万向节内星轮的球道免铣加工方法。
背景技术
汽车传动万向节相对于汽车运动时的“关节”，可实现两根轴线不平行的转轴间的动力传递，是现代汽车中的必备零件，需求量较大。球笼式万向节是比较常见的一种汽车传动万向节，球笼式万向节主要包括外星轮、内星轮、球笼、以及多个钢球，外星轮设置在球笼的外周侧、且外星轮的内周面上设有数道球道，内星轮设置在球笼的内周侧、且内星轮的外周面上设有数道球道，钢球穿设在球笼的窗口中、并同时与外星轮的球道和内星轮的球道接触配合。
进一步地，目前在加工制造外周具有数道球道的内星轮时，通常采用闭塞锻造，然而，该制造方式成形力大，模具变形量大，导致锻件尺寸稳定性比较差。同时，分模面存在明显毛刺，必须通过后续铣削完成球道表面的精细加工。
发明内容
鉴于以上所述现有技术的缺点，本发明的目的在于提供一种汽车万向节内星轮的球道免铣加工方法，在锻造后锻件表面球道尺寸能直接满足产品要求。
为实现上述目的，本发明提供一种汽车万向节内星轮的球道免铣加工方法，所述球道免铣加工方法依次包括以下步骤：
S1、下料：得到圆柱形的坯料；
S2、预镦粗：向下预镦所述坯料，在所述坯料的上端面中心处镦出一个倒圆锥形的定位凹槽，得到预镦坯料；
S3、预锻：冷锻所述预镦坯料，在所述预镦坯料上段部分的中心处冷锻出上沉孔，在所述预镦坯料上段部分的外周面上冷锻出数道上球道，在所述预镦坯料下段部分的中心处冷锻出下沉孔，在所述预镦坯料下段部分的外周面上冷锻出数道下球道、以及分布在相邻两道下球道之间的下段尺寸型面，得到预锻件；所述预锻件中，所述上球道的下端与下球道的上端相连构成预锻球道，所述预锻件在上沉孔和下沉孔之间具有连皮；
S4、冲内孔：去除所述连皮，使上沉孔和下沉孔连通为坯料内孔；
S5、预处理：对所述预锻件依次进行退火、抛丸和润滑；
S6、终锻：使用分流锻造模具对所述预锻件进行分流锻造，得到终锻件；
所述分流锻造模具包括位置固定的下模、以及都能够上下往复移动的上模和扩孔芯棒，所述下模中开设球道下段型面孔，所述上模中开设有星形孔、以及连接在星形孔下端的球道上段型面孔，所述扩孔芯棒用于插入坯料内孔中，所述星形孔向上贯通上模，所述扩孔芯棒穿设在星形孔中、并与星形孔的孔壁之间形成有材料分流腔；
所述终锻件的上端具有在材料分流腔内成形的分流块、由扩孔芯棒成形的轴孔、以及在球道下段型面孔和球道上段型面孔内成形的球道；
S7、精加工：精整所述终锻件的球道，车削掉所述终锻件的外圆余量和分流块。
进一步地，所述步骤S2中，所述坯料的向下预镦量为2～3mm，所述定位凹槽的深度为1～2mm，所述定位凹槽的锥度为15°～20°。
进一步地，所述步骤S3中，所述上沉孔和下沉孔的孔径d都为预锻件最大孔径D的0.25～0.45倍，所述连皮的厚度为10～15mm。
进一步地，所述步骤S5中，所述预锻件的退火温度为650～750℃、退火时间为5～6小时。
进一步地，所述步骤S6中，所述扩孔芯棒的下端具有圆锥段，该圆锥段的外径从上至下逐渐减小。
进一步地，所述步骤S6中，所述材料分流腔的宽度为2～8mm。
进一步地，所述步骤S7依次包括以下分步骤：
S71、粗车：车削掉所述终锻件的部分外圆余量和分流块；
S72、球道冷精整：使用冷精整模具对所述终锻件的球道进行冷精整；
所述冷精整模具包括固定基座、以及数个周向分布且都径向可移动地安装于固定基座的精整模，每个精整模的内端都具有用于和终锻件的球道抵接配合的精整部，所述精整部的外周面为球道型面；
S73、精车：车削掉所述终锻件的全部外圆余量。
如上所述，本发明涉及的汽车万向节内星轮的球道免铣加工方法，具有以下有益效果：
本申请中，采用预锻和终锻两次锻造坯料，特别是终锻时对预锻件采用分流锻造，允许预锻件在成形外周数道球道的过程中，其金属材料可以分流流动到分流锻造模具的材料分流腔内、形成分流块，如此，能够大大降低锻造时的成形力，有助于提升模具寿命，特别是能大大提高终锻后终锻件的尺寸精度和尺寸稳定性，还能消除分模面处的毛刺，终锻件精整后 的球道尺寸可直接满足产品要求，由此省去后续对球道的铣削机加工，降低汽车万向节内星轮的生产成本，提高生产效率。
附图说明
图1为本申请中汽车万向节内星轮的球道免铣加工方法的流程图。
图2为本申请中预镦坯料的结构示意图。
图3为图2的半剖图。
图4为本申请中预锻件的结构示意图。
图5为图4的半剖图。
图6为本申请中预锻件冲内孔后的结构示意图。
图7为图6的半剖图。
图8为本申请中终锻件的结构示意图。
图9为本申请中终锻件粗车后的结构示意图。
图10为本申请中分流锻造模具与预锻件的关系示意图。
图11为图10的半剖图。
图12为图10的俯视图。
图13为图10中上模的结构示意图。
图14为图13的半剖图。
图15为本申请中冷精整模具的结构示意图。
元件标号说明
11                     坯料
12                     预镦坯料
121                    定位凹槽
13                     预锻件
131                    上沉孔
132                    上球道
133                    下沉孔
134                    下球道
135                    连皮
136                    坯料内孔
14                     终锻件
141                    分流块
142                    轴孔
143                    球道
20                     上模
21                     星形孔
22                     球道上段型面孔
30                     扩孔芯棒
31                     圆锥段
40                     材料分流腔
50                     固定基座
60                     精整模
61                     精整部
62                     球道型面
具体实施方式
以下由特定的具体实施例说明本发明的实施方式，熟悉此技术的人士可由本说明书所揭露的内容轻易地了解本发明的其他优点及功效。
须知，本说明书附图所绘的结构、比例、大小等，均仅用以配合说明书所揭示的内容，以供熟悉此技术的人士了解与阅读，并非用以限定本发明可实施的限定条件，故不具技术上的实质意义，任何结构的修饰、比例关系的改变或大小的调整，在不影响本发明所能产生的功效及所能达成的目的下，均应仍落在本发明所揭示的技术内容能涵盖的范围内。同时，本说明书中所引用的如“上”、“下”、“左”、“右”、“中间”及“一”等的用语，亦仅为便于叙述明了，而非用以限定本发明可实施的范围，其相对关系的改变或调整，在无实质变更技术内容下，当亦视为本发明可实施的范畴。
本申请提供一种汽车万向节内星轮的球道免铣加工方法，通过预锻和终锻两次锻造，特别是在终锻时通过分流锻造模具进行分流锻造，由此使终锻冷精整后得到的终锻件14的球道143尺寸能直接满足产品要求，进而后续不再需要对球道143进行铣削加工。
如图1所示，本申请涉及的球道免铣加工方法依次包括以下步骤：
步骤S1、下料：得到圆柱形的坯料11，该坯料11为实心圆柱体。
步骤S2、预镦粗：采用冷镦方式向下预镦坯料12，将圆柱形的坯料11向下预墩2～3mm，如图2和图3所示，在坯料11的上端面中心处镦出一个倒圆锥形的定位凹槽121，得到预镦坯料12。预镦坯料12上端的定位凹槽121的内径从上至下逐渐减小；优选地，定位凹槽121的深度为1～2mm，定位凹槽121的锥度为15°～20°。
步骤S3、预锻：在室温条件下，采用冷锻的方式对预镦坯料12进行预锻，如图4和图5所示，在预镦坯料12上段部分的中心处冷锻出上沉孔131，在预镦坯料12上段部分的外周面上冷锻出数道上球道132，在预镦坯料12下段部分的中心处冷锻出下沉孔133，在预镦坯料12下段部分的外周面上冷锻出数道下球道134、以及分布在相邻两道下球道134之间的下段尺寸型面，得到预锻件13。因此，预锻件13中，上球道132的下端与下球道134的上端相连构成预锻球道，预锻件13在上沉孔131和下沉孔133之间具有连皮135；通过预锻主要是锻造出零件下段部分的尺寸型面，零件上段部分的尺寸型面未锻造出，零件上段部分为具有星形截面的筒体。
优选地，该步骤S3中，上沉孔131和下沉孔133的孔径d都为预锻件13最大孔径D的0.25～0.45倍，即d＝0.25～0.45D；连皮135的厚度为10～15mm。
步骤S4、冲内孔：采用冲床去除预锻件13中心处的连皮135，则上沉孔131和下沉孔133连通为坯料内孔136，如图6和图7所示。
步骤S5、预处理：对预锻件13依次进行退火、抛丸和润滑。退火是指对预锻件13进行软化退火，预锻件13的退火温度为650～750℃、退火时间为5～6小时。抛丸采用抛丸机进行。润滑是指对预锻件13的表面进行磷皂化处理。
步骤S6、终锻：使用分流锻造模具对预锻件13进行分流锻造，得到终锻件14。
如图10至图12所示，分流锻造模具包括位置固定的下模、以及都能够上下往复移动的上模20和扩孔芯棒30，上模20的上下往复移动和扩孔芯棒30的上下往复移动相互独立。下模在图中未示出，下模中开设球道下段型面孔，球道下段型面孔为沉孔结构、开口朝上，球道下段型面孔用于成形球道143的下半部分。如图13和图14所示，上模20中开设有星形孔21、以及连接在星形孔21下端的球道上段型面孔22，球道上段型面孔22用于成形球道143的上半部分；星形孔21向上贯通上模20，使得上模20的上端面不封闭，为敞开结构；扩孔芯棒30用于插入坯料内孔136中，扩孔芯棒30穿设在星形孔21中、并与星形孔21的孔壁之间形成有材料分流腔40，材料分流腔40也位于球道上段型面孔22的上端处、并上下贯通，该材料分流腔40供预锻件13锻造时其金属材料流入，由此降低锻造成形力。优选地， 材料分流腔40为一个环形区域，即扩孔芯棒30的最大外径小于星形孔21的最小内径；本实施例中，材料分流腔40的宽度为2～8mm，即扩孔芯棒30的最大外径比星形孔21的最小内径小4～16mm。
终锻时，将预锻件13放置在下模的球道下段型面孔中，上模20下移后下压预锻件13；之后，扩孔芯棒30下移后将坯料内孔136扩大为轴孔142；在上模20和扩孔芯棒30的共同作用下，锻造出零件外周的所有球道143尺寸，得到终锻件14。如图8所示，终锻件14的上端具有在材料分流腔40内成形的分流块141，则分流块141的厚度为2～8mm，分流块141的内径与芯棒外径相匹配；锻造件的中心位置处具有由扩孔芯棒30扩孔后成形的轴孔142；锻造件的外周面具有数道在下模的球道下段型面孔和上模20的球道上段型面孔22内成形的球道143。
优选地，如图11所示，扩孔芯棒30的下端具有圆锥段31，该圆锥段31的外径从上至下逐渐减小，在扩孔芯棒30下移时，圆锥段31起到较好的导向作用，能够使扩孔芯棒30顺利进入坯料内孔136的上端。
步骤S7、精加工：精整终锻件14的球道143，车削掉终锻件14的外圆余量和分流块141，得到精锻件。具体地，如图1所示，该步骤S7依次包括以下分步骤：
S71、粗车：粗车车削掉终锻件14上端的分流块141，如图9所示；同时，粗车终锻件14的外球面，车削掉终锻件14的部分外圆余量。
S72、球道冷精整：使用冷精整模具对终锻件14的球道143进行冷精整；
如图15所示，冷精整模具包括固定基座50、以及数个周向分布且都径向可移动地安装于固定基座50的精整模60，精整模60的数量与球道143的数量对应；本实施例中，精整模60的数量与球道143的数量都为六个。每个精整模60的内端都具有用于和终锻件14的球道143抵接配合的精整部61，精整部61的外周面为球道型面62。优选地，本实施例中采用液压系统驱动数个精整模60径向移动，实现数个精整模60的径向开合；液压系统驱动精整模60移动的驱动力为250～350Bar。
S73、精车：精车终锻件14的外球面，车削掉终锻件14的全部外圆余量。
因此，本申请中的球道免铣加工方法采用预锻和终锻两次锻造坯料11，特别是终锻时对预锻件13采用分流锻造，在预锻件13的上端面增加了一个材料分流腔40，允许预锻件13在成形外周数道球道143的过程中，其金属材料可以分流流动到分流锻造模具的材料分流腔40内、形成分流块141，分流块141可通过后续车削去除。如此，能够大大降低锻造时的成形力，有助于提升模具寿命，特别是能大大提高终锻后终锻件14的尺寸精度和尺寸稳定性， 还能消除分模面处的毛刺，终锻件14冷精整后的球道143尺寸可直接满足产品要求，由此省去后续对球道143的铣削机加工，降低汽车万向节内星轮的生产成本，提高生产效率。
下述提供一个汽车万向节内星轮的球道免铣加工方法的具体实施例，其实施步骤为：
一、下料获取圆柱形的坯料11。
二、预镦粗：采用冷镦方式向下预镦坯料12，将圆柱形的坯料11向下预墩2mm，在坯料11的上端面中心处镦出一个倒圆锥形的定位凹槽121，定位凹槽121的深度为1mm，定位凹槽121的锥度为18°，得到预镦坯料12。
三、预锻：采用冷锻的方式对预镦坯料12进行预锻；预锻件13中，上沉孔131和下沉孔133的孔径d都为20mm，预锻件13的最大孔径D为58mm，中间连皮135的厚度为12mm。
四、冲内孔：去除连皮135。
五、在720℃的条件下对预锻件13退火6小时，之后对预锻件13抛丸处理，再对预锻件13磷皂化表面处理。
六、终锻：使用分流锻造模具对预锻件13进行分流锻造，上模20下压，扩孔芯棒30下压扩孔，得到上端具有分流块141的终锻件14，终锻件14上六个球道143全部成形，分流块141的内径为20.1mm，分流块141的外径为24mm。
七、粗车车削掉终锻件14上端的分流块141，同时，粗车终锻件14的外球面、车削掉终锻件14的部分外圆余量。
八、球道冷精整：使用冷精整模具对终锻件14的球道143进行冷精整，液压系统的驱动力为275Bar。
九、精车终锻件14的外球面，车削掉终锻件14的全部外圆余量。
经过上述步骤后得到的汽车万向节内星轮精锻件尺寸精确，满足要求，采用分流锻造，成形力降低50％以上，提升了模具寿命；同时消除了分模面位置的毛刺，精锻件尺寸精度达到0.03mm，球道型面完全免铣，经济性大大提升。
综上所述，本发明有效克服了现有技术中的种种缺点而具高度产业利用价值。
上述实施例仅例示性说明本发明的原理及其功效，而非用于限制本发明。任何熟悉此技术的人士皆可在不违背本发明的精神及范畴下，对上述实施例进行修饰或改变。因此，举凡所属技术领域中具有通常知识者在未脱离本发明所揭示的精神与技术思想下所完成的一切等效修饰或改变，仍应由本发明的权利要求所涵盖。

Claims (7)

  1. 一种汽车万向节内星轮的球道免铣加工方法，其特征在于：所述球道免铣加工方法依次包括以下步骤：
    S1、下料：得到圆柱形的坯料(11)；
    S2、预镦粗：向下预镦所述坯料(11)，在所述坯料(11)的上端面中心处镦出一个倒圆锥形的定位凹槽(121)，得到预镦坯料(12)；
    S3、预锻：冷锻所述预镦坯料(12)，在所述预镦坯料(12)上段部分的中心处冷锻出上沉孔(131)，在所述预镦坯料(12)上段部分的外周面上冷锻出数道上球道(132)，在所述预镦坯料(12)下段部分的中心处冷锻出下沉孔(133)，在所述预镦坯料(12)下段部分的外周面上冷锻出数道下球道(134)、以及分布在相邻两道下球道(134)之间的下段尺寸型面，得到预锻件(13)；所述预锻件(13)中，所述上球道(132)的下端与下球道(134)的上端相连构成预锻球道，所述预锻件(13)在上沉孔(131)和下沉孔(133)之间具有连皮(135)；
    S4、冲内孔：去除所述连皮(135)，使上沉孔(131)和下沉孔(133)连通为坯料内孔(136)；
    S5、预处理：对所述预锻件(13)依次进行退火、抛丸和润滑；
    S6、终锻：使用分流锻造模具对所述预锻件(13)进行分流锻造，得到终锻件(14)；
    所述分流锻造模具包括位置固定的下模、以及都能够上下往复移动的上模(20)和扩孔芯棒(30)，所述下模中开设球道下段型面孔，所述上模(20)中开设有星形孔(21)、以及连接在星形孔(21)下端的球道上段型面孔(22)，所述扩孔芯棒(30)用于插入坯料内孔(136)中，所述星形孔(21)向上贯通上模(20)，所述扩孔芯棒(30)穿设在星形孔(21)中、并与星形孔(21)的孔壁之间形成有材料分流腔(40)；
    所述终锻件(14)的上端具有在材料分流腔(40)内成形的分流块(141)、由扩孔芯棒(30)成形的轴孔(142)、以及在球道下段型面孔和球道上段型面孔(22)内成形的球道(143)；
    S7、精加工：精整所述终锻件(14)的球道(143)，车削掉所述终锻件(14)的外圆余量和分流块(141)。
  2. 根据权利要求1所述的球道免铣加工方法，其特征在于：所述步骤S2中，所述坯料(11)的向下预镦量为2～3mm，所述定位凹槽(121)的深度为1～2mm，所述定位凹槽(121)的锥度为15°～20°。
  3. 根据权利要求1所述的球道免铣加工方法，其特征在于：所述步骤S3中，所述上沉孔(131)和下沉孔(133)的孔径d都为预锻件(13)最大孔径D的0.25～0.45倍，所述连皮(135) 的厚度为10～15mm。
  4. 根据权利要求1所述的球道免铣加工方法，其特征在于：所述步骤S5中，所述预锻件(13)的退火温度为650～750℃、退火时间为5～6小时。
  5. 根据权利要求1所述的球道免铣加工方法，其特征在于：所述步骤S6中，所述扩孔芯棒(30)的下端具有圆锥段(31)，该圆锥段(31)的外径从上至下逐渐减小。
  6. 根据权利要求1所述的球道免铣加工方法，其特征在于：所述步骤S6中，所述材料分流腔(40)的宽度为2～8mm。
  7. 根据权利要求1所述的球道免铣加工方法，其特征在于：所述步骤S7依次包括以下分步骤：
    S71、粗车：车削掉所述终锻件(14)的部分外圆余量和分流块(141)；
    S72、球道冷精整：使用冷精整模具对所述终锻件(14)的球道(143)进行冷精整；
    所述冷精整模具包括固定基座(50)、以及数个周向分布且都径向可移动地安装于固定基座(50)的精整模(60)，每个精整模(60)的内端都具有用于和终锻件(14)的球道(143)抵接配合的精整部(61)，所述精整部(61)的外周面为球道型面(62)；
    S73、精车：车削掉所述终锻件(14)的全部外圆余量。
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