A forming apparatus and method for plate-type forgings with ribs

Abstract

This invention relates to a forming apparatus and method for plate-type forgings with ribs, comprising a heating furnace and a forming press. The heating furnace is used for localized heating of the area to be heated in the plate to be processed. The forming press includes a fixed mold, a clamping module, a deformation extrusion module, a height extrusion module, a width extrusion module, and a multi-directional forging hydraulic mechanism. The multi-directional forging hydraulic mechanism is used to control the clamping module to apply pressure to the plate to be processed; it is also used to control the deformation extrusion module to extrude the plate to be processed, causing the locally heated plate to deform and fill the deformation cavity to form a feature rib; it is also used to control the height extrusion module to act towards the feature rib so that the feature rib reaches a preset height; and it is also used to control the width extrusion module to act towards the feature rib so that the feature rib reaches a preset width. The above technical solution allows the forming press to form large-sized feature ribs in one pass, and minimizes human interference during the forming process, facilitating automated production.

Description

Technical Field

[0001] This invention relates to the field of forming plate-shaped forgings with ribs, and particularly to a forming apparatus and method for plate-shaped forgings with ribs. Background Technology

[0002] Ribbed plate forgings have a wide range of applications in transportation and other fields. A typical example is the bearing plate used in bridges, a crucial bridge connector used to withstand the loads and deformations of the bridge superstructure and reliably transfer them to the substructure. For example... Figure 1 As shown, the characteristic ribs 31 of the plate-type ribbed forging 3 are relatively large and unevenly distributed. Such forgings are generally produced using casting and forging processes. Compared to forging, casting produces workpieces that meet shape and size requirements, but the overall performance of castings is far inferior to that of forgings. However, traditional forging processes cannot achieve this size in a single forging because the size of the characteristic ribs exceeds the forging ratio limit. Multi-step forging processes require larger press tonnage and larger machining allowances, making automated production difficult.

[0003] Existing technology discloses patent application number 201821145715.6, entitled "A Forming Device for Bridge Bearing Plates," which discloses a method of forming a closed forming cavity with the plate material through upper and lower molds, and forming feature ribs under the extrusion of left and right molds. Based on a dedicated forming device and conveying device, automated manufacturing is achieved, improving material utilization and forging efficiency. However, the aspect ratio of the formed feature ribs to the plate material is 1.54. When the width of the feature ribs continues to increase, i.e., the aspect ratio exceeds 1.54, products forged using the existing forming device exhibit defects. Summary of the Invention

[0004] Therefore, there is a need to provide a forming device and method for plate-type forgings with ribs, in order to solve the technical problem that when the size of the feature ribs is too large, traditional forging processes cannot forge them in one step under such size conditions or the forged products have defects.

[0005] To achieve the above objectives, in a first aspect, the inventor provides a forming apparatus for plate-type forgings with ribs, comprising a heating furnace and a forming press. The heating furnace is used for local heating of the area to be heated of the plate to be processed. The forming press includes a fixed mold, a clamping module, a deformation extrusion module, a height extrusion module, a width extrusion module, and a multi-directional forging hydraulic mechanism. The fixed mold is disposed below the plate to be processed and is used to place the plate to be processed. The clamping module is disposed above the plate to be processed. The deformation extrusion modules are disposed on both sides of the plate to be processed. The output end of the height extrusion module extends into the clamping module and is located above the plate to be processed. The width extrusion module is disposed between the plate to be processed and the clamping module, and the width extrusion module is positioned between the plate to be processed and the plate to be processed. The components are in contact; a deformation cavity exists between the width extrusion module, the height extrusion module, and the clamping module and the sheet metal to be processed; a multi-directional forging hydraulic mechanism is connected to the clamping module, the deformation extrusion module, the width extrusion module, and the height extrusion module respectively; wherein, the multi-directional forging hydraulic mechanism is used to control the clamping module to apply pressure to the sheet metal to be processed; the multi-directional forging hydraulic mechanism is also used to control the deformation extrusion module to extrude the sheet metal to be processed, so that the locally heated sheet metal to be processed deforms and fills the deformation cavity to form a feature rib; the multi-directional forging hydraulic mechanism is also used to control the height extrusion module to act towards the feature rib so that the feature rib reaches a preset height; the multi-directional forging hydraulic mechanism is also used to control the width extrusion module to act towards the feature rib so that the feature rib reaches a preset width.

[0006] Unlike existing technologies, the above-mentioned technical solution not only includes a deformation extrusion module to extrude the locally heated sheet material, but also a height extrusion module and a width extrusion module to control the height and width of the feature ribs, respectively. Therefore, on the one hand, the forming press can form large-sized feature ribs in one pass; on the other hand, the forming process is less affected by human factors, facilitating automated production. Furthermore, by using locally heated material for cumulative deformation, the formed feature ribs are fully filled, have sharp edges, and high precision.

[0007] In one embodiment of the present invention, the forming press further includes an upper worktable disposed above the clamping module. The upper worktable is used to fix the clamping module and also to provide a limit for the high-extrusion module, thereby restricting the high-extrusion module from moving away from the feature rib. Thus, the upper worktable can fix the clamping module, allowing the clamping module to move along with the upper worktable. Furthermore, the upper worktable can restrict the high-extrusion module from moving away from the feature rib, i.e., the high-extrusion module reaches a rigid limit, thereby ensuring that the height of the formed feature rib reaches a preset height.

[0008] In one embodiment of the present invention, the clamping module includes a clamping die, the deformation extrusion module includes a left die and a right die, the height extrusion module includes a height ejector rod and a height die, and the width extrusion module includes a width ejector rod and a width die. The left die and the right die are respectively disposed on both sides of the sheet metal to be processed. The height ejector rod is connected to the height die, and the width ejector rod is connected to the width die. The multi-directional forging hydraulic mechanism includes a control module and a main cylinder, a left cylinder, a right cylinder, a height cylinder, and a width cylinder connected to the control module. The output end of the main cylinder is connected to the upper worktable, the output end of the left cylinder is connected to the left die, the output end of the right cylinder is connected to the right die, the output end of the height cylinder is connected to the height ejector rod, and the output end of the width cylinder is connected to the width ejector rod. Thus, the multi-directional forging hydraulic mechanism can control the movement of the corresponding dies by controlling the operation of each cylinder, thereby forming the feature ribs according to the preset dimensions under the movement of different dies.

[0009] In one embodiment of the present invention, the deformation extrusion module further includes two displacement sensors. These sensors are communicatively connected to the control module. The two displacement sensors are respectively mounted on the left and right hydraulic cylinders. The displacement sensors detect the displacement data at the output ends of the left and right hydraulic cylinders and send this data to the control module. The control module then controls the operation of the width cylinder, the left cylinder, and the right cylinder based on the displacement data. Thus, due to the principle of constant volume, the operation of the left and right hydraulic cylinders can be controlled by the coordination of the displacement sensors and the control module, making the entire operation more flexible.

[0010] In one embodiment of the present invention, the forming press further includes a bed located on the side of the width extrusion module away from the deformation cavity. The bed is used to restrict the width extrusion module from moving away from the feature rib. Thus, by setting the bed, the movement of the width extrusion module away from the feature rib can be restricted, that is, the width extrusion module reaches a rigid limit, thereby ensuring that the width of the formed feature rib reaches a preset width.

[0011] In one embodiment of the present invention, the forming press further includes a lower worktable, which is disposed below the sheet material to be processed and is used to fix the fixing mold. Thus, the fixing mold can be fixed by the lower worktable, allowing the sheet material to be processed to be placed properly on the fixing mold.

[0012] In one embodiment of the present invention, the forming apparatus for plate-type ribbed forgings further includes a conveying mechanism. The conveying mechanism is disposed between the heating furnace and the forming press, and is used to convey the partially heated sheet material to be processed to the forming press. Thus, the conveying mechanism facilitates the convenient and simple operation of conveying the partially heated sheet material to the forming press for processing.

[0013] In one embodiment of the present invention, the forming apparatus for plate-type ribbed forgings further includes a discharge mechanism, which is located on the other side of the forming press opposite to the conveying mechanism. The discharge mechanism is used to discharge the formed plate. Thus, the formed plate can be conveniently discharged via the discharge mechanism.

[0014] To achieve the above objectives, in a second aspect, the inventor provides a method for forming a ribbed plate forging, comprising a forming apparatus for a ribbed plate forging as described in any of the above-mentioned inventions, and further comprising the following steps:

[0015] Cut the metal sheet into the required dimensions for processing.

[0016] The sheet material to be processed is conveyed to the heating furnace, where the heating furnace locally heats the area of ​​the sheet material to be processed.

[0017] The heated blank is conveyed to the forming press via a conveying mechanism;

[0018] The multi-directional forging hydraulic mechanism operates the main cylinder, left cylinder, right cylinder, height cylinder, and width cylinder through the control module, so that the clamping die, left die, right die, and width die fit into the sheet metal to be processed, and there is a deformation cavity between the width die, height die, and clamping die and the sheet metal to be processed.

[0019] The control module does not operate the height cylinder and the width cylinder. Instead, it operates the main cylinder, the left cylinder, and the right cylinder, causing the left mold and the right mold to move toward each other and squeeze the sheet metal to be processed. This deforms the heated area of ​​the sheet metal to be processed after local heating and fills the deformation cavity to form feature ribs.

[0020] The control module does not operate the width cylinder, but operates the main cylinder, left cylinder, right cylinder and height cylinder. The feature rib moves towards the height mold as the left mold and right mold move towards each other. The height cylinder provides a certain counter-pressure force to the feature rib, so that the feature rib reaches the required height after continuous small deformation.

[0021] The control module does not operate the height cylinder. Instead, it operates the main cylinder, left cylinder, right cylinder, and width cylinder. As the left and right molds move towards each other, the feature ribs are extruded and move towards the width mold. The width cylinder provides a certain counter-pressure force to the feature ribs, allowing them to undergo continuous small deformations to achieve the required width for forming the feature ribs.

[0022] Unlike existing technologies, the above technical solution utilizes a continuous localized heating multi-directional forming process based on cumulative deformation. By optimizing the deformation zone of the pre-formed sheet metal (i.e., reserving deformation cavities), the forming process of the feature ribs is mainly divided into three stages. The first stage primarily involves the extrusion of the sheet metal by the left and right dies, filling the deformation cavities. The second stage uses the height die to cumulatively deform the material, increasing the height of the feature ribs to a preset height. The third stage, after the feature ribs meet the height requirements, uses the width die to cumulatively deform the material, increasing the width of the feature ribs to a preset width, ultimately ensuring the formed feature ribs meet the specified dimensions. These steps solve the technical challenge of one-time forming of large-sized feature ribs on sheet metal, improving the overall performance of the forgings. Furthermore, the forming process is less affected by human factors, facilitating automated production. In addition, by using locally heated material for cumulative deformation, the formed feature ribs are fully filled, have sharp edges, and high precision.

[0023] In one embodiment of the present invention, after the step of "transferring the sheet metal to be processed to the heating furnace, whereby the heating furnace locally heats the area to be heated of the sheet metal to be processed", the following step is further included: after the local heating is completed, the surface oxide scale of the locally heated sheet metal to be processed is removed using high-pressure water. Thus, by removing the surface oxide scale of the sheet metal to be processed, the influence of the oxide scale on subsequent forging is avoided, the forging quality is improved, and die wear is reduced.

[0024] The above description of the invention is merely an overview of the technical solution of this application. In order to enable those skilled in the art to better understand the technical solution of this application and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of this application easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of this application. Attached Figure Description

[0025] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of this application and other related content, and should not be considered as limitations on this application.

[0026] In the accompanying drawings of the instruction manual:

[0027] Figure 1 This is a schematic diagram of the structure of the plate material described in the background art;

[0028] Figure 2 This is a schematic diagram of the structure of the sheet material to be processed according to one embodiment of this application;

[0029] Figure 3 This is a schematic diagram of the structure of a sheet metal to be processed placed on a forming press according to an embodiment of this application;

[0030] Figure 4 This is a schematic diagram of the structure of a sheet metal to be processed on a forming press being compressed and filled with deformation cavities according to an embodiment of this application;

[0031] Figure 5 This is a schematic diagram of a structure in which the feature ribs on a forming press move toward the high extrusion module, according to an embodiment of this application.

[0032] Figure 6 This is a schematic diagram of a structure in which the feature ribs on a forming press move toward the width extrusion module, according to an embodiment of this application.

[0033] Figure 7 This is a schematic diagram of a displacement sensor mounted on the left hydraulic cylinder according to one embodiment of this application;

[0034] Figure 8 This is a schematic diagram of another displacement sensor installed on the right hydraulic cylinder according to one embodiment of this application.

[0035] The reference numerals used in the above figures are explained as follows:

[0036] 1. Forming press;

[0037] 10. Fix the mold;

[0038] 11. Clamping module;

[0039] 111. Press the mold;

[0040] 112. Pad;

[0041] 12. Deformation extrusion module;

[0042] 121. Left mold;

[0043] 122. Right mold;

[0044] 123. Displacement sensor;

[0045] 13. High-pressure extrusion module;

[0046] 131. Height jack;

[0047] 132. High-precision mold;

[0048] 14. Width extrusion module;

[0049] 141. Width top rod;

[0050] 142. Width mold;

[0051] 15. Go to the workbench;

[0052] 161. Left hydraulic cylinder;

[0053] 162. Right hydraulic cylinder;

[0054] 17. Bed frame;

[0055] 18. Remove the workbench;

[0056] 19. Deformation cavity;

[0057] 2. Board material to be processed;

[0058] 21. Area to be heated;

[0059] 22. Characteristic reinforcement;

[0060] 3. Plate-type forgings with ribs;

[0061] 31. Characteristic reinforcement;

[0062] a. Displacement data of the left hydraulic cylinder;

[0063] b. Right cylinder displacement data. Detailed Implementation

[0064] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this application in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this application and are therefore intended to limit the scope of protection of this application.

[0065] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0066] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit this application.

[0067] In the description of this application, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " in this document generally indicates that the preceding and following objects have an "or" logical relationship.

[0068] In this application, terms such as “first” and “second” are used only to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy or order relationship between these entities or operations.

[0069] Unless otherwise specified, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this application is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0070] Similar to the understanding in the Examination Guidelines, in this application, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments in this application, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.

[0071] In the description of the embodiments of this application, the space-related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the purpose of describing the specific embodiments of this application or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0072] Unless otherwise expressly specified or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this application, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral setting; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. For those skilled in the art to which this application pertains, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0073] like Figure 1 As shown, the characteristic ribs 31 of the plate-type forging 3 are large in size and unevenly distributed. Such forgings are generally produced using casting and forging processes. Compared to forging, casting produces workpieces that meet the shape and size requirements, but the overall performance of castings is far lower than that of forgings. However, traditional forging processes cannot form the characteristic ribs in one forging under these size conditions because the size of the characteristic ribs exceeds the forging ratio limit. Multi-step forging processes require large press tonnage and large machining allowances, making automated production difficult. Although existing technologies disclose forming devices that can form in one step, they are only applicable when the width-to-thickness ratio of the characteristic ribs to the plate is less than or equal to 1.54, and cannot obtain characteristic ribs with larger thickness ratios. The inventors discovered the above problems and, to solve these technical problems, optimized the deformation zone of the pre-forming plate 2, i.e., reserved a deformation cavity 19. At the same time, a height extrusion module 13 and a width extrusion module 14 are also provided to control the height and width of the characteristic ribs 22, respectively. Thus, on the one hand, the forming press 1 can form large-sized characteristic ribs 22 in one step, and on the other hand, the human influence factors during the forming process are small, which facilitates automated production. In addition, by using locally heated materials to accumulate deformation, the formed feature ribs 22 are fully filled, have sharp edges and corners, and have high precision.

[0074] The forming apparatus and method for plate-type forgings with ribs disclosed in this application are mainly used for forming bridge structures, especially bridge bearing plates.

[0075] According to some embodiments of this application, please refer to Figures 2 to 6This embodiment relates to a forming apparatus for plate-type forgings with ribs, including a heating furnace and a forming press 1. The heating furnace is used to locally heat the heating area 21 of the plate 2 to be processed. The forming press 1 includes a fixed mold 10, a clamping module 11, a deformation extrusion module 12, a height extrusion module 13, a width extrusion module 14, and a multi-directional die forging hydraulic mechanism. The fixed mold 10 is located below the plate 2 to be processed and is used to place the plate 2. The clamping module 11 is located above the plate 2 to be processed. The deformation extrusion module 12 is located on both sides of the plate 2 to be processed. The output end of the height extrusion module 13 extends into the clamping module 11 and is located above the plate 2 to be processed. The width extrusion module 14 is located between the plate 2 to be processed and the clamping module 11, and the width extrusion module 14 is in contact with the plate 2 to be processed. The extrusion module 14, the height extrusion module 13, and the clamping module 11 have a deformation cavity 19 between them and the sheet metal 2 to be processed. The multi-directional forging hydraulic mechanism is connected to the clamping module 11, the deformation extrusion module 12, the width extrusion module 14, and the height extrusion module 13, respectively. The multi-directional forging hydraulic mechanism is used to control the clamping module 11 to apply pressure to the sheet metal 2 to be processed. The multi-directional forging hydraulic mechanism is also used to control the deformation extrusion module 12 to extrude the sheet metal 2 to be processed, so that the locally heated sheet metal 2 is deformed and fills the deformation cavity 19 to form a feature rib 22. The multi-directional forging hydraulic mechanism is also used to control the height extrusion module 13 to act towards the feature rib 22 so that the feature rib 22 reaches a preset height. The multi-directional forging hydraulic mechanism is also used to control the width extrusion module 14 to act towards the feature rib 22 so that the feature rib 22 reaches a preset width.

[0076] Generally, ribbed forgings on plates have two spaced-apart feature ribs 22. Therefore, the heating furnace has a left and a right electric furnace that can move left and right. The furnace chambers of the left and right electric furnaces can be opened and closed laterally relative to the plate 2 to be processed, for local heating of the areas at both ends of the plate 2. Preferably, the heating furnace is a medium-frequency induction heating furnace, which has a fast heating speed and is energy-saving.

[0077] like Figure 2 As shown, the two ends of the sheet material 2 to be processed are the heating areas 21, meaning that the heating furnace needs to heat the heating areas 21 of the sheet material 2 to be processed. Specifically, according to the forming position and volume of the feature rib 22, the sheet material 2 to be processed in the corresponding size heating area 21 is locally heated for forming. The unheated area of ​​the sheet material 2 can support the material in the heated area, greatly reducing energy consumption.

[0078] After the locally heated sheet material 2 is placed, a deformation cavity 19 needs to be formed between the width extrusion module 14, the height extrusion module 13, and the clamping module 11 and the sheet material 2. The clamping module 11 mainly applies pressure to the sheet material 2 and maintains a constant pressure during deformation. The deformation extrusion module 12 mainly extrudes the sheet material 2 from the left and right sides. The height extrusion module 13 mainly acts on the feature ribs 22 from the top and bottom of the sheet material 2. The width extrusion module 14 mainly acts on the feature ribs 22 from the left and right sides of the sheet material 2. "Act" here means providing a certain counter-pressure force to the feature ribs 22.

[0079] The above technical solution includes a deformation extrusion module 12 to extrude the locally heated sheet material 2, as well as a height extrusion module 13 and a width extrusion module 14 to control the height and width of the feature ribs 22, respectively. Therefore, on the one hand, the forming press 1 can form large-sized feature ribs 22 in one pass; on the other hand, the human influence during the forming process is minimal, facilitating automated production. Furthermore, by using locally heated material for cumulative deformation, the formed feature ribs 22 are fully filled, have sharp edges, and high precision.

[0080] According to some embodiments of this application, optionally, such as Figures 3 to 5 As shown, the forming press 1 also includes an upper worktable 15, which is disposed above the pressing module 11. The upper worktable 15 is used to fix the pressing module 11 and to provide a limit for the high extrusion module 13 to restrict the high extrusion module 13 from moving away from the feature rib 22.

[0081] The position of the upper worktable 15 is set according to the preset height of the feature rib 22. Specifically, the upper worktable 15 includes a limiting member, which is disposed between the upper worktable 15 and the pressing module 11. The upper worktable 15 limits the pressing module 11 by the limiting member. In actual operation, the feature rib 22 moves towards the height extrusion module 13. At this time, the height extrusion module 13 moves towards the upper worktable 15 until it hits the limiting member of the upper worktable 15 and can no longer move. At this time, the height of the feature rib 22 reaches the preset height.

[0082] Thus, the upper worktable 15 can fix the clamping module 11, allowing the clamping module 11 to move together with the upper worktable 15. In addition, the upper worktable 15 can restrict the height extrusion module 13 from moving away from the feature rib 22, that is, the height extrusion module 13 reaches a rigid limit, thereby ensuring that the height of the formed feature rib 22 reaches the preset height.

[0083] According to some embodiments of this application, optionally, such as Figures 3 to 6As shown, the clamping module 11 includes a clamping mold 111, the deformation extrusion module 12 includes a left mold 121 and a right mold 122, the height extrusion module 13 includes a height push rod 131 and a height mold 132, and the width extrusion module 14 includes a width push rod 141 and a width mold 142. The left mold 121 and the right mold 122 are respectively set on both sides of the plate to be processed 2. The height push rod 131 is connected to the height mold 132, and the width push rod 141 is connected to the width mold 142. The multi-directional forging hydraulic mechanism includes a control module and a main cylinder, a left cylinder 161, a right cylinder 162, a height cylinder, and a width cylinder connected to the control module. The output end of the main cylinder is connected to the upper worktable 15, the output end of the left cylinder 161 is connected to the left mold 121, the output end of the right cylinder 162 is connected to the right mold 122, the output end of the height cylinder is connected to the height push rod 131, and the output end of the width cylinder is connected to the width push rod 141.

[0084] The clamping mold 111 is positioned above the sheet material 2 to be processed and is at least partially in contact with it. In some embodiments, the clamping module 11 further includes a pad 112, which is positioned above the clamping mold 111 and fixedly connected to it. The pad 112 strengthens the fixation of the high-pressure extrusion module, making it less prone to lateral movement during operation. The clamping module 11 is fixedly connected to the upper worktable 15, specifically, the clamping module 11 and the upper worktable 15 are connected by bolts, and the clamping module moves with the upper worktable 15. In other embodiments, since the output end of the high-pressure extrusion module 13 needs to extend into the clamping module 11, a channel for the high-pressure extrusion module 13 to extend into needs to be opened inside the clamping module 11. That is, a vertically extending channel is opened inside the clamping mold 111 and the pad 112, and this channel penetrates both the clamping mold 111 and the pad 112. In actual operation, the main hydraulic cylinder is controlled by the control module, which moves the upper worktable 15 and moves the clamping module 11 to clamp the plate to be processed 2 or to loosen the formed plate.

[0085] The deformation extrusion module 12 includes a left mold 121 and a right mold 122, which are respectively disposed on both sides of the sheet material 2 to be processed. The output end of the left hydraulic cylinder 161 is connected to the left mold 121, and the output end of the right hydraulic cylinder 162 is connected to the right mold 122. In actual operation, the left hydraulic cylinder 161 and the right hydraulic cylinder 162 are controlled by the control module to operate, thereby causing the left mold 121 and the right mold 122 to move towards each other and extrude the sheet material 2 to be processed.

[0086] The height extrusion module 13 includes a height ejector rod 131 and a height mold 132. The output end of the height cylinder is connected to the height ejector rod 131. The bottom of the height mold 132 extends sequentially into the pad 112 and the clamping mold 111 through a channel, and the height ejector rod 131 is installed on the top of the height mold 132. In actual operation, the height cylinder is controlled by the control module to provide a certain counter-force to the feature rib 22 moving towards the height mold 132, so that the feature rib 22 reaches the required height after continuous small deformation.

[0087] The width extrusion module 14 includes a width ejector rod 141 and a width mold 142, with the output end of the width cylinder connected to the width ejector rod 141. The width mold 142 can be configured according to the number of deformation cavities 19. Optionally, two width molds 142 are provided, one for each deformation cavity 19. In this case, two width cylinders are also required, one for each width mold 142. In actual operation, the width cylinders are controlled by the control module to provide a certain counter-force to the feature ribs 22 moving towards the width mold 142, causing the feature ribs 22 to undergo continuous small deformations to achieve the required width.

[0088] Since there is a deformation cavity 19 between the width mold 142, the clamping mold 111, and the sheet material 2 to be processed, the clamping mold 111 is T-shaped in cross-section, and the aforementioned channels are provided at both ends of the T-shape, thereby ensuring that the height extrusion module 13 can interact with the feature rib 22. Furthermore, to ensure that the deformation cavity 19 has a certain width and height, it is necessary to restrict the movement of the height mold 132 and the width mold 142 towards the deformation cavity 19. Specifically, the widths of the channels of the clamping module 11 between the clamping mold 111 and the pad 112 are different; the width of the channel on the pad 112 is greater than the width on the clamping mold 111, and the height mold 132 is correspondingly configured with a T-shaped structure. Thus, when the clamping mold 111 contacts the wider side of the height mold 132, the movement of the height mold 132 towards the deformation cavity 19 is restricted. The width mold 142 is set to an L-shape, and the clamping mold 111 is located between the left and right width molds 142. When the clamping mold 111 contacts the two sides of the width mold 142, it restricts the width mold 142 from continuing to move towards the deformation cavity 19.

[0089] In this way, the multi-directional forging hydraulic mechanism can control the movement of the corresponding mold by controlling the operation of each cylinder, so that the feature rib 22 is formed according to the preset size under the movement of different molds.

[0090] According to some embodiments of this application, optionally, such as Figure 7 and Figure 8As shown, the deformation extrusion module 12 also includes two displacement sensors 123. The displacement sensors 123 are communicatively connected to the control module. The two displacement sensors 123 are respectively installed on the left oil cylinder 161 and the right oil cylinder 162. The displacement sensors 123 are used to detect the displacement data of the output end of the left oil cylinder 161 and the right oil cylinder 162 and send the displacement data to the control module. The control module controls the operation of the width cylinders left oil cylinder 161 and right oil cylinder 162 according to the displacement data.

[0091] Based on the principle that the overall volume of the sheet material 2 to be processed remains unchanged, during the forming process of the feature rib 22, the length within the volume is fixed, while the width and height are variable. In this application, the height of the feature rib 22 is fixed first, followed by the width. The displacement sensor 123 can be used to detect the displacement data at the output ends of the left hydraulic cylinder 161 and the right hydraulic cylinder 162 (i.e., ...). Figure 7 The displacement data of the left hydraulic cylinder 161 in section a is as follows: Figure 8 The control module uses the displacement data of the right hydraulic cylinder 162 (as shown in Figure 123) to determine whether the height of the feature rib 22 has been fully formed, and controls the operation of the width hydraulic cylinder accordingly. Specifically, when the control module determines that the height of the feature rib 22 has been fully formed, it can control the width hydraulic cylinder to operate. Since the displacement data detected by the displacement sensor 123 changes in real time, after the height of the feature rib 22 has been fully formed, the control module can also use the displacement data to determine whether the width of the feature rib 22 has been fully formed, and controls the operation of the left hydraulic cylinder 161 and the right hydraulic cylinder 162 accordingly. Specifically, when the control module determines that the width of the feature rib 22 has also been fully formed, it can stop the operation of the left hydraulic cylinder 161 and the right hydraulic cylinder 162.

[0092] Thus, based on the principle of constant volume, the operation of the left cylinder 161 and the right cylinder 162 can be controlled by the displacement sensor 123 in conjunction with the control module, making the entire operation more flexible.

[0093] According to some embodiments of this application, optionally, such as Figure 6 As shown, the forming press 1 also includes a bed 17, which is located on the side of the width extrusion module 14 away from the deformation cavity 19. The bed 17 is used to restrict the width extrusion module 14 from moving away from the feature rib 22.

[0094] The bed 17 is located on the side of the width extrusion module 14 away from the deformation cavity 19. Optionally, the position of the limiting slider is set according to the preset height of the feature rib 22. In actual operation, the feature rib 22 moves towards the width extrusion module 14. At this time, the width extrusion module 14 moves towards the bed 17 until it touches the bed 17 and can no longer move. At this time, the width of the feature rib 22 reaches the preset width.

[0095] Thus, the bed 17 restricts the width extrusion module 14 from moving away from the feature rib 22, that is, the width extrusion module 14 reaches a rigid limit, thereby making the width of the formed feature rib 22 reach the preset width.

[0096] According to some embodiments of this application, optionally, such as Figure 6 As shown, the forming press 1 also includes a lower worktable 18, which is located below the sheet material 2 to be processed. The lower worktable 18 is used to fix the fixing mold 10.

[0097] Above the lower workbench 18, there are sequentially arranged a plate to be processed 2, a width extrusion module 14, a pressing module 11 and a height extrusion module 13, and deformation extrusion modules 12 are arranged on both sides of the plate to be processed 2.

[0098] In this way, the lower worktable 18 can fix the fixed mold 10, so that the plate to be processed 2 can be placed well on the fixed mold 10.

[0099] According to some embodiments of this application, optionally, the forming apparatus for plate-type forgings with ribs further includes a conveying mechanism, which is disposed between the heating furnace and the forming press 1, and is used to convey the plate 2 to be processed after local heating to the forming press 1.

[0100] The conveying mechanism is located between the heating furnace and the forming press 1, and can be equipped with a stepping feeding trolley and a robotic arm to convey the locally heated sheet material 2 to be processed. Optionally, a water spraying mechanism can also be installed above the conveying mechanism to generate high-pressure water through nozzles to wash away the oxide scale on the surface of the sheet material 2 in the heated area.

[0101] In this way, the locally heated sheet material 2 can be easily transported to the forming press 1 for operation via the conveying mechanism, which is simpler and more convenient.

[0102] According to some embodiments of this application, optionally, the forming apparatus for plate-type ribbed forgings further includes a discharge mechanism, which is located on the other side of the forming press 1 opposite to the conveying mechanism, and is used to discharge the formed plate.

[0103] Optionally, the discharge mechanism has a gripper that can extend into the fixed mold 10, so that the formed sheet can be output after demolding. In this way, the formed sheet can be conveniently discharged through the discharge mechanism.

[0104] According to some embodiments of this application, this embodiment also relates to a forming method for a plate-like forging with ribs, including a forming apparatus for the plate-like forging with ribs, and further including the following steps:

[0105] S101: Cut the metal plate into a sheet material 2 with a width of 500mm and a thickness of 40mm by plasma cutting or sawing;

[0106] S102: The plate to be processed 2 is transferred to the heating furnace. The heating furnace locally heats the heating area 21 of the plate to be processed 2 (the heating area 21 on one side is 200mm-300mm) until it reaches the initial forging temperature of 1200℃.

[0107] S103: The heated blank is conveyed to the working area above the fixed mold 10 of the forming press 1 by the conveying mechanism;

[0108] S104: As Figure 3 As shown, the multi-directional forging hydraulic mechanism operates the main cylinder, left cylinder 161, right cylinder 162, height cylinder and width cylinder through the control module, so that the clamping die 111, left die 121, right die 122 and width die 142 fit into the plate 2 to be processed, and so that the width die 142, height die 132 and clamping die 111 and the plate 2 to be processed have a deformation cavity 19.

[0109] S105: First stage of deformation: as shown Figure 4 As shown, the control module does not operate the height cylinder and the width cylinder (i.e., the fixed height mold 132 and the width mold 142). The control module operates the main cylinder, the left cylinder 161 and the right cylinder 162, so that the clamping mold 111 clamps the plate to be processed 2, and the left mold 121 and the right mold 122 move towards each other to squeeze the plate to be processed 2, so that the heated area 21 of the plate to be processed 2 after local heating is deformed and filled into the deformation cavity 19 to form the feature rib 22;

[0110] S106: Second stage of deformation: as follows Figure 5 As shown, the control module does not operate the width cylinder (i.e., the fixed width mold 142), but operates the main cylinder, left cylinder 161, right cylinder 162 and height cylinder, so that the clamping mold 111 continues to clamp the sheet 2 to be processed during the forming process. The feature rib 22 moves towards the height mold 132 as the left mold 121 and right mold 122 move towards each other. The operation of the height cylinder gives the feature rib 22 a certain counter-pushing force, so that the feature rib 22 reaches the required height of the forming feature rib 22 through continuous small deformation.

[0111] S107: Third stage of transformation: as follows Figure 6As shown, the control module does not operate the height cylinder (i.e., the fixed height mold 132). The control module operates the main cylinder, the left cylinder 161, the right cylinder 162, and the width cylinder, so that the clamping mold 111 continues to clamp the sheet 2 to be processed during the forming process. The feature rib 22 moves towards the width mold 142 as the left mold 121 and the right mold 122 move towards each other. The operation of the width cylinder gives the feature rib 22 a certain counter-pushing force, so that the feature rib 22 reaches the required width of the forming feature rib 22 through continuous small deformation.

[0112] The above technical solution utilizes a continuous local heating multi-directional forming process based on cumulative deformation. By optimizing the deformation zone of the pre-formed sheet metal 2 (i.e., reserving the deformation cavity 19), the forming process of the feature rib 22 is mainly divided into three stages. The first stage primarily involves the extrusion process of the left mold 121 and right mold 122 on the sheet metal 2, filling the deformation cavity 19. The second stage uses the height mold 132 to cumulatively deform the material, increasing the height of the feature rib 22 to a preset height. The third stage, after the feature rib 22 meets the height requirement, uses the width mold 142 to cumulatively deform the material, increasing the width of the feature rib 22 to a preset width, ultimately ensuring that the formed feature rib 22 meets the specified dimensions. These steps solve the technical challenge of one-time forming of large-sized feature ribs 22 on the sheet metal 2, improving the overall performance of the forging. Furthermore, the forming process is less affected by human factors, facilitating automated production. In addition, by using locally heated material for cumulative deformation, the formed feature rib 22 is fully filled, has sharp edges, and high precision.

[0113] According to some embodiments of this application, optionally, in step S106, achieving the required width for forming the feature rib 22 requires the limiting action of the upper worktable 15, i.e., the height mold 132 provides rigid limiting. Similarly, in step S107, achieving the required width for forming the feature rib 22 requires the limiting action of the bed 17, i.e., the width mold 142 provides rigid limiting. Alternatively, the feature rib 22 can be formed to the specified dimensions through the cooperation of the displacement sensor 123 and the control module.

[0114] According to some embodiments of this application, optionally, after step S102, the following step is further included:

[0115] S1021: After local heating is completed, the surface oxide scale of the locally heated plate 2 is removed by high-pressure water.

[0116] Optionally, the high-pressure water rinsing time is 2-5 seconds. This removes the oxide scale from the surface of the sheet metal 2, thus avoiding its impact on subsequent forging, improving forging quality, and reducing die wear.

[0117] According to some embodiments of this application, optionally, after step S107, the following step is further included:

[0118] S108: The control module opens the left mold 121, right mold 122, clamping mold 111, width mold 142 and height mold 132 by operating the main oil cylinder, left oil cylinder 161, right oil cylinder 162, height cylinder and width cylinder, and completes the material discharge through the material discharge mechanism.

[0119] It should be noted that although the above embodiments have been described herein, this does not limit the scope of patent protection of the present invention. Therefore, any changes and modifications made to the embodiments described herein based on the innovative concept of the present invention, or equivalent structural or procedural transformations made using the content of the present invention's specification and drawings, directly or indirectly applying the above technical solutions to other related technical fields, are all included within the scope of patent protection of the present invention.

Claims

1. A forming apparatus for plate-type forgings with ribs, characterized in that, include: A heating furnace, used for localized heating of the area to be heated of the sheet material to be processed; A forming press, comprising a fixed mold, a clamping module, a deformation extrusion module, a height extrusion module, a width extrusion module, and a multi-directional forging hydraulic mechanism; The fixing mold is disposed below the material to be processed, and the fixing mold is used for placing the material to be processed; The clamping module is positioned above the material to be processed; The deformation extrusion module is disposed on both sides of the material to be processed; The output end of the high extrusion module extends into the pressing module and is located above the material to be processed; The width extrusion module is disposed between the material to be processed and the pressing module, and the width extrusion module is in contact with the material to be processed; The width extrusion module, the height extrusion module, and the clamping module have a deformation cavity between them and the sheet material to be processed; The multi-directional forging hydraulic mechanism is connected to the clamping module, the deformation extrusion module, the width extrusion module, and the height extrusion module, respectively. The multi-directional forging hydraulic mechanism is used to control the clamping module to apply pressure to the sheet metal to be processed; the multi-directional forging hydraulic mechanism is also used to control the deformation extrusion module to extrude the sheet metal to be processed, so that the locally heated sheet metal to be processed deforms and fills the deformation cavity to form a feature rib; the multi-directional forging hydraulic mechanism is also used to control the height extrusion module to act closer to the feature rib, so that the feature rib reaches a preset height; the multi-directional forging hydraulic mechanism is also used to control the width extrusion module to act closer to the feature rib, so that the feature rib reaches a preset width.

2. The forming apparatus for plate-type ribbed forgings according to claim 1, characterized in that, The forming press also includes an upper worktable, which is disposed above the pressing module. The upper worktable is used to fix the pressing module and to provide a limit for the high extrusion module to restrict the high extrusion module from moving away from the feature rib.

3. The forming apparatus for plate-type ribbed forgings according to claim 2, characterized in that, The clamping module includes a clamping mold, the deformation extrusion module includes a left mold and a right mold, the height extrusion module includes a height push rod and a height mold, and the width extrusion module includes a width push rod and a width mold; The left mold and the right mold are respectively disposed on both sides of the plate to be processed; the height ejector is connected to the height mold; and the width ejector is connected to the width mold. The multi-directional forging hydraulic mechanism includes a control module and a main cylinder, a left cylinder, a right cylinder, a height cylinder, and a width cylinder connected to the control module. The output end of the main cylinder is connected to the upper worktable, the output end of the left cylinder is connected to the left mold, the output end of the right cylinder is connected to the right mold, the output end of the height cylinder is connected to the height ejector rod, and the output end of the width cylinder is connected to the width ejector rod.

4. The forming apparatus for plate-type ribbed forgings according to claim 3, characterized in that, The deformation extrusion module also includes two displacement sensors. The displacement sensors are communicatively connected to the control module. The two displacement sensors are respectively installed on the left hydraulic cylinder and the right hydraulic cylinder. The displacement sensors are used to detect the displacement data at the output ends of the left hydraulic cylinder and the right hydraulic cylinder and send the displacement data to the control module. The control module controls the operation of the width cylinder, the left hydraulic cylinder and the right hydraulic cylinder according to the displacement data.

5. The forming apparatus for plate-type ribbed forgings according to claim 1, characterized in that, The forming press also includes a bed, which is disposed on the side of the width extrusion module away from the deformation cavity, and the bed is used to restrict the width extrusion module from moving away from the feature rib.

6. The forming apparatus for plate-type ribbed forgings according to claim 1, characterized in that, The forming press also includes a lower worktable, which is disposed below the sheet material to be processed and is used to fix the fixed mold.

7. The forming apparatus for plate-type ribbed forgings according to claim 1, characterized in that, The forming device for the plate-type forging with ribs also includes a conveying mechanism, which is disposed between the heating furnace and the forming press. The conveying mechanism is used to convey the plate to be processed after local heating to the forming press.

8. The forming apparatus for plate-type ribbed forgings according to claim 7, characterized in that, The forming device for the plate-type forging with ribs also includes a discharge mechanism, which is located on the other side of the forming press opposite to the conveying mechanism. The discharge mechanism is used to discharge the formed plate.

9. A forming method for a plate-type forging with ribs, characterized in that, The forming apparatus for plate-type ribbed forgings as described in claim 3 or 4 further includes the following steps: Cut the metal sheet into the required dimensions for processing. The sheet material to be processed is conveyed to a heating furnace, where the heating furnace locally heats the area of ​​the sheet material to be processed. The heated blank is conveyed to the forming press via a conveying mechanism; The multi-directional forging hydraulic mechanism operates the main cylinder, left cylinder, right cylinder, height cylinder, and width cylinder through the control module, so that the clamping die, left die, right die, and width die fit into the sheet metal to be processed, and so that there is a deformation cavity between the width die, height die, and clamping die and the sheet metal to be processed. The control module does not operate the height cylinder and the width cylinder. Instead, it operates the main cylinder, the left cylinder, and the right cylinder, causing the left mold and the right mold to move toward each other and squeeze the sheet metal to be processed. This deforms and fills the deformation cavity with the heated area of ​​the sheet metal to be processed after local heating, thereby forming a feature rib. The control module does not operate the width cylinder, but operates the main cylinder, the left cylinder, the right cylinder and the height cylinder. The feature rib moves towards the height mold as the left mold and the right mold move towards each other. The height cylinder provides a certain counter-pressure force to the feature rib, so that the feature rib reaches the required height after continuous small deformation. The control module does not operate the height cylinder, but operates the main cylinder, the left cylinder, the right cylinder, and the width cylinder. The feature rib moves towards the width cylinder as the left mold and the right mold move towards each other. The width cylinder provides a certain counter-pressure force to the feature rib, so that the feature rib undergoes continuous small deformation to achieve the required width for forming the feature rib.

10. The forming method of the plate-type forging with ribs according to claim 9, characterized in that, After the step "transferring the sheet material to be processed to the heating furnace, wherein the heating furnace locally heats the area to be heated of the sheet material to be processed", the following steps are also included: After local heating is completed, the surface oxide scale of the locally heated material is removed by high-pressure water treatment.

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