Automobile axle housing, automobile axle housing mold, and forming method

Abstract

The invention discloses an automobile bridge shell, an automobile bridge shell mold, and a forming method. The method comprises the following steps: selecting a seamless steel pipe with an outer diameter of D1 and an inner diameter of d1, and cutting the seamless steel pipe to a length of L1; applying pressure to trim the steel pipe to form a first deformed piece with an outer diameter of D2, an inner diameter of d1, and a thick middle part and thin ends, which is a pipe wall reduction process, and the first deformed piece is thinner than the pipe wall thickness of the original seamless steel pipe; performing rotary forging treatment on the first deformed piece, extending the two ends of the first deformed piece, and forming a second deformed piece with an outer diameter of D3 and an inner diameter of D2′, which is a diameter reduction process, and the wall thickness of the first deformed piece is increased. Compared with the original seamless steel pipe, the wall thickness of the seamless steel pipe is not increased, and the weight is not increased, thereby solving the problem of pipe damage caused by diameter reduction after large-scale equal wall; placing the second deformed piece into a mold of a medium-high pressure forming device to form an automobile bridge shell matching the shape of the mold.

Description

Technical Field

[0001] The invention belongs to the field of automobile axle housings, and in particular relates to an integrated automobile axle housing, an automobile axle housing mold, and a forming method. Background Art

[0002] The automobile industry has been developing for over a hundred years, and automobile axles, as important parts of load-bearing vehicles, shoulder the heavy tasks of load-bearing and power transmission, and are also constantly improving with the development of the automobile industry. The axle housing is the load-bearing body of the axle, and its own quality also determines the overall performance of the axle.

[0003] In order to meet the market demand, the types of bridge shell manufacturing are roughly divided into two categories, namely welded bridge shells and cast bridge shells. Welded bridge shells are traditional sheet metal stamping parts, which are then welded using electric welding. The biggest disadvantage of this process is that the welding quality is not easy to control, and a series of problems such as desoldering, welding leakage, welding deformation, and oil leakage may occur. The advantage of cast bridge shells is that they can be integrated into complex cross-sectional shapes and have high strength because they are formed by molten steel casting. However, they also generally have problems such as excessive overall weight, high pollution in the production environment, low material utilization, and high cost. Summary of the invention

[0004] In order to solve the problems of easy deformation and oil leakage of the existing automobile bridge housing, the present invention provides a method for forming an automobile bridge housing which is free of any welding, smooth as a whole and has excellent performance.

[0005] The technical solution of the present invention is:

[0006] The invention discloses a method for forming an automobile axle housing, the method comprising the following steps:

[0007] Select a seamless steel pipe with an outer diameter of D1 and an inner diameter of d1, and cut it to a length of L1;

[0008] Apply pressure to trim the steel pipe to form a first deformed piece with an outer diameter of D2, an inner diameter of d1, and a thick middle and thin ends;

[0009] The first deformed member is subjected to rotary forging to extend both ends of the first deformed member to form a second deformed member with an outer diameter D3 and an inner diameter D2′;

[0010] The second deformed part is placed into a mold of a medium-high pressure forming device to form an automobile axle housing matching the shape of the mold.

[0011] Preferably, the method further comprises the steps of:

[0012] The mold includes a first mold and a second mold. The second deformable part is placed in the first mold to form a third deformable part that expands to a circular shape in the middle. The third deformable part is then placed in the second mold to form an automobile bridge shell with a convex structure in the middle.

[0013] Furthermore, the method further comprises the following steps:

[0014] The seamless steel pipe is placed in a double-head spinning machine, the clamp clamps the middle of the steel pipe, and the spinning wheel performs axial trimming on both ends of the steel pipe.

[0015] Furthermore, the method further comprises the following steps:

[0016] The first deformable part is placed in a high-speed rotary forging machine. During the rotation process, multiple rotary forging hammers are distributed around the entire circumference of the outer diameter of the first deformable part. The outer diameter of the first deformable part is hammered around the entire circumference during rotation, so that the two ends of the first deformable part gradually become thinner to form a second deformable part with a reduced diameter.

[0017] Preferably, the middle portion of the first deformable member has a length of L, and the lengths of both ends of the first deformable member are L2 respectively; the middle portion of the second deformable member also has a length of L, and the lengths of both ends of the second deformable member are L3 respectively.

[0018] Furthermore, the method further comprises the following steps:

[0019] The upper and lower molds of the first mold are closed, and the medium and high pressure molding equipment injects high-pressure intermediate liquid into the second deformation part at the same time. As the intermediate liquid is continuously injected, the pressure in the tube cavity increases, causing the tube embryo to expand and deform. The pressure is then adjusted through the CNC system, and finally the second deformation part is fully expanded and deformed to completely fit the cavity in the mold to form a third deformation part.

[0020] Furthermore, the method further comprises the following steps:

[0021] First, inject the intermediate liquid into the third deformation part, apply medium pressure in the early stage, and then close the upper and lower molds of the second mold. The medium and high pressure molding equipment is gradually increased to a high pressure state through the control of the CNC system. The third deformation part is fully expanded and deformed in the mold cavity. The mold cavity begins to extrude the tube blank to make the material flow more fully and smoothly. Finally, the third deformation part is completely fitted with the mold structure surface to form an integral bridge shell product.

[0022] Preferably, D1 is greater than D2, and D2 is greater than D3.

[0023] The present invention also provides an automobile bridge housing, including a bridge tube and a bridge bag, wherein the bridge tube is arranged at both ends of the bridge bag, the bridge tube and the bridge bag are both hollow structures, the bridge bag includes a plane and a convex surface, and the convex surface is an irregular convex surface.

[0024] The present invention also provides an automobile bridge housing forming mold, including a first mold and a second mold, the first mold is spherical, the middle of the upper and lower molds of the first mold are both hemispherical, the second mold is irregular, the middle of the upper mold of the second mold is flat, and the lower mold of the second mold is concave irregular.

[0025] The beneficial effect of the present invention is that the seamless steel pipe is formed into a first deformed part by applying pressure, and then a second deformed part is formed by rotary forging. The bridge tube structure is completed by rotary forging and spinning, and then the convex structure of the bridge package is formed by medium and high pressure secondary expansion extrusion. The integrated forming process of the bridge shell does not require any welding, is smooth as a whole and has excellent performance, and there will be no problems such as desoldering, welding leakage, welding deformation and oil leakage. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 A schematic diagram of a process of forming a vehicle axle housing according to the present invention;

[0027] Figure 2 This is a structural schematic diagram of an automobile axle housing of the present invention;

[0028] Figure 3 It is a schematic diagram of the cross-sectional structure of an automobile axle housing of the present invention;

[0029] Figure 4 It is a structural schematic diagram of the seamless steel pipe of the present invention;

[0030] Figure 5 It is a schematic diagram of the structure of the seamless steel pipe of the present invention when it is spun;

[0031] Figure 6 is a schematic structural diagram of a first deformation member of the present invention;

[0032] Figure 7 It is a schematic structural diagram of the first deformation member of the present invention when rotary forging is performed;

[0033] Figure 8 is a schematic structural diagram of a second deformation member of the present invention;

[0034] Fig. 9 It is a structural schematic diagram of the second deformation part of the present invention being placed into the first mold of the medium-high pressure forming equipment;

[0035] Fig.10 is a schematic structural diagram of a third variant of the present invention;

[0036] Fig.11 It is a schematic structural diagram of the third deformation part of the present invention being placed into the second mold of the medium-high pressure forming equipment;

[0037] In the figure, 1 is a bridge tube, 2 is a bridge package, 21 is a plane, 22 is a convex surface, 3 is a seamless steel tube, 4 is a first deformation part, 41 is a spinning wheel, 5 is a second deformation part, 51 is a rotary forging machine, 6 is a third deformation part, 8 is a first mold, and 9 is a second mold. DETAILED DESCRIPTION

[0038] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention.

[0039] Please refer to Figure 1-Figure 11 The present invention provides a method for forming an automobile axle housing, the method comprising the following steps:

[0040] Select a seamless steel pipe 3 with an outer diameter of D1 and an inner diameter of d1, and cut it to a length of L1;

[0041] Pressing and trimming the steel pipe 3 to form a first deformed part 4 with an outer diameter of D2, an inner diameter of d1, and a thick middle and thin ends;

[0042] The first deformable member 4 is subjected to rotary forging to extend both ends of the first deformable member 4 to form a second deformable member 5 with an outer diameter D3 and an inner diameter D2′;

[0043] The second deformed part 5 is placed into a mold of a medium-high pressure forming device to form an automobile axle housing matching the shape of the mold.

[0044] Preferably, the method further comprises the steps of:

[0045] The mold includes a first mold 8 and a second mold 9. The second deformable part 5 is placed in the first mold 8 to form a third deformable part 6 that expands to a circular shape in the middle. The third deformable part 6 is then placed in the second mold 9 to form a car bridge housing with a convex structure in the middle.

[0046] Furthermore, the method further comprises the following steps:

[0047] The seamless steel pipe 3 is placed in a double-head spinning machine, the clamp holds the middle of the steel pipe 3, and the spinning wheel 41 trims the two ends of the steel pipe 3 in the axial direction. This step is the pipe wall reduction process. Figure 6 The first deformed part obtained in the process has a thinner wall thickness than the original seamless steel pipe.

[0048] Furthermore, the method further comprises the following steps:

[0049] The first deformed part 4 is put into a high-speed rotary forging machine 51. During the rotation process, multiple rotary forging hammers are distributed around the entire circumference of the outer diameter of the first deformed part 4. The outer diameter of the first deformed part 4 is hammered all around during the rotation, so that the two ends of the first deformed part 4 gradually become thinner, forming a second deformed part 5 after the diameter is reduced. This step is a diameter reduction process, which increases the wall thickness of the first deformed part. Compared with the original seamless steel pipe, the wall thickness of the seamless steel pipe is not increased, and the weight is not increased, thereby solving the problem of pipe damage caused by large-scale equal wall diameter reduction.

[0050] Rotary forging will make the metal structure of the pipe more compact and the performance more superior. Because the forming process is a gradual process, the formed pipe is more precise and has higher strength. Because of the gradual reduction in diameter, the forging pressure of the equipment itself is not large, the energy consumption of the equipment is low, and the equipment shell can be miniaturized.

[0051] Preferably, the middle length of the first deformable member 4 is L, and the lengths of both ends of the first deformable member 4 are L2 respectively; the middle length of the second deformable member 5 is also L, and the lengths of both ends of the second deformable member 5 are L3 respectively.

[0052] Furthermore, the method further comprises the following steps:

[0053] The upper and lower molds of the first mold 8 are closed, and the medium and high pressure molding equipment simultaneously injects high-pressure intermediate liquid into the second deformation part 5. As the intermediate liquid is continuously injected, the pressure in the tube cavity increases, causing the tube embryo to expand and deform. The pressure is then adjusted through the CNC system, and finally the second deformation part 5 is fully expanded and deformed to completely fit the cavity in the mold to form the third deformation part 6.

[0054] Furthermore, the method further comprises the following steps:

[0055] First, the intermediate liquid is injected into the third deformation part 6, and the medium pressure is applied in the early stage. Then, the upper and lower molds of the second mold 9 are closed. The medium and high pressure molding equipment is controlled by the numerical control system to gradually increase the pressure to a high pressure state. The third deformation part 6 is fully expanded and deformed in the mold cavity. The mold cavity begins to extrude the tube blank to make it flow more fully and smoothly. Finally, the third deformation part 6 is completely fitted with the mold structure surface to form an integral bridge shell product.

[0056] The flexible expansion using two sets of dies effectively solves the common drawbacks of the traditional manufacturing process. The bridge shell of the present invention is formed in an integrated manner, the bridge shell body has no welding or welds, the overall weight is light, the strength is high, the material utilization rate is high, and there is no pollution.

[0057] Preferably, D1 is greater than D2, and D2 is greater than D3.

[0058] This automobile bridge shell forming method abandons the conventional extrusion diameter reduction process to avoid quality problems such as excessive stretching, internal strain, cracks and warping in the tube diameter reduction. The tube internal expansion adopts medium pressure holding pressure pressing and high pressure extrusion expansion forming process, which solves the series of problems such as the difficulty of material feeding in complex expansion sections, the inability to fully apply film and lack of materials in tube expansion.

[0059] Reference Figure 2 and Figure 3 The present invention also provides an automobile bridge housing, including a bridge tube 1 and a bridge bag 2, wherein the bridge tube 1 is arranged at both ends of the bridge bag 2, the bridge tube 1 and the bridge bag 2 are both hollow structures, the bridge bag 2 includes a plane 21 and a convex surface 22, and the convex surface 22 is an irregular convex surface.

[0060] Reference Fig. 9 and Fig.11 The present invention further provides an automobile bridge housing forming mold, including a first mold 8 and a second mold 9, wherein the first mold 8 is spherical, and the middle of the upper and lower molds of the first mold 8 are both hemispherical, and the second mold 9 is irregular, and the middle of the upper mold of the second mold 9 is flat, and the lower mold of the second mold 9 is concave irregular.

[0061] The above-mentioned embodiment only expresses one implementation mode of the present invention, and its description is relatively specific and detailed, but it cannot be understood as limiting the scope of the patent of the present invention. It should be pointed out that for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be based on the attached claims.

Claims

1. A method for forming an automobile axle housing, characterized in that: The method comprises the following steps: Select a seamless steel pipe with an outer diameter of D1 and an inner diameter of d1, and cut it to a length of L1; Pressurize and trim the steel pipe to form a first deformed piece with an outer diameter of D2, an inner diameter of d1, and a thick middle and thin ends. The seamless steel pipe is placed in a double-head spinning machine, the clamp clamps the middle of the steel pipe, and the spinning wheel axially trims the two ends of the steel pipe; The first deformed part is subjected to rotary forging, and both ends of the first deformed part are extended to form a second deformed part with an outer diameter D3 and an inner diameter D2′. The first deformed part is placed in a high-speed rotary forging machine. During the rotation process, a plurality of rotary forging hammers are distributed around the entire circumference of the outer diameter of the first deformed part. During the rotation, the outer diameter of the first deformed part is hammered around the entire circumference, so that both ends of the first deformed part gradually become thinner, forming a second deformed part with a reduced diameter. The second deformed part is placed into a mold of a medium-high pressure forming device to form an automobile axle housing matching the shape of the mold.

2. The method according to claim 1, characterized in that The method further comprises the steps of: The mold includes a first mold and a second mold. The second deformable part is placed in the first mold to form a third deformable part that expands to a circular shape in the middle. The third deformable part is then placed in the second mold to form an automobile bridge shell with a convex structure in the middle.

3. The method according to claim 1, characterized in that The length of the middle part of the first deformable member is L, and the lengths of both ends of the first deformable member are L2 respectively. The length of the middle part of the second deformable member is also L, and the lengths of both ends of the second deformable member are L3 respectively.

4. The method according to claim 2, characterized in that: The method further comprises the steps of: The upper and lower molds of the first mold are closed, and the medium and high pressure molding equipment injects high-pressure intermediate liquid into the second deformation part at the same time. As the intermediate liquid is continuously injected, the pressure in the tube cavity increases, causing the tube embryo to expand and deform. The pressure is then adjusted through the CNC system, and finally the second deformation part is fully expanded and deformed to completely fit the cavity in the mold to form a third deformation part.

5. The method according to claim 2, characterized in that: The method further comprises the steps of: First, inject the intermediate liquid into the third deformation part, apply medium pressure in the early stage, and then close the upper and lower molds of the second mold. The medium and high pressure molding equipment is gradually increased to a high pressure state through the control of the CNC system. The third deformation part is fully expanded and deformed in the mold cavity. The mold cavity begins to extrude the tube blank to make the material flow more fully and smoothly. Finally, the third deformation part is completely fitted with the mold structure surface to form an integral bridge shell product.

6. The automobile axle housing forming method according to claim 1, characterized in that: The D1 is greater than D2, and the D2 is greater than D3.

7. An automobile axle housing, comprising an automobile axle housing manufactured by the automobile axle housing forming method according to claim 1, characterized in that: It includes a bridge tube and a bridge bag, wherein the bridge tube is arranged at both ends of the bridge bag, the bridge tube and the bridge bag are both hollow structures, the bridge bag includes a plane and a convex surface, and the convex surface is an irregular convex surface.

Images