A forging process for an air spring cup of an air suspension system

Abstract

The present application relates to the field of forging technology, and discloses a kind of forging process of air spring top seat of air suspension system, and is formed by using aluminum alloy bar stock, and the process is as follows: aluminum alloy bar stock is heated;The heated aluminum alloy bar stock is sent into pre-forging die for pre-forging forming, to obtain crude product;The crude product of pre-forging is sent to finish-forging die for finish-forging forming;The finished product is obtained after punching and finishing treatment of finish-forging product.The air spring top seat of the present application is formed by using aluminum alloy bar stock, and the shape of pre-forging die and finish-forging die is designed in the process of forging, which reduces the process of bar stock blanking, so that the aluminum alloy bar stock directly enters the pre-forging process for pre-forming, and then enters the finish-forging process for the final forming of the top seat, reducing the original three-station production to two stations, reducing the circulation in the workpiece forming process, so as to reduce the plastic deformation of the workpiece.

Description

Technical Field

[0001] This invention relates to the field of forging technology, specifically a forging process for an air spring top seat of an air suspension system. Background Technology

[0002] Compared to traditional suspension systems, air suspension systems have fewer metal components, resulting in a lighter overall weight. This allows commercial vehicles to increase payload capacity and reduce fuel consumption. They also improve driving smoothness, provide better grip to maintain vehicle level, reduce body roll, and enhance the transport capacity of commercial vehicles. Furthermore, they effectively protect components and transported precision equipment, reducing vehicle maintenance costs and cargo damage risks. Intelligent electric vehicles are an ideal platform for air suspension systems, helping to increase their driving range. In the future, air suspension systems are expected to rapidly penetrate the market in models priced at 300,000 yuan and below.

[0003] The air spring top mount is an important component of the air suspension system. In order to improve the weight and quality of the entire air suspension system, this application has developed the manufacturing process for this component. Summary of the Invention

[0004] The purpose of this invention is to provide a forging process for the air spring top seat of an air suspension system, which is forged from aluminum alloy bar material through a two-station process, reducing flow between processes and reducing workpiece deformation.

[0005] To achieve the above objectives, the present invention provides a forging process for an air spring top seat of an air suspension system. The air spring top seat is forged from aluminum alloy bar stock, and the specific forging process is as follows:

[0006] S1. Heating the aluminum alloy bar;

[0007] S2. The heated aluminum alloy bar is fed into a pre-forging die for pre-forging. The pre-forged product is demolded using a release agent to obtain a rough product.

[0008] S3. The pre-forged rough product is sent to the final forging die for final forging, and the final forged product is demolded using a release agent.

[0009] S4. The finished product is obtained by punching and finishing the forged product.

[0010] Specifically, the pre-forging mold in S2 includes a pre-forging upper mold and a pre-forging lower mold. The pre-forging upper mold is provided with a pre-forging upper mold cavity. A pre-forging boss is provided at the center of the pre-forging upper mold cavity. A first groove is provided on the end face of the cavity wall of the pre-forging upper mold cavity. A first U-shaped groove is provided on the cavity wall of the pre-forging upper mold cavity. The first U-shaped groove is located below the first groove and the top of the first U-shaped groove is flush with the bottom of the first groove.

[0011] The pre-forging die includes a bottom truncated cone and a first convex ring. The upper surface of the bottom truncated cone is provided with a pre-formed protrusion, and the center of the bottom truncated cone is provided with a central through hole. The first convex ring is disposed on the bottom truncated cone of the pre-forging die, and the first convex ring is provided with three fan-shaped initial forming grooves evenly distributed along the circumference of the convex ring.

[0012] Specifically, the final forging die in S3 includes an upper final forging die, a lower final forging die, and a die core, wherein the die core is disposed inside the lower final forging die;

[0013] The final forging upper die is provided with a final forging upper die cavity, the center of the final forging upper die cavity is provided with a final forging boss, the end face of the cavity wall of the final forging upper die cavity is provided with a second groove, the cavity wall of the final forging upper die cavity is provided with a second U-shaped groove, the second U-shaped groove is located below the second groove, and the top of the second U-shaped groove is flush with the bottom of the second groove.

[0014] The final forging die includes a bottom truncated cone and a second convex ring. The upper surface of the bottom truncated cone is provided with a forming protrusion. The upper end face of the forming protrusion is a stepped surface. The center of the bottom truncated cone is provided with a die core mounting hole. The second convex ring is set on the bottom truncated cone. The second convex ring is provided with three fan-shaped forming grooves evenly distributed along the circumference of the convex ring. The second convex ring is also provided with a semi-circular groove.

[0015] The mold core includes a first frustum, a second frustum, and a third frustum arranged sequentially from bottom to top, with interconnected central holes at the centers of the first frustum, the second frustum, and the third frustum.

[0016] Furthermore, the height of the final forging boss is greater than the height of the pre-forging boss.

[0017] Furthermore, the depth of the fan-shaped forming groove is greater than the depth of the fan-shaped initial forming groove, and the groove wall of the fan-shaped forming groove is symmetrically provided with inner grooves.

[0018] Specifically, in S1, the aluminum alloy bar is heated to 530-560℃ at a heating rate of 1.5 mm / min.

[0019] Furthermore, in S2 and S3, the release agent is a mixture of release agent and water, and the ratio of release agent to water is 1:40.

[0020] Specifically, the punching and finishing process in S4 includes punching, trimming, and shaping.

[0021] The beneficial effects of this invention are:

[0022] The air spring top seat of this invention is forged from aluminum alloy bar stock. During the forging process, the volume distribution technology of forging design is utilized. By designing the shapes of the pre-forging mold and the final forging mold, the billet preparation process of the bar stock is reduced. The aluminum alloy bar stock is first directly put into the pre-forging process for pre-forming, and then enters the final forging process for the bottom and other parts of the top seat to be finally formed. This reduces the amount of deformation of the workpiece during the pre-forging process. At the same time, the original three-station production is reduced to two-station production, reducing the flow of the workpiece during the forming process, further reducing the plastic deformation of the workpiece, and improving the quality of the product.

[0023] In the forging process of this application, controlling the ratio of the mold release lubricant helps to control the formability of the material during the flow process; at the same time, controlling the heating temperature of the mold during the forging process ensures the uniformity of the mold temperature, which is beneficial to the stability of the product thickness and formability. Attached Figure Description

[0024] To more clearly illustrate the technical solution of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a flow chart of the forging process of this invention;

[0026] Figure 2 This is a schematic diagram of the structure of the pre-forging mold of the present invention;

[0027] Figure 3 This is a schematic diagram of the final forging die of the present invention;

[0028] Figure 4 This is a schematic diagram of the structure of the pre-forging upper die of the pre-forging mold of the present invention;

[0029] Figure 5 This is a schematic diagram of the structure of the lower pre-forging die of the pre-forging mold of the present invention;

[0030] Figure 6 This is a schematic diagram of the structure of the upper forging die of the final forging mold of the present invention;

[0031] Figure 7 This is a schematic diagram of the structure of the lower die for final forging of the final forging die of the present invention;

[0032] Figure 8 This is a schematic diagram of the core structure of the final forging die of the present invention;

[0033] In the figure: 1-Pre-forging upper die, 11-Pre-forging boss, 12-First groove, 13-First U-shaped groove, 14-, 2-Pre-forging lower die, 21-Bottom frustum of pre-forging die, 22-First convex ring, 23-Pre-forming protrusion, 24-Central through hole, 25-Fan-shaped initial forming groove, 3-Final forging upper die, 31-Final forging boss, 32-Second groove, 33-Second U-shaped groove, 4-Final forging lower die, 41-Bottom frustum of final forging die, 42-Second convex ring, 43-Forming protrusion, 44-Fan-shaped forming groove, 45-Semi-circular groove, 5-Die core, 51-First frustum, 52-Second frustum, 53-Third frustum. Detailed Implementation

[0034] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] In one specific embodiment of the present invention, such as Figures 1 to 8 As shown, a forging process for an air spring top seat of an air suspension system is described. The air spring top seat is forged from aluminum alloy bar stock. The specific forging process is as follows:

[0036] S1. The aluminum alloy bar is heated to 530-560℃ at a heating rate of 1.5mm / min.

[0037] S2. The heated aluminum alloy bar is fed into a pre-forging mold for pre-forging. The temperature of the pre-forging mold is controlled at the same temperature during pre-forging. A release agent is used to demold the pre-forged product to obtain a rough product. The release agent is a mixture of release agent and water, and the ratio of release agent to water is 1:40.

[0038] S3. The pre-forged rough product is sent to the final forging die for final forging. The temperature of the pre-forging die is controlled at the same temperature during the final forging. A release agent is used to demold the final forged product. The release agent is a mixture of release agent and water, and the ratio of release agent to water is 1:40.

[0039] S4. The finished product is obtained by punching and finishing the final forged product. The punching and finishing process includes punching, trimming and shaping.

[0040] Specifically, the pre-forging mold in S2 includes a pre-forging upper mold 1 and a pre-forging lower mold 2 used in conjunction with each other. The pre-forging upper mold 1 is provided with a pre-forging upper mold cavity. A pre-forging boss 11 is provided at the center of the pre-forging upper mold cavity. A first groove 12 is provided on the end face of the cavity wall of the pre-forging upper mold cavity. A first U-shaped groove 13 is provided on the cavity wall of the pre-forging upper mold cavity. The first U-shaped groove 13 is located below the first groove 12 and the top of the first U-shaped groove 13 is flush with the bottom of the first groove 12.

[0041] The pre-forging die 2 includes a bottom frustum 21 and a first convex ring 22. The upper surface of the bottom frustum 21 is provided with a pre-forming protrusion 23, and the center of the bottom frustum 21 is provided with a central through hole 24. The first convex ring 22 is disposed on the bottom frustum 21, and the first convex ring 22 is provided with three fan-shaped initial forming grooves 25 evenly distributed along the circumference of the convex ring.

[0042] The final forging die in S3 includes an upper final forging die 3 and a lower final forging die 4 used in conjunction with each other, and a die core 5 disposed in the lower final forging die 4.

[0043] The final forging upper die 3 is provided with a final forging upper die cavity, and a final forging boss 31 is provided at the center of the final forging upper die cavity. The height of the final forging boss 31 is greater than the height of the pre-forging boss 11.

[0044] The cavity wall end face of the final forging upper mold cavity is provided with a second groove 32, and the cavity wall of the final forging upper mold cavity is provided with a second U-shaped groove 33. The second U-shaped groove 33 is located below the second groove 32, and the top of the second U-shaped groove 33 is flush with the bottom of the second groove 32.

[0045] Both the second groove 32 and the first groove 12 are V-shaped grooves, and the opening angle of the second groove 32 is greater than the opening angle of the first groove 12.

[0046] The final forging die 4 includes a bottom truncated cone 41 and a second convex ring 42. The upper surface of the bottom truncated cone 41 of the final forging die is provided with a forming protrusion 43. The upper end face of the forming protrusion 43 is a stepped surface. The center of the bottom truncated cone 41 of the final forging die is provided with a die core mounting hole. The second convex ring 42 is disposed on the bottom truncated cone 41 of the final forging die. The second convex ring 42 is provided with three fan-shaped forming grooves 44 evenly distributed along the circumference of the convex ring. The second convex ring 42 is also provided with a semi-circular groove 45.

[0047] The depth of the fan-shaped forming groove 44 is greater than the depth of the fan-shaped initial forming groove 25, and the groove wall of the fan-shaped forming groove 44 is symmetrically provided with inner grooves.

[0048] The mold core 5 includes a first frustum 51, a second frustum 52, and a third frustum 53 arranged sequentially from bottom to top. The first frustum 51, the second frustum 52, and the third frustum 53 have interconnected central holes. The diameter of the second frustum 52 is smaller than the diameter of the first frustum 51, and the diameter of the third frustum 53 is smaller than the diameter of the second frustum 52. The mold core mounting hole at the center of the bottom frustum 41 of the final forging die is a two-stage stepped hole. The outer diameters of the first frustum 51 and the second frustum 52 are both in close contact with the wall of the mold core mounting hole. The diameter of the third frustum 53 is smaller than the diameter of the mold core mounting hole, and the two frustums form the bottom cavity of the top seat.

[0049] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the invention. Therefore, any equivalent variations made in accordance with the claims of the present invention are still within the scope of the present invention.

Claims

1. A forging process for an air spring top mount in an air suspension system, characterized in that, The air spring top seat is forged from aluminum alloy bar stock, and the specific forging process is as follows: S1. Heat the aluminum alloy bar to 530-560℃ at a rate of 1.5mm / min. S2. The heated aluminum alloy bar is fed into the pre-forging mold for pre-forging. The pre-forged product is demolded using a mixture of release agent and water to obtain the rough product. The pre-forging die includes a pre-forging upper die and a pre-forging lower die. The pre-forging upper die has a pre-forging upper die cavity. A pre-forging boss is provided at the center of the pre-forging upper die cavity. A first groove is provided on the end face of the cavity wall of the pre-forging upper die cavity. A first U-shaped groove is provided on the cavity wall of the pre-forging upper die cavity. The first U-shaped groove is located below the first groove and the top of the first U-shaped groove is flush with the bottom of the first groove. The pre-forging die includes a bottom truncated cone and a first convex ring. The upper surface of the bottom truncated cone is provided with a pre-formed protrusion, and the center of the bottom truncated cone is provided with a central through hole. The first convex ring is disposed on the bottom truncated cone of the pre-forging die, and the first convex ring is provided with three fan-shaped initial forming grooves evenly distributed along the circumference of the first convex ring. S3. The pre-forged rough product is sent to the final forging die for final forging. The final forged product is demolded using a mixture of release agent and water. The final forging die includes an upper final forging die, a lower final forging die, and a die core, wherein the die core is disposed inside the lower final forging die; The final forging upper die is provided with a final forging upper die cavity, the center of the final forging upper die cavity is provided with a final forging boss, the end face of the cavity wall of the final forging upper die cavity is provided with a second groove, the cavity wall of the final forging upper die cavity is provided with a second U-shaped groove, the second U-shaped groove is located below the second groove, and the top of the second U-shaped groove is flush with the bottom of the second groove. The final forging die includes a bottom truncated cone and a second convex ring. The upper surface of the bottom truncated cone is provided with a forming protrusion. The upper end face of the forming protrusion is a stepped surface. The center of the bottom truncated cone is provided with a die core mounting hole. The second convex ring is set on the bottom truncated cone. The second convex ring is provided with three fan-shaped forming grooves evenly distributed along the circumference of the second convex ring. The second convex ring is also provided with a semi-circular groove. The mold core includes a first frustum, a second frustum, and a third frustum arranged sequentially from bottom to top, and the first frustum, the second frustum, and the third frustum are provided with interconnected central holes at their centers; The ratio of release agent to water in S2 and S3 is 1:40; S4. The finished product is obtained by punching, trimming and shaping the final forged product.

2. The forging process of the air spring top seat of an air suspension system according to claim 1, characterized in that, The height of the final forging boss is greater than the height of the pre-forging boss.

3. The forging process of the air spring top seat of an air suspension system according to claim 1, characterized in that, The depth of the fan-shaped forming groove is greater than the depth of the fan-shaped initial forming groove, and the groove wall of the fan-shaped forming groove is symmetrically provided with inner grooves.

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