A hinge beam double-station die forging forming die and method for a hinge type six-sided top press

Abstract

The present invention relates to a hinge beam double-station die forging forming die and method for a hinge type six-sided top press. Among them, the hinge beam double-station die forging forming die includes a lower die assembly and a double-station upper die assembly. The lower die assembly includes an outer sleeve, and an inner sleeve is installed inside the outer sleeve. The inner sleeve includes a cross-shaped base and four inserts. The four inserts are evenly distributed at four gap positions around the periphery of the cross-shaped base. The double-station upper die assembly includes a rough forging upsetting rod, a finish forging upsetting rod and a blind hole punch. The rough forging upsetting rod includes a rough forging upsetting rod connecting plate and a rough forging cross-shaped upsetting rod. The top of the rough forging cross-shaped upsetting rod is fixedly connected to the rough forging upsetting rod connecting plate. The finish forging upsetting rod and the blind hole punch include a finish forging upsetting rod and a blind hole punch connecting plate, a finish forging cross-shaped upsetting rod and a blind hole punch. The top of the finish forging cross-shaped upsetting rod is fixedly connected to the finish forging upsetting rod and the blind hole punch connecting plate, and a blind hole punch is installed at the center of the bottom. The present invention can greatly reduce the manufacturing cost and manufacturing difficulty of the hinge beam die forging forming die.

Description

Technical Field

[0001] The present invention relates to the technical field of die forging forming dies and methods, and particularly to a hinge beam double-station die forging forming die and method for a hinge type six-sided top press. Background Art

[0002] Chinese Patent Publication No. CN107414003A discloses a forging die for a large hinge beam and its production process, wherein: the forging die for the large hinge beam is composed of a forging die lower die and an upper die assembly; the forging die lower die is composed of a bottom die assembly and a lower die assembly located on the bottom die assembly; the bottom die assembly is composed of a die cushion, a bottom die, large and small ear inserts, and a lower die insert; the lower die assembly is composed of a die body and an upper die insert, and the upper die insert is arranged above the lower die insert and fixed to the die body; the upper die assembly is composed of an upper flat die, an outer punch, and an inner punch; a cutting knife is movably inserted through the side surface of the large and small ear inserts; the cutting knife includes a large ear cutting knife and a small ear cutting knife that are perpendicular to each other. In addition, the invention also discloses a production process for a large hinge beam, including the following steps: Step 1: Load the blank into a forging heating furnace and heat it to 1180°C - 1220°C, then place it into the forging die; Step 2: Start the main hydraulic cylinder connected to the upper die assembly to make the upper die assembly perform a preliminary stamping on the blank; start the secondary hydraulic cylinder connected to the inner punch to punch the blank; after the inner punch stamps, start the main hydraulic cylinder again, and the outer punch expands the blank; the inner punch and the outer punch alternately stamp until the blank is processed into an extrusion blank; Step 3: Start the hydraulic cylinder in contact with the small ear cutting knife to make the small ear cutting knife perform side pressing on the extrusion blank to process the small ear; Step 4: Separate the upper die assembly from the forging die lower die, rotate the forging die lower die by 90°, and then close the upper die assembly and the forging die lower die; Step 7: Start the hydraulic cylinder in contact with the large ear cutting knife to make the large ear cutting knife perform side pressing on the extrusion blank to process the large ear; Step 8: Separate the upper die assembly from the forging die lower die, move the forging die lower die out; separate the lower die assembly from the bottom die assembly; take out the forging, and then the hinge beam is obtained. However, the structures of both the forging die lower die and the upper die assembly of this invention are relatively complex and difficult to manufacture. At the same time, the production process of this hinge beam is also relatively cumbersome and lengthy, and the production efficiency is low. Summary of the Invention

[0003] The technical problems solved by the present invention are: how to optimize the existing hinge beam die with complex structure to greatly reduce the overall manufacturing difficulty; how to streamline the die forging production process of the existing hinge beam to greatly improve the production efficiency and reduce the production cost.

[0004] To solve the above technical problems, a hinge beam double-station die forging forming die of a hinge type six-sided top press provided by the present invention includes a lower die assembly and a double-station upper die assembly. The lower die assembly includes an outer sleeve and an inner sleeve. The inner sleeve is installed inside the outer sleeve. The inner sleeve includes a cross-shaped base and four inserts. The four inserts are evenly distributed at four gap positions around the periphery of the cross-shaped base. The double-station upper die assembly includes a rough forging upsetting rod, a finish forging upsetting rod, and a blind hole punch. The rough forging upsetting rod includes a rough forging upsetting rod connecting plate and a rough forging cross-shaped upsetting rod. The top of the rough forging cross-shaped upsetting rod is tightly connected to the rough forging upsetting rod connecting plate. The finish forging upsetting rod and the blind hole punch include a finish forging upsetting rod and a blind hole punch connecting plate, a finish forging cross-shaped upsetting rod, and a blind hole punch. The top of the finish forging cross-shaped upsetting rod is tightly connected to the finish forging upsetting rod and the blind hole punch connecting plate, and the blind hole punch is fixedly installed at the center of the bottom.

[0005] By adopting a split-type lower die assembly including an outer sleeve and an inner sleeve, a split-type inner sleeve including a cross-shaped base and four inserts, a split-type double-station upper die assembly including a rough forging upsetting rod, a finish forging upsetting rod, and a blind hole punch, a split-type rough forging upsetting rod including a rough forging upsetting rod connecting plate and a rough forging cross-shaped upsetting rod, and a split-type finish forging upsetting rod and blind hole punch including a finish forging upsetting rod and a blind hole punch connecting plate, a finish forging cross-shaped upsetting rod, and a blind hole punch, the present invention maximally reduces the manufacturing difficulty and manufacturing cost of the hinge beam die forging forming die.

[0006] Specifically, due to the complex structure and geometric contour of the hinge beam, the geometric contour of the overall forming surface of the corresponding hinge beam forging die is also relatively complex. In addition, during the entire die forging process, the forces on different parts of the complex forming surface and the friction between them and the steel ingot billet are quite different. If an integrated lower die assembly is used to integrally cast or forge the complex forming surface, not only will the shaping process be difficult, but only one metal material and one forming process can be selected to complete the process. In other words, the integrated lower die assembly cannot select different materials and suitable forming processes for the different force-bearing parts of the complex forming surface. In response to this technical problem, the present invention, based on the characteristics of different forces on each part of the lower die assembly during the die forging process, separately sets the part of the integrated lower die assembly that is subject to less friction and compressive stress and has a more complex forming surface during the entire die forging process as a cross-shaped base, and separately sets the part that is subject to complex forces and has a greater friction with the steel ingot billet as four inserts. Among them, the cross-shaped base can be cast using low-temperature alloy cast steel. Since low-temperature alloy cast steel has high static strength, impact toughness and high fatigue limit, good hardenability, high creep strength and endurance strength at high temperature, and long-term working temperature can reach 500°C, the cross-shaped base can be guaranteed to work stably for a long time during high-temperature and high-pressure die forging. The four inserts can be manufactured by forging a whole cylinder with hot working die steel and then gas cutting out four inserts with a 90-degree fan-shaped column shape. Since hot working die steel has high high-temperature strength, high thermal stability, excellent thermal fatigue resistance, good toughness, high hardenability, good thermal conductivity and good wear resistance, the four inserts can be guaranteed to work stably for a long time in a high-temperature and high-pressure die forging environment and during repeated contact and friction with the high-temperature steel ingot blank. In addition, when the four inserts fail due to long-term wear, only the four inserts need to be replaced, and there is no need to replace the cross-shaped base. If an integrated lower die assembly is used, the entire lower die assembly needs to be replaced. As can be seen from the above, the use of a split inner sleeve including a cross-shaped base and four inserts not only reduces the manufacturing difficulty of the lower mold assembly, but also saves manufacturing costs.

[0007] Similarly, compared with the integrated upper die assembly, the split double-station upper die assembly's rough forging upsetting rod, finish forging upsetting rod, and blind hole punch also have the technical effects of reducing manufacturing difficulty and saving production costs. For example: In the present invention, the rough forging upsetting rod is set as a split structure including a rough forging upsetting rod connecting plate and a rough forging cruciform upsetting rod. When the rough forging cruciform upsetting rod is worn out and fails due to long-term use, only the rough forging cruciform upsetting rod needs to be replaced, without replacing the entire rough forging upsetting rod. If an integrated upper die assembly is used, the entire upper die assembly needs to be replaced. Another example: In the present invention, the finish forging upsetting rod and the blind hole punch are set as a split structure including a finish forging upsetting rod and blind hole punch connecting plate, a finish forging cruciform upsetting rod, and a blind hole punch. When the blind hole punch is worn out and fails due to the strong friction during the die forging process over a long time, only the blind hole punch needs to be replaced, without replacing the entire finish forging upsetting rod and blind hole punch. If an integrated upper die assembly is used, the entire upper die assembly needs to be replaced.

[0008] Further, the cross-shaped base has an outer shape of a cross-shaped hinge ear forming support pillar. On the four hinge ear forming inclined surfaces inside the cross-shaped hinge ear forming support pillar, there are hinge ear clearance lower die rib plates. The insert block has an outer shape of a 90-degree sector cylinder. The four 90-degree sector cylinders are respectively tightly installed in the four 90-degree interval void positions between the cross-shaped hinge ear forming support pillars. The four outer arc surfaces of the four 90-degree sector cylinders and the four outer arc surfaces of the cross-shaped hinge ear forming support pillar are combined to form a 360-degree outer circle surface. The height of the 90-degree sector cylinder is greater than the height of the cross-shaped hinge ear forming support pillar.

[0009] The position of the hinge ear clearance lower die rib plate arranged in the inner cavity of the cross-shaped base corresponds to the gap position between the hinge beam hinge ears. The hinge ear clearance lower die rib plate can not only achieve near-net shaping of the forging but also improve the overall strength of the cross-shaped base.

[0010] Further, on the four hinge ear forming support pillar planes at the bottom of the finish forging cruciform upsetting rod, there are finish forging hinge ear clearance upper die rib plates.

[0011] The finish forging hinge ear clearance upper die rib plate arranged at the bottom of the finish forging cruciform upsetting rod corresponds to the gap position between the hinge beam hinge ears. The finish forging hinge ear clearance upper die rib plate can not only achieve near-net shaping of the forging but also improve the overall strength of the finish forging cruciform upsetting rod.

[0012] Further, draft angles are provided on both the internal forming surface of the lower die assembly and the external forming surface of the upper die assembly.

[0013] Specifically, the draft angles of both the internal forming surface of the lower die assembly and the external forming surface of the upper die assembly are set to have an angle α of 1 - 3 degrees with the vertical direction.

[0014] Furthermore, the two cross-shaped sides of the cross-shaped base are provided with forging allowance compensation inclined surfaces that extend outward from the root to the top.

[0015] During die forging, it is difficult to fill the rounded corners on both sides of the top of the cross-shaped hinge ear forming strut of the cross-shaped base. Therefore, forging allowance compensation inclined surfaces are provided at this position to increase the forging allowance here and compensate for the dimensional error problem of the cross-shaped hinge ear forming of the hinge beam caused by the difficulty in filling the forging rounded corners.

[0016] Specifically, the inclination angle β of the forging allowance compensation inclined surface is 3-7 degrees.

[0017] The forging allowance compensation inclined surface is formed by inclining outward from the two cross-shaped sides. Furthermore, the inclination angle β of the forging allowance compensation inclined surface is the included angle of the forging allowance compensation inclined surface relative to the cross-shaped side surface in the non-inclined state.

[0018] Furthermore, the cross-shaped base is formed by casting with ZG35CrMo material.

[0019] Since the cross-shaped base is less affected by friction during the entire die forging process, its load is mostly compressive stress, and the structure is relatively complex, it is preferably cast with ZG35CrMo material.

[0020] Furthermore, the insert block is formed by forging with 5CrNiMo.

[0021] Although the insert block is subjected to relatively complex forces and has a large frictional force with the blank during the entire die forging process, the structure of the insert block is simple. Therefore, it is preferably forged with 5CrNiMo material.

[0022] Furthermore, the four 90-degree sector cylinders are made by evenly cutting a forged cylinder at intervals of 90 degrees, which can further reduce the manufacturing difficulty.

[0023] Furthermore, the rough forging upsetting rod, the finish forging upsetting rod, the blind hole punch connecting plate, and the finish forging cross-shaped upsetting rod are all made of chromium molybdenum steel material, and the blind hole punch is made of 5CrNiMo.

[0024] Since the rough forging upsetting rod, the finish forging upsetting rod, the blind hole punch connecting plate, and the finish forging cross-shaped upsetting rod in the two sets of upper die assemblies in the double-station are not significantly affected by friction during the entire die forging process, it is preferably made of ordinary chromium molybdenum steel material. And since the blind hole punch is subjected to relatively strong friction, it is made of 5CrNiMo die steel material with higher hardness, which can not only reduce costs but also facilitate the replacement of the blind hole punch after wear.

[0025] To solve the above technical problems, the present invention also provides a double-station die forging forming method for the hinge beam of a hinge-type six-sided top press. Based on the double-station die forging forming die for the hinge beam of the hinge-type six-sided top press as described in any one of the above preferences, a die forging forming process using a die-cast steel ingot is adopted, including the following steps:

[0026] Step 1: Place the steel ingot with the riser cut off in the middle of the lower die assembly and move it to the center of the press;

[0027] Step 2: Perform an in-die rough forging upsetting process on the steel ingot in the lower die assembly through the rough forging upsetting rod of the double-station upper die assembly. When the rough forging upsetting reaches the designed rough forging machining allowance, withdraw the rough forging upsetting rod from the lower die assembly;

[0028] Step 3: Move the finish forging upsetting rod and the blind hole punch of the double-station upper die assembly to the center of the press, and synchronously perform a finish forging upsetting and blind hole punching process on the steel ingot in the lower die assembly that has been processed by the rough forging upsetting process through the finish forging upsetting rod and the blind hole punch. When the finish forging upsetting and blind hole punching process reaches the designed finish forging and blind hole punching machining allowance, withdraw the finish forging upsetting rod and the blind hole punch from the lower die assembly;

[0029] Step 4: Eject the hinge beam die forging formed part in the lower die assembly through the ejector cylinder at the bottom of the lower die assembly, and remove the scale in the inner cavity of the lower die assembly.

[0030] The double-process die forging forming technical solution of the hinge beam of the present invention realizes the processing and manufacturing of the hinge beam through the cooperation of a large press, a split upper and lower die assembly design, and a reasonable die forging forming process. According to practical verification, the material utilization rate of the hinge beam forging can be increased by 21%, and the manufacturing difficulty and production cost can be greatly reduced.

[0031] On the one hand, the present invention minimizes the manufacturing cost and difficulty of the overall die by setting a split upper and lower die. At the same time, for the easily worn structural parts during the die forging process, die steel materials with higher hardness are used for forming, and for the structural parts with less stress and complex structures, castings are used. Applying the double-station die forging forming die and die forging forming process of the present invention to process and manufacture the hinge beam only requires one heat treatment to complete the entire forming process. In addition, the present invention can further compact the shrinkage cavity in the core of the steel ingot through the three-phase compressive stress formed during the die forging process by using an ultra-large press, thereby replacing the upsetting and drawing process in the existing process. At the same time, through Step 3, the finishing and punching processes are combined and synchronized, which can effectively avoid the problem of blind hole punching deviation. Description of the Drawings

[0032] Figure 1 It is a three-dimensional view of a preferred embodiment of the double-station die forging forming die for the hinge beam of the present invention.

[0033] Figure 2 The Figure 1 top view of the lower die assembly in the illustrated embodiment.

[0034] Figure 3 is Figure 2 the perspective view of the A-A sectional view of the lower die assembly in the illustrated embodiment.

[0035] Figure 4 is Figure 2 the A-A sectional view of the lower die assembly in the illustrated embodiment.

[0036] Figure 5 Figure 2 the perspective view of the B-B sectional view of the lower die assembly in the illustrated embodiment.

[0037] Figure 6 is Figure 1 the perspective view of a preferred embodiment of the inner sleeve one of the lower die assembly in the illustrated embodiment.

[0038] Figure 7 is Figure 6 the top view of the illustrated embodiment.

[0039] Figure 8 is Figure 6 the perspective view of a preferred embodiment of the cross-shaped base in the illustrated embodiment.

[0040] Figure 9 is Figure 8 the front view of the illustrated embodiment.

[0041] Figure 10 is Figure 8 the top view of the illustrated embodiment.

[0042] Figure 11 is Figure 1 the bottom view of a preferred embodiment of the rough forging upsetting rod of one of the double-station upper die assemblies in the illustrated embodiment.

[0043] Figure 12 is Figure 1 the front view of a preferred embodiment of the finish forging upsetting rod and the blind hole punch of the second of the double-station upper die assemblies in the illustrated embodiment.

[0044] Figure 13 is Figure 1 the bottom view of a preferred embodiment of the finish forging upsetting rod and the blind hole punch of the second of the double-station upper die assemblies in the illustrated embodiment.

[0045] Figure 14 is the schematic diagram of the die forging forming process of a preferred embodiment of the hinge beam double-station die forging forming method of the present invention.

[0046] Figure 15 is the perspective view of the hinge beam.

[0047] Description of the reference numerals:

[0048] 1 - Lower die assembly; 1.1 - Outer sleeve; 1.2 - Inner sleeve; 1.2.1 - Cross-shaped base; 1.2.1.1 - Lower die rib plate for hinge ear clearance; 1.2.1.2 - Forging allowance compensation inclined plane; 1.2.2 - Insert block; 2 - Rough forging upsetting rod; 2.1 - Connecting plate of rough forging upsetting rod; 2.2 - Rough forging cross-shaped upsetting rod; 3 - Fine forging upsetting rod and blind hole punch; 3.1 - Connecting plate of fine forging upsetting rod and blind hole punch; 3.2 - Fine forging cross-shaped upsetting rod; 3.2.1 - Upper die rib plate for fine forging hinge ear clearance; 3.3 - Blind hole punch; 4 - Hinge beam; 5 - Ingot. Detailed implementation manners

[0049] To make the above objects, features and advantages of the present invention more obvious and understandable, the following detailed description of the specific embodiments of the present invention will be given with reference to the accompanying drawings.

[0050] In the description of the present invention, it should be noted that the term nouns in each embodiment, such as "upper", "lower", "front", "rear", "left", "right", etc., which indicate directions, are only used to simplify the description of the positional relationship based on the drawings in the specification, and do not represent that the indicated elements and devices, etc. must operate according to the specific directions and limited operations, methods, and structures in the specification. Such directional nouns do not constitute a limitation to the present invention.

[0051] A hinge beam double-station die forging forming die of a hinge type six-sided top press provided by an embodiment of the present invention, as Figures 1 - 13 shown, includes a lower die assembly 1 and a double-station upper die assembly. The lower die assembly 1 includes an outer sleeve 1.1 and an inner sleeve 1.2. The inner sleeve 1.2 is installed in the outer sleeve 1.1. The inner sleeve 1.2 includes a cross-shaped base 1.2.1 and four insert blocks 1.2.2. The four insert blocks 1.2.2 are evenly distributed at four gap positions around the cross-shaped base 1.2.1. The double-station upper die assembly includes a rough forging upsetting rod 2 and a fine forging upsetting rod and blind hole punch 3. The rough forging upsetting rod 2 includes a connecting plate 2.1 of the rough forging upsetting rod and a rough forging cross-shaped upsetting rod 2.2. The top of the rough forging cross-shaped upsetting rod 2.2 is tightly connected to the connecting plate 2.1 of the rough forging upsetting rod. The fine forging upsetting rod and blind hole punch 3 includes a connecting plate 3.1 of the fine forging upsetting rod and blind hole punch, a fine forging cross-shaped upsetting rod 3.2, and a blind hole punch 3.3. The top of the fine forging cross-shaped upsetting rod 3.2 is tightly connected to the connecting plate 3.1 of the fine forging upsetting rod and blind hole punch, and the blind hole punch 3.3 is fixedly installed at the center of the bottom.

[0052] In this embodiment, by adopting a split-type lower die assembly 1 including an outer sleeve 1.1 and an inner sleeve 1.2, a split-type inner sleeve 1.2 including a cross-shaped base 1.2.1 and four inserts 1.2.2, a split-type double-station upper die assembly including a rough forging upsetting rod 2, a finish forging upsetting rod and a blind hole punch 3, a split-type rough forging upsetting rod 2 including a rough forging upsetting rod connecting plate 2.1 and a rough forging cross-shaped upsetting rod 2.2, and a split-type finish forging upsetting rod and blind hole punch 3 including a finish forging upsetting rod and blind hole punch connecting plate 3.1, a finish forging cross-shaped upsetting rod 3.2 and a blind hole punch 3.3, the manufacturing difficulty and manufacturing cost of the hinge beam die forging forming die are reduced to the greatest extent.

[0053] Specifically, due to the relatively complex structure and geometric contour of the hinge beam, the geometric contour of the overall forming surface of the corresponding hinge beam forging die is also relatively complex. In addition, during the entire die forging process, the forces exerted on different parts of the complex forming surface and the friction between the parts and the steel ingot 5 blank are quite different. If an integrated lower die assembly is used to integrally cast or forge the complex forming surface, not only will the molding process be difficult, but only one metal material and one forming process can be selected to complete the process. In other words, the integrated lower die assembly cannot select different materials and suitable forming processes for the different force-bearing parts of the complex forming surface. In response to this technical problem, the present invention, based on the characteristics of different forces exerted on each part of the lower die assembly 1 during the die forging process, separately sets the part of the integrated lower die assembly that is subjected to less friction and compressive stress and has a more complex forming surface during the entire die forging process as a cross-shaped base 1.2.1, and separately sets the part that is subjected to complex forces and has a greater friction between the parts and the steel ingot blank as four inserts 1.2.2. Among them, the cross-shaped base 1.2.1 can be cast using low-temperature alloy cast steel. Since low-temperature alloy cast steel has high static strength, impact toughness and high fatigue limit, good hardenability, high creep strength and endurance strength at high temperatures, and a long-term working temperature of up to 500°C, it can ensure that the cross-shaped base 1.2.1 can work stably for a long time during the high-temperature and high-pressure die forging process; and the four inserts 1.2.2 can be manufactured by using hot-working die steel to forge a whole cylinder and then gas-cut out four inserts with a 90-degree fan-shaped cylinder shape. Since hot working die steel has high high temperature strength, high thermal stability, excellent thermal fatigue resistance, good toughness, high hardenability, good thermal conductivity and good wear resistance, it can ensure that the four inserts 1.2.2 can work stably for a long time in a high temperature and high pressure die forging environment and in the process of repeated contact and friction with the high temperature steel ingot 5 billet. When the four inserts 1.2.2 fail due to long-term wear and tear, only the four inserts 1.2.2 need to be replaced, and there is no need to replace the cross-shaped base 1.2.1. If an integrated lower die assembly is used, the entire lower die assembly needs to be replaced. From the above, it can be seen that the use of a split inner sleeve 1.2 including the cross-shaped base 1.2.1 and the four inserts 1.2.2 not only reduces the manufacturing difficulty of the hinge beam die forging forming die, but also saves manufacturing costs.

[0054] Similarly, compared with the integral upper die assembly, the rough forging upsetting rod 2, the finish forging upsetting rod, and the blind hole punch 3 of the split double-station upper die assembly also have the technical effects of reducing the manufacturing difficulty and saving production costs. For example: in this embodiment, the rough forging upsetting rod 2 is arranged as a split structure including a rough forging upsetting rod connecting plate 2.1 and a rough forging cross-shaped upsetting rod 2.2. When the rough forging cross-shaped upsetting rod 2.2 fails due to wear after long-term use, only the rough forging cross-shaped upsetting rod 2.2 needs to be replaced, without replacing the entire rough forging upsetting rod 2. If an integral upper die assembly is used, the entire upper die assembly needs to be replaced. Another example: in this embodiment, the finish forging upsetting rod and the blind hole punch 3 are arranged as a split structure including a finish forging upsetting rod and blind hole punch connecting plate 3.1, a finish forging cross-shaped upsetting rod 3.2, and a blind hole punch 3.3. When the blind hole punch 3.3 fails due to severe friction and wear during the die forging process after long-term use, only the blind hole punch 3.3 needs to be replaced, without replacing the entire finish forging upsetting rod and the blind hole punch 3. If an integral upper die assembly is used, the entire upper die assembly needs to be replaced.

[0055] Optionally, as Figures 1 - 10 shown, the outer shape of the cross-shaped base 1.2.1 is a cross-shaped hinge ear forming support column. On the four hinge ear forming inclined surfaces inside the cross-shaped hinge ear forming support column, there are hinge ear clearance lower die ribs 1.2.1.1. The outer shape of the insert block 1.2.2 is a 90-degree sector column. The four 90-degree sector columns are respectively tightly installed in the four 90-degree interval gaps between the cross-shaped hinge ear forming support columns. The four outer arc surfaces of the four 90-degree sector columns are combined with the four outer arc surfaces of the cross-shaped hinge ear forming support column to form a 360-degree outer circle surface. The height of the 90-degree sector column is greater than the height of the cross-shaped hinge ear forming support column.

[0056] In this embodiment, the position of the hinge ear clearance lower die ribs 1.2.1.1 arranged in the inner cavity of the cross-shaped base 1.2.1 corresponds to the gap position between the hinge ears of the hinge beam 4. The hinge ear clearance lower die ribs 1.2.1.1 can not only achieve near-net shaping of the forging but also improve the overall strength of the cross-shaped base 1.2.1.

[0057] Optionally, as Figure 1 、 Figure 12 and Figure 13 shown, on the four hinge ear forming support column planes at the bottom of the finish forging cross-shaped upsetting rod 3.2, there are finish forging hinge ear clearance upper die ribs 3.2.1.

[0058] In this embodiment, the position of the finish forging hinge ear clearance upper die ribs 3.2.1 arranged at the bottom of the finish forging cross-shaped upsetting rod 3.2 corresponds to the gap position between the hinge ears of the hinge beam 4. The finish forging hinge ear clearance upper die ribs 3.2.1 can not only achieve near-net shaping of the forging but also improve the overall strength of the finish forging cross-shaped upsetting rod 3.2.

[0059] Optionally, as shown in Figure 4 , Figure 5 , Figure 9 and Figure 12 , draft angles are provided on both the inner forming surface of the lower die assembly 1 and the outer forming surface of the upper die assembly.

[0060] Specifically, as shown in Figure 4 , Figure 5 , Figure 9 and Figure 12 , the draft angles of both the inner forming surface of the lower die assembly 1 and the outer forming surface of the upper die assembly are set to an angle α of 1 - 3 degrees with respect to the vertical direction.

[0061] Optionally, as shown in Figure 10 , the two cross - shaped sides of the cross - shaped base 1.2.1 are provided with forging allowance compensation inclined surfaces 1.2.1.2 that extend outward from the root to the top.

[0062] In this embodiment, since the two rounded corners at the top of the cross - shaped hinge forming struts of the cross - shaped base 1.2.1 are not easily filled during die forging, forging allowance compensation inclined surfaces 1.2.1.2 are provided at this position to increase the forging allowance here and compensate for the dimensional error problem of the cross - shaped hinge forming of the hinge beam 4 caused by the unfilled forging rounded corners.

[0063] Specifically, as shown in Figure 10 , the inclination angle β of the forging allowance compensation inclined surface 1.2.1.2 is 3 - 7 degrees.

[0064] In this embodiment, the forging allowance compensation inclined surface 1.2.1.2 is formed by inclining outward through the two cross - shaped sides. Furthermore, the inclination angle β of the forging allowance compensation inclined surface 1.2.1.2 is the included angle of the forging allowance compensation inclined surface 1.2.1.2 with respect to the cross - shaped side in the non - inclined state.

[0065] Optionally, as shown in Figures 8 - 10 , the cross - shaped base 1.2.1 is formed by casting with ZG35CrMo material.

[0066] In this embodiment, since the cross - shaped base 1.2.1 is less affected by friction during the entire die forging process, its load is mostly compressive stress, and the structure is relatively complex, it is preferably cast with ZG35CrMo material.

[0067] Optionally, as shown in Figures 2 - 7 , the insert 1.2.2 is formed by forging with 5CrNiMo.

[0068] In this embodiment, although the insert block 1.2.2 is subject to relatively complex forces and has a large frictional force with the blank during the entire die forging process, the structure of the insert block 1.2.2 is simple. Therefore, it is preferably forged from 5CrNiMo material.

[0069] Optionally, as Figures 2 - 7 shown, the four 90-degree sector cylinders are made by evenly cutting a forged cylinder at intervals of 90 degrees, which can further reduce the manufacturing difficulty.

[0070] Optionally, as Figure 1 、 Figures 11 - 13 shown, the rough forging upsetting rod 2, the finish forging upsetting rod, the blind hole punch connecting plate 3.1, and the finish forging cross-shaped upsetting rod 3.2 are all made of chromium molybdenum steel, and the blind hole punch 3.3 is made of 5CrNiMo.

[0071] In this embodiment, since the rough forging upsetting rod 2, the finish forging upsetting rod, the blind hole punch connecting plate 3.1, and the finish forging cross-shaped upsetting rod 3.2 in the two sets of upper die assemblies of the double working positions are not significantly affected by friction during the entire die forging process, they are preferably made of ordinary chromium molybdenum steel. And since the blind hole punch 3.3 is subject to relatively strong friction, it is made of 5CrNiMo die steel with a higher hardness. In this way, the cost can be reduced, and it is also convenient to replace the blind hole punch 3.3 after wear.

[0072] The embodiment of the present invention also provides a hinge-type six-sided top press hinge beam double working position die forging forming method. Based on any of the above preferred hinge-type six-sided top press hinge beam double working position die forging forming dies, as Figure 14 and Figure 15 shown, a die casting ingot die forging forming process is adopted, including the following steps:

[0073] Step 1: Place the ingot 5 with the riser cut off in the middle of the lower die assembly 1 and move it to the center of the press;

[0074] Step 2: Perform an in-die rough forging upsetting process on the ingot in the lower die assembly 1 through the rough forging upsetting rod 2 of the double working position upper die assembly. When the rough forging upsetting reaches the designed rough forging machining allowance, withdraw the rough forging upsetting rod 2 from the lower die assembly 1;

[0075] Step 3: Move the finish forging upsetting rod and the blind hole punch 3 of the double working position upper die assembly to the center of the press, and synchronously perform a finish forging upsetting and blind hole punching process on the ingot in the lower die assembly 1 that has been processed by the rough forging upsetting process through the finish forging upsetting rod and the blind hole punch 3. When the finish forging upsetting and blind hole punching process reaches the designed finish forging and blind hole punching machining allowance, withdraw the finish forging upsetting rod and the blind hole punch 3 from the lower die assembly 1;

[0076] Step 4: Push out the hinge beam die forging formed part in the lower die assembly 1 through the ejector cylinder at the bottom of the lower die assembly 1 to remove the scale in the inner cavity of the lower die assembly 1.

[0077] The technical solution of the double-process die forging of the hinge beam in the present invention realizes the processing and manufacturing of the hinge beam 4 through a large press in cooperation with the design of split upper and lower die assemblies and a reasonable die forging process. According to practical verification, the material utilization rate of the forged hinge beam 4 can be increased by 21%, greatly reducing the manufacturing difficulty and production cost.

[0078] On the one hand, the present invention sets split upper and lower dies to minimize the manufacturing cost and difficulty of the overall die. At the same time, the wear-prone structural parts in the die forging process are made of die steel with higher hardness, and for the structural parts with less force and complex structures, castings are used. Using the double-station die forging die and die forging process of the present invention to process and manufacture the hinge beam 4, the entire forming process can be completed in only one heat treatment. In addition, the present invention can further compact the shrinkage cavity in the core of the ingot 5 through the triaxial compressive stress formed during the die forging process by using an extra-large press, thus replacing the upsetting and drawing process in the existing process. At the same time, through Step 3, the finishing and punching processes are combined and synchronized, effectively avoiding the problem of blind hole punching deviation.

[0079] Although the present invention discloses the above preferred embodiments, the present invention is not limited thereto. Those skilled in the art can make various permutations and combinations of the above preferred embodiments without departing from the spirit and scope of the present invention and form a complete technical solution. The protection scope of the present invention shall be subject to the scope defined by the claims.

Claims

1. A hinge - type six - sided top press hinge beam double - station die - forging forming die, characterized in that it includes a lower die assembly (1) and a double - station upper die assembly. The lower die assembly (1) includes an outer sleeve (1.1) and an inner sleeve (1.2). The inner sleeve (1.2) is installed inside the outer sleeve (1.1). The inner sleeve (1.2) includes a cross - shaped base (1.2.1) and four inserts (1.2.2). The four inserts (1.2.2) are evenly distributed at four void positions around the periphery of the cross - shaped base (1.2.1). The double - station upper die assembly includes a rough - forging upsetting rod (2) and a fine - forging upsetting rod and a blind - hole punch (3.3). The rough - forging upsetting rod (2) includes a rough - forging upsetting rod connecting plate (2.1) and a rough - forging cross - shaped upsetting rod (2.2). The top of the rough - forging cross - shaped upsetting rod (2.2) is tightly connected to the rough - forging upsetting rod connecting plate (2.1). The fine - forging upsetting rod and blind - hole punch (3.3) includes a fine - forging upsetting rod and blind - hole punch connecting plate (3.1), a fine - forging cross - shaped upsetting rod (3.2), and a blind - hole punch (3.3). The top of the fine - forging cross - shaped upsetting rod (3.2) is tightly connected to the fine - forging upsetting rod and blind - hole punch connecting plate (3.1), and the blind - hole punch (3.3) is fixedly installed at the center of the bottom. The outer shape of the cross - shaped base (1.2.1) is a cross - shaped hinge - ear forming support column, and on the four hinge - ear forming inclined surfaces inside the cross - shaped hinge - ear forming support column, there are hinge - ear clearance lower die rib plates ( 1.2.1.1), the insert block (1.2.2) is in the shape of a 90-degree sector cylinder. The four 90-degree sector cylinders are respectively tightly installed in the four 90-degree interval gaps between the cross-shaped hinge ear forming struts. The four outer arc surfaces of the four 90-degree sector cylinders and the four outer arc surfaces of the cross-shaped hinge ear forming struts are combined to form a 360-degree outer circle surface. The height of the 90-degree sector cylinder is greater than the height of the cross-shaped hinge ear forming strut. On the four hinge ear forming strut planes at the bottom of the precision forging cross-shaped upset rod (3.2), there are precision forging hinge ear clearance upper die rib plates (3.2.1). The inner forming surface of the lower die assembly (1) and the outer forming surface of the upper die assembly are both provided with draft angles. The two cross-shaped sides of the cross-shaped base (1.2.1) are set as forging allowance compensation inclined surfaces (1.2.1.2) that extend outward from the root to the top. The four 90-degree sector cylinders are made by evenly cutting a forged cylindrical body at 90-degree intervals.

2. The hinge beam double-station die forging forming die of the hinge type six-sided top press according to claim 1, characterized in that, The cross-shaped base (1.2.1) is formed by casting with ZG35CrMo material.

3. The hinge beam double-station die forging forming die of the hinge type six-sided top press according to claim 1, characterized in that, The insert block (1.2.2) is formed by forging with 5CrNiMo.

4. The hinge beam double-station die forging forming die of the hinge type six-sided top press according to claim 1, characterized in that The rough forging upset rod (2), the precision forging upset rod and blind hole punch connecting plate (3.1), and the precision forging cross-shaped upset rod (3.2) are all made of chrome molybdenum steel material. The blind hole punch (3.3) is made of 5CrNiMo.

5. A double-station die forging forming method for the hinge beam of a hinge type six-sided top press, based on the double-station die forging forming die for the hinge beam of a hinge type six-sided top press according to any one of claims 1-4, characterized in that, Adopt the die-casting ingot die forging forming process, including the following steps: Step 1: Place the ingot (5) with the riser cut off in the middle of the lower die assembly (1) and move it to the center of the press; Step 2: Carry out the in-die rough forging upset process on the ingot in the lower die assembly (1) through the rough forging upset rod (2) of the double-station upper die assembly. When the rough forging upset reaches the designed rough forging machining allowance, withdraw the rough forging upset rod (2) from the lower die assembly (1); Step 3: Move the precision forging upset rod and blind hole punch (3.3) of the double-station upper die assembly to the center of the press. Synchronously carry out the precision forging upset and blind hole punching processes on the ingot in the lower die assembly (1) that has been processed by the rough forging upset process through the precision forging upset rod and blind hole punch (3.3). When the precision forging upset and blind hole punching processes reach the designed precision forging and blind hole punching machining allowance, withdraw the precision forging upset rod and blind hole punch (3.3) from the lower die assembly (1); Step 4: Eject the hinge beam die forging in the lower die assembly (1) through the ejector cylinder at the bottom of the lower die assembly (1), and remove the scale in the inner cavity of the lower die assembly (1).

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