U-shaped support precision forging forming process and bending machine

Abstract

The present application relates to the technical field of die forging forming, and discloses a U-shaped support precision forging forming process, which comprises the following steps: synchronously forging two L-shaped blank pieces by a forging die; the forging of the L-shaped blank piece comprises forging a flow guide groove of a bottom flat surface part of the forging and a forging inverted pull; the bottom flat surface part of the L-shaped forging is positioned, the inflection point of the finished product U-shaped forging is taken as a bending point, online hot bending is carried out through a hydraulic bending machine, the hot bending temperature is 650-850 DEG C, and the U-shaped forging is formed. Through the design of the L-shaped forging, direct forging forming is facilitated, and the troubles of multiple forging forming or bottom surface milling are avoided. The process has the advantages of short production process, one die for two pieces, high production efficiency, long die service life, stable production quality, 3-5% improvement of product production material utilization rate, 50% improvement of production efficiency, and 98% of product quality pass rate.

Description

Technical Field

[0001] This invention relates to the field of die forging technology, specifically to a U-shaped bracket precision forging forming process and bending machine. Background Technology

[0002] Typical bracket products are symmetrical components, while U-shaped forgings belong to the category of spatial bending forgings. The bottom plane of the forging has a guide groove, and the inner side of the head forms an angle with the inner side of the plate, resulting in a backward draft. For this type of U-shaped forging, regardless of the angle of the product, it is impossible to directly design a mold for parting, let alone obtain the product required by the drawing through forging. Therefore, existing U-shaped forgings are often formed through multiple processing steps.

[0003] The existing U-shaped die forging process includes: (first forging) blanking → heating → billet making → forging pre-formed billet → trimming → flash removal → shot blasting; (second forging) heating → pre-forging → precision forging → trimming → shot blasting. This type of product is generally a symmetrical part, requiring four forging processes, resulting in low production efficiency, high manufacturing costs, and high mold costs. The long production process and high turnover frequency are detrimental to on-time product delivery, leading to low production line utilization, a large workforce, and high energy consumption. The mold parting surface follows a U-shape, resulting in low mold material utilization. Furthermore, the mold experiences concentrated heat during production, hindering cooling and resulting in a short mold lifespan. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a U-shaped bracket precision forging forming process and bending machine, which has the advantages of short process flow, high production efficiency, long mold life, and stable production quality.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a U-shaped bracket precision forging forming process, comprising: simultaneously forging two L-shaped blanks by a forging die, wherein the forging die is designed to rotate and tilt at an angle of 32° to 75° during the forging of the L-shaped blanks;

[0006] The forged L-shaped blank includes the guide groove on the bottom plane of the forging and the forging back drawing;

[0007] Trim the edges of the forging to determine its preliminary shape;

[0008] Position the bottom plane of the L-shaped forging, and use the inflection point of the U-shaped forging to be finished as the bending point. Perform online hot bending using a hydraulic bending machine at a temperature of 650-850℃ to form a U-shaped forging.

[0009] The formed U-shaped forging is further shot-blasted to obtain a finished U-shaped support precision forging.

[0010] Preferably, the L-shaped cavity design process of the forging die is as follows:

[0011] The forging is rotated and unfolded using the corner of the U-shaped original as a fulcrum;

[0012] The curved sections are compensated according to the bending development calculation method to transform the U-shape into an L-shape.

[0013] Design the forging die cavity using an L-shaped part;

[0014] The cavity of the forging die is designed to rotate and tilt at an angle of 32° to 75°, which facilitates the demolding of the finished product after forging.

[0015] Symmetrical arrangement of forging dies is beneficial for die design, reduces die thickness, lowers die processing difficulty, reduces displacement forces during forging, and prevents the risk of early die breakage.

[0016] Preferably, the forging process of the L-shaped part is as follows:

[0017] 1) Heat the billet; the heating temperature of the steel batching is 800-1200℃.

[0018] 2) The heated billet is placed in a symmetrically arranged forging die, and the billet is forged into shape by a press through the forging die;

[0019] 3) Remove the two forged L-shaped forgings by demolding;

[0020] 4) Trim the edges of the forging to determine its preliminary shape.

[0021] Preferably, the final forging temperature of the L-shaped forging is not less than 800°C.

[0022] Preferably, the bending process of the L-shaped forging is as follows:

[0023] 1) Preheat the two hot-forged L-shaped forgings to a temperature of 650-850℃;

[0024] 2) Place the two hot-forged L-shaped forgings on the positioning support blocks on both sides of the hydraulic bending machine;

[0025] 3) Fix the bottom plane of the L-shaped forging, control the push plate of the hydraulic bending machine to move downward, and control the push block to squeeze the L-shaped forging, pressing and fixing the rod part of the L-shaped forging. At this time, the bending inflection point of the L-shaped forging is located at the corner of the positioning support block of the hydraulic bending machine, and the part to be bent outside the bending inflection point of the L-shaped forging is suspended.

[0026] 4) Control the roller to move vertically downwards, bend the L-shaped forging with the roller, and bend the L-shaped forging in the unfolded state to obtain the U-shaped forging.

[0027] Preferably, the outer side of the bent head of the L-shaped forging is parallel to the displacement direction of the roller.

[0028] Preferably, the positioning support block of the bending machine is adapted to the size and shape of the formed U-shaped forging. The top of the positioning support blocks on both sides is inclined inward. The symmetrical design of the positioning support blocks on both sides facilitates the adjustment of bending force during bending. The horizontal bending pressure on both sides cancels each other out, which facilitates the bending processing of L-shaped forgings.

[0029] A bending machine includes a worktable. A pad is fixedly connected to the top of the worktable, a reference block is fixedly connected to the top of the pad, a guide plate is fixedly connected to the back of the reference block, and a wedge block is provided on the outside of the pad. A support column is fixedly connected to the top of the worktable, a hydraulic cylinder support plate is fixedly connected to the top of the support column, a main hydraulic cylinder and an auxiliary hydraulic cylinder are fixedly connected to the top of the hydraulic cylinder support plate, a main hydraulic cylinder connecting rod is fixedly connected to the bottom of the main hydraulic cylinder, a push block is fixedly connected to the bottom of the main hydraulic cylinder connecting rod, a roller shaft is provided inside the push block, a roller is rotatably connected to the outside of the roller shaft, a guide slider is provided on the outside of the guide plate, a stroke scale A is fixedly connected to the outside of the guide slider, a stroke scale B is fixedly connected to the outside of the push block, an auxiliary hydraulic cylinder connecting column is fixedly connected to the bottom of the auxiliary hydraulic cylinder, a push plate is fixedly connected to the bottom of the auxiliary hydraulic cylinder connecting column, a working pressure gauge is provided on the outside of the auxiliary hydraulic cylinder connecting column, and an operation panel, a power distribution box, and an oil storage tank are installed on the outside of the worktable.

[0030] Preferably, the reference blocks are symmetrically arranged on both sides of the pad, the rollers are located between the two reference blocks, two sets of rollers are provided, and the inner sides of the push block are symmetrically arranged, the push block and the push plate are movably connected.

[0031] Preferably, the bottom of the push plate is provided with a pressure block adapted to the reference block, and the pressure block is used to fix the L-shaped forging under pressure.

[0032] Beneficial effects:

[0033] 1. The U-shaped bracket precision forging forming process and bending machine, through the design of L-shaped forging, facilitates direct forging and avoids the trouble of multiple forging or bottom milling. This process has a short production flow, produces two parts in one mold, has high production efficiency, long mold life, stable production quality, increases material utilization rate by 3% to 5%, increases production efficiency by 50%, and achieves a product quality qualification rate of 98%.

[0034] 2. The U-shaped bracket precision forging forming process and bending machine utilizes an L-shaped forging die cavity design. The left and right parts are designed with symmetrical die distribution based on die strength design elements. This includes determining the parting line and balancing the locking mechanism to improve the die's resistance to displacement. Symmetrical arrangement of the forging dies facilitates die design, reduces die thickness, lowers die processing difficulty, reduces misalignment forces during forging, and prevents the risk of early die breakage.

[0035] 3. The U-shaped bracket precision forging forming process and bending machine uses the bottom plane of the converted L-shaped forging as the clamping part in the bending process. It is designed with symmetrical forming rollers on both sides and uses hydraulic equipment to perform online hot bending of the product, simultaneously clamping the two symmetrical parts. Through the vertical movement of the forming rollers, the two products are symmetrically clamped and bent, realizing the restoration of the forging from the L-shaped state to the original U-shaped state. It effectively reduces the displacement and surface scratches during the bending process. The mold cost of this process is low, the production efficiency is matched with the machine, and high-temperature hot bending will not generate residual stress. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the bending process of the L-shaped forging of the present invention;

[0037] Figure 2 This is a schematic diagram of the L-shaped forging of the present invention;

[0038] Figure 3 This is a schematic diagram of the U-shaped forging of the present invention;

[0039] Figure 4 This is a schematic diagram of the bending machine assembly of the present invention;

[0040] Figure 5 This is a front view schematic diagram of the bending machine of the present invention;

[0041] Figure 6 This is a side view schematic diagram of the bending machine of the present invention.

[0042] In the diagram: 1. Workbench; 2. Pad; 3. Reference block; 4. Guide plate; 5. Wedge block; 6. Support column; 7. Cylinder support plate; 8. Main cylinder; 9. Auxiliary cylinder; 10. Main cylinder connecting rod; 11. Push block; 12. Roller shaft; 13. Roller; 14. Guide slider; 15. Stroke scale A; 16. Stroke scale B; 17. Auxiliary cylinder connecting column; 18. Push plate; 19. Working pressure gauge; 20. Control panel; 21. Electrical distribution box; 22. Workbench; 23. Oil storage tank. Detailed Implementation

[0043] The technical solutions of 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.

[0044] Example 1

[0045] Please see Figure 1-3A precision forging process for a U-shaped bracket includes: simultaneously forging two L-shaped blanks using a forging die; during the forging of the L-shaped blanks, the forging die is designed to rotate and tilt at an angle of 32°.

[0046] The forged L-shaped blank includes the guide groove on the bottom plane of the forging and the forging back drawing;

[0047] Trim the edges of the forging to determine its preliminary shape;

[0048] The bottom plane of the L-shaped forging is positioned, and the inflection point of the U-shaped forging to be finished is used as the bending point. The U-shaped forging is then hot-bent online using a hydraulic bending machine at a temperature of 650℃ to form the U-shaped forging.

[0049] The formed U-shaped forging is further shot-blasted to obtain a finished U-shaped support precision forging.

[0050] Example 2

[0051] Please see Figure 1-3 A precision forging process for a U-shaped bracket includes: simultaneously forging two L-shaped blanks using a forging die; during the forging of the L-shaped blanks, the forging die is designed to rotate and tilt at an angle of 32°.

[0052] The forged L-shaped blank includes the guide groove on the bottom plane of the forging and the forging back drawing;

[0053] Trim the edges of the forging to determine its preliminary shape;

[0054] The bottom plane of the L-shaped forging is positioned, and the inflection point of the U-shaped forging to be finished is used as the bending point. The U-shaped forging is then hot-bent online using a hydraulic bending machine at a temperature of 650℃ to form the U-shaped forging.

[0055] The formed U-shaped forging is further shot-blasted to obtain a finished U-shaped support precision forging.

[0056] The design process for the L-shaped cavity of the forging die is as follows:

[0057] The left and right parts are symmetrically distributed to eliminate the misalignment force of the die during the forging process and reduce the risk of early die breakage. The corner of the U-shaped original is used as a fulcrum to rotate and unfold the forging, transforming the U into an L-shape.

[0058] Design the forging die cavity using an L-shaped part;

[0059] Using "UG" software, the forging is rotated to ensure that the bottom plane guide groove of the forging can be formed and can be demolded. The rotation angle is determined to be 32°.

[0060] The design of the support arm is carried out according to the plate bending process parameters to complete the design of the forgeable state.

[0061] The left and right parts are designed according to the mold strength design elements, and the mold is designed to be symmetrically distributed, the parting line is determined, and the locking buckle is balanced to improve the mold's ability to resist displacement.

[0062] Symmetrical arrangement of forging dies facilitates die design, reduces die thickness, lowers die machining difficulty, reduces misalignment forces during forging, and prevents the risk of early die breakage. Calculate the cross-sectional changes of the forging along its length to design a reasonable billet-making process.

[0063] The forging process for L-shaped parts is as follows:

[0064] S1. Heat the billet to a temperature of 1200℃.

[0065] S2. Place the heated billet in a symmetrically arranged forging die, and forge the billet into shape using a press.

[0066] S3. Demold the two forged L-shaped forgings and remove them from the die.

[0067] S4. Trim the edges of the forging to determine its preliminary shape.

[0068] The final forging temperature of the L-shaped forging shall not be less than 800℃.

[0069] This process has a short production flow, produces two parts from one mold, has high production efficiency, long mold life, stable production quality, increases material utilization by 3% to 5%, increases production efficiency by 50%, and achieves a product quality pass rate of 98%.

[0070] Example 3

[0071] Please see Figure 1-3 A precision forging process for a U-shaped bracket includes: simultaneously forging two L-shaped blanks using a forging die; during the forging of the L-shaped blanks, the forging die is designed to rotate and tilt at an angle of 32°.

[0072] The forged L-shaped blank includes the guide groove on the bottom plane of the forging and the forging back drawing;

[0073] Trim the edges of the forging to determine its preliminary shape;

[0074] The bottom plane of the L-shaped forging is positioned, and the inflection point of the U-shaped forging to be finished is used as the bending point. The U-shaped forging is then hot-bent online using a hydraulic bending machine at a temperature of 650℃ to form the U-shaped forging.

[0075] The formed U-shaped forging is further shot-blasted to obtain a finished U-shaped support precision forging.

[0076] The design process for the L-shaped cavity of the forging die is as follows:

[0077] The left and right parts are symmetrically distributed to eliminate the misalignment force of the die during the forging process and reduce the risk of early die breakage. The corner of the U-shaped original is used as a fulcrum to rotate and unfold the forging, transforming the U-shape into an L-shape.

[0078] Design the forging die cavity using an L-shaped part;

[0079] Using "UG" software, the forging is rotated to ensure that the bottom plane guide groove of the forging can be formed and can be demolded. The rotation angle is determined to be 32°.

[0080] The design of the support arm is carried out according to the plate bending process parameters to complete the design of the forgeable state.

[0081] The left and right parts are designed according to the mold strength design elements, and the mold is designed to be symmetrically distributed, the parting line is determined, and the locking buckle is balanced to improve the mold's ability to resist displacement.

[0082] Symmetrical arrangement of forging dies facilitates die design, reduces die thickness, lowers die machining difficulty, reduces misalignment forces during forging, and prevents the risk of early die breakage. Calculate the cross-sectional changes of the forging along its length to design a reasonable billet-making process.

[0083] The forging process for L-shaped parts is as follows:

[0084] S1. Heat the billet to a temperature of 1200℃.

[0085] S2. Place the heated billet in a symmetrically arranged forging die, and forge the billet into shape using a press.

[0086] S3. Demold the two forged L-shaped forgings and remove them from the die.

[0087] S4. Trim the edges of the forging to determine its preliminary shape.

[0088] The final forging temperature of the L-shaped forging shall not be less than 800℃.

[0089] Based on sheet metal bending theory, the single-angle bending process changes the traditional bending die design concept. The bottom plane of the converted L-shaped forging is used as the clamping point during the bending process. Symmetrical forming rollers are designed, and hydraulic equipment is used for online hot bending of the product, simultaneously clamping the two symmetrical parts. Through the vertical movement of the forming rollers, the two products are symmetrically clamped and bent, realizing the restoration of the forging from the L-shape to the original U-shape. This effectively reduces the displacement and surface scratches during the bending process. The die cost of this process is low, the production efficiency matches the machine, and hot bending at 850℃ will not generate residual stress.

[0090] The specific process for bending L-shaped forgings is as follows:

[0091] H1. Preheat the two hot-forged L-shaped forgings to 850°C.

[0092] H2. Place the two hot-forged L-shaped forgings on the positioning support blocks on both sides of the hydraulic bending machine;

[0093] H3. Fix the bottom plane of the L-shaped forging, control the push plate of the hydraulic bending machine to move downward, and control the push block to squeeze the L-shaped forging, pressing and fixing the rod part of the L-shaped forging. At this time, the bending inflection point of the L-shaped forging is located at the corner of the positioning support block of the hydraulic bending machine, and the part to be bent outside the bending inflection point of the L-shaped forging is suspended.

[0094] H4. Control the roller to move vertically downwards, and bend the L-shaped forging. The L-shaped forging in the unfolded state is bent to obtain a U-shaped forging.

[0095] In this case, the outer side of the head of the L-shaped forging after bending is parallel to the displacement direction of the roller.

[0096] The positioning support block of the bending machine is adapted to the size and shape of the U-shaped forging. The top of the positioning support blocks on both sides is inclined inward. The symmetrical design of the positioning support blocks on both sides facilitates the adjustment of bending force during bending. The horizontal bending pressure on both sides cancels each other out, which facilitates the bending process of L-shaped forgings.

[0097] Example 4

[0098] refer to Figure 4-5 A bending machine includes a worktable 1, a pad 2 fixedly connected to the top of the worktable 1, a reference block 3 fixedly connected to the top of the pad 2, a guide plate 4 fixedly connected to the back of the reference block 3, a wedge block 5 disposed on the outside of the pad 2, a support column 6 fixedly connected to the top of the worktable 1, a hydraulic cylinder support plate 7 fixedly connected to the top of the support column 6, a main hydraulic cylinder 8 and a secondary hydraulic cylinder 9 fixedly connected to the top of the hydraulic cylinder support plate 7, a main hydraulic cylinder connecting rod 10 fixedly connected to the bottom of the main hydraulic cylinder 8, and a push block 11 fixedly connected to the bottom of the main hydraulic cylinder connecting rod 10. The workbench 1 has an internal roller shaft 12, and an external roller 13 is rotatably connected to the external roller shaft 12. The external guide plate 4 has a guide slider 14, and the external guide slider 14 has a fixed stroke scale A15. The external push block 11 has a fixed stroke scale B16. The bottom of the auxiliary oil cylinder 9 has a fixed auxiliary oil cylinder connecting column 17, and the bottom of the auxiliary oil cylinder connecting column 17 has a fixed push plate 18. The external auxiliary oil cylinder connecting column 17 has a working pressure gauge 19. The external workbench 1 has an operation panel 20, a power distribution box 21, and an oil storage tank 23.

[0099] Among them, the reference blocks 3 are symmetrically arranged on both sides of the pad plate 2, and the rollers 13 are located between the two reference blocks 3. There are two sets of rollers 13, which are symmetrically arranged on both sides of the inside of the push block 11. The push block 11 and the push plate 18 are movably connected.

[0100] The bottom of the push plate 18 is provided with a pressure block that is adapted to the reference block 3. The pressure block is used to fix the L-shaped forging under pressure.

[0101] When bending L-shaped forgings, two L-shaped forgings are placed on top of the reference block 3. The auxiliary oil cylinder 9 controls the auxiliary oil cylinder connecting column 17 to move downward. The auxiliary oil cylinder connecting column 17 controls the push plate 18 to move downward. The push plate 18 presses the L-shaped forgings with the pressure block.

[0102] The main hydraulic cylinder 8 controls the push block 11 to move downward through the main hydraulic cylinder connecting rod 10. The push block 11 controls the roller 13 to move downward, and the roller 13 bends the L-shaped forging to perform bending.

[0103] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A precision forging process for U-shaped brackets, characterized in that, include: Two L-shaped blanks are forged simultaneously using a forging die. The design process of the L-shaped cavity of the forging die is as follows: the corner of the U-shaped original is used as a fulcrum to rotate and unfold the forging; the bent part is compensated according to the bending unfolding calculation method to transform the U-shape into an L-shape. The forging die cavity is designed using L-shaped forgings, and the cavity design of the forging die has a rotation tilt angle of 32° to 75°, with the forging dies arranged symmetrically. The forged L-shaped blank includes the guide groove on the bottom plane of the forging and the forging back drawing; Trim the edges of the forging to determine its preliminary shape; The bottom plane of the L-shaped forging is positioned, and the bending point of the U-shaped forging to be finished is used as the bending point. The bending process of the L-shaped forging is as follows: 1) Preheat two hot-forged L-shaped forgings to a temperature of 650-850℃; 2) Place the two hot-forged L-shaped forgings on the positioning support blocks on both sides of the bending machine; 3) Fix the bottom plane of the L-shaped forgings, control the push plate of the bending machine to move downwards, and control the push block to squeeze the L-shaped forgings, pressing and fixing the rod part of the L-shaped forgings. At this time, the bending inflection point of the L-shaped forgings is located at the corner of the positioning support block of the bending machine, and the part to be bent outside the bending inflection point of the L-shaped forgings is suspended; 4) Control the roller to move vertically downwards, and the roller bends the L-shaped forgings, bending the L-shaped forgings in the unfolded state to obtain the U-shaped forgings. The formed U-shaped forging is further shot-blasted to obtain a finished U-shaped structure bracket precision forging.

2. The U-shaped bracket precision forging forming process according to claim 1, characterized in that: The forging process of the L-shaped forging is as follows: 1) Heat the billet; the heating temperature of the steel batching is 800-1200℃. 2) The heated billet is placed in symmetrically arranged forging dies, and the billet is forged into shape by a press and forging dies; 3) Remove the two forged L-shaped forgings by demolding; 4) Trim the edges of the forging to determine its preliminary shape.

3. The U-shaped bracket precision forging forming process according to claim 2, characterized in that: The final forging temperature of the L-shaped forging is not less than 800℃.

4. The U-shaped bracket precision forging forming process according to claim 1, characterized in that: The outer side of the head of the L-shaped forging after bending is parallel to the displacement direction of the roller.

5. The U-shaped bracket precision forging forming process according to claim 1, characterized in that: The positioning support block of the bending machine is adapted to the size and shape of the formed U-shaped forging, and the top of the positioning support blocks on both sides is inclined inward.

6. The U-shaped bracket precision forging forming process according to claim 1, 2, 3, 4, or 5, characterized in that: The bending machine for L-shaped forgings includes a worktable (1), a pad (2) fixedly connected to the top of the worktable (1), a reference block (3) fixedly connected to the top of the pad (2), a guide plate (4) fixedly connected to the back of the reference block (3), a wedge block (5) provided on the outside of the pad (2), a support column (6) fixedly connected to the top of the worktable (1), a cylinder support plate (7) fixedly connected to the top of the support column (6), a main cylinder (8) and an auxiliary cylinder (9) fixedly connected to the top of the cylinder support plate (7), a main cylinder connecting rod (10) fixedly connected to the bottom of the main cylinder (8), and a push block (11) fixedly connected to the bottom of the main cylinder connecting rod (10). 11) is equipped with a roller shaft (12) inside, and a roller (13) is rotatably connected to the outside of the roller shaft (12). A guide slider (14) is provided on the outside of the guide plate (4). A stroke scale A (15) is fixedly connected to the outside of the guide slider (14). A stroke scale B (16) is fixedly connected to the outside of the push block (11). A secondary oil cylinder connecting column (17) is fixedly connected to the bottom of the secondary oil cylinder (9). A push plate (18) is fixedly connected to the bottom of the secondary oil cylinder connecting column (17). A working pressure gauge (19) is provided on the outside of the secondary oil cylinder connecting column (17). An operation panel (20), a power distribution box (21), and an oil storage tank (23) are installed on the outside of the workbench (1).

7. The U-shaped bracket precision forging forming process according to claim 6, characterized in that: The reference blocks (3) are symmetrically arranged on both sides of the pad (2), and the rollers (13) are located between the two reference blocks (3). There are two sets of rollers (13), which are symmetrically arranged on both sides of the inside of the push block (11). The push block (11) and the push plate (18) are movably connected.

8. The U-shaped bracket precision forging forming process according to claim 7, characterized in that: The bottom of the push plate (18) is provided with a pressure block that is adapted to the reference block (3), and the pressure block is used to fix the L-shaped forging under pressure.

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