Linkage type forging die

Abstract

The application discloses a linkage type forging die, which is provided with an upper die base, a lower die base, a guide piece and a linkage structure, the lower end surface of the upper die base is provided with an upper forging groove facing downward, a forging upper die is fixedly arranged in the upper forging groove, the lower end surface of the forging upper die is provided with a first die cavity facing downward, the upper end surface of the lower die base is provided with a lower forging groove facing downward, a forging lower die is movably arranged in the lower forging groove, the upper end surface of the forging lower die is provided with a second die cavity facing upward, and the linkage structure drives the forging lower die to move upward while the upper die base moves downward, so as to be combined with the forging upper die to forge a bent workpiece. In the application, the linkage structure drives the forging lower die to move upward while the upper die base moves downward, so as to be combined with the forging upper die to forge the bent workpiece, the opposite movement of the forging upper die and the forging lower die realizes bidirectional forging of the bent workpiece, the active forging of two sides of the bent workpiece further enhances the forging effect, and the forging times are reduced.

Description

Technical Field

[0001] This invention relates to the field of forging die technology, and specifically to a linkage forging die. Background Technology

[0002] Forging is a processing method that uses forging machinery to apply pressure to metal billets, causing them to undergo plastic deformation to obtain forgings with certain mechanical properties, shapes, and dimensions. Forging machinery includes forging hammers, mechanical presses, hydraulic presses, screw presses, and flat forging machines for forming, as well as auxiliary machinery such as uncoilers, straighteners, shearing machines, and forging manipulators.

[0003] Among them, the screw press is a machine that uses a descending screw die to press and deform metal materials. In the forging process, the metal material is first heated to a certain temperature to make it soft and easy to shape. Then, the metal material is placed in the center of the press, and the various parameters of the press are adjusted. Finally, the motor is turned on, and the screw begins to rotate, pressing and deforming the metal material.

[0004] During the pressing process, the screw rotates continuously, generating strong pressure to press the metal material into the required shape and size. Existing screw presses usually apply force from top to bottom for forging. The forging action on the metal material also causes the lower surface of the metal material to act on the lower forging die. However, the interaction between the lower surface of the metal material and the lower forging die is passive, resulting in poor forging effect. Therefore, it is necessary to repeat the process many times to forge the metal material into the ideal product. Summary of the Invention

[0005] To address this issue, the present invention provides a linkage forging die, which effectively solves the problem in the prior art where the lower surface of the metal material is passively pressed onto the lower forging die, and the interaction between the lower surface of the metal material and the lower forging die is passive, resulting in poor forging effect.

[0006] To solve the above-mentioned technical problems, the present invention specifically provides the following technical solution: a linkage forging die, comprising:

[0007] The upper die base has a downward-facing upper forging groove on its lower end face. A forging upper die is fixedly installed in the upper forging groove. A downward-facing first die cavity is opened on the lower end face of the forging upper die. A screw press is installed on the upper die base.

[0008] The lower die base has a downward-facing lower forging groove on its upper end face. A forging lower die is movably disposed in the lower forging groove. A second die cavity facing upward is opened on the upper end face of the forging lower die. The second die cavity and the first die cavity together form a forging cavity for forging and shaping a bent workpiece.

[0009] A guide member is disposed through the upper mold base and the lower mold base, and the guide member is used to limit the movement of the upper mold base towards the lower mold base along the length direction of the guide member;

[0010] A linkage structure is provided inside the lower die holder. The linkage structure drives the lower forging die to move upward while the upper die holder moves downward, so as to work together with the upper forging die to forge the bent workpiece.

[0011] Furthermore,

[0012] The height of the upper end face of the forging die is not higher than the height of the upper surface of the die base;

[0013] The thickness of the lower forging groove is greater than the height of the lower forging die.

[0014] Furthermore,

[0015] The linkage structure includes a connecting motor disposed in the lower mold base and a screw rod disposed at the output end of the connecting motor;

[0016] The bottom of the forging die is provided with a spiral groove, the spiral rod cooperates with the spiral groove, the upper end of the spiral rod is connected to a limiting block, the lower forging die is also provided with a limiting groove, the limiting block is movably disposed in the limiting groove, and the outer diameter of the limiting block is larger than the outer diameter of the spiral rod.

[0017] Furthermore,

[0018] The guide component includes a guide post disposed on the upper mold base and a guide groove disposed on the lower mold base;

[0019] The guide post is directly opposite the guide groove, and the outer diameter of the guide post is the same as the inner diameter of the guide groove.

[0020] Furthermore,

[0021] The bottom of the lower forging groove is provided with a mounting slot, the mounting slot is provided with an electromagnetic coil, and the bottom of the forging die is provided with a magnetic base, which is movably disposed in the mounting slot.

[0022] A control circuit is connected to the electromagnetic coil, and a switch is provided on the control circuit.

[0023] Furthermore,

[0024] The guide component includes a guide post disposed on the upper mold base and a guide groove disposed on the lower mold base;

[0025] The guide post is directly opposite the guide groove and the outer diameter of the guide post is the same as the inner diameter of the guide groove. A guide head is provided at the bottom of the guide post, and the guide head is shaped like a frustum.

[0026] The guide post is retractable.

[0027] Furthermore,

[0028] The linkage structure includes a horizontal groove and a vertical groove disposed in the lower mold base, a lifting cylinder seat disposed in the vertical groove, and a transmission column disposed in the lifting cylinder seat;

[0029] One end of the transmission column is provided with a first engaging block, and the other end of the transmission column is provided with a second engaging edge. The first engaging block engages with the side edge of the guide head.

[0030] Furthermore,

[0031] The horizontal groove and the vertical groove are connected. A lifting column is provided in the vertical groove. A hydraulic cylinder is connected to the bottom of the lifting column. A connecting cylinder is sleeved on the lifting column. The connecting cylinder is connected to the bottom of the lifting cylinder seat. A connecting spring is provided between the lifting column and the connecting cylinder.

[0032] The bottom of the lifting cylinder seat is directly connected to the connecting cylinder, the top of the lifting column is connected to a triangular block, and the bottom of the transmission column is provided with a triangular groove along the length direction, and the triangular block fits into the triangular groove.

[0033] Furthermore, the bottom side of the forging die is provided with a first inclined edge, which engages with the second mating edge;

[0034] An ejector is provided in the lower die of forging. The ejector is a Z-shaped structure. A second inclined edge is provided at the bottom of the ejector. The second inclined edge is parallel to the first inclined edge and is directly above the first inclined edge. The second inclined edge and the second mating edge are mated.

[0035] The forging die is provided with a connecting groove and an ejector groove. The ejector groove is Z-shaped. The width of the horizontal groove in the ejector groove is greater than the width of the ejector. When the bottom of the ejector is disengaged from the connecting groove, the middle position of the ejector just abuts against the inner wall of the horizontal groove in the ejector groove.

[0036] At least two ejector slots and ejector components are provided. The connecting slot is connected to the ejector slot. The top of the ejector slot is connected to the lower forging slot and the top of the ejector component is flush with the top of the ejector slot. The ejector component is vertically disposed in the lower forging die, and the transmission column slides in the connecting slot.

[0037] Furthermore, the screw press includes a mounting frame disposed on the upper die base, a drive motor disposed on the mounting frame, and a rotating screw disposed on the drive motor;

[0038] The rotating screw is connected to the output end of the drive motor, and the upper mold base has a threaded groove that mates with the rotating screw.

[0039] Compared with the prior art, the present invention has the following advantages:

[0040] In this invention, the linkage structure moves the upper die base downward while simultaneously driving the lower forging die upward, so that it can work together with the upper forging die to forge the bent workpiece. The opposing movements of the upper and lower forging dies achieve bidirectional forging of the bent workpiece. The active forging effect on both sides of the bent workpiece further enhances the forging effect and reduces the number of forging operations. Attached Figure Description

[0041] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0042] Figure 1 A flowchart of a casting-forging coupling forming method for an aluminum alloy rear control arm provided in an embodiment of the present invention;

[0043] Figure 2 A data table comparing the mechanical properties of cast-forged coupled and forged aluminum alloy rear control arms;

[0044] Figure 3 This is a front view of the casting blank;

[0045] Figure 4 This is a top view of the casting blank;

[0046] Figure 5 A schematic diagram of a linkage structure provided in an embodiment of the present invention, using the second embodiment;

[0047] Figure 6 This is a schematic diagram of a forging die in which the lower forging die is driven upward under the downward pressure of a guide member, according to an embodiment of the present invention.

[0048] Figure 7 This is a schematic diagram of a structure in which the lifting cylinder seat and transmission column are moved upward in a forging die according to an embodiment of the present invention;

[0049] Figure 8 for Figure 7 A schematic diagram of a structure in which the guide member presses down and drives the ejector member to be ejected outward;

[0050] Figure 9This is a schematic diagram of a triangular block moving upward and locking transmission column in a forging die, provided by an embodiment of the present invention;

[0051] Figure 10 This is a partial structural diagram of the linkage structure in an embodiment of the present invention;

[0052] Figure 11 This is a schematic diagram of the cross-sectional structure of the linkage structure in an embodiment of the present invention;

[0053] Figure 12 The linkage structure in this embodiment of the invention is a schematic diagram of the first embodiment;

[0054] Figure 13 for Figure 12 A schematic diagram of the combined structure of the upper and lower forging dies.

[0055] The labels in the diagram represent the following:

[0056] 1- Casting blank; 2- Screw press; 3- Upper die holder; 4- Lower die holder; 5- Guide component; 6- Linkage structure; 7- Forging cavity; 8- Ejector component;

[0057] 21-Mounting bracket; 22-Drive motor; 23-Rotating screw;

[0058] 31-Upper forging groove; 32-Upper forging die; 33-First die cavity;

[0059] 41-Lower forging groove; 42-Lower forging die; 43-Second die cavity; 44-Mounting slot; 45-Electromagnetic coil; 46-Magnetic base; 47-First inclined edge;

[0060] 51-Guide post; 52-Guide groove; 53-Guide head;

[0061] 61-Horizontal groove; 62-Vertical groove; 63-Lifting cylinder seat; 64-Transmission column; 65-First mating block; 66-Second mating edge; 67-Lifting column; 68-Hydraulic cylinder; 69-Connecting cylinder; 610-Connecting spring; 611-Triangular block; 612-Triangular groove; 613-Connecting motor; 614-Screw rod; 615-Screw groove; 616-Limiting block; 617-Limiting groove;

[0062] 81-Second inclined edge; 82-Connecting groove; 83-Top groove. Detailed Implementation

[0063] 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.

[0064] like Figure 5 and Figure 12 As shown, the present invention provides a linkage forging die, comprising:

[0065] The upper die base 3 has a downward-facing upper forging groove 31 on its lower end face. A forging upper die 32 is fixedly installed in the upper forging groove 31. A downward-facing first die cavity 33 is opened on the lower end face of the forging upper die 32. A screw press 2 is installed on the upper die base 3.

[0066] The lower die base 4 has a downward-facing lower forging groove 41 on its upper end face. A forging lower die 42 is movably arranged in the lower forging groove 41. A second die cavity 43 facing upward is opened on the upper end face of the forging lower die 42. The second die cavity 43 and the first die cavity 33 together form a forging cavity 7 for forging and shaping the bent workpiece.

[0067] Guide member 5 is disposed through the upper mold base 3 and the lower mold base 4. Guide member 5 is used to limit the movement of the upper mold base 3 to the lower mold base 4 along the length direction of guide member 5.

[0068] Linkage structure 6 is set inside the lower die base 4. While the upper die base 3 moves downward, linkage structure 6 drives the lower forging die 42 to move upward, so as to forge the bent workpiece in turn with the upper forging die 32.

[0069] In this invention, the linkage structure moves the upper die base downward while simultaneously driving the lower forging die upward, so that it can work together with the upper forging die to forge the bent workpiece. The opposing movements of the upper and lower forging dies achieve bidirectional forging of the bent workpiece. The active forging effect on both sides of the bent workpiece further enhances the forging effect and reduces the number of forging operations.

[0070] In the above embodiments, the forging lower die 42 is movable. The forging dies with transmission are basically forging upper dies 32 for forging. In this invention, the forging lower die 42 can move upward while forging upper dies 32 forging, so as to make the forging effect better. In this invention, the height of the upper end face of the forging lower die 42 is not higher than the height of the upper surface of the lower die base 4, and the thickness of the lower forging groove 41 is greater than the height of the forging lower die 42. That is to say, the upward movement of the forging lower die 42 does not exceed the opening position of the lower forging groove 41, which is the height of the upper surface of the lower die base 4. The forging lower die 42 in this invention is a structure with a small range of movable forging.

[0071] The present invention uses a screw press 2 to drive the upper die holder 3 to move. The screw press 2 adopts the following preferred embodiment: the screw press 2 includes a mounting frame 21 set on the upper die holder 3, a drive motor 22 set on the mounting frame 21, and a rotating screw 23 set on the drive motor 22. The rotating screw 23 is connected to the output end of the drive motor 22. The upper die holder 3 is provided with a threaded groove 24 that cooperates with the rotating screw 23.

[0072] The drive motor 22 drives the rotating screw 23 to rotate, thereby causing the upper mold base 3 to descend.

[0073] In this invention, the linkage structure 6 can drive the forging lower die 42 to perform an upward punching action, thereby forging the lower surface of the bent workpiece. The linkage structure 6 of this invention is provided in two embodiments, the first of which is as follows:

[0074] like Figure 12 and Figure 13 As shown, the linkage structure 6 includes a connecting motor 613 disposed in the lower die base 4 and a spiral rod 614 disposed at the output end of the connecting motor 613; a spiral groove 615 is provided at the bottom of the forging lower die 42, the spiral rod 614 cooperates with the spiral groove 615, a limit block 616 is connected to the upper end of the spiral rod 614, a limit groove 617 is also provided in the forging lower die 42, the limit block 616 is movably disposed in the limit groove 617, and the outer diameter of the limit block 616 is larger than the outer diameter of the spiral rod 614.

[0075] The motor 613 drives the screw rod 614 to rotate, thereby causing the forging die 42 to move upward. Under the limiting action of the limiting block 616 and the limiting groove 617, the upward movement distance of the forging die 42 is limited to a certain range.

[0076] Corresponding to different embodiments of the linkage structure 6, the guide member 5 also has different embodiments. Corresponding to the first embodiment of the linkage structure 6, the guide member 5 adopts the first embodiment, as follows: the guide member 5 includes a guide post 51 disposed on the upper mold base 3 and a guide groove 52 disposed on the lower mold base 4. The guide post 51 is directly opposite the guide groove 52 and the outer diameter of the guide post 51 is the same as the inner diameter of the guide groove 52.

[0077] Corresponding to the second embodiment, the lower forging groove 41 also includes the following structure: a mounting base 44 is provided at the bottom of the lower forging groove 41, an electromagnetic coil 45 is provided in the mounting base 44, a magnetic base 46 is provided at the bottom of the forging lower die 42, the magnetic base 46 is movably disposed in the mounting base 44, a control circuit is connected to the electromagnetic coil 45, and a switch is provided on the control circuit.

[0078] When the electromagnetic coil 45 is energized, the magnetic base 46 is subjected to the magnetic field force inside the mounting slot 44, causing the forging die 42 to be subjected to a vertically downward magnetic force along with the magnetic base 46. Under the action of gravity and magnetic force, the forging die 42 is initially placed at the bottom of the lower forging groove 41. However, due to the presence of the mounting slot 44, the bottom of the forging die 42 is restricted, and the bottom of the forging die 42 does not contact the bottom of the lower forging groove 41.

[0079] The second embodiment of the guide member 5 is as follows: The guide member 5 includes a guide post 51 disposed on the upper mold base 3 and a guide groove 52 disposed on the lower mold base 4; the guide post 51 is directly opposite the guide groove 52 and the outer diameter of the guide post 51 is the same as the inner diameter of the guide groove 52; a guide head 53 is disposed at the bottom of the guide post 51 and the guide head 53 is configured as a frustum.

[0080] In this invention, the guide head 53 is set in the shape of a frustum so that if there is an initial offset between the upper die holder 3 and the lower die holder 4, the guide head 53 can smoothly enter the guide groove 52 and correct the offset during the movement. In addition, it can also cooperate with the linkage structure 6 to realize the ejection of the corresponding ejector 8 and the upward movement of the forging lower die 42.

[0081] In addition, the guide post 51 in this invention is telescopic, so that when the ejector 8 needs to eject the workpiece, the upper mold base 3 does not move down. The downward movement of the guide post 51 directly drives the ejector 8 to eject, thus avoiding the upper mold base 3 from blocking the ejection action of the workpiece.

[0082] In the second embodiment of this invention, when the linkage structure 6 is in the lower position, the downward pressure of the guide member 5 causes the lower forging die 42 to move within the lower forging groove 41 near the upper forging die 32. When the linkage structure 6 is in the upper position, the downward pressure of the guide member 5 causes the ejector 8 to move upward. The linkage structure 6 of this invention adopts the following preferred embodiments, such as... Figure 10 and Figure 11 As shown, the linkage structure 6 includes a horizontal groove 61 and a vertical groove 62 disposed in the lower mold base 4, a lifting cylinder seat 63 disposed in the vertical groove 62, and a transmission column 64 disposed in the lifting cylinder seat 63; a first engaging block 65 is disposed at one end of the transmission column 64, and a second engaging edge 66 is disposed at the other end of the transmission column 64, and the first engaging block 65 engages with the side of the guide head 53.

[0083] As the guide head 53 moves downward, it drives the second mating edge 66 to move toward the forging lower die 42, and drives the transmission column 64 to move toward the forging lower die 42.

[0084] In this invention, the height of the linkage structure 6 is adjustable so that the height of the transmission column 64 can be adjusted. To this end, the invention is designed as follows: the horizontal groove 61 and the vertical groove 62 are connected, a lifting column 67 is provided in the vertical groove 62, a hydraulic cylinder 68 is connected to the bottom of the lifting column 67, a connecting cylinder 69 is sleeved on the lifting column 67, the connecting cylinder 69 is connected to the bottom of the lifting cylinder seat 63, and a connecting spring 610 is provided between the lifting column 67 and the connecting cylinder 69.

[0085] Hydraulic cylinder 68 drives the lifting column 67 to move upward, which in turn drives the connecting cylinder 69 to move upward, and the lifting cylinder seat 63 to move upward or downward. Under the action of connecting spring 610, under normal circumstances, the upward movement of the lifting column 67 can drive the connecting cylinder 69 to move upward. When the upper wall of the lifting cylinder seat 63 is blocked, the connecting cylinder 69 can no longer move upward. At this time, the lifting column 67 can continue to move upward, but the lifting column 67 gradually approaches the lifting cylinder seat 63, and the connecting spring 610 is gradually squeezed.

[0086] In order to control the activity state of the linkage structure 6, the present invention also makes the following design: the bottom of the lifting cylinder seat 63 is directly connected to the connecting cylinder 69, the top of the lifting column 67 is connected to a triangular block 611, and the bottom of the transmission column 64 is provided with a triangular groove 612 along the length direction, and the triangular block 611 fits into the triangular groove 612.

[0087] As the lifting column 67 gradually approaches the lifting cylinder seat 63, the triangular block 611 gradually approaches the triangular groove 612. When the triangular block 611 is engaged in the triangular groove 612, the transmission column 64 cannot move within the lifting cylinder seat 63.

[0088] In order to enable the transmission column 64 to move the forging lower die 42 upward, the present invention is designed as follows: a first inclined edge 47 is provided on the bottom side of the forging lower die 42, and the first inclined edge 47 is engaged with the second mating edge 66.

[0089] An ejector 8 is provided inside the forging die 42. The transmission column 64 can move to drive the ejector 8 to be ejected. The ejector 8 is a Z-shaped structure. A second inclined edge 81 is provided at the bottom of the ejector 8. The second inclined edge 81 is parallel to the first inclined edge 47 and is directly above the first inclined edge 47. The second inclined edge 81 and the second mating edge 66 are mated.

[0090] The lower forging die 42 is provided with a connecting groove 82 and an ejector groove 83. The ejector groove 83 is Z-shaped. The width of the horizontal groove in the ejector groove 83 is greater than the width of the ejector 8. When the bottom of the ejector 8 is removed from the connecting groove 82, the middle position of the ejector 8 just abuts against the inner wall of the horizontal groove in the ejector groove 83. There are at least two ejector grooves 83 and ejector 8. The connecting groove 82 and the ejector groove 83 are connected. The top of the ejector groove 83 is connected to the lower forging groove 41, and the top of the ejector 8 is flush with the top of the ejector groove 83. The ejector 8 is vertically arranged in the lower forging die 42. The transmission column 64 slides in the connecting groove 82.

[0091] The drive column 64 moves toward the inside of the connecting groove 82, causing the ejector 8 to move upward. During the upward movement, the middle position of the ejector 8 gradually abuts against the horizontal inner wall of the ejector groove 83. At this time, the bottom of the ejector 8 just disengages from the connecting groove 82.

[0092] In the second embodiment, the main process by which the guide member 5 drives the ejector member 8 or the forging die 42 to move through the linkage structure 6 is as follows:

[0093] like Figure 5 As shown, in the initial state, the lifting cylinder seat 63 is located at the bottom of the transverse groove 61. The drive motor 22 drives the rotating screw 23 to rotate, thereby causing the upper mold seat 3 to descend. The guide column 51 moves down, causing the guide head 53 to move down, as shown. Figure 6 As shown, during the downward movement of the guide head 53, the second mating edge 66 moves toward the forging lower die 42, and the transmission column 64 moves toward the forging lower die 42. Under the action of the second mating edge 66, the forging lower die 42 moves upward and impacts the forging upper die 32. The downward movement and forging time of the forging upper die 32 and the upward movement time of the forging lower die 42 need to be controlled to be consistent. That is to say, the point at which the downward movement of the forging upper die 32 stops corresponds exactly to the point at which the upward movement of the forging lower die 42 stops. Forging is completed at this point.

[0094] After forging is completed, the drive motor 22 drives the upper die holder 3 to reset. The electromagnetic coil 45 is energized, so that the magnetic seat 46 is subjected to the magnetic force inside the mounting slot 44, so that the lower forging die 42 follows the magnetic seat 46 and is subjected to a vertically downward magnetic force. Under the action of gravity and magnetic force, the lower forging die 42 moves down, so that the transmission column 64 is reset.

[0095] like Figure 7 As shown, hydraulic cylinder 68 drives the lifting column 67 to move upward, which in turn drives the connecting cylinder 69 to move upward, and the lifting cylinder seat 63 to move upward, until the upper wall of the lifting cylinder seat 63 abuts against the inner wall of the transverse groove 61. At this point, the guide column 51 extends downward, as shown. Figure 8As shown, the guide head 53 moves downward, causing the second mating edge 66 to move toward the connecting groove 82, which in turn causes the transmission column 64 to move toward the connecting groove 82. The transmission column 64 moves toward the inside of the connecting groove 82, causing the ejector 8 to move upward and eject the workpiece, thus removing the workpiece.

[0096] After ejection, the guide column 51 returns to its original position. Under the gravity of the ejector 8, the transmission column 64 returns to its original position, continuing to drive the hydraulic cylinder 68 to move the lifting column 67 upward. At this point, the upper wall of the lifting cylinder seat 63 is blocked, and the connecting cylinder 69 can no longer move upward. The lifting column 67 can continue to move upward, gradually approaching the lifting cylinder seat 63. Figure 9 As shown, the triangular block 611 gradually approaches the triangular groove 612. When the triangular block 611 is engaged in the triangular groove 612, the transmission column 64 cannot move in the lifting cylinder seat 63. Before the next workpiece is placed into the forging cavity 7, the transmission column 64 is kept in a braking state to prevent the machine from accidentally striking and damaging the lower die seat 4 of the machine.

[0097] The forging die provided by this invention is mainly used in casting-forging combined forming processes, but is not limited to casting-forging combined forming processes. Correspondingly, such as Figure 1 , Figure 3 and Figure 4 As shown, the aluminum alloy rear control arm casting and forging combined forming method includes the following steps:

[0098] Step 100: Establish the relationship between the mechanical properties of the product and the stress-strain of the casting billet;

[0099] Step 200: Prepare a casting billet of aluminum alloy rear control arm within the target stress-strain range by low-pressure casting to match forging requirements and product performance.

[0100] Step 300: Heat-treat the casting billet;

[0101] Step 400: The heated casting billet is bent to match the shape characteristics of the product.

[0102] Step 500: The bent casting blank is placed into a forging die and forged into shape to obtain an aluminum alloy rear control arm.

[0103] In this invention, the relationship between the mechanical properties of the product and the stress and strain of the casting billet is established. The casting billet of the aluminum alloy rear control arm within the target stress and strain range is prepared by low-pressure casting to match the forging requirements and product performance. This allows the casting billet to be formed in a state more suitable for the mechanical property shaping process of forging. With the forging process as the core, casting and forging are combined to shape the mechanical properties of the product. During the forging process, the internal structure of the casting billet is refined, the material becomes more compact, and the mechanical properties are enhanced.

[0104] Compared to the traditional separate casting and forging process, the casting process adjusts process parameters based on a basis more suitable for the forging process, reducing the requirements for product performance in the casting process. In the forging process, more suitable casting blanks can be obtained for forging to form products with better mechanical properties and standard product shapes. The coupling effect of the casting and forging processes influences each other to form a process of gradually shaping the product's shape and performance. On the one hand, it reduces the process requirements of the casting process and shortens the process cycle. On the other hand, it makes full use of the cooperative forming of casting and forging processes and improves the process utilization rate.

[0105] Traditional forging processes use extruded bars, which are cast and then extruded. The forming process of extruded bars is: aluminum ingot smelting - conditioning - shaping - extrusion - straightening and correction - artificial aging. Therefore, the overall process of extruded bars is: aluminum ingot smelting - conditioning - shaping - extrusion - straightening and correction - artificial aging - forging - post-forging work. The forming process of cast bars is: aluminum ingot smelting - conditioning - cavity shaping. Correspondingly, the overall process of cast bars is: aluminum ingot smelting - conditioning - cavity shaping - forging - post-forging work. Before and after forging, the mechanical properties of extruded bars and products forged using extruded bars do not change significantly. For forging processes of products using extruded bars as raw materials, the forging process is only a process of extruding the extruded bars to adjust the structural shape.

[0106] Therefore, compared to the extruded bars of traditional forging, the raw material of the casting-forging coupling forming process in this scheme is the cast bar. The casting process produces a casting blank with a structure similar to the product. Compared to the extruded bars, the mechanical properties of the product remain almost unchanged after forging. In this design, the internal structure of the blank is refined and the material is more compact during the forging process, resulting in enhanced mechanical properties.

[0107] The forging process reduces two steps—roll forging and pre-forging—shortening the forging cycle and lowering product production costs.

[0108] The forging process recycles forging waste and then reprocesses it into casting billets, promoting waste recycling and improving material utilization.

[0109] Furthermore, the casting and forging coupling forming method in the above-mentioned aluminum alloy rear control arm casting and forging coupling forming method is not limited to the aluminum alloy product forming process; aluminum alloy forming is merely one embodiment of the present invention.

[0110] This invention provides an example of a casting blank for a control arm made of 6082 aluminum alloy, with a target stress-strain range of 0.2 to 0.4.

[0111] In addition, the liquid aluminum alloy used for casting the control arm of the 6082 aluminum alloy rear control arm is melted in an electric furnace. The liquid aluminum alloy used in the casting billet includes the following components by mass percentage: Si: 1.19%, Mg: 1.003%, Mn: 0.712%, Cr: 0.17%, Zn: 0.0235%, Cu: 0.0789%, Fe: 0.21%, with the remainder being Al. The mass ratio of Mg to Si is 0.75 to 1.

[0112] According to experimental comparison and analysis, the mechanical properties of the formed product are the highest when the mass ratio of Mg to Si is between 0.75 and 1. In actual production, a ratio of 0.85 is generally used.

[0113] Establishing the relationship between the mechanical properties of the product and the stress-strain of the cast billet includes:

[0114] Using liquid aluminum alloys of the same composition, casting billets with different stress-strain parameters were prepared by controlling the casting compression ratio;

[0115] Forging cast billets into products;

[0116] Determine the mechanical properties of casting blanks and products;

[0117] And establish the relationship between the mechanical properties of the product and the stress and strain of the casting billet.

[0118] Specifically, the present invention discloses the following embodiments: using liquid aluminum alloy of the same composition, casting billets with different stress-strain parameters are prepared by controlling the casting compression ratio. The casting billets are then forged into products, and the mechanical properties of the casting billets and products are measured. Through comparative experiments, it can be found that when the strain is less than 0.2, the mechanical properties of the product cannot meet the requirements. When the strain is greater than 0.4, the mechanical properties are significantly improved compared to 0.2. When the strain is greater than 0.6, the forming mechanical properties of the product are the highest. For long rod-like products with relatively uniform structure, a strain greater than 0.6 will lead to a decrease in product material utilization and an increase in production costs. Considering economic benefits and production costs (reducing the corresponding requirements of the casting process), the optimal strain coefficient of the cast aluminum alloy should be between 0.2 and 0.4. Therefore, based on the cross-sectional area change curve of the casting billet during the casting process (by controlling the casting compression ratio), the strain of the casting billet is controlled between 0.2 and 0.4.

[0119] The specific steps for placing the casting blank into the heating furnace for heating are as follows:

[0120] Set the temperature inside the heating furnace to 520℃ and check it periodically.

[0121] After the furnace temperature stabilizes, the casting blank is sent into the heating furnace;

[0122] The casting blank is placed in the groove inside the heating furnace.

[0123] Among them, the heating time of the casting billet should not exceed 2 hours. For billets with a diameter of less than 50mm, if the heating time exceeds 2 hours, the grains in the microstructure will gradually become larger, coarser, and have voids. As a result, the mechanical properties of the products formed by using this casting billet are generally low. Generally, it is necessary to keep it at the temperature for 1 hour before taking it out.

[0124] The above process is generally checked every 30 minutes. The temperature of the casting billet is checked every 30 minutes. If the billet temperature deviation is greater than 5℃ during the product forming process, it will cause the performance of the batch of products to be inconsistent. After waiting for the furnace temperature to stabilize, the casting billet 1 is sent into the heating furnace and kept warm for one hour. The casting billet 1 is placed in the groove, two in each row, and each one is staggered by about one groove position. The casting billet 1 is scrapped if the heating time exceeds 2 hours.

[0125] The main steps of bending heated casting blanks using a bending die include:

[0126] Inspect the surface of the bending die;

[0127] Place the casting blank into the bending mold and adjust the mold gap to 38±2mm;

[0128] The bending die closes to compress the casting blank into a casting blank with the same curvature as the product.

[0129] Before bending the casting blank 1, it is necessary to confirm that there are no defects such as cracks and dents on the surface of the bending mold. After the bending mold is installed, the gap between the bending molds is adjusted to 38±2mm. The temperature of the casting blank after completing the bending process is ≥480℃.

[0130] The casting blank is placed in a forging die for forging, including the following steps:

[0131] Adjust the temperature of the forging die to maintain the temperature inside the forging die at 200±20℃;

[0132] A release agent is evenly sprayed onto the inner wall of the forging cavity;

[0133] Place the casting blank into the forging die;

[0134] Calculate the tonnage of the control arm forging after casting-forging coupled aluminum alloy;

[0135] According to the forming tonnage, the forging die is driven by a screw press to forge the casting blank.

[0136] The forging waste is then recycled.

[0137] During the forging process, the temperature of the forging die needs to be controlled to ensure that the temperature before forging is 200±20℃. Before placing the casting blank, a release agent needs to be sprayed. In order to ensure that the product can be successfully demolded, and to prevent carbon buildup at the rounded corners of the forging cavity 7, which may lead to incomplete filling of the rounded corners and other defects, the ratio of graphite to water in the release agent needs to be controlled between 1:10 and 1:15. When spraying the release agent, it should be sprayed evenly on the inner wall of the forging cavity 7, and the spraying time for a single forging cavity 7 should be ≥5 seconds.

[0138] After the forging process, the aluminum alloy rear control arm needs to be trimmed. After trimming, it is necessary to ensure that the product appearance is free from defects such as chipping, scratches, and severe oxidation. No bumps or knocks are allowed on the non-machined surfaces of the product. All dimensions are fully inspected according to the product bubble diagram requirements.

[0139] After the trimming is completed, the aluminum alloy rear control arm is heat-treated using the T6 heat treatment method. The T6 heat treatment method includes solution treatment and aging treatment. Solution treatment involves heating the aluminum alloy casting to a certain temperature and holding it at that temperature for a period of time to allow the excess phase to fully dissolve into the solid solution, followed by rapid cooling to obtain a supersaturated solid solution. Aging treatment uses a higher aging temperature and a longer holding time to obtain the maximum hardness and the highest tensile strength, achieving dimensional stability. In this embodiment, the solution temperature is set to 540±5℃ and the holding time is 150 min, and the aging temperature is set to 175±5℃ and the holding time is 10 hours.

[0140] The final product obtained after the above process is subjected to mechanical property tests according to the requirements of GB / T 228-2010, and the data is obtained as shown in the table below. Figure 2 The data table shows that all the mechanical properties of the aluminum alloy rear control arm formed by the two processes are higher than the standard level. The mechanical properties of the aluminum alloy rear control arm formed by casting and forging coupling are 16.18%, 18.88%, and 10.4% lower than those of the forged version, respectively. At present, the mechanical properties of the 6082 aluminum alloy control arm formed by casting and forging coupling can meet the strength requirements of aluminum alloy automotive parts. Current experiments can prove that aluminum alloy products that meet the performance requirements can be manufactured through the casting and forging coupling forming process.

[0141] In summary, the product performance proposed above meets the standard requirements, and it can shorten the forging cycle and reduce the product production cost on the basis of forging; and improve the internal mechanical properties of the structure on the basis of casting.

[0142] In the above forging process, the casting blank is forged using the linkage forging die provided by the present invention.

[0143] The above embodiments are merely exemplary embodiments of this application and are not intended to limit this application. The scope of protection of this application is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to this application within its substance and scope of protection, and such modifications or equivalent substitutions should also be considered to fall within the scope of protection of this application.

Claims

1. A linkage forging die, characterized in that, have: The upper die base (3) has a downward-facing upper forging groove (31) on its lower end face. A forging upper die (32) is fixedly installed in the upper forging groove (31). A downward-facing first die cavity (33) is opened on the lower end face of the forging upper die (32). A screw press (2) is installed on the upper die base (3). The lower die base (4) has an upward-facing lower forging groove (41) on its upper end face. A forging lower die (42) is movably arranged in the lower forging groove (41). A second die cavity (43) facing upward is opened on the upper end face of the forging lower die (42). The second die cavity (43) and the first die cavity (33) together form a forging cavity (7) for forging and shaping the bent workpiece. A guide member (5) is disposed through the upper mold base (3) and the lower mold base (4). The guide member (5) is used to limit the movement of the upper mold base (3) towards the lower mold base (4) along the length direction of the guide member (5). The guide member (5) includes a guide post (51) disposed on the upper mold base (3) and a guide groove (52) disposed on the lower mold base (4). A guide head (53) is disposed at the bottom of the guide post (51). The linkage structure (6) is set inside the lower die base (4). The linkage structure (6) moves downward while the upper die base (3) moves downward, driving the lower forging die (42) to move upward so as to meet the upper forging die (32) to forge the bent workpiece. The linkage structure (6) includes a horizontal groove (61) and a vertical groove (62) provided in the lower mold base (4), a lifting cylinder seat (63) provided in the vertical groove (62), and a transmission column (64) provided in the lifting cylinder seat (63). One end of the transmission column (64) is provided with a first engaging block (65), and the other end of the transmission column (64) is provided with a second engaging edge (66). The first engaging block (65) engages with the side of the guide head (53). The horizontal groove (61) and the vertical groove (62) are connected. A lifting column (67) is provided in the vertical groove (62). A hydraulic cylinder (68) is connected to the bottom of the lifting column (67). A connecting cylinder (69) is sleeved on the lifting column (67). The connecting cylinder (69) is connected to the bottom of the lifting cylinder seat (63). A connecting spring (610) is provided between the lifting column (67) and the connecting cylinder (69). The bottom of the lifting cylinder seat (63) is directly connected to the connecting cylinder (69), the top of the lifting column (67) is connected to a triangular block (611), and the bottom of the transmission column (64) is provided with a triangular groove (612) along the length direction. The triangular block (611) fits into the triangular groove (612). The bottom side of the forging die (42) is provided with a first inclined edge (47), which is engaged with the second mating edge (66); An ejector (8) is provided in the lower forging die (42). The ejector (8) is a Z-shaped structure. A second inclined edge (81) is provided at the bottom of the ejector (8). The second inclined edge (81) is parallel to the first inclined edge (47) and directly above the first inclined edge (47). The second inclined edge (81) and the second mating edge (66) are mated. The forging lower die (42) is provided with a connecting groove (82) and an ejector groove (83). The ejector groove (83) is Z-shaped. The width of the horizontal groove in the ejector groove (83) is greater than the width of the ejector (8). When the bottom of the ejector (8) is disengaged from the connecting groove (82), the middle position of the ejector (8) just abuts against the inner wall of the horizontal groove in the ejector groove (83). At least two ejector slots (83) and ejector components (8) are provided. The connecting slot (82) and the ejector slot (83) are connected. The top of the ejector slot (83) is connected to the lower forging slot (41) and the top of the ejector component (8) is flush with the top of the ejector slot (83). The ejector component (8) is vertically disposed in the lower forging die (42). The transmission column (64) slides in the connecting slot (82).

2. The linkage forging die according to claim 1, characterized in that, The height of the upper end face of the forging die (42) is not higher than the height of the upper surface of the die base (4); The thickness of the lower forging groove (41) is greater than the height of the lower forging die (42).

3. The linkage forging die according to claim 2, characterized in that, The linkage structure (6) includes a connecting motor (613) disposed in the lower mold base (4) and a screw rod (614) disposed at the output end of the connecting motor (613). The bottom of the forging die (42) is provided with a spiral groove (615), the spiral rod (614) cooperates with the spiral groove (615), the upper end of the spiral rod (614) is connected to a limiting block (616), the lower forging die (42) is also provided with a limiting groove (617), the limiting block (616) is movably disposed in the limiting groove (617), and the outer diameter of the limiting block (616) is larger than the outer diameter of the spiral rod (614).

4. The linkage forging die according to claim 3, characterized in that, The bottom of the lower forging groove (41) is provided with a mounting slot (44), and an electromagnetic coil (45) is provided in the mounting slot (44). The bottom of the forging die (42) is provided with a magnetic seat (46), and the magnetic seat (46) is movably disposed in the mounting slot (44). A control circuit is connected to the electromagnetic coil (45), and a switch is provided on the control circuit.

5. The linkage forging die according to claim 4, characterized in that, The guide post (51) is directly opposite the guide groove (52) and the outer diameter of the guide post (51) is the same as the inner diameter of the guide groove (52). The guide head (53) is configured as a frustum. The guide post (51) is retractable.

6. The linkage forging die according to claim 5, characterized in that, The screw press (2) includes a mounting bracket (21) on the upper die base (3), a drive motor (22) on the mounting bracket (21), and a rotating screw (23) on the drive motor (22). The rotating screw (23) is connected to the output end of the drive motor (22), and the upper mold base (3) is provided with a threaded groove (24) that cooperates with the rotating screw (23).

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