A stamping-forging aluminum alloy wheel and a manufacturing process thereof

Abstract

The present application relates to a kind of stamping forging aluminum alloy wheel hub and its preparation process, S1, mold making, and four dies are installed on four different presses;S2, the O state material of 6061 aluminum alloy, placed on the initial drawing die, draw out half-round blank;S3, the half-round blank in S2 is placed on the forming die, and is shaped to U modeling;S4, the blank after S3 processing is placed on the flanging die, and is shaped to negative angle;S5, the flanging blank after S4 processing is annealed;S6, the blank after annealing in S5 is placed on the folding flanging die, and is shaped to the required blank shape;S7, the blank after S6 processing is machined, surface treatment;S8, the rim of rolling forming is connected with stamping forging spoke plate using aviation friction stir welding technology, to obtain stamping forging wheel hub, in the process of preparing wheel hub using the present application, spoke plate and rim are combined using split friction welding, material utilization is high, compared with the cost of forging spinning aluminum wheel, it is reduced by 30%.

Description

TECHNICAL FIELD

[0001] The present application relates to a stamping forging aluminum alloy wheel hub and its preparation process, in particular to a stamping forging aluminum alloy wheel hub and its preparation process applied to the field of wheel hub processing. BACKGROUND

[0002] Aluminum alloy wheel hub is more suitable for passenger cars than steel wheel hub. At present, its manufacturing process can be basically divided into three kinds. The first kind is casting, which is currently selected by most automobile manufacturers. The second kind is forging, which is mainly used in high-end sports cars, high-performance cars and high-end modification market. The third kind is special spinning technology, which combines the process characteristics of extrusion and forging. According to the plasticity of the material itself, reasonable process parameters are set, and the process method of continuous deformation of the blank. At present, this technology is not as widely used as the first two in China.

[0003] The disadvantages of these three processes are as follows:

[0004] a) The cost of forging wheel hub process is high, which cannot be mass-produced;

[0005] b) The utilization rate of forging wheel hub process equipment is low, and a hot stamping workshop is needed, which has high processing risk;

[0006] c) The casting wheel hub process leads to casting defects;

[0007] e) The raw materials of the casting wheel hub process contain non-alloy components, and the flowability of the material is high, the thermal conductivity is poor, and the impact performance is poor;

[0008] f) The spinning wheel hub process is dependent on the first two processes, and the advantages and disadvantages of the spinning process depend on which process it depends on.

[0009] The specification of Chinese invention patent CN202110441711.2 discloses a forging method for an aluminum alloy wheel hub of an automobile, comprising the following steps: S10, heating the blank and heating the blank to a preset forging temperature; S20, placing the heated blank in the first forging station of the lower die assembly, aligning the upper die with the lower die of the first forging station and lowering, the upper die, the half die ring and the lower die are matched with each other, realizing the first forging process of the blank, and obtaining a first forged formed wheel hub; S30, the lower die assembly moves the second forging station to the lower side of the upper die, the upper die and the half die ring are lowered and matched with the lower die, and the first forged formed wheel hub is subjected to the second forging process, and a second forged formed wheel hub is obtained.

[0010] The above method is a one-time forming forging process with a weight reduction of 20% compared with the original technology, but it cannot improve the carbon emission effect. SUMMARY

[0011] In view of the above-mentioned prior art, the technical problem to be solved by the present invention is how to mass-produce products equivalent to forging grade while ensuring product quality and reducing costs.

[0012] To solve the above problems, the present invention provides a stamped forged aluminum alloy wheel hub, including a spoke plate, a welding block connected to the tail end of the spoke plate, a wheel rim connected to the tail end of the welding block, a cover connected to the surface of the spoke plate, a locking ring provided on the surface of the spoke plate, a threaded bushing connected inside the locking ring, a bolt connected inside the threaded bushing, a valve for inflation installed on the surface of the spoke plate, and an anti-sway ring arranged outside the valve, the anti-sway ring being a spiral design.

[0013] In the aforementioned stamped and forged aluminum alloy wheel hub, the design of the welded block allows for segmented forming between the spoke plate and the rim. The spoke plate is formed by stamping and forging, while the rim is formed using rolling technology and connected by aerospace friction stir welding. The cold forming technology eliminates the need for heat energy consumption, reducing carbon emissions by 30%. Compared to cast aluminum wheels, it reduces weight by 10% under the same load. Furthermore, during use, the anti-sway ring can reduce the swaying of the rubber valve stem, thereby preventing valve stem aging and ensuring normal valve stem operation.

[0014] As a further improvement of this application, the tightening torque between the threaded bushing and the bolt is 28-35 Newton-meters.

[0015] As a further improvement of this application, a plurality of balls are embedded in the surface of the anti-sway ring, and the balls are movably connected to the surface of the anti-sway ring. A support rod is connected to the surface of the balls, and a movable part is connected to the end of the support rod.

[0016] As a further improvement of this application, the moving part consists of two moving chain plates, one of which is rotatably connected to the surface of the other moving chain plate.

[0017] As a further improvement to this application, the anti-sway ring has multiple counterweight cavities inside, and counterweight balls are arranged inside the counterweight cavities.

[0018] As a further improvement to this application, a manufacturing process for a stamped and forged aluminum alloy wheel hub includes the following steps:

[0019] S1. Mold making: According to the requirements of the wheel spoke plate, four molds of corresponding size are made for initial stretching, forming, flanging and folding flanging, and the four molds are installed on four different presses;

[0020] S2. Using 6061 aluminum alloy in O state, place it on the initial stretching die, pull out a semi-circular blank, and complete the initial stretching process;

[0021] S3. Place the semi-circular blank from S2 onto the forming mold and shape it into a U-shape to complete the initial forming process;

[0022] S4. Place the blank processed in S3 onto the flanging mold and shape it to a negative angle to complete the initial flanging process.

[0023] S5. Anneal the flanging blank after S4 treatment. Heat the blank, keep it at that temperature for a certain time, and then cool it to 300° so that the blank can be folded at 90°.

[0024] S6. Place the annealed blank from S5 onto the folding and flanging mold and shape it into the required blank shape.

[0025] S7. The blank processed in S6 is machined and surface treated to obtain the required stamped forged wheel spoke plate;

[0026] S8. The rolled rim and the stamped forged spoke plate are welded together using aerospace friction stir welding technology to obtain the stamped forged wheel hub.

[0027] As a further improvement to this application, the heating temperature in S5 is 390-430℃, and the holding time is 30-120min.

[0028] As a further improvement to this application, the hydraulic pressure value used by the four presses in S1 is not less than 1000T.

[0029] In summary, the manufacturing process of this application has a high equipment utilization rate, with a thousand-ton hydraulic press for stretching replacing the hammering of a ten-thousand-ton equipment, resulting in a fast production cycle and enabling large-scale production of wheel hubs.

[0030] In addition, the experimental data of stamped forged wheel spokes show a tensile strength of 310 MPa, compared to only 230 MPa for traditional cast aluminum wheels, representing a 35% increase in strength. This is close to that of high-performance forged and spun aluminum wheels, resulting in higher quality finished wheels.

[0031] In addition, according to the "Performance Requirements and Test Methods for Passenger Car Wheels", the experimental data of the stamped forged wheel spokes requires a minimum of 100,000 cycles for the light alloy strengthening coefficient of 1.6 in the rotational bending test method. The stamped forged wheel spokes in this application reach 430,000 cycles, which is a high-quality wheel spoke.

[0032] Finally, the cold forming technology used in this manufacturing process eliminates the need for heat energy consumption, reducing carbon emissions by 30%. Furthermore, the spokes and rims are assembled using a separate friction welding method, resulting in high material utilization and a 30% cost reduction compared to forged and spun aluminum wheels. Attached Figure Description

[0033] Figure 1This is a top view of the wheel hub according to the first embodiment of this application;

[0034] Figure 2 This is a side view of the wheel hub according to the first embodiment of this application;

[0035] Figure 3 This is an enlarged schematic diagram of section A in the first embodiment of this application;

[0036] Figure 4 This is the first embodiment of the present application. Figure 2 Enlarged view of point B in the image;

[0037] Figure 5 This is a cross-sectional view at point C in the first embodiment of this application;

[0038] Figure 6 This is a schematic diagram of the anti-sway hoop structure according to the first embodiment of this application;

[0039] Figure 7 This is a schematic diagram of the moving part, support rod, and ball bearings according to the first embodiment of this application.

[0040] Figure 8 This is a cross-sectional view of the anti-sway hoop according to the first embodiment of this application;

[0041] Figure 9 This is a schematic diagram of the working state of the anti-sway hoop of the first embodiment of this application when subjected to vertical swaying.

[0042] Figure 10 This is a schematic diagram of the working state of the anti-sway ring according to the first embodiment of this application when subjected to horizontal swaying.

[0043] Figure 11 This is a flowchart of the preparation process according to the second embodiment of this application;

[0044] Figure 12 This is a cross-sectional view of the workpiece to be initially drawn according to the second embodiment of this application;

[0045] Figure 13 This is a schematic diagram of the cross-sectional structure of the workpiece to be formed according to the second embodiment of this application;

[0046] Figure 14 This is a cross-sectional view of the workpiece requiring flanges according to the second embodiment of this application.

[0047] Figure 15 This is a cross-sectional view of the workpiece requiring folding and flanging according to the second embodiment of this application.

[0048] Explanation of the labels in the diagram:

[0049] 1. Wheel spokes; 2. Wheel rim; 201. Welded block; 3. Threaded bushing; 4. Bolt; 5. Locking ring; 6. Cover; 7. Valve nozzle; 71. Anti-sway ring; 72. Moving parts; 73. Support rod; 74. Ball bearing; 75. Counterweight chamber. Detailed Implementation

[0050] The two embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0051] Implementation method 1:

[0052] Figures 1-10 A stamped forged aluminum alloy wheel hub is shown, including a spoke plate 1, a welding block 201 connected to the tail end of the spoke plate 1, a wheel rim 2 connected to the tail end of the welding block 201, a cover 6 connected to the surface of the spoke plate 1, a locking ring 5 provided on the surface of the spoke plate 1, a threaded bushing 3 connected inside the locking ring 5, a bolt 4 connected inside the threaded bushing 3, a valve 7 for inflation installed on the surface of the spoke plate 1, an anti-sway ring 71 arranged outside the valve 7, and the anti-sway ring 71 is a spiral design, and the tightening torque between the threaded bushing 3 and the bolt 4 is 28-35 Newton-meters.

[0053] Specifically, when a vehicle is in normal driving, the rubber valve stem 7 will swing back and forth due to centrifugal force and undergo various deformations, which will undoubtedly accelerate the aging of the valve stem 7. The elasticity of the anti-sway ring 71 is less than that of the valve stem 7. The anti-sway ring 71 can provide anti-sway protection for the rubber valve stem 7, thereby delaying the aging of the valve stem 7.

[0054] The surface of the anti-sway ring 71 is inlaid with multiple balls 74, and the balls 74 are movably connected to the surface of the anti-sway ring 71. The surface of the balls 74 is connected to a support rod 73, and the end of the support rod 73 is connected to a movable part 72. The movable part 72 is composed of two movable chain plates, one of which is rotatably connected to the surface of the other movable chain plate. The anti-sway ring 71 has multiple counterweight cavities 75 inside, and counterweight balls are arranged inside the counterweight cavities 75.

[0055] Specifically, the design of the ball bearing 74 allows the support rod 73 to move, so that when the anti-sway ring 71 is subjected to vertical vibration, the gap is maximized under the action of the movable part 72, so that the movable part 72 remains vertical, thereby maximizing the gap of the anti-sway ring 71, and thus maximizing the anti-sway interception distance of the anti-sway ring 71.

[0056] When the anti-sway ring 71 is subjected to horizontal swaying, under the action of gravity, the counterweight ball can force the gap between the support rods 73 to shrink by its own weight, thereby causing the movable part 72 to form a V-shaped structure, causing the anti-sway ring 71 to collapse downward, and thus the gap on its surface to shrink, thereby strengthening the resistance to horizontal swaying.

[0057] In the counterweight cavity 75, the size of the counterweight ball is smaller than that of the counterweight cavity 75. Therefore, when the anti-sway ring 71 is subjected to vertical swaying, the counterweight ball can assist the longitudinal extension of the anti-sway ring 71 under the action of inertia.

[0058] The second implementation method:

[0059] Figures 11-15 As shown, components that are the same as or corresponding to those in the first embodiment are represented by the same reference numerals as those in the first embodiment. For simplicity, only the differences from the first embodiment are described below. The difference between this second embodiment and the first embodiment lies in the following: a manufacturing process for a stamped forged aluminum alloy wheel hub includes the following steps:

[0060] S1. Mold making: According to the requirements of wheel spoke plate 1, four molds of corresponding size are made for initial stretching, forming, flanging and folding, and the four molds are installed on four different presses.

[0061] The O-state material of S2 and 6061 aluminum alloy is placed on the initial stretching die and a semi-circular blank is drawn out to complete the initial stretching process.

[0062] S3. Place the semi-circular blank from S2 onto the forming mold and shape it into a U-shape to complete the initial forming process;

[0063] S4. Place the blank processed in S3 onto the flanging mold and shape it to a negative angle to complete the initial flanging process.

[0064] S5. Anneal the flanging blank after S4 treatment. Heat the blank, keep it at that temperature for a certain time, and then cool it to 300° so that the blank can be folded at 90°.

[0065] S6. Place the annealed blank from S5 onto the folding and flanging mold and shape it into the required blank shape.

[0066] S7. The blank processed in S6 is machined and surface treated to obtain the required stamped forged wheel spoke plate 1;

[0067] S8. The rolled rim 2 and the stamped forged spoke plate 1 are welded together in the area of ​​the welding block 201 using aerospace friction stir welding technology to obtain the stamped forged wheel hub.

[0068] The heating temperature in S5 is 390-430℃, and the holding time is 30-120 minutes.

[0069] The hydraulic pressure value used by the four presses in S1 is not less than 1000T.

[0070] Specifically, cold forming technology eliminates the need for heat energy consumption, reducing carbon emissions by 30%. Compared to cast aluminum wheels, it reduces weight by 10% under the same load, thereby lowering costs while maintaining product quality and enabling mass production of products equivalent to forging grade.

[0071] In light of current practical needs, the above-described embodiments adopted in this application are not limited to these. Any changes made within the scope of knowledge possessed by those skilled in the art without departing from the concept of this application still fall within the protection scope of this invention.

Claims

1. A stamped forged aluminum alloy wheel hub, comprising a spoke plate (1), characterized in that: The tail end of the spoke plate (1) is connected to a welding block (201), the tail end of the welding block (201) is connected to a rim (2), the surface of the spoke plate (1) is connected to a cover (6), the surface of the spoke plate (1) is provided with a locking ring (5), the inside of the locking ring (5) is connected to a threaded bushing (3), the inside of the threaded bushing (3) is connected to a bolt (4), the surface of the spoke plate (1) is installed with a valve (7) for inflation, the outside of the valve (7) is provided with an anti-sway ring (71), and the anti-sway ring (71) is a spiral design; The surface of the anti-sway ring (71) is inlaid with a plurality of balls (74), and the balls (74) are movably connected to the surface of the anti-sway ring (71). The surface of the balls (74) is connected to a support rod (73), and the end of the support rod (73) is connected to a movable part (72). The movable component (72) consists of two movable chain plates, one of which is rotatably connected to the surface of the other movable chain plate; The anti-sway ring (71) has multiple counterweight cavities (75) inside, and counterweight balls are arranged inside the counterweight cavities (75).

2. The stamped forged aluminum alloy wheel hub according to claim 1, characterized in that: The tightening torque between the threaded bushing (3) and the bolt (4) is 28-35 Newton-meters.

3. The manufacturing process of a stamped and forged aluminum alloy wheel hub according to claim 1, characterized in that, The work includes the following steps: S1. Mold making: According to the requirements of the spoke plate (1), four molds of corresponding size are made for initial stretching, forming, flanging and folding, and the four molds are installed on four different presses. S2. Using 6061 aluminum alloy in O state, place it on the initial stretching die, pull out a semi-circular blank, and complete the initial stretching process; S3. Place the semi-circular blank from S2 onto the forming mold and shape it into a U-shape to complete the initial forming process; S4. Place the blank processed in S3 onto the flanging mold and shape it to a negative angle to complete the initial flanging process. S5. Anneal the flanging blank after S4 treatment. Heat the blank, keep it at that temperature for a certain time, and then cool it to 300° so that the blank can be folded at 90°. S6. Place the annealed blank from S5 onto the folding and flanging mold and shape it into the required blank shape. S7. The blank processed by S6 is machined and surface treated to obtain the required stamped forged wheel spoke plate (1). S8. The rolled rim (2) and the stamped forged spoke plate (1) are welded together in the area of ​​the welding block (201) using aerospace friction stir welding technology to obtain the stamped forged wheel hub.

4. The manufacturing process of a stamped forged aluminum alloy wheel hub according to claim 3, characterized in that: The heating temperature in S5 is 390-430℃, and the holding time is 30-120min.

5. The manufacturing process of a stamped forged aluminum alloy wheel hub according to claim 3, characterized in that: The hydraulic pressure value used by the four presses in S1 is not less than 1000T.

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