A wire clamp forging process and its fixing tool

Abstract

The application discloses a wire clamp forging process, which comprises cutting, casting, blanking, forging, edge cutting, shot blasting, edge cutting, welding and welding; and a wire clamp fixing tool, which comprises a tool plate, a first clamp is assembled on the bottom upper surface of the tool plate, and a second clamp is assembled on the top upper surface of the tool plate, the first clamp comprises a clamp column, a clearance hole is formed in the side surface of the clamp column, a wire clamp made by the wire clamp forging process is inserted into the clamp column, and the wire clamp groove is aligned with the clearance hole. The wire clamp forging process is used for NX wedge type wire clamps, NUT wire clamps and the like, in order that the wire clamp after forging can be kept fixed during welding, the wire clamp fixing tool is arranged, different types of wire clamps can be simultaneously spliced and fixed through the wire clamp fixing tool, thereby facilitating welding, and the clearance hole specially reserved on the tool facilitates the exposure of the welding groove gap during the welding of the XN wire clamp.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of accessories for power distribution networks, and particularly relates to a line clamp forging process and a fixing tool thereof. BACKGROUND

[0002] NX wedge type line clamps and NUT line clamps are two types of line clamps that are widely used in power fittings. Although the forging process technology of power fittings is relatively mature, the components of the line clamps such as NX wedge type line clamps and NUT line clamps are complex and thin-walled, and it is difficult to use the forging process to integrally form such line clamps. Specifically, the line clamp body of the NX wedge type line clamp is thin-walled and has a through hole for installing a wedge in the middle, and the line clamp body of the NX wedge type line clamp cannot be integrally formed by using the forging process. Similarly, the line clamp body of the NUT line clamp is thin-walled and has a through hole for installing a wedge in the middle, and the line clamp body of the NUT line clamp also cannot be integrally formed by using the forging process.

[0003] Therefore, the line clamps are currently integrally formed by using the casting process. However, the casting process is a high-energy-consumption process, and the production process produces waste gas and waste residue that pollute the environment. If not properly treated, it can easily cause serious air pollution and environmental pollution. Casting is currently a process that is limited in the development of production capacity by the state. Therefore, the technical problem of how to produce and manufacture line clamps with complex components and thin-walled components by using the forging process needs to be solved urgently. SUMMARY

[0004] This section is intended to summarize some aspects of the embodiments of the application and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the abstract and title of the specification to avoid obscuring the purpose of this section, the abstract and the title, and such simplifications or omissions cannot be used to limit the scope of the application.

[0005] To solve the above problems, the application adopts the following technical solutions.

[0006] A line clamp forging process, comprising the following steps:

[0007] Step 1: cutting, the sample line clamp is cut in half;

[0008] Step 2: casting, a forging mold is manufactured according to the line clamp cut in step 1;

[0009] Step 3: blanking, the metal band saw bed is used to blank to the required size;

[0010] Step 4: forging, the obtained material is placed in the mold cavity, and a 1600T electric screw press is used to forge the forging;

[0011] Step 5: edge cutting, the forging is placed in the cavity of the edge cutting lower mold and the excess flash is cut off;

[0012] Step 6: shot blasting, using a shot blaster to remove impurities;

[0013] Step 7: edge cutting, using a shearing device to cut the outer surface of the forged half-shell clip to a bevel;

[0014] Step 8: welding, using a clip fixing tool to combine the two clip shells, and using a welding tool to weld and fill the bevel;

[0015] Step 9: welding, polishing the welding points and the surface of the clip.

[0016] In step 4, the electric screw press co-forges three times, with a drop speed of 650±50r / min in the first forging, 550±50r / min in the second forging, and 300±50r / min in the third forging.

[0017] In step 6, shot blasting is divided into shot blasting cleaning and shot blasting strengthening. Shot blasting cleaning is to remove surface oxides and other impurities to improve the appearance quality. Shot blasting strengthening uses high-speed moving projectiles to continuously impact the surface of the strengthened workpiece, forcing the target surface and surface layer to undergo microstructure modification during the cyclic deformation process.

[0018] In step 7, the outer surface of the half-shell clip is cut to a 30° bevel, and the inner end of the bevel of the half-shell clip is integrally cut with a welding bevel reserved seam, with a reserved seam spacing of 3mm.

[0019] In step 8, welding is performed in three layers, using manual argon arc welding to bottom, and electric welding to cover the surface. The first layer uses a diameter of 2.4mm argon arc welding wire, current: 160-180A, voltage: 20-25V, the second and third layers use a diameter of 3.2mm high-strength welding rod CHE507R, and the welding rod is dried before welding. The welding current is 110-130A.

[0020] The clip forged by the above process needs to be welded and assembled, and the clip needs to be fixed during welding, so the application also provides another technical solution for fixing the clip.

[0021] A clip fixing tool, comprising a tool plate, a first clamp is assembled on the bottom surface of the tool plate, and a second clamp is assembled on the top surface of the tool plate, the first clamp comprises a clamp column, a clearance hole is formed on the side surface of the clamp column, a clip made by a clip forging process is inserted into the clamp column, and the clip bevel is aligned with the clearance hole;

[0022] The second clamp comprises a cylinder, a force arm is connected to the output end pin of the cylinder, a presser foot is installed on the lower surface of the front end of the force arm, the cylinder drives the force arm to rotate, and the presser foot fixes the wire clamp made by the wire clamp forging process on the upper surface of the tool plate, a tool hole is formed on the upper surface of the tool plate, and the second clamp is symmetrically arranged on both sides of the tool hole.

[0023] A lengthening plate is integrally connected to the upper surface of the clamping column, the lengthening plate is a half cylinder, a groove is formed in the center of the outer surface of the lengthening plate, a sliding plate is slidably connected in the groove, and bolts are symmetrically arranged on the sliding plate, the symmetrically arranged bolts are respectively connected with the arc-shaped abutting plates after penetrating the inner wall of the lengthening plate.

[0024] A ring-shaped bottom plate is integrally connected to the bottom of the clamping column, and connecting holes are equidistantly arranged on the bottom plate, and the first clamp is fixed on the upper surface of the bottom of the tool plate through the bottom plate.

[0025] A special-shaped pin connecting piece is connected to the output end pin of the cylinder on the second clamp, the top end of the special-shaped pin connecting piece is connected with the force arm, a fixing piece is connected to the front surface of the special-shaped pin connecting piece, and cantilevers are symmetrically welded to the rear surface of the fixing piece, and the tail portions of the cantilevers are connected to the outer wall of the cylinder.

[0026] Compared with the prior art, the beneficial effects of the present application are:

[0027] (1) The "forging + welding" process is adopted for the NX wedge type wire clamp, the NUT wire clamp and the like, that is, the wire clamp is indirectly integrally formed by forging and welding. Considering the forging property and the welding property, Q345 material is selected, the comprehensive mechanical property of Q345 is good, the plasticity and the weldability are good, and preheating is not required before welding, and heat treatment is not required after welding.

[0028] (2) The wire clamp is made by the forging process in the present application, so that the existing technology, equipment and detection capacity can be used for manufacturing and detecting the wire clamp, thereby reducing the cost in improving the manufacturing process, creating profits, reducing the waste of personnel, equipment and other resources, the NX type wire clamp and the NUT wire clamp can be made by forging, the forged wire clamp has high density, no porosity, pinhole and air hole on the surface, the defects of the casting process are avoided, the requirements of corrosion resistance, fatigue resistance and wear resistance of the wire are met, the service life of the product is prolonged, the operation and maintenance cost is reduced, the comprehensive cost of the overhead transmission line in the whole life cycle can be effectively reduced, and significant economic benefits are obtained.

[0029] (3) Since the application is made by forging process, in order to facilitate forging and later splicing, the same mold is used to forge two half-shell clamps of the same structure, and the two half-shell clamps of the same structure are welded into a whole, in this process, in order to make the welding effect better and make the welding place more smooth, the welding gap is left on both sides of the half-shell clamp before welding, after leaving a certain width gap, the welder can have enough space to operate when welding, ensure that the welding seam can be fully penetrated, the gap can make the auxiliary metal more conveniently added into the welding seam, so as to better play the role of the auxiliary metal, in the welding process, affected by factors such as thermal stress and deformation, metal materials often produce residual stress, and through the gap welding method, the welding seam can be more uniform, so as to relieve the generation of residual stress.

[0030] (4) Through test, by using welding gap, using manual argon arc welding to lay the foundation, electric welding cover surface

[0031] Welding method, three layers of welding, the first layer uses manual argon arc welding to lay the foundation, the second and third layers use manual welding.

[0032] (5) In order to make the clamp after forging can keep fixed when welding, the application is provided with a clamp fixing tool, through the clamp fixing tool, different types of clamps can be spliced and fixed at the same time, so as to facilitate welding, the special reserved hole on the tool facilitates the exposure of the welding gap when welding the XN clamp, and the NUT type clamp is fixed on the upper surface of the tool by pressing nails, so as to facilitate welding. BRIEF DESCRIPTION OF DRAWINGS

[0033] Figure 1 It is an assembly view of the fixing tool and the NX wedge type clamp body and the NUT clamp body.

[0034] Figure 2 It is a fixing tool structure diagram.

[0035] Figure 3 It is a right view of the fixing tool.

[0036] Figure 4 It is a first clamp structure diagram.

[0037] Figure 5 It is a second clamp structure diagram.

[0038] Figure 6 It is an NX wedge type clamp body and a NUT clamp body made by forging process.

[0039] The correspondence between each figure mark and component name in the figure is as follows:

[0040] 100, tool plate; 101, tool hole; 200, first clamp; 201, base plate; 202, clamping column; 2021, extension plate; 2022, clearance hole; 203, sliding plate; 2031, bolt; 300, second clamp; 301, air cylinder; 302, cantilever; 3021, fixing piece; 303, special-shaped pin piece; 304, force arm; 3041, press stud; 4, NX wedge type wire clamp body; 5, NUT wire clamp body. DETAILED DESCRIPTION

[0041] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application will be described in detail below with reference to the accompanying drawings.

[0042] In the following description, a large number of specific details are set forth in order to facilitate a thorough understanding of the present application, but the present application can also be implemented in other ways different from those described herein, and those skilled in the art can make similar generalizations without departing from the connotation of the present application, therefore the present application is not limited by the specific embodiments disclosed below.

[0043] Secondly, "one embodiment" or "embodiment" referred to herein means that a specific feature, structure or characteristic can be included in at least one implementation of the present application. "In one embodiment" appearing in different places in the specification does not mean the same embodiment, nor is it an embodiment that is separate or alternative to other embodiments. The present application provides the following embodiments.

[0044] A wire clamp forging process, comprising the following steps:

[0045] Step 1: cutting, the sample wire clamp is cut in half, and the cut wire clamp sample needs to be fully inspected to ensure that the mold parameters made by the sample do not deform;

[0046] Step 2: mold making, a forging mold is made according to the wire clamp cut in step 1;

[0047] Step 3: blanking, the metal band saw bed is used to blank to the required size, the raw material in the present application considers the forgeability and weldability, Q345 material is selected, Q345 has good comprehensive mechanical properties, good plasticity and weldability, and does not need preheating before welding and does not need heat treatment after welding;

[0048] Step 4: forging, the obtained material is placed in the mold cavity, and a forged piece is obtained by using a 1600T electric screw press, the electric screw press is forged three times, wherein the descending speed in the first forging is 650±50r / min, the descending speed in the second forging is 550±50r / min, and the descending speed in the third forging is 300±50r / min;

[0049] Step 5: trimming, the forging is placed in the cavity of the trimming lower die and the excess flash is trimmed off;

[0050] Step 6: shot blasting, the shot blaster is used to remove surface oxides and other impurities to improve the quality of the workpiece, shot blasting is divided into shot blasting cleaning and shot blasting strengthening, wherein the shot blasting cleaning is to remove surface oxides and other impurities to improve the appearance quality, and the shot blasting strengthening uses high-speed moving pellets with a speed of 60-110 m / s to continuously impact the surface of the workpiece to be strengthened, forcing the target surface and surface layer to undergo microstructure modification in the cyclic deformation process, and the surface layer depth is 0.10-0.85 mm;

[0051] Step 7: trimming, the shears are used to cut the outer surface of the forged half-shell clip to form a bevel, the bevel on the side of the outer surface of the half-shell clip is cut to a 30° angle, and the inner end of the bevel of the half-shell clip is integrally cut with a welding bevel reserved seam, and the reserved seam spacing is 3㎜;

[0052] Step 8: welding, the two clip shells are combined using the clip fixing tool, and the bevel is welded and filled using the welding tool, and the welding is divided into three layers, the manual argon arc welding is used for bottoming, and the electric welding method is used for covering surface welding, wherein the first layer uses argon arc welding wire with a diameter of 2.4 mm, the current is 160-180 A, and the voltage is 20-25 V, the second and third layers use high-strength welding rod CHE507R with a diameter of 3.2 mm, the welding rod is dried before welding, and the welding current is 110-130 A;

[0053] Step 9: finished product processing, polishing the welding points and the clip surface.

[0054] In summary: the clamp body of the NX wedge type clamp and the clamp body of the NUT clamp are complex and thin-walled components for forging process, the present application adopts the "forging + welding" process to forge such steel parts, considering the forgeability and weldability, selects Q345 material, Q345 has good comprehensive mechanical properties, good plasticity and weldability, and does not need preheating before welding and does not need heat treatment after welding, and the clamp is made by forging process, so that the existing technology, equipment and detection capacity can be used for manufacturing and detecting the clamp, thereby reducing the cost of improving the manufacturing process, creating profits, reducing the waste of personnel, equipment and other resources, and the NX clamp and the NUT clamp can be made by forging, the forged clamp has high density, no porosity, pinhole and surface pore, avoids the defects of the casting process, meets the requirements of line corrosion resistance, fatigue resistance and wear resistance, prolongs the service life of the product, reduces the operation and maintenance cost, can effectively reduce the comprehensive cost of the whole life cycle of the overhead transmission line, has significant economic benefits, in order to make the welding effect better and make the welding place more smooth, the welding gap is left on the two sides of the half-shell clamp before welding, after leaving a certain width gap, the welder can have enough space to operate when welding, ensure that the welding seam can be fully penetrated, the gap can make the auxiliary metal more easily added to the welding seam, so that the auxiliary metal can play a better role.

[0055] The clamp forged by the above process needs to be assembled by welding, and the clamp needs to be fixed during welding, therefore the present application further provides another technical solution for fixing the clamp.

[0056] Referring to Figures 1-5The utility model provides a wire clamp fixing tool, including tool plate 100, tool plate 100 provides the installation basis for other tool parts, the first clamp 200 is equipped on the bottom upper surface of tool plate 100, can be fixed to NX type wire clamp using first clamp 200, the second clamp 300 is equipped on the top upper surface of tool plate 100, can be fixed to NUT wire clamp using second clamp 300, first clamp 200 includes clamping post 202, let hole 2022 is set up in the side of clamping post 202, the wire clamp of NX type made by wire clamp forging process is inserted in clamping post 202, and the wire clamp bevel is aligned with let hole 2022 to facilitate the welding device to weld the bevel, the bottom integral connection of clamping post 202 has annular bottom disc 201, and the connecting hole is equidistantly arranged on bottom disc 201, and first clamp 200 is fixed on the bottom upper surface of tool plate 100 through bottom disc 201, second clamp 300 includes air cylinder 301, air cylinder 301 is used as the driving part, the output end pin of air cylinder 301 is connected with force arm 304, the press nail 3041 of force arm 304 is installed on the lower surface of the front end, air cylinder 301 drives force arm 304 to rotate, and the NUT wire clamp made by wire clamp forging process is fixed on the upper surface of tool plate 100 through press nail 3041 to facilitate the welding device to weld the bevel of NUT wire clamp, further, in order to facilitate the observation to the inner wall of NUT wire clamp when welding, and the inner wall of NUT wire clamp is welded by handheld welding part, tool hole 101 is set up on the upper surface of tool plate 100, when NUT wire clamp is placed on the upper surface of tool plate 100, the bottom is opposite to tool hole 101, the inside of NUT wire clamp can be observed through tool hole 101, and the inner wall of NUT wire clamp can also be welded through tool hole 101 by small-sized welding device, and second clamp 300 is symmetrically arranged on both sides of tool hole 101 and presss and fixes NUT wire clamp.

[0057] In Figure 4 In the simple fixing of NX type wire clamp by clamping post 202 is unstable, so auxiliary parts are needed to be arranged to abut against and fix NX type wire clamp, so the elongated plate 2021 is integrally connected to the upper surface of clamping post 202, which is a half cylinder, a groove is formed in the center of the outer surface of elongated plate 2021, a sliding plate 203 is slidably connected in the groove, two bolts 2031 are symmetrically arranged on the sliding plate 203, the two bolts 2031 pass through the inner wall of elongated plate 2021 and are respectively connected with the arc-shaped abutment plate, after the NX type wire clamp is inserted into clamping post 202, the sliding plate 203 is moved up and down on elongated plate 2021 according to the force point, the sliding plate 203 is moved to the appropriate position, the bolt 2031 is rotated, the abutment plate abuts against the outer wall of NX type wire clamp through the bolt 2031, in this process, the NX type wire clamp of the two half-shell wire clamps is adjusted to be aligned, and then the welding device is used to weld the reserved bevel.

[0058] InFigure 5 In the second clamp 300, the output end pin of the air cylinder 301 is connected with a special-shaped pin connecting piece 303, the special-shaped pin connecting piece 303 is connected with the driving part, the fixing part and the pressing part as a force transmission part, so that the force transmission is realized, the NUT clamp is pressed and fixed, the top end of the special-shaped pin connecting piece 303 is connected with the force arm 304, the front surface of the special-shaped pin connecting piece 303 is connected with the fixing piece 3021, the second clamp 300 is assembled on the upper surface of the tool plate 100 through the fixing piece 3021, the rear surface of the fixing piece 3021 is symmetrically welded with the cantilever 302, and the tail of the cantilever 302 is connected with the outer wall of the air cylinder 301, so that the air cylinder 301 can be assembled on the fixing piece 3021, the air cylinder 301 is movably connected with the fixing piece 3021, when the output end of the air cylinder 301 is extended and retracted, the force is transmitted to the cantilever 302 through the special-shaped pin connecting piece 303, so that the cantilever 302 rotates, when the cantilever 302 rotates to the front end close to the upper surface of the tool plate 100, the press nail 3041 installed on the lower surface of the front end of the cantilever 302 extrudes and abuts against the NUT clamp.

[0059] In summary: the fixed tool provided by the present application can fix two kinds of clamps at the same time, so that the two half-shell clamps of the NUT clamp or the NX type clamp are aligned and fixed, the bevel reserved during forging is conveniently welded and filled by the welding device, so that the half-shell clamps of the NUT clamp or the NX type clamp form a whole. Specifically, when the NX type clamp is fixed, the NX type clamp is inserted into the clamp column 202, the sliding plate 203 is moved up and down on the extension plate 2021 according to the force point, when the sliding plate 203 is moved to the appropriate position, the bolt 2031 is rotated, the abutting plate abuts against the outer wall of the NX type clamp through the bolt 2031, in this process, the NX type clamps of the two half-shell clamps are adjusted to be aligned, and then the welding device is used to weld the reserved bevel. When the NUT clamp is fixed, the NUT clamp is inverted on the upper surface of the tool plate 100, when the output end of the air cylinder 301 is extended and retracted, the force is transmitted to the cantilever 302 through the special-shaped pin connecting piece 303, so that the cantilever 302 rotates, when the cantilever 302 rotates to the front end close to the upper surface of the tool plate 100, the press nail 3041 installed on the lower surface of the front end of the cantilever 302 extrudes and abuts against the NUT clamp.

[0060] The above is a further detailed description of the present application in combination with the specific embodiments, and cannot be regarded as a limitation of the specific embodiments of the present application. For ordinary skilled persons in the technical field to which the present application belongs, without departing from the concept of the present application, a number of simple deductions or replacements can be made, which should be regarded as falling within the protection scope determined by the claims of the present application.

Claims

1. A wire clamp fixing fixture, comprising a fixture plate (100), a first clamp (200) mounted on the bottom upper surface of the fixture plate (100), and a second clamp (300) mounted on the top upper surface of the fixture plate (100), characterized in that: The first fixture (200) includes a clamping post (202), and a clearance hole (2022) is provided on the side of the clamping post (202). A wire clamp made by wire clamp forging process is inserted into the clamping post (202), and its wire clamp bevel is aligned with the clearance hole (2022). The second fixture (300) includes a cylinder (301), a lever arm (304) is pinned to the output end of the cylinder (301), and a push pin (3041) is installed on the lower surface of the front end of the lever arm (304). The cylinder (301) drives the lever arm (304) to rotate, and the push pin (3041) fixes the wire clamp made by the wire clamp forging process to the upper surface of the tooling plate (100).

2. The wire clamp fixing fixture according to claim 1, characterized in that: An extension plate (2021) is integrally connected to the upper surface of the clamping column (202). The extension plate (2021) is a half-cylinder. A groove is provided at the center of the outer surface of the extension plate (2021). A sliding plate (203) is slidably connected in the groove. Bolts (2031) are symmetrically arranged on the sliding plate (203). The symmetrically arranged bolts (2031) penetrate the inner wall of the extension plate (2021) and are respectively connected to the arc-shaped abutment plate.

3. The wire clamp fixing fixture according to claim 2, characterized in that: An annular base plate (201) is integrally connected to the bottom of the clamping column (202), and connecting holes are provided at equal intervals on the base plate (201). The first clamp (200) is fixed to the bottom upper surface of the tooling plate (100) through the base plate (201).

4. The wire clamp fixing fixture according to claim 1, characterized in that: A shaped pin plate (303) is pinned to the output end of the cylinder (301) on the second fixture (300). The top end of the shaped pin plate (303) is pinned to the lever arm (304). A fixing plate (3021) is pinned to the front surface of the shaped pin plate (303). A cantilever (302) is symmetrically welded to both sides of the rear surface of the fixing plate (3021), and the tail of the cantilever (302) is pinned to the outer wall of the cylinder (301).

5. The wire clamp fixing fixture according to claim 1, characterized in that: A tooling hole (101) is provided on the upper surface of the tooling plate (100), and a second fixture (300) is symmetrically arranged on both sides of the tooling hole (101).

6. A wire clamp forging process using the wire clamp fixing fixture according to any one of claims 1 to 5, characterized in that: Includes the following steps: Step 1: Cut the sample by centering the wire clamps; Step 2: Casting mold, manufacture forging mold based on the wire clamp cut in Step 1; Step 3: Cutting the material, using a metal band saw to cut the material to the required size; Step 4: Forging. Place the obtained material in the mold cavity and forge it using a 1600T electric screw press to obtain the forging. Step 5: Trim the edges. Place the forging in the cavity of the trimming die and remove any excess flash. Step 6: Shot blasting, using a shot blaster to remove impurities; Step 7: Beveling. Use a shearing tool to cut the outer surfaces of the forged half-shell wire clamp into bevels on both sides. Step 8: Welding. Use the wire clamp fixing fixture to merge the two wire clamp housings, and use a welding tool to weld and fill the bevel. Step 9: Finished product processing, grinding and polishing the welding points and the surface of the clamps.

7. The wire clamp forging process according to claim 6, characterized in that: In step 4, the electric screw press performs three forging operations. The downward speed during the first forging operation is 650±50 r / min, the downward speed during the second forging operation is 550±50 r / min, and the downward speed during the third forging operation is 300±50 r / min.

8. The wire clamp forging process according to claim 7, characterized in that: In step 6, shot blasting is divided into shot blasting cleaning and shot blasting strengthening. Shot blasting cleaning removes surface oxide scale and impurities. Shot blasting strengthening uses a high-speed shot flow to continuously impact the surface of the workpiece to be strengthened, forcing the surface and surface layer of the target material to undergo microstructure modification during cyclic deformation.

9. The wire clamp forging process according to claim 6, characterized in that: In step 7, the outer surface side of the half-shell clamp is beveled at a 30° angle, and the inner end of the bevel of the half-shell clamp is integrally cut with a reserved weld bevel, with a reserved weld spacing of 3 mm.

10. The wire clamp forging process according to claim 9, characterized in that: In step 8, welding is carried out in three layers. The welding method is manual argon arc welding for the root pass and electric welding for the cover pass. The first layer uses 2.4mm diameter argon arc welding wire, current: 160-180A, voltage: 20-25V. The second and third layers use 3.2mm diameter high-strength welding rod CHE507R. The welding rod is dried before welding, and the welding current is 110-130A.

Images