A method for manufacturing an axial lead of a collector ring device

Abstract

The present invention discloses a method for manufacturing an axial lead of a collector ring device, and the method comprises: selecting raw materials and performing hot forging to obtain a preliminary forging, specifically, upsetting, drawing, and rounding the raw materials; performing cold forging on the preliminary forging, specifically, reheating the preliminary forging to 300-350°C, keeping the temperature for 5-6 hours, and performing rounding on the preliminary forging after keeping the temperature by a slamming die manufactured by a preset process; performing solid solution aging heat treatment on the preliminary forging after cold forging; processing the preliminary forging after solid solution aging heat treatment to obtain a final forging, including: dividing the preliminary forging into two along the axial direction, processing a dividing surface; assembling two axial leads on a turning template and performing external cylindrical processing on the preliminary forging to a predetermined size, disassembling the turning template, and obtaining a final forging. The present invention can effectively reduce consumables, shorten processing time, and significantly improve the strength of forgings.

Description

Technical Field

[0001] The invention relates to the field of electromechanics, and in particular to a method for manufacturing an axial lead of a collector ring device. Background Art

[0002] Collector rings, also known as slip rings, are generally used in high-performance, high-precision equipment. They are of great help to the rotational movement of high-end industrial electrical equipment and precision electrical equipment. They are often used in aerospace equipment, automatic processing equipment, mining equipment, medical equipment, radar equipment, etc. Slip rings provide these equipment with a reliable energy signal transmission solution, thereby achieving more complex movements. Among them, the role of the axial lead in the slip ring rotor is to transmit electrical energy from the fixed part (stator) to the rotating part (rotor), ensuring that the rotating body can obtain the necessary power supply while rotating continuously.

[0003] The current manufacturing of such products is to forge into strip copper forgings and then process the products. The products will form larger forging inclusion blocks due to the change in product shape. The larger the forging, the more difficult it is to fully knead the material during the deformation process, so large-tonnage forging equipment and extended heating time will be selected. At the same time, in order to improve the performance assessment requirements, the forgings also increase the amount of deformation for cold forging technology, making the process more complicated. Large inclusion blocks also increase heat treatment time and machining time, and the energy and material consumption are very serious, which cannot meet the development needs of modern enterprises. Summary of the invention

[0004] In view of the above-mentioned shortcomings currently existing, the present invention provides a method for manufacturing an axial lead of a collector ring device, which can effectively reduce consumables, shorten processing time, and significantly improve the strength of forgings.

[0005] To achieve the above object, the embodiments of the present invention adopt the following technical solutions:

[0006] A method for manufacturing an axial lead of a collector ring device, the method comprising:

[0007] Selecting raw materials and performing hot forging to obtain initial forgings, specifically, performing upsetting, drawing, and rounding treatments on the raw materials;

[0008] The initial forgings are cold forged, specifically, the initial forgings are reheated to 300-350°C, kept warm for 5-6 hours, and the initial forgings after heat preservation are rounded by a tumbling die manufactured by a preset process;

[0009] Performing solid solution aging heat treatment on the initial forgings after cold forging;

[0010] The final forging is obtained by processing the initial forging after the solid solution aging heat treatment, including: dividing the initial forging into two parts along the axial direction and processing the dividing surface; assembling two axial leads on the turning template and performing external cylindrical processing on the initial forging to a predetermined size, disassembling the turning template, and obtaining the final forging.

[0011] According to one aspect of the present invention, the raw material is a chromium-zirconium-copper material, wherein Zr: 0.05-0.25%, Cr: 0.50-1.50%, and Cu+Cr+Zr≥99.7%.

[0012] According to one aspect of the present invention, the initial forging after heat preservation is subjected to rounding treatment by a tumbling die manufactured by a preset process. Specifically, the forging is subjected to rounding treatment by the tumbling die so that the deformation of the forging is 15-20 mm.

[0013] According to one aspect of the present invention, the raw material is selected and hot forged to obtain the initial forging, specifically, the raw material is heated to 650-850°C, the raw material is upset and stretched, and after the last stretching, the raw material is shouldered, the residual material is pulled out, and the raw material is rounded to obtain the initial forging.

[0014] According to one aspect of the present invention, the preset process includes: selecting a blank that meets the forging requirements; casting the blank to obtain a casting; and processing the casting to obtain a die.

[0015] According to one aspect of the present invention, the falling mold includes a falling mold base, a falling mold upper buckle and a falling mold lower buckle.

[0016] According to one aspect of the present invention, the casting is processed to obtain a falling mold, specifically, the cavities of the falling mold upper buckle and the falling mold lower buckle are processed, and the cavities of the falling mold upper buckle and the falling mold lower buckle are processed to leave a mold gap.

[0017] According to one aspect of the present invention, the mold clearance is 10-15 mm.

[0018] According to one aspect of the present invention, the planar symmetry of the vehicle template is not greater than 0.05 mm, and the flatness is not greater than 0.05 mm.

[0019] The advantages of the implementation of the present invention are as follows: (1) The amount of forging surface removed is small, which shortens the processing time and can also maximize the integrity of the original metal flow lines inside the forging and the amount of heat-treated surface retention, so that the product has higher strength performance and is easy to extend the product's service life.

[0020] (2) Assembling two products is suitable for batch processing of products. It can also ensure the uniformity and interchangeability of product dimensions, avoid trimming during equipment assembly, and facilitate equipment installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0022] Figure 1 It is a structural schematic diagram of the present invention;

[0023] Figure 2 is a flow chart of the present invention;

[0024] Figure 3 This is a schematic diagram of forming a raw material by hot forging to obtain a preliminary forging according to the present invention;

[0025] Figure 4 This is a first forming schematic diagram of cold forging a rough forging according to the present invention;

[0026] Figure 5 This is a second forming schematic diagram of cold forging the initial forging according to the present invention;

[0027] Figure 6 It is the heat treatment process curve diagram of the present invention;

[0028] Figure 7 It is a structural schematic diagram of the vehicle template of the present invention;

[0029] Figure 8 It is a structural schematic diagram of the mold breaking tooling of the present invention;

[0030] Fig. 9 It is a schematic diagram of Comparative Example 1 of the present invention;

[0031] Fig.10 It is a schematic diagram of the product of the present invention.

[0032] 1. Slip ring; 2. Diverter ring; 3. Drop mold seat; 4. Drop mold upper buckle; 5. Drop mold lower buckle; 6. Turning mold plate. DETAILED DESCRIPTION

[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] Comparative Example 1:

[0035] Existing methods for manufacturing axial leads:

[0036] like Fig. 9 As shown, a method for manufacturing an axial lead of a collector ring device, the method for manufacturing an axial lead of a collector ring device comprising:

[0037] S1: Select raw materials and perform hot forging to obtain initial forgings;

[0038] Select the raw materials and forge them to obtain rectangular long strips of initial forgings (such as Fig. 9 (shown by the solid line).

[0039] The raw material is chromium-zirconium-copper material.

[0040] S2: machining the initial forging to obtain the product;

[0041] Machining of the initial forging to obtain a semi-circular product with a step (such as Fig. 9 (shown by dashed line)

[0042] Products manufactured using the above method will form larger forging inclusion blocks due to the change in product shape. The larger the forging, the more difficult it is to fully knead the material during the deformation process, so large-tonnage forging equipment and extended heating time will be selected. At the same time, in order to improve the performance assessment requirements, the forging will also increase the amount of deformation for cold forging technology, making the process more complicated. Large inclusion blocks also increase heat treatment time and machining time. Example

[0043] like Figure 1 , Figure 2 As shown, a method for manufacturing an axial lead of a collector ring device, the method for manufacturing an axial lead of a collector ring device comprising:

[0044] S1: Select raw materials and perform hot forging to obtain initial forgings.

[0045] The axial lead is accompanied by the collector ring rotor running at high speed under the condition of 3000r / min, so the raw material is selected from chromium-zirconium-copper material, and the chemical composition should meet the following requirements: Zr: 0.05-0.25%, Cr: 0.50-1.50%, Cu+Cr+Zr≥99.7%, and the performance requirements should meet the following table:

[0046]

[0047] The raw material is heated to 650-850℃ to make full use of the excellent plasticity of the raw material. After the first fire: upsetting height ≤300, drawing length ≥600; second fire: upsetting height ≤300, drawing length ≥900, end shoulder pressing, excess material, excess material foot pulling, buckle round (such as Figure 3As shown in the figure, the initial forging is obtained. After the initial forging is subjected to multiple upsetting and stretching by the forging hammer, the internal metal flow lines are complete and the structure is compact.

[0048] S2: Cold forging the initial forging.

[0049] In order to ensure that copper forgings have reliable mechanical properties, cold forging at low temperatures is a necessary process choice.

[0050] S201: heating the initial forging after cooling treatment.

[0051] After the hot forging is completely cooled, the cooled forging is reheated to 300-350°C and given a longer insulation time of 5-6 hours to allow the forging to be fully heated through.

[0052] S202: The heat-insulated initial forgings are subjected to rounding treatment by using a tumbling die manufactured by a preset process.

[0053] Mold throwing: The process R&D personnel follow the requirement that the tooling and molds should be economical and have a high reuse rate, and design the mold throwing tooling separately into a mold throwing base, a mold upper buckle, and a mold lower buckle to improve the versatility of the mold throwing.

[0054] In this embodiment, the hole size of the die base is φ350 mm, and the buckle circle range of the upper and lower buckles of the die is set at φ20 mm~φ300 mm. In actual production, upper and lower buckles of various specifications of the die can be designed and manufactured according to product requirements, and replaced in the die base to complete the forging of products of different specifications.

[0055] Using a throw mold (such as Figure 4 As shown in the figure, the initial forgings after insulation are subjected to rounding treatment so that the forgings maintain a deformation of 15-20mm, which can make the forgings have high strength in the original state and prepare for the subsequent solution aging heat treatment.

[0056] Forgings are cold deformed in the temperature range of 300-350℃ to ensure the best mechanical properties. This is a new attempt in process development, and it is a reflection of the process personnel's skilled control of copper material properties and a summary of process experience in this manufacturing field.

[0057] Preset process:

[0058] Before forging, the forging process plan is determined through dimensional design and 3D simulation.

[0059] S211: Select the blank that meets the tooling forging requirements.

[0060] The material used for the mold throwing tooling is 40Cr.

[0061] S212: Casting the blank to obtain a die seat, a die upper buckle and a die lower buckle.

[0062] The die base, die upper buckle and die lower buckle are obtained by casting. Since the die base needs to be used for a long time under the impact of the forging hammer, impact resistance, high strength and heavy structure are its important characteristics.

[0063] S213: Processing the cavity of the upper buckle of the throwing mold and the lower buckle of the throwing mold.

[0064] The cavities of the upper and lower buckles of the throwing die are processed, and a 10mm-15mm gap is left for the die. The upper and lower buckles of the post-throwing die are also used for a long time under the impact of the forging hammer, and require sufficient strength, but the surface hardness should be controlled at 300-330HBW to prevent breakage.

[0065] S3: Perform solid solution aging heat treatment on the initial forging after cold forging.

[0066] After cold rounding, the initial forging has high strength performance, but it cannot meet the design requirements of normal operation of the equipment, and it still needs to be heat treated. The heat treatment system should adopt the solid solution aging method. After a long time of heat preservation at 350℃ in the furnace, the internal structure of the forging will be more uniform and the performance data will be more representative.

[0067] The cold forged forgings are subjected to solution aging heat treatment. Specifically, the temperature is heated to no higher than 600°C, the temperature is averaged to 350±10°C, 1 to 3 hours, the temperature is kept for 3 hours, and the temperature is cooled to no higher than 70°C in air. The heat treatment process curve is as follows: Figure 6 shown.

[0068] S4: Processing the heat-treated initial forgings to obtain final forgings.

[0069] Embodiment 2:

[0070] like Figure 1 , Figure 2 As shown, a method for manufacturing an axial lead of a collector ring device, the method for manufacturing an axial lead of a collector ring device comprising:

[0071] S1: Select raw materials and perform hot forging to obtain initial forgings.

[0072] The axial lead is accompanied by the collector ring rotor running at high speed under the condition of 3000r / min, so the raw material is selected from chromium-zirconium-copper material, and the chemical composition should meet the following requirements: Zr: 0.05-0.25%, Cr: 0.50-1.50%, Cu+Cr+Zr≥99.7%, and the performance requirements should meet the following table:

[0073]

[0074] The raw material is heated to 650-850℃ to make full use of the excellent plasticity of the raw material. After the first fire: upsetting height ≤300, drawing length ≥600; second fire: upsetting height ≤300, drawing length ≥900, end shoulder pressing, excess material, excess material foot pulling, buckle round (such as Figure 3 As shown in the figure, the initial forging is obtained. After the initial forging is subjected to multiple upsetting and stretching by the forging hammer, the internal metal flow lines are complete and the structure is compact.

[0075] S2: Cold forging the initial forging.

[0076] In order to ensure that copper forgings have reliable mechanical properties, cold forging at low temperatures is a necessary process choice.

[0077] S201: heating the initial forging after cooling treatment.

[0078] After the hot forging is completely cooled, the cooled forging is reheated to 300-350°C and given a longer insulation time of 5-6 hours to allow the forging to be fully heated through.

[0079] S202: The heat-insulated initial forgings are subjected to rounding treatment by using a tumbling die manufactured by a preset process.

[0080] Mold throwing: The process R&D personnel follow the requirement that the tooling and molds should be economical and have a high reuse rate, and design the mold throwing tooling separately into a mold throwing base, a mold upper buckle, and a mold lower buckle to improve the versatility of the mold throwing.

[0081] In this embodiment, the hole size of the die base is φ350 mm, and the buckle circle range of the upper and lower buckles of the die is set at φ20 mm~φ300 mm. In actual production, upper and lower buckles of various specifications of the die can be designed and manufactured according to product requirements, and replaced in the die base to complete the forging of products of different specifications.

[0082] Using a throw mold (such as Figure 4 As shown in the figure, the initial forgings after insulation are subjected to rounding treatment so that the forgings maintain a deformation of 15-20mm, which can make the forgings have high strength in the original state and prepare for the subsequent solution aging heat treatment.

[0083] Forgings are cold deformed in the temperature range of 300-350℃ to ensure the best mechanical properties. This is a new attempt in process development, and it is a reflection of the process personnel's skilled control of copper material properties and a summary of process experience in this manufacturing field.

[0084] Preset process:

[0085] Before forging, the forging process plan is determined through dimensional design and 3D simulation.

[0086] S211: Select the blank that meets the tooling forging requirements.

[0087] The material used for the mold throwing tooling is 40Cr.

[0088] S212: Casting the blank to obtain a die seat, a die upper buckle and a die lower buckle.

[0089] The die base, die upper buckle and die lower buckle are obtained by casting. Since the die base needs to be used for a long time under the impact of the forging hammer, impact resistance, high strength and heavy structure are its important characteristics.

[0090] S213: Processing the cavity of the upper buckle of the throwing mold and the lower buckle of the throwing mold.

[0091] The cavities of the upper and lower buckles of the throwing die are processed, and a 10mm-15mm gap is left for the die. The upper and lower buckles of the post-throwing die are also used for a long time under the impact of the forging hammer, and require sufficient strength, but the surface hardness should be controlled at 300-330HBW to prevent breakage.

[0092] S3: Perform solid solution aging heat treatment on the initial forging after cold forging.

[0093] After cold rounding, the initial forging has high strength performance, but it cannot meet the design requirements of normal operation of the equipment, and it still needs to be heat treated. The heat treatment system should adopt the solid solution aging method. After a long time of heat preservation at 350℃ in the furnace, the internal structure of the forging will be more uniform and the performance data will be more representative.

[0094] The cold forged forgings are subjected to solution aging heat treatment. Specifically, the temperature is heated to no higher than 600°C, the temperature is averaged to 350±10°C, 1 to 3 hours, the temperature is kept for 3 hours, and the temperature is cooled to no higher than 70°C in air. The heat treatment process curve is as follows: Figure 6 shown.

[0095] S4: Before processing, physical and chemical tests are carried out on the initial forgings after heat treatment.

[0096] Physical and chemical tests are used to detect whether the initial forgings after heat treatment meet the predetermined standards.

[0097] S5: Processing the heat-treated initial forging to obtain the final forging.

[0098] S501: Divide the forged piece into two parts along the axial direction and process the dividing surface;

[0099] The forging is divided into two parts along the axial direction, and the dividing surface is milled.

[0100] In this embodiment, the forging is first divided into two along the axial direction, and the dividing surface is milled; a 35 mm process step and a φ17 mm process hole are processed at both ends of the forging.

[0101] S502: Assemble the two axial leads on the turning template and perform external cylindrical machining on the initial forging.

[0102] like Figure 4 As shown, two axial leads are assembled, a turning template is added in the middle, and the outer circle of the turned product is increased to a predetermined size.

[0103] The turning template mainly acts as a cushion between two axial leads, so that two axial leads can be processed simultaneously during turning, and the axial leads are processed to the same size. The thickness of the turning template is 12mm (+0.05, -0.10), the plane symmetry is ≤0.05mm, and the flatness is ≤0.05mm. This design accuracy requirement is a prerequisite to ensure that the size of the axial lead is met after processing.

[0104] In this embodiment, after the two axial leads are assembled, a 12 mm thick turning template is installed in the middle, and two sets of M16 bolts are used to fasten the two ends of the turning template.

[0105] S503: Process the initial forging after the outer circle processing to a predetermined size to obtain a final forging.

[0106] like Figure 5 As shown in the figure, after the outer circle machining is completed, the lathe plate is removed and the product design length is milled. The machining of two axial leads is completed at one time, saving nearly half the time.

[0107] like Figure 4 As shown, the mechanical data comparison before and after optimization:

[0108]

[0109] The final product is Fig.10 shown.

[0110] The process advantages of the present invention are:

[0111] 1. Save raw materials:

[0112] The forgings before optimization (Comparative Example 1) were forged according to the original specifications (forging size 1570mm×230mm×125mm), consuming 390kg / piece of raw materials, and the equipment consumed 780kg of raw materials for two products. The forgings after optimization (Example 1) were forged to obtain the same product specifications as Comparative Example 1, consuming 367kg of raw materials in total, saving 2.13 times the raw materials before.

[0113] 2. Improved mechanical properties:

[0114] The forgings are cold forged at low temperature and then forged by tumbling and rounding. The forgings have a small processing allowance, a round surface, a uniform and tight internal structure, and a significantly improved strength, leaving enough margin for subsequent solution aging heat treatment of the forgings.

[0115] 3. Time-saving processing:

[0116] The product processing method before optimization required the combination of a plane milling machine and a machining center, which would place high demands on the selection of processing equipment.

[0117] First, the surface milling machine is used for roughing and removing the surface machining allowance. Then the machining center is used to mill the product outline size. During the processing, due to the high requirements for the surface roughness of the product, the machining center needs to process in layers, so each piece of processing takes 35-40 hours. In addition, due to the large amount of surface removal of the forging, the metal flow inside the product is incomplete and the heat treatment surface removal is large, which affects the service life of the product.

[0118] In this embodiment, only 8-10mm machining allowance is left on the surface of the forging after optimization. The processing method is to first divide the forging into two along the axial direction, milling the dividing surface; processing 35mm process steps and φ17mm process holes at both ends of the forging; and then assembling the two axial leads ( Figure 5 ), add 12mm car template in the middle ( Figure 8 ), two sets of M16 bolts are used to tighten each end; the outer diameter of the product is turned to the designed size; after the outer diameter is processed, the lathe template is removed and the product is milled to the designed length. The processing of two axial leads is completed at one time, saving nearly half the time.

[0119] Benefits of optimized manufacturing process:

[0120] 1. No amount of forging surface needs to be removed, which shortens the processing time and can also maximize the integrity of the original metal flow lines inside the forging and the amount of heat-treated surface retention, making the product have higher strength performance and easily extending the product's service life.

[0121] 2. The cold bending (cold forging buckle circle) forming process is easy to master, the manufacturing process is convenient and fast, the product shape is stable and uniform, and it is suitable for mass production.

[0122] The above is only an embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by any technician familiar with the art within the technical scope disclosed in the present invention should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention shall be based on the protection scope of the claims.

Claims

1. A method for manufacturing an axial lead of a collector ring device, characterized in that: The manufacturing method of the axial lead of the collector ring device comprises: Selecting raw materials and performing hot forging to obtain initial forgings, specifically, performing upsetting, drawing, and rounding treatments on the raw materials; The initial forgings are cold forged, specifically, the initial forgings are reheated to 300-350°C, kept warm for 5-6 hours, and the initial forgings after heat preservation are rounded by a tumbling die manufactured by a preset process; Performing solid solution aging heat treatment on the initial forgings after cold forging; The final forging is obtained by processing the initial forging after the solid solution aging heat treatment, including: dividing the initial forging into two parts along the axial direction and processing the dividing surface; assembling two axial leads on the turning template and performing external cylindrical processing on the initial forging to a predetermined size, disassembling the turning template, and obtaining the final forging.

2. The method for manufacturing an axial lead of a slip ring device according to claim 1, characterized in that: The raw material is chromium-zirconium-copper material, wherein Zr: 0.05-0.25%, Cr: 0.50-1.50%, Cu+Cr+Zr≥99.7%.

3. The method for manufacturing an axial lead of a slip ring device according to claim 1, characterized in that: The initial forgings after heat preservation are subjected to rounding treatment by a dropping die manufactured by a preset process. Specifically, the forgings are subjected to rounding treatment by the dropping die so that the deformation of the forgings is 15-20 mm.

4. The method for manufacturing an axial lead of a slip ring device according to claim 1, characterized in that: The raw material is selected and hot forged to obtain the initial forging, specifically, the raw material is heated to 650-850° C., the raw material is upset and stretched, and after the last stretching, the raw material is shouldered, the residual material is pulled out, and the raw material is rounded to obtain the initial forging.

5. The method for manufacturing an axial lead of a slip ring device according to claim 1, characterized in that: The preset process includes: selecting a blank that meets the forging requirements; casting the blank to obtain a casting; and processing the casting to obtain a die.

6. The method for manufacturing an axial lead of a slip ring device according to claim 5, characterized in that: The throwing mold comprises a throwing mold base, an upper throwing mold buckle and a lower throwing mold buckle.

7. A method for manufacturing an axial lead of a slip ring device according to claim 6, characterized in that: The casting is processed to obtain a throwing mold, specifically, the cavities of the upper buckle and the lower buckle of the throwing mold are processed, and a mold clearance is left after the cavities of the upper buckle and the lower buckle of the throwing mold are processed.

8. The method for manufacturing an axial lead of a slip ring device according to claim 7, characterized in that: The mold clearance is 10-15 mm.

9. The method for manufacturing an axial lead of a slip ring device according to claim 8, characterized in that: The plane symmetry of the car template is not greater than 0.05mm, and the flatness is not greater than 0.05mm.

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