A high-precision positioning gear shaft forging device and method

Abstract

The present invention discloses a high-precision positioning gear shaft forging device and method, belonging to the technical field of forging equipment. A high-precision positioning gear shaft forging device, including a forging machine case, and also includes: a forging base fixedly installed in the forging machine case, a forging shaping die fixedly installed on the forging base; a mounting plate, which is lifted and arranged in the forging machine case; a hydraulic forging part, which is fixedly installed at the bottom of the mounting plate; the present invention can monitor the downward pressing distance and internal pressure in the forging process in real time by integrating a distance measuring sensor and a pressure sensor, and the real-time data feedback ensures the precise control of the forging process, avoiding errors caused by inaccurate manual judgment, and the precise design and positioning mechanism of the forging shaping die ensure that the metal rod can be shaped according to the predetermined shape during the forging process, thereby improving the dimensional accuracy and shape consistency of the product and reducing the scrap rate caused by shape deviation.

Description

Technical Field

[0001] The invention relates to the technical field of forging equipment, and in particular to a high-precision positioning gear shaft forging device. Background Art

[0002] During the forging process of the gear shaft, the metal rod (or blank) does need to be heated to an appropriate temperature, then placed in a die, and the metal rod is forged through a close fit between the hydraulic press and the die to obtain a gear shaft of the desired shape and size.

[0003] At present, during the forging process, the heat of the metal rod will be conducted to the mold, and the inside of the mold will be worn due to the heat of the metal rod and the impact during forging, which will lead to reduced forging accuracy and ultimately cause the processed gear shaft to be unqualified in accuracy. For this reason, a high-precision positioning gear shaft forging device is proposed herein. Summary of the invention

[0004] The present invention is to solve the problem in the prior art that the forging precision is reduced due to the wear of the forging die, and proposes a high-precision positioning gear shaft forging device.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A high-precision positioning gear shaft forging device, comprising a forging machine case, and also comprising: a forging base fixedly mounted in the forging machine case, a forging shaping die fixedly mounted on the forging base; a mounting plate, which is arranged in the forging machine case for lifting; a hydraulic forging part, which is fixedly mounted on the bottom of the mounting plate; a position limiting tube, which is fixedly mounted on the top of the forging shaping die, and the output end of the hydraulic forging part extends into the position limiting tube; an installation cavity is opened in the position limiting tube, a third spring is arranged in the installation cavity, a positioning plate is fixedly mounted on the top of the third spring, and the positioning plate A positioning rod is fixedly installed on the top, and the top of the positioning rod extends to the top of the limiting tube; a distance sensor is fixedly installed in the installation cavity, and is used to detect the height of the positioning plate; a pressure sensor is fixedly installed in the hydraulic forging part, and is used to detect the pressure in the hydraulic forging part; a lower pressure plate is fixedly installed on the moving end of the hydraulic forging part; when the output end of the hydraulic forging part descends to forge the workpiece, the lower pressure plate descends and drives the positioning plate to descend through the positioning rod, and at the same time, the pressure sensor detects the pressure inside the hydraulic forging part, and the distance sensor detects the height of the positioning plate.

[0007] As a preferred embodiment of the present invention: the forging shaping die includes: a mounting base, fixedly mounted on the forging base; a limiting base, which is lifted and lowered on the mounting base, and a lifting mechanism for driving the limiting base to rise and fall is provided at the bottom of the forging base; a gear forging ring, fixedly mounted on the limiting base; a pressing upper die, which is clamped on the gear forging ring, and the limiting tube is fixedly mounted on the top of the pressing upper die.

[0008] As a preferred embodiment of the present invention: the lifting mechanism includes: a third piston cylinder, fixedly mounted on the bottom inner wall of the forging machine box; a piston rod, slidably connected to the third piston cylinder, the bottom of the piston rod extends into the third piston cylinder and is fixedly connected to a third piston plate; a mounting frame, fixedly mounted on the top of the piston rod, a push rod is fixedly connected to the mounting frame, and the push rod passes through the mounting base and is fixedly connected to the limiting base.

[0009] As a preferred embodiment of the present invention: a pressing plate is fixedly connected to the bottom of the mounting plate, and the pressing plate is fixedly connected to the pressing upper die.

[0010] As a preferred embodiment of the present invention: the hydraulic forging part includes: a first piston cylinder fixedly mounted on the bottom of the mounting plate, a first piston plate slidably connected inside the first piston cylinder, a forging rod fixedly mounted on the bottom of the first piston plate, and the forging rod extends into the limiting tube; a first spring, which is sleeved on the forging rod, and its two ends are respectively connected with the first piston cylinder and the first piston plate in abutting relation.

[0011] As a preferred embodiment of the present invention: a driving motor is fixedly installed on the outer wall of the forging machine box, a crankshaft is rotatably installed in the forging machine box, a driving shaft is fixedly installed on the output end of the driving motor, and the driving shaft is connected to the crankshaft through a first ratchet mechanism; a first connecting rod is rotatably connected to the crankshaft, a connecting frame is fixedly connected to the mounting plate, the connecting frame is rotatably connected to the first connecting rod, a cam is arranged on the driving shaft, and the cam is connected to the driving shaft through a second ratchet mechanism, wherein the ratchet directions of the first ratchet mechanism and the second ratchet mechanism are opposite.

[0012] As a preferred embodiment of the present invention: a hydraulic oil tank is fixedly installed in the forging case, a second piston cylinder is fixedly installed on the inner wall of the side wall of the forging case, a second piston plate is slidably connected in the second piston cylinder, a connecting rod is fixedly connected to the second piston plate, a clamping block is fixedly connected to the top of the connecting rod, and the clamping block is slidably connected to the groove of the cam side wall, a first oil pipe connected to the first piston cylinder is fixedly installed at the input end of the bottom of the second piston cylinder, a second oil pipe connected to the hydraulic oil tank is fixedly installed at the input end of the second piston cylinder, and a one-way valve is provided at the output and input ends of the second piston cylinder.

[0013] As a preferred embodiment of the present invention: a mounting cylinder is fixedly connected to the top of the first piston cylinder, the pressure sensor is fixedly installed in the mounting cylinder, a third oil pipe is fixedly installed on the side wall of the mounting cylinder, the third oil pipe is connected to the third piston cylinder, a fourth oil pipe is fixedly connected to the oil discharge port of the third piston cylinder, the fourth oil pipe is connected to the hydraulic oil tank, and an overflow valve is arranged on the fourth oil pipe, and a one-way valve is arranged on the input end of the third piston cylinder; a mounting rod is slidably connected to the mounting cylinder, a flat plate is fixedly connected to the top of the mounting rod, the mounting rod extends to the mounting cylinder and is fixedly connected with a sealing block, a second spring is sleeved on the mounting rod, and the two ends of the second spring are respectively connected to the flat plate and the mounting cylinder in abutment with each other, a driving plate is fixedly installed in the forging machine case, and when the mounting cylinder rises, the driving plate drives the sealing block to descend through the flat plate.

[0014] As a preferred embodiment of the present invention: the crankshaft is rotatably connected with a second connecting rod, the second connecting rod is rotatably connected with a fourth piston plate, a fourth piston cylinder is fixedly installed on the top inner wall of the forging machine box, the output end and the input end of the fourth piston cylinder are both provided with a one-way valve, and the fourth piston plate is slidably arranged in the fourth piston cylinder, and the output end of the fourth piston cylinder is fixedly connected with an air pipe; a cavity is opened in the forging base, and when the limit base rises, the cavity is communicated with the chamber where the casting is placed, and the air pipe is communicated with the cavity;

[0015] When the driving shaft rotates forward from 0° to 180°, the pressing plate is driven to press the forging molding die. In the process of the driving shaft rotating forward from 180° to 360°, the air or cleaning liquid is driven from the bottom of the forging molding die and, with the cooperation of the forging molding die and the gear shaft, high-pressure gas or high-pressure cleaning liquid is formed and evenly dispersed from the bottom of the gear shaft to the side of the gear shaft, and then the high-pressure gas or high-pressure cleaning liquid is sprayed out from the gap between the gear shaft and the top of the forging molding die.

[0016] A high-precision gear shaft forging method comprises the following steps:

[0017] Step 1: Install the heated metal rod into the forging mold;

[0018] Step 2: Drive the pressing upper die to descend and press the gear forging ring;

[0019] Step 3, driving the forging rod to descend to forge the metal rod;

[0020] Step 4: Detect the pressure inside the hydraulic forging part through the pressure sensor, and measure the position of the position measuring plate through the distance measuring sensor. When the value detected by the pressure sensor and the value detected by the distance measuring sensor do not meet the threshold set by the computer system, the computer system alarms;

[0021] Step 5: After forging, the limiting base rises and blows air from the bottom of the forged gear shaft. The gas blows to the surface of the gear shaft and the inner cavity of the forging mold, and is finally discharged through the top of the forging mold.

[0022] Compared with the prior art, the present invention provides a high-precision positioning gear shaft forging device, which has the following beneficial effects:

[0023] 1. The high-precision positioning gear shaft forging device can monitor the pressing distance and internal pressure in the forging process in real time by integrating distance measuring sensors and pressure sensors. Real-time data feedback ensures accurate control of the forging process and avoids errors caused by inaccurate manual judgment. The precise design and positioning mechanism of the forging shaping die ensure that the metal rod can be shaped according to the predetermined shape during the forging process, thereby improving the dimensional accuracy and shape consistency of the product and reducing the scrap rate caused by shape deviation.

[0024] 2. The high-precision positioning gear shaft forging device drives the pressing plate to descend to fix the forging shaping die when the driving shaft rotates forward from 0° to 180°, so as to prevent the forging shaping die from displacement during forging, thereby reducing the forging accuracy. In the process of the driving shaft rotating forward from 180° to 360°, the air or cleaning liquid is driven from the bottom of the forging shaping die and, under the cooperation of the forging shaping die and the gear shaft, high-pressure gas or high-pressure cleaning liquid is formed to be evenly dispersed from the bottom of the gear shaft to the side of the gear shaft, and then the high-pressure gas or high-pressure cleaning liquid is sprayed from the top gap between the gear shaft and the forging shaping die, so as to cool the gear shaft and the forging shaping die and clean both of them. During the cooling and cleaning process, the high-pressure airflow (or water flow) can effectively remove the debris and impurities generated during the forging process, keep the forging die clean, further improve the accuracy and surface quality of the forging parts, and reduce the deformation and cracking caused by thermal stress, thereby improving the stability and durability of the product.

[0025] 3. The high-precision positioning gear shaft forging device makes it easier to demould the forged gear shaft by spraying airflow or cleaning liquid upward from the bottom and cooperating with the rising ejector rod. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the three-dimensional structure of a high-precision positioning gear shaft forging device proposed by the present invention;

[0027] Figure 2 This is a schematic diagram of the internal structure of a high-precision positioning gear shaft forging device proposed by the present invention;

[0028] Figure 3 A high-precision positioning gear shaft forging device proposed by the present invention is a schematic diagram of the crankshaft structure Figure 1 ;

[0029] Figure 4 A cross-sectional view of the internal structure of a forging case of a high-precision positioning gear shaft forging device proposed by the present invention;

[0030] Figure 5 A high-precision positioning gear shaft forging device proposed by the present invention Figure 4 Schematic diagram of the structure of part A;

[0031] Figure 6 A high-precision positioning gear shaft forging device proposed by the present invention Figure 4 The structural diagram of part B;

[0032] Figure 7 A high-precision positioning gear shaft forging device proposed by the present invention Figure 4 Schematic diagram of the structure of part C;

[0033] Figure 8 A high-precision positioning gear shaft forging device proposed by the present invention is a schematic diagram of the crankshaft structure Figure 2 .

[0034] In the figure: 1, forging chassis; 2, forging base; 3, mounting base; 4, limiting base; 5, gear forging ring; 6, pressing upper die; 7, limiting tube; 8, driving shaft; 9, cam; 10, crankshaft; 11, first connecting rod; 12, driving plate; 13, first ratchet mechanism; 14, second ratchet mechanism; 15, driving motor; 16, connecting frame; 17, mounting plate; 18, first piston cylinder; 19, first piston plate; 20, forging rod; 21, first spring; 22, mounting cylinder; 23, sealing block; 24, mounting rod; 25, flat plate; 26, second spring; 27, second spring Plug cylinder; 28, block; 29, connecting rod; 30, second piston plate; 31, first oil pipe; 33, third oil pipe; 34, third piston cylinder; 35, piston rod; 36, third piston plate; 37, fourth oil pipe; 38, relief valve; 39, pressure sensor; 40, hydraulic oil tank; 41, mounting frame; 43, push rod; 45, fourth piston cylinder; 46, second connecting rod; 47, fourth piston plate; 48, air pipe; 49, cavity; 50, pressing plate; 51, mounting cavity; 52, third spring; 53, distance sensor; 54, positioning plate; 55, positioning rod; 56, lower pressure plate. DETAILED DESCRIPTION

[0035] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0036] In the description of the present invention, it is necessary to understand that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0037] Example: Refer to Figure 1-Figure 8A high-precision positioning gear shaft forging device includes a forging machine case 1, and also includes: a forging base 2 fixedly installed in the forging machine case 1, and a forging shaping mold is fixedly installed on the forging base 2, wherein the forging shaping mold includes: a mounting base 3, fixedly installed on the forging base 2; a limiting base 4, which is lifted and arranged on the mounting base 3, and a lifting mechanism for driving the limiting base 4 to lift and lower is arranged at the bottom of the forging base 2; a gear forging ring 5, fixedly installed on the limiting base 4; a pressing upper die 6, which is clamped on the gear forging ring 5, and a limiting tube 7 is fixedly installed on the top of the pressing upper die 6; a mounting plate 17, which is lifted and arranged in the forging machine case 1; a hydraulic forging part, which is fixedly installed at the bottom of the mounting plate 17; a limiting tube 7, which is fixedly installed on the top of the forging shaping mold, and the output end of the hydraulic forging part extends to the limiting tube 7; an installation cavity 51 is opened in the limiting tube 7, a third spring 52 is arranged in the installation cavity 51, a measuring plate 54 is fixedly installed on the top of the third spring 52, a positioning rod 55 is fixedly installed on the top of the measuring plate 54, and the top of the positioning rod 55 extends to the top of the limiting tube 7; a distance sensor 53 is fixedly installed in the installation cavity 51, and is used to detect the height of the measuring plate 54; a pressure sensor 39 is fixedly installed in the hydraulic forging part, and is used to detect the pressure in the hydraulic forging part; a lower pressure plate 56 is fixedly installed on the moving end of the hydraulic forging part; when the output end of the hydraulic forging part descends to forge the workpiece, the lower pressure plate 56 descends and drives the measuring plate 54 to descend through the positioning rod 55, and at the same time, the pressure sensor 39 detects the pressure inside the hydraulic forging part, and the distance sensor 53 detects the height of the measuring plate 54.

[0038] When in use, the heated metal rod is inserted into the limiting base 4, and then the upper die 6 is closed and pressed. After merging, the output end of the hydraulic forging part is driven down to forge the metal rod. During this process, the heated part of the metal rod is squeezed and deformed, and shaped under the action of the forging shaping die.

[0039] During the forging process, the lower pressing plate 56 descends. When the lower pressing plate 56 abuts against the positioning rod 55, the positioning rod 55 drives the positioning plate 54 to descend, and the positioning plate 54 drives the third spring 52 to contract. At the same time, the distance sensor 53 measures the distance between it and the positioning plate 54.

[0040] During the forging process, the pressure inside the hydraulic forging portion increases, and during this process, the pressure sensor 39 detects the pressure inside the hydraulic forging portion.

[0041] It also includes a computer host for controlling the operation of the device, wherein a pressure threshold and a distance threshold are set in the computer host;

[0042] When the pressure reaches the threshold but the distance threshold is not reached, it indicates that there are problems in the forging process:

[0043] 1. The material is too hard or the gap between the dies is inappropriate: If the material hardness of the metal bar is higher than expected, or the gap between the dies is not set enough, then when the predetermined pressure is reached, the metal bar may not be fully compressed to the predetermined position, which may cause the forged gear shaft to be larger in size or the shape to not meet the requirements.

[0044] 2. Hydraulic forging performance issues: The hydraulic forging may have excess performance or inaccurate pressure control, resulting in the pressure threshold being reached before the expected distance is reached.

[0045] When the distance threshold is reached but the pressure threshold is not reached, it indicates the following problems in the forging process:

[0046] 1. The material is too soft or the gap between the dies is too large: If the material hardness of the metal bar is lower than expected, or the gap between the dies is set too large, the required pressure may not reach the predetermined pressure threshold when the predetermined distance is reached, which may result in insufficient strength or density of the forged gear shaft.

[0047] 2. Insufficient pressure in the hydraulic forging section: The hydraulic forging section may have insufficient pressure, resulting in failure to generate sufficient pressure to reach the pressure threshold when the predetermined distance is reached.

[0048] In summary, compared with the existing forging device, this device has the following advantages:

[0049] 1. High-precision positioning and monitoring: "By integrating the distance sensor 53 and the pressure sensor 39, the device can monitor the pressing distance and internal pressure in the forging process in real time to ensure accurate control of the forging process. Combined with the preset threshold in the computer host, when the actual measurement value deviates from the preset range, the system will issue an alarm to prompt the operator to make adjustments in time, thereby avoiding the production of unqualified products."

[0050] 2. Automation and intelligence: "The lifting mechanism, hydraulic forging unit and other components in the device are all automatically controlled, reducing manual intervention and improving production efficiency and consistency. Through the data processing capabilities of the computer host, the device can intelligently judge the status of the forging process and provide decision support for operators."

[0051] 3. Improve product quality: "The precise design and positioning mechanism of the forging shaping die ensures that the metal bar can be shaped according to the predetermined shape during the forging process, improving the dimensional accuracy and shape consistency of the product; real-time monitoring and intelligent feedback mechanisms help to promptly detect and correct problems in the forging process, reducing product defects caused by material, die or equipment problems."

[0052] Reference Figure 7The lifting mechanism includes: a third piston cylinder 34, fixedly mounted on the bottom inner wall of the forging machine box 1; a piston rod 35, slidably connected to the third piston cylinder 34, the bottom of the piston rod 35 extends into the third piston cylinder 34 and is fixedly connected to the third piston plate 36; a mounting frame 41, fixedly mounted on the top of the piston rod 35, a push rod 43 is fixedly connected to the mounting frame 41, and the push rod 43 passes through the mounting base 3 and is fixedly connected to the limiting base 4.

[0053] When the upper die 6 is pressed to separate from the gear forging ring 5, hydraulic oil is injected into the third piston cylinder 34, and the third piston plate 36 and the piston rod 35 are driven to rise by the hydraulic oil. The piston rod 35 drives the push rod 43 to rise through the mounting frame 41, and the push rod 43 drives the limiting base 4 to rise.

[0054] Reference Figure 2 A pressing plate 50 is fixedly connected to the bottom of the mounting plate 17, and the pressing plate 50 is fixedly connected to the pressing upper die 6. During the forging process, the pressing plate 50 applies pressure to the pressing upper die 6 to improve the stability of the forging shaping die and prevent the shaping die from separating during the forging process.

[0055] Reference Figure 2-Figure 8 The hydraulic forging part includes: a first piston cylinder 18 fixedly mounted on the bottom of the mounting plate 17, a first piston plate 19 slidably connected in the first piston cylinder 18, a forging rod 20 fixedly mounted at the bottom of the first piston plate 19, and the forging rod 20 extends into the limiting tube 7; a first spring 21, which is sleeved on the forging rod 20, and the two ends are respectively connected with the first piston cylinder 18 and the first piston plate 19 in abutment with each other; a driving motor 15 is fixedly mounted on the outer wall of the forging machine box 1, a crankshaft 10 is rotatably mounted in the forging machine box 1, and a driving shaft 8 is fixedly mounted on the output end of the driving motor 15, and the driving shaft 8 is connected to the crankshaft 10 through a first ratchet mechanism 13; a first connecting rod 11 is rotatably connected to the crankshaft 10, a connecting frame 16 is fixedly connected to the mounting plate 17, and the connecting frame 16 is rotatably connected to the first connecting rod 11, and a driving shaft 8 is set There is a cam 9, which is connected to the driving shaft 8 through a second ratchet mechanism 14, wherein the ratchet directions of the first ratchet mechanism 13 and the second ratchet mechanism 14 are opposite; a hydraulic oil tank 40 is fixedly installed in the forging case 1, a second piston cylinder 27 is fixedly installed on the inner wall of the side wall of the forging case 1, a second piston plate 30 is slidably connected in the second piston cylinder 27, a connecting rod 29 is fixedly connected to the second piston plate 30, a clamping block 28 is fixedly connected to the top of the connecting rod 29, and the clamping block 28 is slidably connected to the groove of the side wall of the cam 9, a first oil pipe 31 connected to the first piston cylinder 18 is fixedly installed at the input end of the bottom of the second piston cylinder 27, a second oil pipe 32 connected to the hydraulic oil tank 40 is fixedly installed at the input end of the second piston cylinder 27, and a one-way valve is provided at both the output end and the input end of the second piston cylinder 27.

[0056] During forging, first, the driving motor 15 drives the driving shaft 8 to rotate 180° forward. Under the action of the first ratchet mechanism 13 and the second ratchet mechanism 14, the driving shaft 8 drives the crankshaft 10 to rotate 180° forward. The crankshaft 10 drives the mounting plate 17 to descend through the first connecting rod 11. The mounting plate 17 drives the pressing upper die 6 to descend through the pressing plate 50 to engage with the gear forging ring 5. Then, the driving motor 15 drives the driving shaft 8 to rotate in the reverse direction. Under the action of the first ratchet mechanism 13 and the second ratchet mechanism 14, the driving shaft 8 drives the crankshaft 10 to rotate in the forward direction 180°. The crankshaft 10 drives the mounting plate 17 to descend through the first connecting rod 11. The mounting plate 17 drives the pressing upper die 6 to descend through the pressing plate 50 to engage with the gear forging ring 5. The movable cam 9 rotates, and the cam 9 drives the block 28 to reciprocate and rise and fall through the groove of the side wall. During this process, the block 28 drives the second piston plate 30 to reciprocate and rise and fall through the connecting rod 29, absorbs the hydraulic oil in the hydraulic oil tank 40 through the second oil pipe 32, and then transports it into the first piston cylinder 18 through the first oil pipe 31, increasing the pressure in the first piston cylinder 18, driving the first piston plate 19 to descend, and the first piston plate 19 drives the forging rod 20 to descend to cast the metal rod. During this process, the first spring 21 is compressed.

[0057] Reference Figure 4 and Figure 5 The top of the first piston cylinder 18 is fixedly connected to the mounting cylinder 22, the pressure sensor 39 is fixedly installed in the mounting cylinder 22, the side wall of the mounting cylinder 22 is fixedly installed with a third oil pipe 33, the third oil pipe 33 is connected to the third piston cylinder 34, the oil discharge port of the third piston cylinder 34 is fixedly connected with a fourth oil pipe 37, the fourth oil pipe 37 is connected to the hydraulic oil tank 40, and the fourth oil pipe 37 is provided with a relief valve 38, and the input end of the third piston cylinder 34 is provided with a one-way valve; the mounting cylinder 22 is slidably connected with a mounting rod 24, the top of the mounting rod 24 is fixedly connected with a plate 25, the mounting rod 24 extends to the mounting cylinder 22 and is fixedly connected with a sealing block 23, the mounting rod 24 is sleeved with a second spring 26, and the two ends of the second spring 26 are respectively connected with the plate 25 and the mounting cylinder 22 in abutment with each other, and a driving plate 12 is fixedly installed in the forging machine case 1, when the mounting cylinder 22 rises, the driving plate 12 drives the sealing block 23 to descend through the plate 25.

[0058] When the metal rod is cast into a gear shaft, the drive motor 15 is started, and the drive motor 15 is used to drive the active shaft 8 to rotate forward, and the crankshaft 10 is driven to rotate 180° again. The crankshaft 10 drives the mounting plate 17 to rise through the first connecting rod 11. During this process, the flat plate 25 contacts the drive plate 12, and the drive plate 12 drives the flat plate 25 to descend. The flat plate 25 drives the mounting rod 24 to descend, and the mounting rod 24 drives the sealing block 23 to descend. The sealing block 23 descends to connect the third oil pipe 33 with the mounting cylinder 22, and then the first spring 21 is reset. During this process, the hydraulic oil in the first piston cylinder 18 and the mounting cylinder 22 enters the third oil pipe 33, enters the third piston cylinder 34 through the third oil pipe 33, and drives the third piston plate 36 to rise.

[0059] When the pressing plate 50 descends, the pressing upper die 6 applies downward pressure, driving the limit base 4 to descend through the gear forging ring 5 to increase the pressure in the third piston cylinder 34 . When the pressure exceeds the threshold of the overflow valve 38 , the hydraulic pressure in the third piston cylinder 34 enters the hydraulic oil tank 40 .

[0060] Reference Figure 3 , Figure 5 and Figure 8 A second connecting rod 46 is rotatably connected to the crankshaft 10, and a fourth piston plate 47 is rotatably connected to the second connecting rod 46. A fourth piston cylinder 45 is fixedly installed on the top inner wall of the forging case 1. Both the output end and the input end of the fourth piston cylinder 45 are provided with a one-way valve, and the fourth piston plate 47 is slidably arranged in the fourth piston cylinder 45, and the output end of the fourth piston cylinder 45 is fixedly connected to the air pipe 48; a cavity 49 is opened in the forging base 2, and when the limit base 4 rises, the cavity 49 is communicated with the chamber where the casting is placed, and the air pipe 48 is communicated with the cavity 49.

[0061] When the crankshaft 10 rotates to drive the mounting plate 17 to descend, the crankshaft 10 drives the fourth piston plate 47 to descend through the second connecting rod 46, sucking external air into the fourth piston cylinder 45. When the crankshaft 10 rotates to drive the mounting plate 17 to rise, the fourth piston plate 47 rises, driving the air in the fourth piston cylinder 45 to enter the cavity 49. At the same time, the hydraulic oil in the first piston cylinder 18 enters the third piston cylinder 34 to drive the limiting base 4 to rise, so that a gap appears between the limiting base 4 and the mounting base 3, so that the cavity 49 is connected to the inside of the mounting base 3, and the gas is discharged from the bottom of the mounting base 3 to the third piston cylinder 34. Discharge from above. During this process, the gas forms a high-pressure airflow under the cooperation of the gear shaft, the mounting base 3 and the limiting base 4. The high-pressure airflow drives the gear shaft to rise and creates a gap between the gear shaft and the forging molding die. The high-pressure airflow blows through the gap, taking away the heat on the gear shaft and the forging die, accelerating the cooling of both, and taking away the debris (oxidized material) separated from the metal rod during forging, keeping the forging die clean, thereby ensuring the forging accuracy of the next gear shaft. It should be noted that the input end of the fourth piston cylinder 45 can also be connected to a water tank to use water for cooling and cleaning.

[0062] In summary, during the forging process, when the active shaft 8 rotates forward from 0° to 180°, the pressing plate 50 is driven to descend to fix the forging molding die to prevent the forging molding die from displacement during forging, resulting in reduced forging accuracy. During the process of the active shaft 8 rotating forward from 180° to 360°, the air or cleaning liquid is driven from the bottom of the forging molding die and, with the cooperation of the forging molding die and the gear shaft, high-pressure gas or high-pressure cleaning liquid is formed to be evenly dispersed from the bottom of the gear shaft to the side of the gear shaft, and then the high-pressure gas or high-pressure cleaning liquid is sprayed from the top gap between the gear shaft and the forging molding die to cool the gear shaft and the forging molding die while cleaning both. During the cooling and cleaning process, the high-pressure airflow (or water flow) can effectively remove the debris and impurities generated during the forging process, keep the forging mold clean, further improve the accuracy and surface quality of the forging parts, and at the same time reduce problems such as deformation and cracks caused by thermal stress, thereby improving the stability and durability of the product.

[0063] A high-precision gear shaft forging method comprises the following steps:

[0064] Step 1: Install the heated metal rod into the forging mold;

[0065] Step 2: drive the pressing upper die 6 to descend and press the gear forging ring 5;

[0066] Step 3, driving the forging rod 20 downward to forge the metal rod;

[0067] Step 4: Detect the pressure inside the hydraulic forging part through the pressure sensor 39, and measure the position of the position measuring plate 54 through the distance measuring sensor 53. When the value detected by the pressure sensor 39 and the value detected by the distance measuring sensor 53 do not meet the threshold set by the computer system, the computer system alarms;

[0068] Step 5: After forging, the limiting base 4 rises and blows air from the bottom of the forged gear shaft. The gas blows toward the surface of the gear shaft and the inner cavity of the forging mold, and is finally discharged through the top of the forging mold.

[0069] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A high-precision positioning gear shaft forging device, comprising a forging machine box (1), characterized in that: Also includes: A forging base (2) fixedly mounted in the forging machine box (1), wherein a forging shaping die is fixedly mounted on the forging base (2); A mounting plate (17) which is arranged in a lifting manner in the forging machine box (1); A hydraulic forging part, fixedly mounted on the bottom of the mounting plate (17); A limit tube (7) is fixedly mounted on the top of the forging and shaping die, and the output end of the hydraulic forging part extends into the limit tube (7); The limiting tube (7) is provided with an installation cavity (51), a third spring (52) is arranged in the installation cavity (51), a positioning plate (54) is fixedly mounted on the top of the third spring (52), a positioning rod (55) is fixedly mounted on the top of the positioning plate (54), and the top of the positioning rod (55) extends to the top of the limiting tube (7); A distance measuring sensor (53) is fixedly mounted in the mounting cavity (51) and is used to detect the height of the positioning plate (54); a pressure sensor (39), fixedly mounted in the hydraulic forging part, and used for detecting the pressure in the hydraulic forging part; A lower pressing plate (56) fixedly mounted on the moving end of the hydraulic forging section; When the output end of the hydraulic forging section descends to forge the workpiece, the lower pressing plate (56) descends and drives the positioning plate (54) to descend through the positioning rod (55), and at the same time, the pressure sensor (39) detects the pressure inside the hydraulic forging section, and the distance sensor (53) detects the height of the positioning plate (54); The forging shaping die comprises: A mounting base (3) fixedly mounted on the forged base (2); A limiting base (4) is arranged on the mounting base (3) for lifting, and a lifting mechanism for driving the limiting base (4) to be lifted and lowered is arranged at the bottom of the forging base (2); A gear forging ring (5) is fixedly mounted on the limiting base (4); A pressing upper die (6) is clamped on the gear forging ring (5), and the limiting tube (7) is fixedly mounted on the top of the pressing upper die (6); The lifting mechanism comprises: A third piston cylinder (34) fixedly mounted on the bottom inner wall of the forging machine box (1); A piston rod (35) is slidably connected to the third piston cylinder (34), wherein the bottom of the piston rod (35) extends into the third piston cylinder (34) and is fixedly connected to a third piston plate (36); A mounting frame (41) is fixedly mounted on the top of the piston rod (35); a push rod (43) is fixedly connected to the mounting frame (41); the push rod (43) passes through the mounting base (3) and is fixedly connected to the limit base (4); The hydraulic forging section comprises: a first piston cylinder (18) fixedly mounted on the bottom of the mounting plate (17), a first piston plate (19) being slidably connected inside the first piston cylinder (18), a forged rod (20) fixedly mounted on the bottom of the first piston plate (19), and the forged rod (20) extending into the limiting tube (7); The first spring (21) is sleeved on the forged rod (20), and its two ends are respectively in contact with the first piston cylinder (18) and the first piston plate (19).

2. A high-precision positioning gear shaft forging device according to claim 1, characterized in that: A pressing plate (50) is fixedly connected to the bottom of the mounting plate (17), and the pressing plate (50) is fixedly connected to the pressing upper die (6).

3. A high-precision positioning gear shaft forging device according to claim 1, characterized in that: A driving motor (15) is fixedly mounted on the outer wall of the forging machine box (1), a crankshaft (10) is rotatably mounted in the forging machine box (1), a driving shaft (8) is fixedly mounted on the output end of the driving motor (15), and the driving shaft (8) is connected to the crankshaft (10) via a first ratchet mechanism (13); The crankshaft (10) is rotatably connected to a first connecting rod (11), the mounting plate (17) is fixedly connected to a connecting frame (16), the connecting frame (16) is rotatably connected to the first connecting rod (11), the driving shaft (8) is provided with a cam (9), the cam (9) and the driving shaft (8) are connected via a second ratchet mechanism (14), wherein the ratchet teeth of the first ratchet mechanism (13) and the second ratchet mechanism (14) have opposite directions.

4. A high-precision positioning gear shaft forging device according to claim 3, characterized in that: A hydraulic oil tank (40) is fixedly installed in the forging machine case (1), a second piston cylinder (27) is fixedly installed on the inner wall of the side wall of the forging machine case (1), a second piston plate (30) is slidably connected in the second piston cylinder (27), a connecting rod (29) is fixedly connected to the second piston plate (30), a clamping block (28) is fixedly connected to the top of the connecting rod (29), the clamping block (28) is slidably connected to a groove on the side wall of the cam (9), a first oil pipe (31) connected to the first piston cylinder (18) is fixedly installed at the input end of the bottom of the second piston cylinder (27), a second oil pipe (32) connected to the hydraulic oil tank (40) is fixedly installed at the input end of the second piston cylinder (27), and a one-way valve is provided at both the output end and the input end of the second piston cylinder (27).

5. A high-precision positioning gear shaft forging device according to claim 4, characterized in that: The top of the first piston cylinder (18) is fixedly connected to a mounting cylinder (22), the pressure sensor (39) is fixedly installed in the mounting cylinder (22), a third oil pipe (33) is fixedly installed on the side wall of the mounting cylinder (22), the third oil pipe (33) is connected to the third piston cylinder (34), a fourth oil pipe (37) is fixedly connected to the oil discharge port of the third piston cylinder (34), the fourth oil pipe (37) is connected to the hydraulic oil tank (40), and a relief valve (38) is provided on the fourth oil pipe (37), and a one-way valve is provided at the input end of the third piston cylinder (34); The mounting cylinder (22) is slidably connected to a mounting rod (24), a flat plate (25) is fixedly connected to the top of the mounting rod (24), the mounting rod (24) extends into the mounting cylinder (22) and is fixedly connected to a sealing block (23), a second spring (26) is sleeved on the mounting rod (24), two ends of the second spring (26) are respectively connected to the flat plate (25) and the mounting cylinder (22), a driving plate (12) is fixedly installed in the forging machine box (1), and when the mounting cylinder (22) is ascending, the driving plate (12) drives the sealing block (23) to descend via the flat plate (25).

6. A high-precision positioning gear shaft forging device according to claim 3, characterized in that: A second connecting rod (46) is rotatably connected to the crankshaft (10), a fourth piston plate (47) is rotatably connected to the second connecting rod (46), a fourth piston cylinder (45) is fixedly mounted on the top inner wall of the forging machine case (1), both the output end and the input end of the fourth piston cylinder (45) are provided with a one-way valve, and the fourth piston plate (47) is slidably arranged in the fourth piston cylinder (45), and the output end of the fourth piston cylinder (45) is fixedly connected to an air pipe (48); A cavity (49) is provided in the forging base (2); when the limiting base (4) rises, the cavity (49) is communicated with a chamber in which the casting is placed, and the air pipe (48) is communicated with the cavity (49); When the driving shaft (8) rotates forward from 0° to 180°, the pressing plate (50) is driven to press the forging and shaping die. In the process of the driving shaft (8) rotating forward from 180° to 360°, air or cleaning liquid is driven from the bottom of the forging and shaping die and, under the cooperation of the forging and shaping die and the gear shaft, high-pressure gas or high-pressure cleaning liquid is formed and evenly dispersed from the bottom of the gear shaft to the side of the gear shaft, and then the high-pressure gas or high-pressure cleaning liquid is ejected from the gap between the gear shaft and the top of the forging and shaping die.

7. A high-precision gear shaft forging method, using the high-precision positioning gear shaft forging device according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step 1: Install the heated metal rod into the forging mold; Step 2: driving the upper pressing die (6) to descend and press the gear forging ring (5); Step 3, driving the forging rod (20) downward to forge the metal rod; Step 4: Detect the pressure inside the hydraulic forging part through the pressure sensor (39), and at the same time measure the position of the position measuring plate (54) through the distance measuring sensor (53). When the value detected by the pressure sensor (39) and the value detected by the distance measuring sensor (53) do not meet the threshold value set by the computer system, the computer system alarms; Step 5: After forging, the limiting base (4) rises and blows air from the bottom of the forged gear shaft. The gas blows toward the surface of the gear shaft and the inner cavity of the forging mold, and is finally discharged through the top of the forging mold.

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