Molding process of lightweight hub of new energy automobile
By combining forging and casting processes, the problems of poor performance and high cost in the manufacturing of existing aluminum alloy automobile wheels are solved, and lightweight wheels with excellent performance are achieved, reducing production costs and improving structural strength.
Patent Information
- Application Number
- CN202411316782.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-20
- Publication Date
- 2024-12-27
AI Technical Summary
In the existing aluminum alloy automobile wheel hub manufacturing methods, the use of gravity casting or low-pressure casting alone leads to poor performance. However, the forging process is fully adopted, although the performance is excellent, the process procedures are many, the cost is high, and a large number of forging molds is required, which has low production efficiency.
Combining the forging and casting process, the forging device and casting device are used for processing. Through the mutual cooperation of forging and casting, the number of forging molds is reduced, and the production cost is reduced. The residual material ring is wrapped by the rim during the casting process, strengthening the spokes and rims between the spokes and rims. bond density.
It realizes lightweight wheel hub manufacturing with excellent performance, reduces production costs, improves the structural strength of the wheel hub, simplifies the manufacturing process, reduces the number of forged molds, and improves production efficiency.
Smart Images
Figure CN119188174A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of aluminum alloy automobile wheel hub manufacturing, and specifically relates to a molding process for a lightweight wheel hub of a new energy vehicle. Background Art
[0002] The wheels on the market can be divided into steel wheels and alloy wheels according to their materials. Among them, alloy wheels are mostly aluminum alloy wheels. Compared with steel wheels, they are lighter and have better performance. They are high-quality lightweight wheels.
[0003] Existing aluminum alloy automobile wheel manufacturing methods mainly include gravity casting, low-pressure casting, casting spinning and forging spinning. The aluminum alloy wheel manufacturing in my country is mainly based on casting. Due to the constraints of its own cost and forming process, the performance of aluminum alloy automobile wheels produced by gravity casting and low-pressure casting alone is inferior to that of forged aluminum alloy wheels. Although the aluminum alloy automobile wheels that are completely forged have better performance, they have more process procedures and require a large number of forging molds, resulting in low production efficiency and high production costs. Summary of the invention
[0004] In view of the drawbacks of the above-mentioned prior art, the present invention provides a forming process for a lightweight wheel hub for new energy vehicles, which combines forging and casting processes to produce lightweight wheels with better performance and requires fewer forging dies, thereby reducing production costs.
[0005] The invention objective of the present invention is achieved through the following technical solutions: A molding process for a lightweight wheel hub of a new energy vehicle, using a forging device and a casting device for processing, The forging device comprises a first forging upper die, a first forging lower die, a second forging upper die, a second forging lower die, and two first half dies, the two first half dies are matched to form a half die ring; the first forging upper die, the first forging lower die and the half die ring can form a cavity for forging a wheel hub after being assembled; the second forging lower die can be installed on the first forging lower die, the second forging upper die, the second forging lower die and the first forging lower die can form a cavity at the mounting plate, the spoke and the excess material ring of the wheel hub after being assembled, and the cavity space at the excess material ring is smaller than the space at the wheel rim of the wheel hub; The casting device comprises a casting lower film, a casting side mold assembly and a cooling mechanism, the casting side mold assembly comprises two second half molds, the two second half molds are matched to form a half mold ring, the casting lower film extends from bottom to top into the half mold ring of the casting side mold assembly, the second half mold part of the casting side mold assembly covers the casting lower film, the top of the casting lower film is provided with a positioning groove for placing a mounting plate and a spoke, and the casting lower film is provided with a pouring port; the casting lower film and the casting side mold assembly are assembled to form a cavity for pouring a rim; the cooling mechanism is provided in both the second half mold and the casting lower film; The process includes the following steps: Step 1: Select a forged aluminum alloy bar for forging. The second forging upper die, the second forging lower die and the first forging lower die in the forging device cooperate with each other to implement the first forging process on the forged aluminum alloy bar to forge a forged blank, which includes a mounting plate, a spoke and a residual ring; Step 2: placing the forged blank on the casting lower membrane on the casting device, so that the spoke outer end of the forged blank and the residual material ring extend into the mold cavity of the casting device, preheating the residual material ring in the forged blank, pouring aluminum alloy liquid into the mold cavity of the casting device through the pouring port on the casting lower membrane to fill the mold, and solidifying the aluminum alloy liquid from bottom to top through the cooling mechanism to cast the rim blank. At this time, the forged blank and the rim blank are combined, and the residual material ring is wrapped by the rim blank; Step 3: preheat the rim blank and the forging blank, place the forging blank on the first forging lower die, set the rim blank part upward, make the first forging upper die, the first forging lower die and the first half die cooperate with each other, realize the second forging process, and obtain a lightweight wheel hub blank. In the second forging process, the excess ring is deformed together with the rim blank so that the excess ring and the rim blank are more tightly combined; Step 4: Perform machining and painting on the lightweight wheel hub blank to obtain the lightweight wheel hub.
[0006] Preferably, the residual material ring processed in step one is provided with connecting grooves, and the casting aluminum alloy liquid in step two fills the connecting grooves.
[0007] Preferably, the cooling mechanism adopts a water cooling structure.
[0008] Preferably, an exhaust hole is provided at the top of the second half mold.
[0009] Preferably, a guide rail is provided on the outer side of the first half mold, a slider fixed on the first half mold is slidably provided on the guide rail, a laterally arranged oil cylinder is connected to the slider, and the piston rod end of the oil cylinder is fixedly connected to the slider.
[0010] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention combines forging and casting processes to produce lightweight wheel hubs, and requires fewer forging dies. During the first forging, the second forging lower die and the first forging lower die are assembled to form the lower die for the first forging process. During the second forging, the second forging lower die is removed, and the first forging lower die is used as the lower die for the second forging process. The second forging lower die has a simple structure and a low manufacturing cost, which can greatly reduce the forging cost. At the same time, the casting device only includes a casting lower film, a casting side mold assembly and a cooling mechanism, and there is no need for a casting upper film, which simplifies the structure of the forging device and can further reduce the cost of manufacturing lightweight wheel hubs.
[0011] 2. Compared with the casting process, the lightweight wheel hub produced by the present invention combines the forging and casting processes, and has better performance, which can be directly derived from the advantages and disadvantages of the forging process and the casting process; 3. Compared with the complete forging process, the present invention requires fewer forging dies and has lower costs; 4. The excess ring obtained by the first forging is wrapped by the rim blank during the casting process, and by setting the connecting groove, the excess ring and the rim blank are more tightly combined, so that the strength of the combination between the spoke and the rim can be better. In the second forging process, the excess ring and the rim blank are deformed together, which can make the excess ring and the rim blank more tightly combined, so that the final lightweight hub structure has better strength. BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 It is a schematic diagram of the structure between the first forging upper die, the first forging lower die, and the second forging lower die; Figure 2 It is a schematic diagram of the state in which the first forging upper die, the first forging lower die and the second forging lower die cooperate to forge a forging blank; Figure 3 A schematic diagram of placing a forging blank into a casting device; Figure 4 is a schematic diagram of the second forging process; Figure 5 It is a schematic diagram of the forging blank structure; Figure 6 It is a schematic diagram of the state after the casting blank and the rim blank are combined after the casting process; Figure 7 This is a schematic diagram of the structure of a lightweight wheel hub blank; Markings in the figure: 1. first forging upper die, 2. first forging lower die, 3. second forging upper die, 4. second forging lower die, 5. first half die, 6. guide rail, 7. slider, 8. cylinder, 9. casting lower membrane, 10. casting side die assembly, 11. cooling mechanism, 12. second half die, 13. positioning groove, 14. pouring mouth, 15. exhaust hole, 16. mounting plate, 17. spoke, 18. residual material ring, 19. rim, 20. flange. DETAILED DESCRIPTION
[0013] The present invention will be further described below with reference to the embodiments shown in the accompanying drawings: Example 1
[0014] The invention discloses a forming process for a lightweight wheel hub of a new energy vehicle, which is processed by using a forging device and a casting device. like Figure 1 , Figure 2 , Figure 4 As shown, the forging device includes a first forging upper die 1, a first forging lower die 2, a second forging upper die 3, a second forging lower die 4, and two first half dies 5, and the two first half dies 5 are matched to form a half die ring; the first forging upper die 1, the first forging lower die 2 and the half die ring can form a cavity for forging a wheel hub after being assembled; the second forging lower die 4 can be installed on the first forging lower die 2, and the second forging lower die 4 is fixedly connected to the first forging lower die 2 by bolts. The second forging upper die 3, the second forging lower die 4 and the first forging lower die 2 can form the cavity of the mounting plate 16, the spoke 17 and the excess ring 18 of the wheel hub after being assembled. The cavity space of the excess ring 18 is smaller than the space of the wheel rim 20 of the wheel hub; the outer side of the first half die 5 is provided with a guide rail 6, and a slider 7 fixed to the first half die 5 is slidably provided on the guide rail 6, and a horizontally arranged oil cylinder 8 is connected to the slider 7, and the piston rod end of the oil cylinder 8 is fixedly connected to the slider 7.
[0015] like Figure 3 As shown, the casting device includes a casting lower film 9, a casting side mold assembly 10 and a cooling mechanism 11, the casting side mold assembly 10 includes two second half molds 12, the two second half molds 12 are matched to form a half mold ring, and the top position of the second half mold 12 is provided with an exhaust hole 15; the casting lower film 9 extends from bottom to top into the half mold ring of the casting side mold assembly 10, and the second half mold 12 of the casting side mold assembly 10 partially covers the casting lower film 9, and the top of the casting lower film 9 is provided with a positioning groove 13 for placing the mounting plate 16 and the spoke 17, and the casting lower film 9 is provided with a pouring port 14; the casting lower film 9 and the casting side mold assembly 10 are assembled to form a cavity for pouring the rim 19; the cooling mechanism 11 is provided in both the second half mold 12 and the casting lower film 9, and the cooling mechanism 11 adopts a water-cooling structure.
[0016] The process includes the following steps: Step 1: Select a forged aluminum alloy bar for forging. The second forging upper die 3, the second forging lower die 4, and the first forging lower die 2 in the forging device cooperate with each other to implement the first forging process on the forged aluminum alloy bar to forge a forged blank. Figure 5 As shown, the forged blank includes a mounting plate 16, a spoke 17 and a residual material ring 18. The processed residual material ring 18 is provided with connecting grooves. The setting of the connecting grooves makes the outer surface of the residual material ring 18 not a flat plane. The second forging lower die 4 is used in the first forging process to reserve a certain space for the subsequent casting of the rim blank so that the cast rim blank can fully or partially wrap the residual material ring 18.
[0017] Step 2: Place the forged blank on the casting lower film 9 on the casting device, so that the outer end of the spoke 17 of the forged blank and the residual ring 18 extend into the mold cavity of the casting device, preheat the residual ring 18 in the forged blank, and pour the cast aluminum alloy liquid into the mold cavity of the casting device through the pouring port 14 on the casting lower film 9 to fill the mold. The cast aluminum alloy liquid fills the connecting groove, and the aluminum alloy liquid is solidified from bottom to top through the cooling mechanism 11 to cast the rim blank. At this time, the forged blank and the rim blank are combined, and the residual ring 18 is wrapped by the rim blank. Figure 6 shown.
[0018] Step 3: preheat the rim blank and the forging blank, place the forging blank on the first forging lower die 2, set the rim blank part upward, make the first forging upper die 1, the first forging lower die 2 and the first half die 5 cooperate with each other, realize the second forging process, and obtain a lightweight wheel hub blank, such as Figure 7 As shown, in the second forging process, the residual ring 18 is deformed together with the rim blank so that the residual ring 18 and the rim blank are more tightly combined; Step 4: Perform machining and painting on the lightweight wheel hub blank to obtain the lightweight wheel hub.
[0019] According to tests, the lightweight wheel hub formed by the present invention has a structural strength that is significantly better than that of a wheel hub formed entirely by casting.
[0020] It should be understood that in the claims and description of the present invention, all "including..." should be understood as an open-ended meaning, that is, its meaning is equivalent to "at least contains...", and should not be understood as a closed meaning, that is, its meaning should not be understood as "only includes...".
[0021] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.
Claims
1. A molding process for a lightweight wheel hub for a new energy vehicle, characterized in that: Processing using forging and casting equipment, The forging device comprises a first forging upper die, a first forging lower die, a second forging upper die, a second forging lower die, and two first half dies, the two first half dies are matched to form a half die ring; the first forging upper die, the first forging lower die and the half die ring can form a cavity for forging a wheel hub after being assembled; the second forging lower die can be installed on the first forging lower die, the second forging upper die, the second forging lower die and the first forging lower die can form a cavity at the mounting plate, the spoke and the excess material ring of the wheel hub after being assembled, and the cavity space at the excess material ring is smaller than the space at the wheel rim of the wheel hub; The casting device comprises a casting lower film, a casting side mold assembly and a cooling mechanism, the casting side mold assembly comprises two second half molds, the two second half molds are matched to form a half mold ring, the casting lower film extends from bottom to top into the half mold ring of the casting side mold assembly, the second half mold part of the casting side mold assembly covers the casting lower film, the top of the casting lower film is provided with a positioning groove for placing a mounting plate and a spoke, and the casting lower film is provided with a pouring port; the casting lower film and the casting side mold assembly are assembled to form a cavity for pouring a rim; the cooling mechanism is provided in both the second half mold and the casting lower film; The process includes the following steps: Step 1: Select a forged aluminum alloy bar for forging. The second forging upper die, the second forging lower die and the first forging lower die in the forging device cooperate with each other to implement the first forging process on the forged aluminum alloy bar to forge a forged blank, which includes a mounting plate, a spoke and a residual ring; Step 2: placing the forged blank on the casting lower membrane on the casting device, so that the spoke outer end of the forged blank and the residual material ring extend into the mold cavity of the casting device, preheating the residual material ring in the forged blank, pouring aluminum alloy liquid into the mold cavity of the casting device through the pouring port on the casting lower membrane to fill the mold, and solidifying the aluminum alloy liquid from bottom to top through the cooling mechanism to cast the rim blank. At this time, the forged blank and the rim blank are combined, and the residual material ring is wrapped by the rim blank; Step 3: preheat the rim blank and the forging blank, place the forging blank on the first forging lower die, set the rim blank part upward, make the first forging upper die, the first forging lower die and the first half die cooperate with each other, realize the second forging process, and obtain a lightweight wheel hub blank. In the second forging process, the excess ring is deformed together with the rim blank so that the excess ring and the rim blank are more tightly combined; Step 4: Perform machining and painting on the lightweight wheel hub blank to obtain the lightweight wheel hub.
2. The molding process of a lightweight wheel hub for new energy vehicles according to claim 1 is characterized in that The residual material ring processed in step one is provided with connecting grooves, and the casting aluminum alloy liquid in step two fills the connecting grooves.
3. The molding process of a lightweight wheel hub for new energy vehicles according to claim 1 is characterized in that ,The cooling mechanism adopts a water cooling structure.
4. The molding process of a lightweight wheel hub for new energy vehicles according to claim 1 is characterized in that , an exhaust hole is provided at the top of the second half mold.
5. The molding process of a lightweight wheel hub for new energy vehicles according to claim 1 is characterized in that A guide rail is provided on the outer side of the first half mold, and a slider fixed on the first half mold is slidably provided on the guide rail. The slider is connected to a horizontally arranged oil cylinder, and the end of the piston rod of the oil cylinder is fixedly connected to the slider.
Citation Information
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