Integral forming process of aluminum piston

Abstract

The present invention discloses an integrated forming process for aluminum pistons, which relates to the technical field of integrated forming of aluminum pistons. The present invention includes the following steps: aluminum rod cutting, flame heating, primary forming, secondary stamping, and high-temperature and low-temperature switching heating. By adjusting the height of the cylinder column through an electric push rod, non-electric clamping and fixing during the piston stamping and forming process can be completed. At the same time, the piston during the clamping process can be limited in movement, improving the overall stability during secondary stamping in the piston integrated forming process. Meanwhile, in combination with the clamping mechanism on the first transmission mechanism and the limit handling mechanism installed on the second transmission mechanism, mechanical handling of the aluminum column in the stamping table during the piston integrated forming process is realized, improving the piston stamping and forming efficiency while enhancing the overall safety of the operation.

Description

Technical Field

[0001] The present invention relates to the technical field of integrated forming of aluminum pistons, and specifically to an integrated forming processing technology for aluminum pistons. Background Art

[0002] With the increasingly strict requirements of the whole vehicle for the power performance, economy, environmental protection and reliability of the engine, pistons have developed into high-tech products integrating a number of new technologies such as lightweight and high-strength new materials, special-shaped outer circle composite surfaces, and special-shaped pin holes, so as to ensure the heat resistance, wear resistance, stable guiding performance and good sealing function of the pistons, reduce the frictional work loss of the engine, and reduce fuel consumption, noise and emissions.

[0003] As a typical key automotive component, the piston has strong process characteristics in cutting processing. In the domestic piston manufacturing industry, the machining production line is usually composed of general machine tools and special equipment combined with the process characteristics of the piston. Therefore, the special equipment has become the key equipment for piston cutting processing, and its function and accuracy will directly affect the quality indexes of the key characteristics of the final product.

[0004] According to the patent document with the publication number CN103978057A, the forming of the aluminum piston is carried out in a mold. Considering the stability during the piston forming process, operations such as intermediate cooling and secondary stamping are also carried out to improve the overall quality of the piston. However, for the subsequent operations and movement of the piston, the movement operations involved in the production line cannot ensure the stable posture of the formed piston, so it is easy to cause the piston to be deformed during the secondary stamping process, resulting in an increase in the rejection rate of the integrated forming of the piston.

[0005] Therefore, we propose an integrated forming processing technology for aluminum pistons. Summary of the Invention

[0006] The purpose of the present invention is to provide an integrated forming processing technology for aluminum pistons to solve the problems raised in the above background art.

[0007] To achieve the above purpose, the present invention provides the following technical solution: an integrated forming processing technology for aluminum pistons, including the following steps:

[0008] Step 1: Aluminum bar cutting. According to the forming length of the piston, use the cutting component to cut the aluminum bar.

[0009] Step 2: Flame heating. Use a flame with a temperature of 800 °C to heat the cut aluminum block, and move the heated aluminum block to the top of the placement table.

[0010] Step 3: Primary forming. Use the transmission mechanism 1 to cooperate with the lifting mechanism to move, clamp the heated aluminum block, and move it to the top of the mold cavity 1. Apply a pressure of 2000 t with the upper punching table 1 to extrude the aluminum block to complete the piston forming.

[0011] Step 4: Secondary stamping. After the stamping is completed, the piston is ejected from the first die cavity. At the same time, the limiting handling mechanism on one side of the upper sliding table of the second transmission mechanism carries the piston to the sliding rack. Meanwhile, the first transmission mechanism drives a new aluminum block into the first die cavity. Along with the shaping of the aluminum block, the piston cooled in the cooling cavity moves to the second die cavity again through the limiting handling mechanism, and the first transmission mechanism drives the newly formed piston to the sliding rack. Finally, the limiting handling mechanism on the second sliding table clamps and discharges the piston after the secondary stamping from the stamping table.

[0012] Step 5: Switch between high temperature and low temperature heating. The aluminum piston is baked twice using a heating furnace. The high temperature baking temperature is controlled at 250 °C, the low temperature baking temperature is controlled at 120 °C, and the single baking time is controlled at 1 - 1.5 h.

[0013] Among them, this integrated forming processing technology of the aluminum piston is realized depending on a processing device, which specifically includes a stamping table. An upper stamping table 1 and an upper stamping table 2 are installed inside the stamping table. The inner wall of the bottom of the stamping table is provided with a lower die table. The top of the lower die table is provided with a first die cavity and a second die cavity. A cooling cavity is opened between the first die cavity and the second die cavity on the top of the lower die table. A sliding rack is slidably connected inside the cooling cavity. The bottom of the lower die table is fixed with a liquid inlet box by bolts.

[0014] Further, a first transmission mechanism is fixed on the stamping table by bolts. A material clamping mechanism is installed on the first transmission mechanism. A placing table is installed at the bottom of the first transmission mechanism. A lifting mechanism is installed at the bottom of the placing table.

[0015] Further, a second transmission mechanism is fixed on the inner wall of the stamping table by bolts. A first sliding table and a second sliding table are slidably connected to the second transmission mechanism evenly. A limiting handling mechanism is installed on the first sliding table and the second sliding table.

[0016] Further, the limiting handling mechanism includes a cylinder column, a first limiting cylinder and a second limiting cylinder. The cylinder column is slidably connected to the tops of the first sliding table and the second sliding table. The inner wall of the top of the cylinder column is fixed with the first limiting cylinder by bolts. The inner wall of the bottom of the cylinder column is fixed with the second limiting cylinder by bolts.

[0017] Further, the limiting handling mechanism further includes a toothed column and an abutting column. The toothed column is symmetrically fixed to the outer wall of the cylinder column by spot welding. The abutting column is slidably connected inside the cylinder column and the second limiting cylinder. The protrusion on the outer wall of the abutting column abuts against the second limiting cylinder. One end of the abutting column penetrates through the cylinder column and is fixed with a lock head by spot welding.

[0018] Furthermore, a placement plate is slidably connected to the two gear columns, a tooth plate is symmetrically slidably connected in the groove on the top of the placement plate, a transmission box is symmetrically fixed on both sides of the top of the placement plate, the gear in the transmission box is meshed and connected to the outer wall of the gear column, and the other side of the gear is correspondingly meshed and connected to the tooth plate, and an arc clamp is symmetrically slidably connected to the bottom of the placement plate, and one side of the top of the arc clamp passes through the groove and is fixed to the tooth plate accordingly.

[0019] Furthermore, a positioning block is fixedly connected to the bottom of the placement plate and located on the opposite side of the arc clamp, a locking block is fixed to the top of the placement plate by bolts, and the locking block and the locking head are arranged correspondingly, and an electric push rod is fixed to the top of slide one and slide two by bolts, and one end of the electric push rod is fixed to the outer wall of the cylinder.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] 1. In the present invention, by installing relevant conveying mechanisms on the stamping table, the clamping mechanism and the limit conveying mechanism are used to position and move the placed aluminum column and the stamped piston semi-finished product. Compared with manual clamping and placement, the moving efficiency is high and the operation safety performance is improved. At the same time, it is convenient to improve the aluminum piston forming rate. The upper punching platform 1 and the upper punching platform 2 are set on the entire stamping table, and a cooling chamber is installed between the two. The circuit design is carried out through the piston integrated forming process, which improves the overall stamping forming efficiency of the piston;

[0022] 2. In the present invention, an electric push rod is used to move the position of the cylinder on the slide, so that when the arc clamp at the bottom of the placement plate reaches the outer wall of the piston, the position of the cylinder itself is adjusted to automatically control the rotation of the gear in the transmission box, and drive the arc clamp connected to the gear plate to move. At the same time, when the cylinder rises, the arc clamp automatically fits the outer wall of the piston. At the same time, the positioning block set at the bottom of the placement plate squeezes the piston groove to avoid deflection of the piston during clamping. Finally, after the arc clamp completely clamps the piston, the slide moves to drive the entire piston to leave the stamping table. The limiting and transporting mechanism as a whole adjusts the height of the cylinder through the electric push rod, thereby completing the non-electrical clamping and fixing of the piston. At the same time, the piston can be limited during the clamping process, thereby improving the overall stability of the piston during the secondary stamping in the one-piece forming process. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a process flow chart of the integrated forming process of the aluminum piston of the present invention;

[0024] Figure 2 It is an overall schematic diagram of the aluminum piston integrated molding processing equipment of the present invention;

[0025] Figure 3 It is a schematic diagram of the installation of the transmission mechanism 1 and the transmission mechanism 2 on the top of the lower die table of the present invention;

[0026] Figure 4 Schematic diagram of the installation structure of the liquid inlet tank at the bottom of the lower die table of the present invention;

[0027] Figure 5 Schematic diagram of the installation structure of the upper sliding table and the second sliding table of the second transmission mechanism of the present invention;

[0028] Figure 6 Schematic diagram of the overall structure of the upper limit handling mechanism of the second sliding table of the present invention;

[0029] Figure 7 Schematic diagram of the installation structure of the first limit cylinder and the second limit cylinder inside the cylinder column of the present invention;

[0030] Figure 8 Schematic diagram of the structure for the toothed plate to drive the arc clamp to complete the clamping of the piston of the present invention.

[0031] In the figure: 1, stamping table; 2, first upper stamping table; 3, second upper stamping table; 4, placing table; 5, lifting mechanism; 6, first transmission mechanism; 7, material clamping mechanism; 8, second transmission mechanism; 9, first sliding table; 10, second sliding table; 11, lower die table; 12, first die cavity; 13, cooling cavity; 14, sliding frame; 15, second die cavity; 16, liquid inlet tank; 17, limit handling mechanism; 171, cylinder column; 172, first limit cylinder; 173, second limit cylinder; 174, toothed column; 175, abutting column; 176, lock head; 18, electric push rod; 19, placing plate; 20, lock block; 21, toothed plate; 22, arc clamp; 23, transmission box; 24, positioning block. Detailed implementation manners

[0032] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0033] Please refer to Figure 1-8 , the present invention provides a technical solution:

[0034] Embodiment 1: To accelerate the piston stamping and forming rate and avoid the time-consuming and laborious problems existing in manually clamping the piston on the upper and lower dies. As Figure 2 shown, by installing the first transmission mechanism 6 and the second transmission mechanism 8 inside the stamping table 1, the automatic clamping and displacement of the piston during the stamping process are carried out, and multiple forming stampings and cooling and blanking of the piston are completed during the displacement process;

[0035] According to Figure 1For the piston one-piece stamping and forming steps shown, the aluminum column heated by high-temperature flame spraying at 800 °C is placed on the placement table 4. With the cooperation of the lifting mechanism 5 and the vertical clamping of the material clamping mechanism 7, the heated aluminum column is moved into the upper die cavity 12 of the lower die table 11. Compared with the limit handling mechanism 17 installed on the transmission mechanism 2, the entire material clamping mechanism 7 does not need to pay attention to the position and direction of the aluminum column during the clamping process. Only a conventional fixture needs to be set to clamp the outer wall of the aluminum column, and under the operation of the transmission mechanism 1, the aluminum column can be moved into the die cavity 12;

[0036] For the stamping work of the entire aluminum column, an upper punch table 1 and an upper punch table 2 are installed on the stamping table 1. At the same time, a die cavity 12 and a die cavity 15 are respectively opened on the surface of the lower die table 11 corresponding to the upper punch table 1 and the upper punch table 2. According to the appearance of the piston forming, upper punch heads are installed on the stamping sides of the entire upper punch table 1 and the upper punch table 2 for stamping and forming unilateral grooves of the aluminum column. At the same time, telescopic pads are installed in the entire die cavity 12 and the die cavity 15. When the punch head extrudes the aluminum column in the die cavity 12 or the die cavity 15, after stamping, the piston semi-finished product is automatically ejected. At the same time, the radius of the pad is smaller than that of the piston, which is convenient for the subsequent limit handling mechanism 17 to grab and transfer the piston semi-finished product;

[0037] The surface temperature of the piston semi-finished product after stamping with 2000 tons is relatively high, and lubricating oil is also used for cooling during the stamping process. At high temperatures, the position of the die cavity 12 is prone to catching fire. Subsequently, water cooling is required after the first stamping and forming of the piston semi-finished product. A cooling cavity 13 is opened on the lower die table 11 between the die cavity 12 and the die cavity 15;

[0038] As Figure 4 shown, a liquid inlet tank 16 is installed at the bottom of the entire cooling cavity 13, continuously transporting cooling water into the cooling cavity 13. After the punch head at the bottom of the upper punch table 1 descends, it will also drive the piston semi-finished product placed on the top of the sliding frame 14 to descend together, so as to press the piston semi-finished product on the top of the sliding frame 14 into the water body in the cooling cavity 13 to complete the rapid cooling work of the piston semi-finished product. Compared with cutting the material from the surface of the stamping table 1 and then cooling it, the cooling rate of the obtained cooled piston semi-finished product is reduced;

[0039] With the water cooling operation of the semi-finished piston, in order to further complete the forming and stabilization of the piston groove, another stamping is required. Therefore, under the operation of the upper punching table 2 3, the stamping work of the semi-cooled piston is completed in the die cavity 2 15. For the limited movement of the entire semi-finished piston, it is necessary to use the upper limit handling mechanism 17 on the transmission mechanism 2 8 to prevent the steering deviation of the semi-finished piston during the movement, which may cause the piston stamping to fail during the secondary stamping. After the secondary stamping of the piston is completed, it is moved out of the stamping table 1 through the limit handling mechanism 17, and then uniformly moved to the baking oven for high and low temperature switching heating to strengthen the high-temperature piston and stabilize the low-temperature piston. Finally, the piston surface is cut with a blade and drilled on a lathe to complete the entire piston forming.

[0040] Embodiment 2: As Figure 5 shown, the sliding table 1 9 and the sliding table 2 10 are installed on the transmission mechanism 2 8. The clamping mechanism on the sliding table 1 9 and the transmission mechanism 1 6 is used to move the piston on the surfaces of the die cavity 1 12 and the die cavity 2 15, while the limit handling mechanism 17 on the sliding table 2 10 is responsible for clamping and discharging the piston formed by the secondary stamping on the die table 2. Through the coordinated sliding of the sliding table 1 9 and the sliding table 2 10, the movement during the piston stamping process on the top of the lower die table 11 is carried out, improving the continuity and stamping rate of the entire piston stamping;

[0041] For the entire limit handling mechanism 17 as Figure 6 shown, electric push rods 18 are symmetrically fixed on the sliding table 2 10 through bolts. The electric push rods 18 are connected to the limit handling mechanism 17. The cylindrical column 171 of the main body is slidably connected to the sliding table 2 10 and is slid up and down on the surface of the sliding table 2 10 through the electric push rods 18. A placement plate 19 is slidably connected to the bottom of the tooth columns 174 symmetrically connected to the outer wall of the cylindrical column 171. Transmission boxes 23 are symmetrically arranged on the placement plate 19, and a gear set is installed in the transmission boxes 23;

[0042] The outer gear of the gear set is meshed and connected with the tooth plate 21 on the placement plate 19, while the inner gear of the transmission box 23 is meshed and connected with the tooth column 174. Therefore, by sliding the tooth column 174 on the placement plate 19, the sliding of the tooth plate 21 on the top of the placement plate 19 is realized. At the same time, arc clamps 22 symmetrically arranged at the bottom of the placement plate 19 are correspondingly connected to the tooth plate 21. Along with the sliding of the tooth plate 21, the two bottom arc clamps 22 can clamp the outer wall of the piston. At the same time, balls are evenly embedded at the bottom of the arc clamps 22, which is convenient for smoothly moving the entire arc clamp 22 down to the lower die table 11 later;

[0043] A limit cylinder 1 172 and a limit cylinder 2 173 are also fixedly connected inside the entire cylindrical column 171, as Figure 7As shown, the abutting column 175 slidably connected within the cylinder column 171 is hung on the second limiting cylinder 173 through the protrusions on its outer wall. At the same time, a lock head 176 is fixedly connected to the outer wall of the abutting column 175 within the cylinder column 171, as Figure 8 shown. Under normal conditions, the lock head 176 is engaged with the groove of the lock block 20 fixedly installed at the top of the placement plate 19, and the entire arc-shaped clamp 22 is controlled to move on the top of the lower die table 11 along with the movement of the electric push rod 18;

[0044] When the arc-shaped clamp 22 moves to the outside of the piston where the stamping on the surface of the first die cavity 12 ends, the arc-shaped clamp 22 presses down to push the entire placement plate 19 to slide upward on the tooth column 174. During the sliding process, the gears within the transmission box 23 come into contact with the tooth column 174, and during rotation, they drive the distance between the two arc-shaped clamps 22 at the bottom of the placement plate 19 to increase. At the same time, the lock head 176 within the lock block 20 starts to push the abutting column 175 to slide within the cylinder column 171 as the placement plate 19 rises. The protrusions on the outer wall of the abutting column 175 start to slide upward within the cylinder column 171, and after the protrusions on the abutting column 175 come into contact with the first limiting cylinder 172, the entire abutting column 175 is driven to perform an angular rotation through the limiting of the section of the first limiting cylinder 172;

[0045] Subsequently, when the electric push rod 18 drives the entire cylinder column 171 to rise, the placement plate 19 at this time remains stationary, and the gears within the transmission box 23 are driven to rotate during the sliding process of the tooth column 174, thereby driving the arc-shaped clamps 22 connected to the tooth plate 21 to move towards each other, so as to clamp the pistons placed on the surface of the first die cavity 12, the second die cavity 15, and the top of the sliding frame 14. At the same time, the positioning block 24 installed at the bottom of the placement plate 19 abuts against the stamping port of the piston, preventing rotation during the process of clamping and moving the piston, which may cause the piston forming to fail during subsequent stamping;

[0046] After the entire arc-shaped clamp 22 completes clamping the outer wall of the piston, at this time, the electric push rod 18 drives the entire cylinder column 171 to rise, and the tooth column 174 cannot slide normally on the placement plate 19. At this time, the stable placement plate 19 carries the piston at the bottom and moves together. After the piston at the bottom of the electric push rod 18 contacts the tabletop, the arc-shaped clamp 22 automatically unfolds, and at the same time, the lock head 176 starts to move into the lock block 20 and rotates under the limitation of the first limiting cylinder 172. After the lock head 176 rotates, it re-completes the locking of the lock block 20, and at this time, the piston has been separated from the fixation of the arc-shaped clamp 22, completing the limited movement of the entire piston and ensuring the stability of the placement position during piston stamping.

[0047] In the present invention: according to the forming length of the piston, the aluminum rod is cut by the cutting assembly, and the aluminum column is heated by the flame ejected by the heating mechanism. The cut aluminum block is heated by the flame at a temperature of 800 °C, and the heated aluminum block is moved to the top of the placing table 4. The first transmission mechanism 6 cooperates with the lifting mechanism 5 to move, clamp the heated aluminum block, and move it to the top of the first die cavity 12. The first punching table 2 applies a pressure of 2000 t to extrude the aluminum block, and the piston forming is completed;

[0048] After the stamping, the first die cavity 12 ejects the piston. At the same time, the side limit handling mechanism 17 of the upper sliding table 9 of the second transmission mechanism 8 is driven by the electric push rod 18 to drive the cylinder column 171 to move, so that the arc clamp 22 carries the piston to the sliding frame 14. At the same time, the first transmission mechanism 6 drives a new aluminum block into the first die cavity 12. Along with the forming of the aluminum block, the piston cooled in the cooling cavity 13 moves to the second die cavity 15 through the limit handling mechanism 17 again, and the first transmission mechanism 6 drives the newly formed piston to the sliding frame 14. Finally, the limit handling mechanism 17 on the second sliding table 10 clamps and discharges the piston after the second stamping from the stamping table 1, realizing the integral forming of the piston on the stamping table 1.

[0049] The preferred embodiments of the present invention disclosed above are only used to help explain the present invention. The preferred embodiments do not describe all the details in detail, nor limit the present invention to the specific implementation manners. Obviously, many modifications and changes can be made according to the content of this specification. These embodiments are selected and specifically described in this specification to better explain the principle and practical application of the present invention, so that those skilled in the art in the relevant technical field can well understand and utilize the present invention. The present invention is only limited by the claims and their full scope and equivalents.

Claims

1. An aluminum piston integral forming process, which is realized by an aluminum piston integral forming process device, specifically comprising a stamping table, wherein an upper stamping table 1 and an upper stamping table 2 are installed in the stamping table, a lower die table is installed on the inner wall of the bottom of the stamping table, a die cavity 1 and a die cavity 2 are opened on the top of the lower die table, a cooling cavity is opened on the top of the lower die table and located between the die cavity 1 and the die cavity 2, a slide is slidably connected in the cooling cavity, and a liquid inlet box is fixed to the bottom of the lower die table by bolts; A transmission mechanism 1 is fixed on the stamping table by bolts, a material clamping mechanism is installed on the transmission mechanism 1, a placing table is installed at the bottom of the transmission mechanism 1, and a lifting mechanism is installed at the bottom of the placing table; The inner wall of the punching table is fixed with a transmission mechanism 2 by bolts, the transmission mechanism 2 is evenly slidably connected with a slide 1 and a slide 2, and a limited position transport mechanism is installed on the slide 1 and the slide 2; The position-limiting transport mechanism comprises a cylinder, a position-limiting cylinder 1 and a position-limiting cylinder 2. The tops of the slides 1 and 2 are slidably connected with the cylinder. The top inner wall of the cylinder is fixed with the position-limiting cylinder 1 by bolts, and the bottom inner wall of the cylinder is fixed with the position-limiting cylinder 2 by bolts. The position limiting transport mechanism further comprises a tooth column and an abutment column, the outer wall of the cylinder column is symmetrically fixed with a tooth column by spot welding, the cylinder column is slidably connected with an abutment column in the second position limiting cylinder, and a protrusion on the outer wall of the abutment column abuts against the second position limiting cylinder, one end of the abutment column penetrates the cylinder column and is fixed with a lock head by spot welding, characterized in that: The aluminum piston one-piece forming process includes the following steps: Step 1: Cut the aluminum rod using a cutting assembly according to the piston forming length; Step 2: Flame heating: use a flame at 800°C to heat the cut aluminum block, and move the heated aluminum block to the top of the placement table; Step 3: One-time forming: use the transmission mechanism 1 to cooperate with the lifting mechanism to clamp the heated aluminum block and move it to the top of the mold cavity 1. Use the upper punch 1 to apply 2000t pressure to extrude the aluminum block to complete the piston forming; Step 4: Secondary stamping: After the stamping is completed, the piston is ejected from the die cavity 1, and at the same time, the limit conveying mechanism on the side of the upper slide of the transmission mechanism 2 carries the piston to the slide. At the same time, the transmission mechanism 1 drives the new aluminum block to the die cavity 1. As the aluminum block is formed, the piston cooled in the cooling chamber is moved to the die cavity 2 again through the limit conveying mechanism, and the transmission mechanism 1 drives the newly formed piston to the slide. Finally, the limit conveying mechanism on the slide 2 clamps the piston after the secondary stamping and discharges it from the stamping table; Step 5: High-temperature and low-temperature switching heating, use a heating furnace to bake the aluminum piston twice, the high-temperature baking temperature is controlled at 250°C, the low-temperature baking temperature is controlled at 120°C, and the single baking time is controlled at 1-1.5h.

2. The aluminum piston integral molding process according to claim 1, characterized in that: A placement plate is slidably mounted on the two gear columns, a tooth plate is symmetrically slidably connected in the groove at the top of the placement plate, a transmission box is symmetrically fixed on both sides of the top of the placement plate, the gear in the transmission box is meshed with the outer wall of the gear column, and the other side of the gear is correspondingly meshed with the tooth plate, an arc clamp is symmetrically slidably connected to the bottom of the placement plate, one side of the top of the arc clamp passes through the groove and is fixed correspondingly to the tooth plate.

3. The aluminum piston integral molding process according to claim 2, characterized in that: A positioning block is fixedly connected to the bottom of the placement plate and located on the opposite side of the arc clamp. A locking block is fixed to the top of the placement plate by bolts, and the locking block and the locking head are correspondingly arranged. An electric push rod is fixed to the top of the slide 1 and the slide 2 by bolts, and one end of the electric push rod is fixed to the outer wall of the cylinder.

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