Aluminum alloy material forming process

Abstract

The invention discloses an aluminum alloy material forming process. The aluminum alloy material forming process comprises the following steps that firstly, materials are supplied in batches; 2, single-piece material placing, wherein a full-automatic ring cutting machine is adopted for discharging; 3, heating, wherein a heating furnace is used for conducting heating and heat preservation on the material; 4, tool preparation is conducted, specifically, equipment is checked, and it is ensured that the electric screw press can operate safely and normally through water, electricity, gas, oil and a safety protection device; firstly, whether the mold corresponds to the model of a produced product or not and whether a mold cavity is damaged or not are checked. According to the aluminum alloy material forming process, through the solid die forging process, a solid die forging aluminum alloy spacer can obtain better mechanical performance under the condition that the structure of the solid die forging aluminum alloy spacer is kept the same as that of a traditional product, and the forged aluminum spacer is high in density, free of looseness and pinholes and free of surface air holes and has good surface treatment performance; and the requirements of corrosion resistance, fatigue resistance and galloping resistance of the extra-high voltage line can be met.

Description

Technical Field

[0001] The invention relates to the technical field of aluminum alloy material forming, in particular to an aluminum alloy material forming process. Background Art

[0002] For a long time, most of the transmission line spacers in my country have been formed by casting, which is divided into gravity casting and pressure casting. The products produced by the casting method have poor tissue density and uniformity, low mechanical properties, and castings will cause pores to remain inside the product, which cannot be seen by the naked eye and cannot be completely eliminated even with instrument inspection. In addition, the strength and elongation of cast aluminum alloys have certain limitations, resulting in loose tissue and easy oxidation corrosion on the product surface, which will pose hidden dangers in long-term operation. Summary of the invention

[0003] In view of the deficiencies in the prior art, the present invention provides an aluminum alloy material forming process to solve the above-mentioned problems.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solutions: A forming process of an aluminum alloy material comprises the following steps: Step 1: feeding in batches; Step 2: Place the single piece of material: Use a fully automatic ring cutting machine to cut the material; Step 3: Heating: Use a heating furnace to heat and keep the material warm; Step 4. Tooling preparation: Check the equipment to ensure that the electric screw press can operate safely and normally, including water, electricity, gas, oil, and safety protection devices; first check whether the mold corresponds to the product model and whether the mold cavity is damaged; before installing the mold, the mold closing height must be checked; before starting, the positioning device and buffer pad must be checked to see if they are intact, and whether the mold fastening screws are loose; Step 5: Multiple forging: Place the heated aluminum bar into the mold for three forgings; Step 6. Edge trimming inspection: After normal production, check whether the forgings are complete and have any defects. If there are any, report them for resolution. If not, select samples for inspection within half an hour of normal production, and then trim the forgings to remove the excess edges of the products. Then grind the trimmed forgings to remove the flash and burrs on the products. Step 7: Machining: Machining the installation holes that need to be processed according to the drawings; Step 8. Heat treatment: According to the requirements of the product process card, use the quenching furnace and aging furnace to perform T6 heat treatment on the product; Step 9: Surface treatment: Shot blast the surface of the finished semi-finished product; Step 10: Assembly: Assemble all parts; Step 11, Inspection and warehousing: Before assembly, the mechanical properties of the parts are tested, and after passing the test, batch assembly is carried out, and the assembled products are inspected and put into storage after the inspection is completed.

[0005] Preferably, the step three uses four heating furnaces with heat circulation systems, and the heating furnaces are mesh belt furnaces or resistance furnaces.

[0006] Preferably, the step 4 also requires preheating the mold to 150-200° C. and spraying a release agent in the cavity.

[0007] Preferably, in step six, a hydraulic press or a punch press is used to trim the remaining edges, and a sanding machine is used to perform the grinding operation.

[0008] Preferably, the heating temperature in step three is 480-520° C., and the heating time is 5-8 hours.

[0009] Preferably, the step seven uses a vertical machining center to perform drilling processing.

[0010] Preferably, the step eight uses an aluminum alloy quenching furnace and an aluminum alloy annealing furnace for heat treatment.

[0011] Preferably, the step nine uses a semi-automatic shot blasting machine for shot blasting.

[0012] Preferably, in step ten, the wire clamp is assembled using a customized wire clamp CNC bead-assembling machine.

[0013] Preferably, in the step eleven, the identification information of the assembled product is inspected, and the identification information includes the order number, product name, model, quantity, production personnel, production date, current process, and next process, and the inspector inspects and confirms the signature.

[0014] The present invention provides a forming process for aluminum alloy materials. Compared with the prior art, it has the following beneficial effects: The aluminum alloy material forming process, through the solid die forging process, makes the forged product of the same model and specification of spacer bars reach 3 times the strength of the casting, and the elongation at break reaches 4 times the casting. The solid die forged aluminum alloy spacer bars can obtain better mechanical properties while maintaining the same structure as traditional products. The forged aluminum spacer bars have high density, no looseness, pinholes, no pores on the surface, and good surface treatment performance, which can meet the corrosion resistance, fatigue resistance and dancing resistance requirements of UHV lines. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a process flow chart of the present invention. DETAILED DESCRIPTION

[0016] The technical solutions in the embodiments of the present invention are described clearly and completely. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0017] See also Figure 1 The embodiment of the present invention provides a technical solution: a forming process of aluminum alloy material. 6000 series (Al-Mg-Si) aluminum alloy has good formability, strong corrosion resistance, high strength, high temperature resistance and other properties. 6082 material is used as the raw material for forging, including the following steps: Step 1: feeding in batches; Step 2: Place the single piece of material: Use a fully automatic ring cutting machine to cut the material; Step 3, heating: Use a heating furnace to heat and keep the material warm. Step 3 uses four heating furnaces with a heat circulation system. The heating furnace uses a mesh belt furnace or a resistance furnace. The heating temperature in step 3 is 480-520℃, and the insulation time is 5-8h. The heating furnace is a double-door design to ensure the uniformity of the material forging temperature, so that the temperature of each bar can be controlled, ensuring the forging process requirements; Step 4. Tooling preparation: Check the equipment to ensure that the electric screw press can operate safely and normally, including water, electricity, gas, oil, and safety protection devices; first check whether the mold corresponds to the product model and whether the mold cavity is damaged. When installing the upper mold, align the mold handle hole to avoid damaging the hole edge when the slider falls. The template area should not be too small to avoid collapsing the upper mold hole; before installing the mold, the mold closing height must be checked. The mold can only be installed if the closing height is within the allowable range. Adjust the up and down stroke of the punch to keep it within the specified safety range; when using the ejector , the lengths of the tie rods on both sides should be adjusted to be consistent and not skewed. Before driving, it is necessary to check whether the positioning device and the buffer pad are intact and whether the mold fastening screws are loose. In step 4, the mold needs to be preheated to 150-200℃, and the mold release agent should be sprayed in the cavity and evenly applied for lubrication. After testing several parts, the mold should be tightened again to avoid accidents. When working, the operating lever should be held steadily and forcefully, and no violent pressure should be applied to avoid strong collision between the hammer head and the bed to avoid accidents. When working, attention should be paid to whether the oil pump pressure or compressed air pressure is normal; Step 5: Multiple forging: Place the heated aluminum bar into the mold for three forgings. Use the J58K-4000 CNC electric screw press to forge the frame. Use the J58SZ-1600 servo direct drive screw press to forge the wire clamp and cover plate. Ensure that the temperature of the aluminum bar out of the furnace is controlled at 460-490℃. Forge the first piece and confirm it. Strict regulations are made for the shape of each forged blank. After three forgings, the product thickness meets the design thickness requirements and eliminates surface defects, greatly improving the product qualification rate. The product qualification rate can reach more than 98%, effectively controlling the generation of defective products. Step 6, trimming inspection: After normal production, check whether the forgings are complete and have defects. If there are any, report them for resolution. If not, select samples for inspection within half an hour of normal production, and then trim the forgings. Use a YH32-500 hydraulic press to trim the frame, and use a JH21-100A open press to trim the wire clamp, cover plate and cross shaft. Cut off the excess edges of the product, and then grind the trimmed forgings to remove the flash and burrs on the product. In step 6, a hydraulic press or punch is used for trimming the edges, and a sanding machine is used for grinding. Step 7, machining: The positions of the mounting holes to be machined are machined according to the drawings. In step 7, a TV-700 vertical machining center is used to drill the wire clamp and cover plate, and a YH32-40T hydraulic press (eight-split multi-drill) is used to drill the frame. Step 8, heat treatment: According to the requirements of the product process card, use the quenching furnace and aging furnace to perform T6 heat treatment on the product. Step 8 uses aluminum alloy quenching furnace (CLC-160-6) and aluminum alloy annealing furnace (ZL-65-2) for heat treatment; Step 9, surface treatment: The finished semi-finished product is subjected to surface shot blasting treatment. In step 9, a semi-automatic shot blasting cleaning machine is used for shot blasting treatment to achieve a beautiful appearance; Step 10, assembly: assemble all parts, step 10 uses customized wire clamp CNC beading machine to assemble the wire clamp; Step 11, inspection and warehousing: Before assembly, the mechanical properties of the parts are tested, and batch assembly is carried out after passing the test. The assembled products are inspected and put into storage after the inspection is completed. In step 11, the identification information of the assembled products is inspected. The identification information includes the order number, product name, model, quantity, production personnel, production date, current process, next process, and the inspector checks and confirms the signature.

[0018] In order to improve the qualification rate, the blank size is constantly adjusted during trial production to find the most reasonable blank size, which can not only eliminate the influence of human factors, but also allow the folding parts to flow out completely, reducing the chance of product defects.

[0019] The mechanical properties of the solid die-forged aluminum alloy spacer produced by this process were compared with the cast spacer on the market. The comparison is as follows:

[0020] It can be seen from the table that for the same model and specification of spacer bars, the strength of forged products can reach 3 times that of castings, and the elongation at break can reach 4 times that of castings. Solid die-forged aluminum alloy spacer bars can obtain better mechanical properties while maintaining the same structure as traditional products. Forged aluminum spacer bars have high density, no looseness, pinholes, and no pores on the surface. They have good surface treatment performance and can meet the requirements of corrosion resistance, fatigue resistance, and dancing resistance of UHV lines.

[0021] Meanwhile, the contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0022] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0023] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A process for forming an aluminum alloy material, characterized in that: The following steps are involved: Step 1: feeding in batches; Step 2: Place the single piece of material: Use a fully automatic ring cutting machine to cut the material; Step 3: Heating: Use a heating furnace to heat and keep the material warm; Step 4. Tooling preparation: Check the equipment to ensure that the electric screw press can operate safely and normally, including water, electricity, gas, oil, and safety protection devices; first check whether the mold corresponds to the product model and whether the mold cavity is damaged; before installing the mold, the mold closing height must be checked; before starting, the positioning device and buffer pad must be checked to see if they are intact, and whether the mold fastening screws are loose; Step 5: Multiple forging: Place the heated aluminum bar into the mold for three forgings; Step 6. Edge trimming inspection: After normal production, check whether the forgings are complete and have any defects. If there are any, report them for resolution. If not, select samples for inspection within half an hour of normal production, and then trim the forgings to remove the excess edges of the products. Then grind the trimmed forgings to remove the flash and burrs on the products. Step 7: Machining: Machining the installation holes that need to be processed according to the drawings; Step 8. Heat treatment: According to the requirements of the product process card, use the quenching furnace and aging furnace to perform T6 heat treatment on the product; Step 9: Surface treatment: Shot blast the surface of the finished semi-finished product; Step 10: Assembly: Assemble all parts; Step 11, Inspection and warehousing: Before assembly, the mechanical properties of the parts are tested, and after passing the test, batch assembly is carried out, and the assembled products are inspected and put into storage after the inspection is completed.

2. The aluminum alloy material forming process according to claim 1, characterized in that: The step three uses four heating furnaces with heat circulation systems, and the heating furnaces are mesh belt furnaces or resistance furnaces.

3. The aluminum alloy material forming process according to claim 1, characterized in that: The step 4 also requires preheating the mold to 150-200° C. and spraying a release agent in the cavity.

4. The aluminum alloy material forming process according to claim 1, characterized in that: In step six, a hydraulic press or a punch press is used to trim the remaining edges, and a sanding machine is used to perform grinding operations.

5. The aluminum alloy material forming process according to claim 1, characterized in that: The heating temperature in step 3 is 480-520° C. and the temperature is kept for 5-8 hours.

6. The aluminum alloy material forming process according to claim 1, characterized in that: In step seven, a vertical machining center is used for drilling.

7. The aluminum alloy material forming process according to claim 1, characterized in that: The step eight uses an aluminum alloy quenching furnace and an aluminum alloy annealing furnace for heat treatment.

8. The aluminum alloy material forming process according to claim 1, characterized in that: The step nine uses a semi-automatic shot blasting machine to perform shot blasting.

9. The aluminum alloy material forming process according to claim 1, characterized in that: In step ten, the wire clamp is assembled using a customized wire clamp CNC bead-assembling machine.

10. The aluminum alloy material forming process according to claim 1, characterized in that: In the step eleven, the identification information of the assembled product is inspected, and the identification information includes the order number, product name, model, quantity, production personnel, production date, current process, and next process, and the inspector checks and confirms the signature.

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