Booster shell forming process

Abstract

The invention discloses a forming process of a booster shell. Rebounding deformation of the workpiece is eliminated by forming and shaping all parts of the workpiece and all steps of planes for multiple times in a regional mode, and the forming precision is ensured. In the middle stage of workpiece machining, workpiece machining is positioned by punching the positioning through hole and the auxiliary positioning pin hole, the situation that the workpiece machining precision is not up to the standard due to pin hole deformation possibly generated in the machining process is avoided, and the high precision of a finished product is effectively guaranteed; in the later stage of the workpiece machining process, a small amount of multiple times of punching are conducted by rotating positioning pin holes, so that the coaxiality precision of four through holes in the upper surface of an annular protrusion in the middle of a workpiece and a motor output shaft hole in the middle of the workpiece is reliably guaranteed; a larger convex hull is formed in advance, a material is stamped, raised and stored in advance, and then the convex hull is gradually reduced to a set size range through multiple procedures, so that the problem that the size precision of a small-specification convex hull processed by a thick plate is not easy to reach the standard can be well solved.

Description

Technical Field

[0001] The invention relates to a booster stamping technology, in particular to a booster shell forming process. Background Art

[0002] Booster housing Figure 1 As shown, it is stamped from S550MC sheet with a thickness of 3mm. It is provided with a middle mounting through hole with extremely high precision requirements, and a pair of relatively close sensor convex bumps are provided on the connecting plane of the booster housing; an annular protrusion is provided in the middle of the booster housing, and an outward-extending epitaxial convex bump is provided on the annular protrusion, and a downward-bending portion is provided on the outer side of the epitaxial convex bump on the connecting plane. Two pairs of positioning pin holes are provided on the upper surface of the annular protrusion; an inner concave hole is provided on the upper surface of the annular protrusion near the epitaxial convex bump. The sensor convex bump, annular protrusion, epitaxial convex bump, lower bending portion, positioning pin hole and inner concave hole all have strict precision requirements, which makes the processing difficulty of the booster housing very high, and parts such as the sensor convex bump are prone to cracking, the scrap rate of the finished product is high, and it is difficult to mass produce. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a booster housing forming process with high yield rate and high finished product precision.

[0004] In order to solve the above technical problems, the technical solution adopted by the present invention is: a forming process of a booster housing, comprising the following steps:

[0005] Step 1: punch a pair of positioning concave holes in the middle of the workpiece and preliminarily form an annular protrusion in the middle of the workpiece;

[0006] Step 2: punch a positioning through hole in the positioning concave hole and shape the annular protrusion in the middle;

[0007] Step 3: Preliminarily punch out the outer extension bulge beside the central annular bulge and a pair of first bulges of the sensors; the distance between the central axes of the two first bulges of the sensors is equal to the distance between the central axes of the two finished bulges, the opening diameter of the first bulge of the sensor is more than twice the outer diameter of the finished bulge, the height of the first bulge of the sensor is more than 1.5mm greater than the finished bulge, the radius of the flattened part of the top surface of the first bulge of the sensor is not less than the radius of the flattened part of the top surface of the finished bulge, and the radius of the fillet of the top surface of the first bulge of the sensor is not less than 3.5mm; the side surface of the first bulge of the sensor is formed by the connection of the upper arc chamfer and the lower arc chamfer;

[0008] Step 4: Punch a pair of auxiliary positioning pin holes at positions perpendicular to a pair of positioning through holes on the inner plate of the annular protrusion of the workpiece, and perform preliminary trimming on a pair of first convex hulls of the sensors, reduce the height of the first convex hulls of the sensors, reduce the radius of the upper arc chamfer, and maintain the radius of the lower arc chamfer, so that the top surface of the obtained second convex hull of the sensor becomes wider, the opening is reduced, and the distance between the central axes of the two second convex hulls of the sensors is equal to the distance between the central axes of the two finished convex hulls of the sensors;

[0009] Step 5: Punch out the waste materials on both sides of the second convex hull of a pair of sensors on the workpiece and on the outside of the epitaxial convex hull; punch out four mounting concave holes on the upper surface of the annular convex; punch out the inner concave hole on the upper surface of the annular convex near the epitaxial convex hull; punch out three wire holes on the outside of the epitaxial convex hull of the workpiece;

[0010] Step 6: Punch out the remaining three wastes on the outer edge of the workpiece; punch through holes at the four mounting recessed holes on the upper surface of the annular protrusion;

[0011] Step 7: Perform a second shaping on the second convex hulls of a pair of sensors, further reduce the height of the second convex hulls of the sensors, further reduce the radius of the upper arc chamfer angle and the lower arc chamfer angle, maintain the angle between the side surface and the horizontal plane, reduce the opening of the second convex hull of the sensors so that the distance between the side walls of the two third convex hulls of the sensors after forming is further increased, and the distance between the central axes of the two third convex hulls of the sensors is equal to the distance between the central axes of the two finished convex hulls of the sensors;

[0012] At the same time, the edge portion of the outer side of the outer convex hull on the workpiece is initially punched downward to form a portion corresponding to the lower bending portion;

[0013] Step 8: Perform three shaping steps on the third convex hulls of a pair of sensors, perform shrinkage stamping on the third convex hulls of the sensors, so that the side of the convex hulls is perpendicular to the bottom plate, and the height of the convex hulls is controlled within a range of no more than 0.3mm more than the height of the convex hulls of the finished sensor products. At the same time, the upper part of the formed convex hulls reaches the size of the convex hulls of the finished sensor products, including the radius of the flat part of the top surface of the convex hulls reaches the radius of the flat part of the top surface of the finished convex hulls and the upper chamfer radius reaches the upper chamfer radius of the finished convex hulls, and further reduce the lower chamfer radius, so that the side distance of the two formed fourth convex hulls of the sensors is finally formed to the distance of the convex hulls of the finished sensors, and the distance between the central axes of the two fourth convex hulls of the sensors is equal to the distance between the central axes of the two finished convex hulls of the sensors;

[0014] Step 9: Reshape the entire part of the workpiece except for the annular protrusion on the middle part of the workpiece and the fourth convex hull of the pair of sensors, so that the height of the convex hull is further reduced and the radius of the lower chamfer is further reduced, thereby forming a finished convex hull of the sensor;

[0015] Step 10, cutting off the waste materials on both sides of the workpiece and the edge of the outer side of the epitaxial convex hull; punching a number of through holes on the outer periphery of the annular protrusion in the middle of the workpiece; expanding and punching the four through holes on the upper surface of the annular protrusion in the middle of the workpiece;

[0016] Step 11: Punch and cut the motor output shaft hole in the middle of the workpiece, and perform preliminary punching processing on the inner concave hole on the upper surface of the annular protrusion in the middle of the workpiece close to the outer convex hull;

[0017] Step 12: Expand and shape the motor output shaft hole in the middle of the workpiece, and further expand and punch the through hole in the inner concave hole on the upper surface of the annular protrusion in the middle of the workpiece close to the outer convex hull; punch each connection hole on the workpiece;

[0018] Step 13: stamping and shaping the workpiece as a whole;

[0019] Step 14: tap the threaded holes on the workpiece.

[0020] As a preferred solution, in step eight, the edge portion of the outer side of the epitaxial convex hull on the workpiece is further formed in a second step.

[0021] As a preferred solution, in step eleven, two oppositely disposed through holes on the upper surface of the annular protrusion are used as positioning pin holes; and the remaining two oppositely disposed through holes on the upper surface of the middle annular protrusion on the workpiece are further expanded and punched.

[0022] As a preferred solution, in step twelve, the two through holes on the upper surface of the middle annular protrusion on the workpiece expanded and punched in the previous process are used as positioning pin holes to further expand and punch the other two opposite through holes on the upper surface of the middle annular protrusion on the workpiece.

[0023] As a preferred solution, in step thirteen, the outer edge of the workpiece is also chamfered and stamped.

[0024] The beneficial effects of the present invention are:

[0025] This process forms and reshapes the various parts and planes of the workpiece multiple times in different areas to resolve the rebound deformation of the workpiece and ensure the forming accuracy; in the middle stage of the workpiece processing, the workpiece is positioned by punching positioning through holes and auxiliary positioning pin holes, which avoids the workpiece processing accuracy that may not meet the standards due to the pin hole deformation that may occur in the processing process, and effectively ensures the high precision of the finished product; in the later stage of the workpiece processing process, a small amount of multiple punching is performed by rotating the positioning pin holes, so that the coaxiality accuracy of the four through holes on the upper surface of the annular protrusion in the middle of the workpiece and the motor output shaft hole in the middle of the workpiece is reliably guaranteed; by first forming a larger convex hull, the material is first stamped into the convex storage, and then the convex hull is gradually reduced to the set size range through multiple processes, which can better solve the problem that the size accuracy of small-sized convex hulls in thick plate processing is not easy to meet the standards, which not only ensures the processing accuracy, but also avoids the cracking of the convex hull, thereby completing the processing of high-strength thick plates to high-precision booster housings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is the finished structure diagram of the booster housing.

[0027] Figure 2 This is the status diagram of the parts after processing from step one to step three.

[0028] Figure 3 This is the status diagram of the parts after processing from step 4 to step 7.

[0029] Figure 4 This is the status diagram of the parts after processing from step eight to step eleven.

[0030] Figure 5 This is the status diagram of the parts after processing from step 12 to step 14.

[0031] Figure 6 This is a diagram showing the molding effect of the sensor convex hull in each process.

[0032] In the figure: 1 positioning concave hole, 2 middle annular protrusion, 3 outer convex bulge, 4 first convex bulge of sensor; 5 auxiliary positioning pin hole, 6 second convex bulge of sensor; 7 installation concave hole; 8 inner concave hole; 9 wire hole; 10 third convex bulge of sensor, 11 fourth convex bulge of sensor, 12 finished convex bulge of sensor. DETAILED DESCRIPTION

[0033] The specific embodiments of the present invention are described in detail below in conjunction with the accompanying drawings.

[0034] like Figure 1-6 As shown, a forming process of a booster housing includes the following steps:

[0035] Step 1: punch a pair of positioning recessed holes 1 in the middle of the workpiece, and preliminarily form an annular protrusion 2 in the middle of the workpiece;

[0036] Step 2: punch a positioning through hole in the positioning concave hole 1 and shape the middle annular protrusion 2;

[0037] Step 3: Preliminarily punch out the extended convex hull 3 next to the central annular protrusion 2 and a pair of sensor first convex hulls 4; the distance between the central axes of the two sensor first convex hulls 4 is equal to the distance between the central axes of the two finished product convex hulls, the opening diameter of the sensor first convex hull 4 is more than twice the outer diameter of the finished product convex hull, the height of the sensor first convex hull 4 is more than 1.5mm greater than the finished product convex hull, the radius of the flattened portion of the top surface of the sensor first convex hull 4 is not less than the radius of the flattened portion of the top surface of the finished product convex hull, and the radius of the fillet of the top surface of the sensor first convex hull 4 is not less than 3.5mm; the side surface of the sensor first convex hull 4 is formed by connecting the upper arc chamfer and the lower arc chamfer;

[0038] Step 4: Punch a pair of auxiliary positioning pin holes 5 at the positions perpendicular to the pair of positioning through holes on the inner plate of the annular protrusion of the workpiece, and perform preliminary trimming on the pair of first sensor bumps 4, reduce the height of the first sensor bumps 4, reduce the radius of the upper arc chamfer, and maintain the radius of the lower arc chamfer, so that the top surface of the obtained second sensor bump 6 becomes wider, the opening is reduced, and the distance between the central axes of the two second sensor bumps 6 is equal to the distance between the central axes of the two finished sensor bumps 12;

[0039] Step 5: Punch out the waste on both sides of the second convex hull 6 of the pair of sensors and on the outside of the epitaxial convex hull 3 on the workpiece; punch out four mounting concave holes 7 on the upper surface of the annular protrusion; punch out an inner concave hole 8 on the upper surface of the annular protrusion near the epitaxial convex hull 3; punch out three wire holes 9 on the outside of the epitaxial convex hull 3 of the workpiece;

[0040] Step 6: Punch out the remaining three wastes on the outer edge of the workpiece; punch through holes at the four mounting recessed holes 7 on the upper surface of the annular protrusion;

[0041] Step 7: Perform a second shaping process on a pair of sensor second convex bumps 6, further reduce the height of the sensor second convex bumps 6, further reduce the radius of the upper arc chamfer angle and the lower arc chamfer angle, maintain the angle between the side surface and the horizontal plane, reduce the opening of the sensor second convex bump 6 so that the distance between the side walls of the two sensor third convex bumps 10 after forming is further increased, and the distance between the central axes of the two sensor third convex bumps 10 is equal to the distance between the central axes of the two sensor finished convex bumps 12;

[0042] At the same time, the edge portion of the outer side of the outer convex hull 3 on the workpiece is initially punched downward to form a portion corresponding to the lower bending portion;

[0043] Step 8, perform three shaping steps on the third convex bumps 10 of a pair of sensors, perform shrinkage stamping on the third convex bumps 10 of the sensors, so that the side of the convex bump is perpendicular to the bottom plate, and the height of the convex bump is controlled within a range of no more than 0.3mm higher than the height of the finished convex bump 12 of the sensor, and at the same time, the upper half of the formed convex bump reaches the size of the finished convex bump 12 of the sensor, including the radius of the flat part of the top surface of the convex bump reaches the radius of the flat part of the top surface of the finished convex bump and the upper chamfer radius reaches the upper chamfer radius of the finished convex bump, and further reduce the lower chamfer radius, and finally make the side distance of the two formed fourth convex bumps 11 of the sensor be formed to the distance of the finished convex bump 12 of the sensor, and the distance between the central axes of the two fourth convex bumps 11 of the sensor is equal to the distance between the central axes of the two finished convex bumps 12 of the sensor;

[0044] At the same time, the edge portion of the outer side of the epitaxial convex hull 3 on the workpiece is subjected to a second forming process;

[0045] Step nine, the workpiece is overall reshaped except for the annular protrusion 2 on the middle part, except for a pair of fourth convex bumps 11 of the sensor, so that the height of the convex bump is further reduced and the radius of the lower chamfer is further reduced, thereby forming a finished convex bump 12 of the sensor;

[0046] Step 10, remove the waste materials on both sides of the workpiece and the edge of the outer side of the epitaxial convex hull 3; punch a number of through holes on the outer periphery of the middle annular protrusion 2 on the workpiece; expand and punch the four through holes on the upper surface of the middle annular protrusion 2 on the workpiece;

[0047] Step 11: Punch and cut the motor output shaft hole in the middle of the workpiece, and use the two oppositely arranged through holes on the upper surface of the annular protrusion as positioning pin holes; and further expand and punch the remaining two oppositely arranged through holes on the upper surface of the annular protrusion 2 in the middle of the workpiece, and perform preliminary punching processing on the inner concave hole 8 on the upper surface of the annular protrusion 2 in the middle of the workpiece close to the outer convex hull 3;

[0048] Step 12: Expand and shape the motor output shaft hole in the middle of the workpiece, and use the two through holes on the upper surface of the middle annular protrusion 2 of the workpiece expanded and punched in the previous process as positioning pin holes, so as to further expand and punch the other two opposite through holes on the upper surface of the middle annular protrusion 2 of the workpiece, and further expand and punch the through hole in the inner concave hole 8 on the upper surface of the middle annular protrusion 2 of the workpiece close to the outer convex hull 3; punch each connecting hole on the workpiece;

[0049] Step 13: stamping and shaping the workpiece as a whole, and chamfering and stamping the outer edge of the workpiece;

[0050] Step 14: tap the threaded holes on the workpiece.

[0051] The above-mentioned embodiments are only illustrative of the principles and effects of the invention, as well as some embodiments of its application, and are not intended to limit the invention. It should be pointed out that a person skilled in the art can make several modifications and improvements without departing from the inventive concept of the invention, and all of these belong to the protection scope of the invention.

Claims

1. A forming process for a booster housing, comprising the following steps: Step 1: punch a pair of positioning concave holes in the middle of the workpiece and preliminarily form an annular protrusion in the middle of the workpiece; Step 2: punch a positioning through hole in the positioning concave hole and shape the annular protrusion in the middle; Step 3: Preliminarily punch out the outer extension bulge beside the central annular bulge and a pair of first bulges of the sensors; the distance between the central axes of the two first bulges of the sensors is equal to the distance between the central axes of the two finished bulges, the opening diameter of the first bulge of the sensor is more than twice the outer diameter of the finished bulge, the height of the first bulge of the sensor is more than 1.5mm greater than the finished bulge, the radius of the flattened part of the top surface of the first bulge of the sensor is not less than the radius of the flattened part of the top surface of the finished bulge, and the radius of the fillet of the top surface of the first bulge of the sensor is not less than 3.5mm; the side surface of the first bulge of the sensor is formed by the connection of the upper arc chamfer and the lower arc chamfer; Step 4: Punch a pair of auxiliary positioning pin holes at positions perpendicular to a pair of positioning through holes on the inner plate of the annular protrusion of the workpiece, and perform preliminary trimming on a pair of first convex hulls of the sensors, reduce the height of the first convex hulls of the sensors, reduce the radius of the upper arc chamfer, and maintain the radius of the lower arc chamfer, so that the top surface of the obtained second convex hull of the sensor becomes wider, the opening is reduced, and the distance between the central axes of the two second convex hulls of the sensors is equal to the distance between the central axes of the two finished convex hulls of the sensors; Step 5: Punch out the waste materials on both sides of the second convex hull of a pair of sensors on the workpiece and on the outside of the epitaxial convex hull; punch out four mounting concave holes on the upper surface of the annular convex; punch out the inner concave hole on the upper surface of the annular convex near the epitaxial convex hull; punch out three wire holes on the outside of the epitaxial convex hull of the workpiece; Step 6: Punch out the remaining three wastes on the outer edge of the workpiece; punch through holes at the four mounting recessed holes on the upper surface of the annular protrusion; Step 7: Perform a second shaping on the second convex hulls of a pair of sensors, further reduce the height of the second convex hulls of the sensors, further reduce the radius of the upper arc chamfer angle and the lower arc chamfer angle, maintain the angle between the side surface and the horizontal plane, reduce the opening of the second convex hull of the sensors so that the distance between the side walls of the two third convex hulls of the sensors after forming is further increased, and the distance between the central axes of the two third convex hulls of the sensors is equal to the distance between the central axes of the two finished convex hulls of the sensors; At the same time, the edge portion of the outer side of the outer convex hull on the workpiece is initially punched downward to form a portion corresponding to the lower bending portion; Step 8: Perform three shaping steps on the third convex hulls of a pair of sensors, perform shrinkage stamping on the third convex hulls of the sensors, so that the side of the convex hulls is perpendicular to the bottom plate, and the height of the convex hulls is controlled within a range of no more than 0.3mm more than the height of the convex hulls of the finished sensor products. At the same time, the upper part of the formed convex hulls reaches the size of the convex hulls of the finished sensor products, including the radius of the flat part of the top surface of the convex hulls reaches the radius of the flat part of the top surface of the finished convex hulls and the upper chamfer radius reaches the upper chamfer radius of the finished convex hulls, and further reduce the lower chamfer radius, so that the side distance of the two formed fourth convex hulls of the sensors is finally formed to the distance of the convex hulls of the finished sensors, and the distance between the central axes of the two fourth convex hulls of the sensors is equal to the distance between the central axes of the two finished convex hulls of the sensors; Step 9: Reshape the entire part of the workpiece except for the annular protrusion on the middle part of the workpiece and the fourth convex hull of the pair of sensors, so that the height of the convex hull is further reduced and the radius of the lower chamfer is further reduced, thereby forming a finished convex hull of the sensor; Step 10, cutting off the waste materials on both sides of the workpiece and the edge of the outer side of the epitaxial convex hull; punching a number of through holes on the outer periphery of the annular protrusion in the middle of the workpiece; expanding and punching the four through holes on the upper surface of the annular protrusion in the middle of the workpiece; Step 11: Punch and cut the motor output shaft hole in the middle of the workpiece, and perform preliminary punching processing on the inner concave hole on the upper surface of the annular protrusion in the middle of the workpiece close to the outer convex hull; Step 12: Expand and shape the motor output shaft hole in the middle of the workpiece, and further expand and punch the through hole in the inner concave hole on the upper surface of the annular protrusion in the middle of the workpiece close to the outer convex hull; punch each connection hole on the workpiece; Step 13: stamping and shaping the workpiece as a whole; Step 14: tap the threaded holes on the workpiece.

2. A forming process for a booster housing as claimed in claim 1, characterized in that: In the step eight, the edge portion of the outer side of the epitaxial convex hull on the workpiece is also subjected to a second forming process.

3. A forming process for a booster housing as claimed in claim 1, characterized in that: In the step eleven, two oppositely disposed through holes on the upper surface of the annular protrusion are used as positioning pin holes; and the remaining two oppositely disposed through holes on the upper surface of the middle annular protrusion on the workpiece are further expanded and punched.

4. A forming process for a booster housing as claimed in claim 3, characterized in that: In step twelve, the two through holes on the upper surface of the middle annular protrusion of the workpiece expanded and punched in the previous process are used as positioning pin holes to further expand and punch the other two opposite through holes on the upper surface of the middle annular protrusion of the workpiece.

5. A forming process for a booster housing as claimed in claim 1, characterized in that: In the step thirteen, the outer edge of the workpiece is also chamfered and punched.

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