Integral disc shaft part rolling forming equipment and method

Abstract

The invention discloses integral disc shaft rolling forming equipment which comprises a clamping device, a rolling forming device, a rolling forming device, a rolling forming device and a rolling forming device, wherein the clamping device is clamped at the end of a prefabricated blank; the induction heating devices are arranged on the two sides of the periphery of the prefabricated blank; the rolling head moving device comprises a rolling head moving part, a rolling head rotating part and an angle adjusting part, the rolling head moving part comprises an axial moving part and a radial moving part, the rolling head rotating part and the angle adjusting part are assembled above the rolling head moving part, and the angle adjusting part is connected with the rolling head rotating part; a forming rolling head in the rolling head rotating component penetrates through the induction heating device to conduct rolling forming on the disc face part and the shaft rod part of the prefabricated blank, and an integral disc shaft piece with a specific spoke shape and a stepped shaft rod is formed. The problem that a high-quality forge piece which is complex in shape, close to the final product shape and small in machining allowance is difficult to efficiently manufacture through an existing integral disc shaft piece forging forming technology can be solved.

Description

Technical Field

[0001] The present application relates to the technical field of metal parts processing, and in particular to an apparatus and method for rolling and forming an integral disc shaft. Background Art

[0002] Integral disc-and-shaft components are key rotating parts in aircraft engines and gas turbines, such as the integral disc-and-shaft components of aircraft engine compressors and front journals. These parts are characterized by a large diameter disc portion and a relatively small diameter shaft portion. In addition, these parts are typically made of high-strength titanium alloys or high-temperature resistant alloys, making the integral forging or extrusion forming process more difficult. Therefore, a two-fire forging process has to be adopted, in which the disc portion is first formed by die forging, and then the shaft portion is formed by free forging. Two-fire forging not only consumes energy, but also increases the difficulty of controlling the uniformity of the forging structure.

[0003] Patents CN201510720877.2 and CN201811112146.X both describe methods for forming large disc-shaft forgings using pendulum forging. These methods can only produce disc-shaft parts with simple shapes similar to T-shaped cross-sections. Patent CN200910102899.7 describes a method for forming large, integral disc-shaft forgings using a near-isothermal forging process, which requires a large-tonnage forging press.

[0004] The final product of the integral disc shaft is obtained by cutting on the basis of forgings. At present, whether it is swing forging or isothermal die forging technology, the integral disc shaft forging can only be formed into a shape similar to the final product, so a large machining allowance is required, which leads to a large amount of machining cutting and workload, not only causing material waste, but also in the structure of the disc shaft, due to the cutting of metal streamlines during the turning process, it will also lead to a reduction in part performance.

[0005] In summary, existing processes for forming integral disc shaft forgings are primarily limited to open die forging, die forging, and pendulum forging. These methods can only produce disc shafts with simple shapes. Even with near-isothermal forging technology, it is impossible to produce forgings with more complex structures, closer to the final shape, and with smaller machining allowances. Summary of the Invention

[0006] In view of this, the main purpose of this application is to provide an integral disc shaft rolling forming device and method, which is conducive to solving the problem that the existing integral disc shaft forging forming process is difficult to efficiently produce high-quality forgings with complex shapes, close to the final product form and small machining allowance, so as to achieve efficient, energy-saving and high-quality one-time forming of integral disc shaft parts with complex shapes.

[0007] The present application provides a rolling forming device for an integral disc shaft component, which comprises:

[0008] A clamping device that clamps on the end of the preform;

[0009] Induction heating devices are provided on both sides of the periphery of the preform;

[0010] The rolling head movement device includes a rolling head movement component, a rolling head rotating component and an angle adjustment component, wherein the rolling head movement component includes an axial movement component and a radial movement component, the rolling head rotating component and the angle adjustment component are assembled above the rolling head movement component, the angle adjustment component is connected to the rolling head rotating component, and the forming rolling head in the rolling head rotating component passes through the induction heating device to roll the disk surface part and the shaft part of the prefabricated blank to form an integral disk-shaft component with a specific spoke shape and a stepped shaft.

[0011] As shown above, the clamping device can clamp the center of the prefabricated blank and drive the prefabricated blank to rotate, the induction heating device can realize online heating of the prefabricated blank, and the forming rolling head can produce rotation, feed and tilt angle adjustment through the rolling head movement device, so that the movement position of the forming rolling head can be accurately adjusted, the forming accuracy is high, and the local minimum processing allowance of the prefabricated blank can be reduced to 2-3mm, which creates favorable conditions for reducing the subsequent machining workload, reducing metal streamline damage, and improving the mechanical properties of the component.

[0012] Optionally, the clamping device includes two clamping assemblies, which are clamped at both ends of the preform, wherein each group of clamping assemblies includes: a clamping head, whose front end protrusion is inserted into the center hole at one end of the preform; a clamping head seat, one end of which is equipped with a clamping head tail end, and the opposite end of the clamping head seat is equipped with a rotary drive motor; a rotary drive motor, whose drive shaft passes through the clamping head seat and is connected to the clamping head tail end.

[0013] From above, the clamping head seat plays a supporting role, which can support the clamping head and the rotary drive motor; the front end protrusion of the clamping head realizes the support and clamping of the prefabricated blank, and the rotary drive motor can realize the rotation of the prefabricated blank.

[0014] Optionally, the induction heating device includes two induction heaters, which are symmetrically arranged on both sides of a horizontal plane where the central axis of the preform is located.

[0015] From above, there is a gap between the two induction heaters to facilitate the horizontal movement of the forming roller head.

[0016] Optionally, the distance between the two induction heaters is determined according to the space required for the movement of the forming roller head.

[0017] As described above, by accurately calculating and setting the distance between the two induction heaters, sufficient horizontal movement space can be provided for the forming roller head. This ensures that the forming roller head will not be hindered by the induction heaters during the rolling operation, and can freely perform the required axial, radial and angular adjustments.

[0018] Optionally, in the rolling head moving component, the axial moving component is arranged below the radial moving component, and the axial moving component is perpendicular to the radial moving component.

[0019] From the above, the vertical stacking configuration can reduce the mutual interference between the movements in the two directions, and also help to reduce the overall volume of the device, making the device more compact.

[0020] Optionally, the axial motion component includes an axial motion guide rail, an axial motion frame and an axial motion electric cylinder, wherein the axial motion electric cylinder is connected to one end of the axial motion frame, and the axial motion guide rail is equipped with an axial motion electric cylinder connected to the axial motion frame; the radial motion component includes a radial motion guide rail, a radial motion frame and a radial motion electric cylinder, wherein the radial motion electric cylinder is connected to one end of the radial motion frame, the radial motion guide rail is equipped with a radial motion electric cylinder connected to the radial motion frame, and the radial motion guide rail is arranged on the axial motion frame.

[0021] As can be seen from the above, the structures of the axial motion component and the radial motion component are similar. They are defined as independent modules containing guide rails, frames and electric cylinders respectively. By assembling the electric cylinder on the guide rails and connecting it to the frame, the mechanical structure is simplified. The design of setting the radial motion guide rail on the axial motion frame fully utilizes the vertical space.

[0022] Optionally, the rolling head rotating component includes: a rolling head seat, which is arranged on the upper surface of the radial motion frame; a forming rolling head, which is supported on the rolling head seat; a rolling head rotating motor, which is arranged on the upper surface of the radial motion frame, and the rotating shaft of the rolling head rotating motor passes through the interior of the rolling head seat and is connected to the forming rolling head.

[0023] From above, the rolling head seat plays a supporting role, and can simultaneously support the forming rolling head and the rolling head rotating motor. The rolling head rotating motor is directly connected to the forming rolling head to drive the rotation of the forming rolling head.

[0024] Optionally, the angle adjustment component includes an angle adjustment electric cylinder.

[0025] As shown above, the angle adjustment electric cylinder has a fast response speed, can complete the angle adjustment in a short time, and improve production efficiency. At the same time, its movement is smooth and controllable, reducing unnecessary vibration or impact, and ensuring the stability of the forming process.

[0026] Optionally, an infrared temperature measuring probe is also included to detect the temperature of the preform online during the rolling forming process of the preform.

[0027] As described above, when the induction heating device is heating the preform online, the infrared temperature probe is used to detect whether the temperature of the preform reaches a predetermined temperature, so as to determine the timing of the subsequent rolling process.

[0028] The present application also provides a method for rolling and forming an integral disc-shaft component, which uses any of the above-mentioned integral disc-shaft component rolling and forming equipment to roll and form the disc surface portion and the shaft portion of a prefabricated blank in a single heating process to form an integral disc-shaft component with spokes of a specific shape and a stepped shaft, comprising:

[0029] In the preparation stage, the preform is clamped and rotated by a clamping device;

[0030] In the induction heating stage, the induction heating device is started to heat the preform to a predetermined temperature;

[0031] In the rolling forming stage, the disc part and the shaft part of the prefabricated blank are rolled and formed by controlling the axial feed, radial feed and tilt angle of the forming rolling head in the rolling head movement device.

[0032] As described above, first use the clamping head in the clamping device to clamp the preform, cover the induction heating device on both sides of the preform, and use the rotary drive motor in the clamping device to drive the clamping head to rotate the preform, then start the induction heating device, and use the infrared temperature probe to detect online whether the preform reaches the predetermined temperature. When the preform is heated to the predetermined temperature, adjust the starting inclination angle of the forming rolling head in the rolling head movement device so that the forming rolling head busbar is parallel to the radial direction of the preform, complete the axial feeding and radial movement through the rolling head movement component, complete the rolling movement through the rolling head rotating component, complete the forming of the disk spoke part of the preform, and then after the forming rolling head leaves the preform axially, the angle adjustment component is used to swing the inclination angle so that the forming rolling head busbar is parallel to the axial direction of the preform, and then the radial feeding, axial movement and rolling movement of the rolling head are performed by the rolling head movement component and the rolling head rotating component to complete the forming of the shaft part of the preform.

[0033] To sum up, the integral disc shaft part rolling forming equipment and method provided in this application belongs to the dieless rolling forming technology, which is a flexible forming technology that can use local continuous plastic deformation to finally form larger parts. It has unique advantages in saving forming molds, reducing the tonnage of forming equipment, and facilitating digital flexible production. Based on the dieless rolling forming process, the equipment can realize the precise adjustment of the movement position of multiple groups of forming rolling heads through axial feeding, radial feeding and angular swinging of multiple groups of forming rolling heads in one heating, with high forming accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The following further illustrates the various technical features of the present application and the relationships between them with reference to the accompanying drawings. The accompanying drawings are exemplary, and some technical features are not shown in actual proportion. In addition, some drawings may omit technical features that are commonly used in the technical field to which the present application belongs and are not essential for understanding and implementing the present application, or additional technical features that are not essential for understanding and implementing the present application may be shown. In other words, the combination of the various technical features shown in the accompanying drawings is not intended to limit the present application. In addition, throughout the present application, the same figure numbers refer to the same content. The specific description of the drawings is as follows:

[0035] Figure 1 A top view of the integral disc-shaft rolling forming apparatus in this application;

[0036] Figure 2a-2b This is a schematic diagram of the positional relationship between the induction heater, preform, and forming rolling head;

[0037] Figure 3 Schematic diagram of the rolling forming process of the disc surface portion of the integral disc shaft component;

[0038] Figure 4 A schematic diagram of the forming rolling head position when the rolling of the disc surface portion of the integral disc shaft component is completed and the shaft portion of the integral disc shaft component is ready to be rolled;

[0039] Figure 5 Schematic diagram of the rolling forming process of the shaft portion of the integral disc shaft component;

[0040] Figure 6 Schematic diagram of completing the rolling forming of the overall disc shaft.

[0041] Description of Reference Numerals

[0042] 1-first axial motion electric cylinder, 11-second axial motion electric cylinder, 20-third axial motion electric cylinder, 30-fourth axial motion electric cylinder;

[0043] 2-first axial motion frame, 12-second axial motion frame, 21-third axial motion frame, 31-fourth axial motion frame;

[0044] 3-first axial motion guide rail, 22-second axial motion guide rail;

[0045] 4-first radial motion electric cylinder, 13-second radial motion electric cylinder, 23-third radial motion electric cylinder, 32-fourth radial motion electric cylinder;

[0046] 7-first radial motion rack, 16-second radial motion rack, 26-third radial motion rack, 35-fourth radial motion rack;

[0047] 5-first radial motion guide rail, 14-second radial motion guide rail, 24-third radial motion guide rail, 33-fourth radial motion guide rail;

[0048] 6- first angle adjustment electric cylinder, 15- second angle adjustment electric cylinder, 25- third angle adjustment electric cylinder, 34- fourth angle adjustment electric cylinder;

[0049] 8-first rolling head rotating motor, 17-second rolling head rotating motor, 27-third rolling head rotating motor, 36-fourth rolling head rotating motor;

[0050] 9-first rolling head seat, 18-second rolling head seat, 28-third rolling head seat, 37-fourth rolling head seat;

[0051] 10-first forming rolling head, 19-second forming rolling head, 29-third forming rolling head, 38-fourth forming rolling head;

[0052] 39-first rotary drive motor, 44-second rotary drive motor, 40-first clamping head holder, 45-second clamping head holder, 41-first clamping head, 46-second clamping head, 42-preform, 43-induction heater, 47-infrared temperature probe.

[0053] The above drawings illustrate specific embodiments of the present application, which will be described in more detail below. These drawings and the textual description are not intended to limit the scope of the present application in any way, but rather to illustrate the concepts of the present application to those skilled in the art by reference to specific embodiments. DETAILED DESCRIPTION

[0054] The preferred embodiments of the present application are described in detail below in conjunction with the accompanying drawings so that the advantages and features of the present application can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the protection scope of the present application.

[0055] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article, or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article, or device. In the absence of further limitations, the elements defined by the phrase "comprising..." do not exclude the presence of other identical elements in the process, method, article, or device comprising the elements.

[0056] The following describes in detail the technical solution of the present application and how the technical solution of the present application solves the above-mentioned technical problems using specific embodiments. The specific embodiments described below can be combined with each other to form new embodiments. The same or similar ideas or processes described in one embodiment may not be repeated in other embodiments. The embodiments of the present application will be described below in conjunction with the accompanying drawings.

[0057] The present application provides a rolling forming device for an integral disc shaft component, which comprises:

[0058] A clamping device that clamps on the end of the preform;

[0059] Induction heating devices are provided on both sides of the periphery of the preform;

[0060] The rolling head movement device includes a rolling head movement component, a rolling head rotating component and an angle adjustment component, wherein the rolling head movement component includes an axial movement component and a radial movement component, the rolling head rotating component and the angle adjustment component are assembled above the rolling head movement component, the angle adjustment component is connected to the rolling head rotating component, and the forming rolling head in the rolling head rotating component passes through the induction heating device to roll the disk surface part and the shaft part of the prefabricated blank to form an integral disk-shaft component with a specific spoke shape and a stepped shaft.

[0061] Specifically, the clamping device can clamp the center of the preform and drive the preform to rotate, the induction heating device can realize online heating of the preform, and the rolling head movement device can make the forming rolling head rotate, feed and adjust the tilt angle, so that the movement position of the forming rolling head can be accurately adjusted, the forming accuracy is high, and the local minimum processing allowance of the preform can be reduced to 2 to 3 mm, which creates favorable conditions for reducing the subsequent machining workload, reducing the damage to metal streamlines, and improving the mechanical properties of the component.

[0062] Optionally, the clamping device includes two clamping assemblies, which are clamped at both ends of the preform, wherein each group of clamping assemblies includes: a clamping head, whose front end protrusion is inserted into the center hole at one end of the preform; a clamping head seat, one end of which is equipped with a clamping head tail end, and the opposite end of the clamping head seat is equipped with a rotary drive motor; a rotary drive motor, whose drive shaft passes through the clamping head seat and is connected to the clamping head tail end.

[0063] Specifically, the clamping head seat plays a supporting role and can support the clamping head and the rotary drive motor; the front end protrusion of the clamping head realizes the support and clamping of the prefabricated blank, and the rotary drive motor can realize the rotation of the prefabricated blank.

[0064] Optionally, the induction heating device includes two induction heaters, which are symmetrically arranged on both sides of a horizontal plane where the central axis of the preform is located.

[0065] Specifically, a gap is left between the two induction heaters to facilitate the horizontal movement of the forming roller head.

[0066] Optionally, the distance between the two induction heaters is determined according to the space required for the movement of the forming roller head.

[0067] Specifically, by precisely calculating and setting the distance between the two induction heaters, sufficient horizontal movement space is provided for the forming roller head. This ensures that the forming roller head is not hindered by the induction heaters during the rolling operation, and can freely perform the required axial, radial and angular adjustments.

[0068] Optionally, in the rolling head moving component, the axial moving component is arranged below the radial moving component, and the axial moving component is perpendicular to the radial moving component.

[0069] Specifically, the vertically stacked configuration can reduce the mutual interference between the movements in the two directions, while also helping to reduce the overall volume of the device, making the device more compact.

[0070] Optionally, the axial motion component includes an axial motion guide rail, an axial motion frame and an axial motion electric cylinder, wherein the axial motion electric cylinder is connected to one end of the axial motion frame, and the axial motion guide rail is equipped with an axial motion electric cylinder connected to the axial motion frame; the radial motion component includes a radial motion guide rail, a radial motion frame and a radial motion electric cylinder, wherein the radial motion electric cylinder is connected to one end of the radial motion frame, the radial motion guide rail is equipped with a radial motion electric cylinder connected to the radial motion frame, and the radial motion guide rail is arranged on the axial motion frame.

[0071] Specifically, the structures of the axial motion component and the radial motion component are similar, and they are respectively defined as independent modules containing guide rails, frames and electric cylinders. By assembling the electric cylinder on the guide rails and connecting it to the frame, the mechanical structure is simplified, and the design of setting the radial motion guide rail on the axial motion frame makes full use of the vertical space.

[0072] Optionally, the rolling head rotating component includes: a rolling head seat, which is arranged on the upper surface of the radial motion frame; a forming rolling head, which is supported on the rolling head seat; a rolling head rotating motor, which is arranged on the upper surface of the radial motion frame, and the rotating shaft of the rolling head rotating motor passes through the interior of the rolling head seat and is connected to the forming rolling head.

[0073] Specifically, the rolling head seat plays a supporting role and can simultaneously support the forming rolling head and the rolling head rotating motor. The rolling head rotating motor drives the rotation of the forming rolling head by being directly connected to the forming rolling head.

[0074] Optionally, the angle adjustment component includes an angle adjustment electric cylinder.

[0075] Specifically, the angle adjustment electric cylinder has a fast response speed, capable of completing angle adjustments in a short time, improving production efficiency. At the same time, its movement is smooth and controllable, reducing unnecessary vibration or impact and ensuring the stability of the forming process.

[0076] Optionally, an infrared temperature measuring probe is also included to detect the temperature of the preform online during the rolling forming process of the preform.

[0077] Specifically, when the induction heating device heats the preform online, an infrared temperature measuring probe is used to detect whether the temperature of the preform reaches a predetermined temperature, so as to determine the timing of the subsequent rolling process.

[0078] Below, Figure 1 The top view in the figure is a specific embodiment of the present application, which introduces the components in the integral disc-shaft rolling forming equipment. The prefabricated blank in this embodiment includes a disc surface part and a shaft rod part, so the cross-section of the prefabricated blank is T-shaped.

[0079] Clamping device

[0080] The two clamping assemblies include a first clamping assembly and a second clamping assembly, wherein the first clamping assembly includes a first clamping head 41, a first clamping head seat 40 and a first rotation drive motor 39, and the second clamping assembly includes a second clamping head 46, a second clamping head seat 45 and a second rotation drive motor 44, wherein the front end protrusion of the first clamping head 41 is inserted into the center hole of one end of the shaft portion of the preformed blank 42, and the front end protrusion of the second clamping head 46 is inserted into the center hole of one end of the disk portion of the preformed blank 42. Through the cooperation of the first clamping head 41 and the second clamping head 46, the support and clamping of the preformed blank 42 are achieved; the tail end of the first clamping head 41 is supported and installed in the first clamping head seat 40, and the second The tail ends of the second clamping heads 46 are supported and installed in the second clamping head seat 45, the first rotary drive motor 39 is arranged at the other end of the first clamping head seat 40, and the driving shaft of the first rotary drive motor 39 passes through the first clamping head seat 40 and is connected to the tail end of the first clamping head 41. Similarly, the second clamping head seat 45 is respectively provided with a second clamping head 46 and a second rotary drive motor 44 at both ends, and the driving shaft of the second rotary drive motor 44 passes through the second clamping head seat 45 and is connected to the tail end of the second clamping head 46. The first rotary drive motor 39 and the second rotary drive motor 44 run simultaneously, respectively driving the first clamping head 41 and the second clamping head 46 to rotate, so as to drive the preform 42 to rotate.

[0081] Induction heating device

[0082] The induction heating device includes two induction heaters 43, which are connected in parallel and symmetrically arranged on the upper and lower sides of the horizontal plane where the central axis of the preform 42 is located, that is, the two induction heaters 43 respectively cover the upper and lower sides of the preform 42 to achieve online heating of the preform 42; a gap is left between the upper and lower induction heaters 43 to facilitate horizontal movement of the forming rolling head.

[0083] In the present application, the gap between the two induction heaters 43 is determined according to the space required for the horizontal movement of the forming rolling head, so as to ensure that the forming rolling head can move freely to perform the rolling operation.

[0084] It should be noted that different rolling head models will result in slight differences in size, shape and thickness. These differences are designed based on specific processing tasks and technical requirements to ensure that the predetermined rolling forming work can be completed efficiently and accurately.

[0085] Rolling head movement device

[0086] The rolling head moving device comprises a rolling head moving part, a rolling head rotating part and an angle adjusting part.

[0087] Among them, the rolling head movement parts include axial movement parts and radial movement parts, among which the axial movement parts include the first axial movement guide rail 3, the second axial movement guide rail 22, the first axial movement frame 2, the second axial movement frame 12, the third axial movement frame 21, the fourth axial movement frame 31, the first axial movement electric cylinder 1, the second axial movement electric cylinder 11, the third axial movement electric cylinder 20, and the fourth axial movement electric cylinder 30; the radial movement parts include the first radial movement guide rail 5, the second radial movement guide rail 14, the third radial movement guide rail 24, the fourth radial movement guide rail 33, the first radial movement frame 7, the second radial movement frame 16, the third radial movement frame 26, the fourth radial movement frame 35, the first radial movement electric cylinder 4, the second radial movement electric cylinder 13, the third radial movement electric cylinder 23, and the fourth radial movement electric cylinder 32.

[0088] The rolling head rotating parts include a first rolling head rotating motor 8, a second rolling head rotating motor 17, a third rolling head rotating motor 27, a fourth rolling head rotating motor 36, a first rolling head seat 9, a second rolling head seat 18, a third rolling head seat 28, a fourth rolling head seat 37, a first forming rolling head 10, a second forming rolling head 19, a third forming rolling head 29, and a fourth forming rolling head 38.

[0089] The angle adjustment components include a first angle adjustment electric cylinder 6 , a second angle adjustment electric cylinder 15 , a third angle adjustment electric cylinder 25 , and a fourth angle adjustment electric cylinder 34 .

[0090] Along the central axis direction of the shaft portion of the preform 42, a first axial motion guide rail 3 and a second axial motion guide rail 22 are provided on the left and right sides of the preform 42, and a first axial motion frame 2 and a second axial motion frame 12 are provided on the first axial motion guide rail 3. On the first axial motion guide rail 3, the first axial motion frame 2 and the second axial motion frame 12 are arranged opposite to each other, and the first axial motion frame 2 is arranged at the left rear of the preform 42, and the second axial motion frame 12 is arranged at the left front of the preform 42. The rear end of the first axial motion frame 2 is connected to the first axial motion electric cylinder 1. Under the operation function of the first axial motion electric cylinder 1, the first axial motion frame 2 moves along the first axial motion guide rail 3, and the second axial motion frame 12 moves along the first axial motion guide rail 3. The front end of the motion frame 12 is connected to the second axial motion electric cylinder 11. Under the operation function of the second axial motion electric cylinder 11, the second axial motion frame 12 moves along the first axial motion guide rail 3; similarly, the second axial motion guide rail 22 is provided with a third axial motion frame 21 and a fourth axial motion frame 31. On the second axial motion guide rail 22, the third axial motion frame 21 and the fourth axial motion frame 31 are arranged opposite to each other, and the third axial motion frame 21 is arranged at the right rear of the preformed blank 42, the rear end of the third axial motion frame 21 is connected to the third axial motion electric cylinder 20, the fourth axial motion frame 31 is arranged at the right front of the preformed blank 42, and the front end of the fourth axial motion frame 31 is connected to the fourth axial motion electric cylinder 30.

[0091] In a direction perpendicular to the axis of the preform 42 , a first radial motion guide rail 5 , a second radial motion guide rail 14 , a third radial motion guide rail 24 and a fourth radial motion guide rail 33 are provided on both sides of the preform.

[0092] Among them, the first radial motion guide rail 5 is arranged on the upper surface of the first axial motion frame 2, and the intersection line of the two is perpendicular; the upper surface of the first radial motion guide rail 5 is provided with a first radial motion electric cylinder 4 and a first radial motion frame 7, the first radial motion electric cylinder 4 is connected to the left end of the first radial motion frame 7, under the operation of the first radial motion electric cylinder 4, the first radial motion frame 7 is extended and retracted to the right along the upper surface of the first radial motion guide rail 5, and the upper surface of the first radial motion frame 7 is installed with a tilted first angle adjustment electric cylinder 6 and a tilted first rolling head seat 9, that is, the first angle adjustment electric cylinder 6 is tilted left front and right rear. The first rolling head seat 9 is set to be tilted at the left rear and right front, the right end of the first angle adjustment electric cylinder 6 is movably connected to the left side of the first rolling head seat 9 body, and the angle of the first angle adjustment electric cylinder 6 and the first rolling head seat 9 is adjustable, the left rear end of the first rolling head seat 9 is installed with the first rolling head rotating motor 8, the right front end of the first rolling head seat 9 is installed with the first forming rolling head 10, and the rotating shaft of the first rolling head rotating motor 8 passes through the interior of the first rolling head seat 9 and is connected to one end of the first forming rolling head 10, and the other end of the first forming rolling head 10 passes through the gap between the two induction heaters 43 to roll one side of the disk part and the shaft part of the prefabricated blank 42.

[0093] The second radial motion guide rail 14 is arranged on the upper surface of the second axial motion frame 12, and the intersection line of the two is perpendicular; the second radial motion guide rail 14 is provided with a second radial motion electric cylinder 13 and a second radial motion frame 16 on the upper surface, and the second radial motion electric cylinder 13 is connected to the left end of the second radial motion frame 16. Under the operation of the second radial motion electric cylinder 13, the second radial motion frame 16 is extended and retracted to the right along the upper surface of the second radial motion guide rail 14. The upper surface of the second radial motion frame 16 is installed with a second angle adjustment electric cylinder 15 and a second rolling head seat 18 that are tilted, that is, the second angle adjustment electric cylinder 15 is moved left, rear and right. The second rolling head seat 18 is tilted to the front left and tilted to the rear right. The right end of the second angle adjustment electric cylinder 15 is movably connected to the left side of the second rolling head seat 18 body, and the angle of the second angle adjustment electric cylinder 15 and the second rolling head seat 18 is adjustable. The left front end of the second rolling head seat 18 is equipped with a second rolling head rotating motor 17, and the right rear end of the second rolling head seat 18 is equipped with a second forming rolling head 19, and the rotating shaft of the second rolling head rotating motor 17 passes through the interior of the second rolling head seat 18 and is connected to one end of the second forming rolling head 19. The other end of the second forming rolling head 19 passes through the gap between the two induction heaters 43 to roll the other side of the disk portion of the prefabricated blank 42.

[0094] The third radial motion guide rail 24 is arranged on the upper surface of the third axial motion frame 21, and the intersection line of the two is perpendicular; the third radial motion electric cylinder 23 and the third radial motion frame 26 are arranged on the upper surface of the third radial motion guide rail 24, the third radial motion electric cylinder 23 is connected to the right end of the third radial motion frame 26, under the operation of the third radial motion electric cylinder 23, the third radial motion frame 26 extends and contracts to the left along the upper surface of the third radial motion guide rail 24, and the third angle adjustment electric cylinder 25 and the third rolling head seat 28 with an inclined setting are installed on the upper surface of the third radial motion frame 26. The third angle adjustment electric cylinder 25 is movably connected to the third rolling head seat 28, that is, the third angle The electric cylinder 25 is adjusted to be tilted left and rear and right, and the third rolling head seat 28 is tilted left and front and right. The left end of the third angle adjustment electric cylinder 25 is movably connected to the right side of the third rolling head seat 28 body, and the angle of the third angle adjustment electric cylinder 25 and the third rolling head seat 28 is adjustable. The right rear end of the third rolling head seat 28 is equipped with a third rolling head rotating motor 27, and the left front end of the third rolling head seat 28 is equipped with the first forming rolling head 10, and the rotating shaft of the third rolling head rotating motor 27 passes through the interior of the third rolling head seat 28 and is connected to one end of the third forming rolling head 29. The other end of the third forming rolling head 29 passes through the gap between the two induction heaters 43 to roll one side of the disk part and the shaft part of the prefabricated blank 42.

[0095] The fourth radial motion guide rail 33 is arranged on the upper surface of the fourth axial motion frame 31, and the intersection line of the two is perpendicular; the fourth radial motion electric cylinder 32 and the fourth radial motion frame 35 are arranged on the upper surface of the fourth radial motion guide rail 33, and the fourth radial motion electric cylinder 32 is connected to the right end of the fourth radial motion frame 35. Under the operation of the fourth radial motion guide rail 33, the fourth radial motion frame 35 is extended and retracted to the left along the upper surface of the fourth radial motion guide rail 33. The upper surface of the fourth radial motion frame 35 is installed with a fourth angle adjustment electric cylinder 34 and a fourth rolling head seat 37 that are tilted, that is, the fourth angle adjustment electric cylinder 34 is left front right. The fourth rolling head seat 37 is tilted to the left rear and right front, the right end of the fourth angle adjustment electric cylinder 34 is movably connected to the right side of the fourth rolling head seat 37 body, and the angle of the fourth angle adjustment electric cylinder 34 and the fourth rolling head seat 37 is adjustable, the right rear end of the fourth rolling head seat 37 is installed with the fourth rolling head rotating motor 36, the left front end of the fourth rolling head seat 37 is installed with the fourth forming rolling head 38, and the rotating shaft of the fourth rolling head rotating motor 36 passes through the interior of the fourth rolling head seat 37 and is connected to one end of the fourth forming rolling head 38, and the other end of the fourth forming rolling head 38 passes through the gap between the two induction heaters 43 to roll the other side of the disk portion of the prefabricated blank 42.

[0096] It should be noted that, since the radial motion guide rail is arranged above the axial motion guide rail, the axial motion guide rail can be set as two, each axial motion guide rail is equipped with two radial motion guide rails, and the radial motion guide rails intersect the axial motion guide rail vertically; when the radial motion guide rail is arranged below the axial motion guide rail, the radial motion guide rail can be set as two, and the radial motion guide rail passes under the clamping device, and each radial motion guide rail is vertically equipped with two axial motion guide rails, that is, the first radial motion guide rail 5 and the third radial motion guide rail 24 are combined into one radial motion guide rail, and the second radial motion guide rail 14 The first axial motion guide rail 3 is combined with the fourth radial motion guide rail 33 to form a radial motion guide rail, and the first axial motion guide rail 3 is divided into two axial motion guide rails from the middle, which are respectively arranged on two radial motion frames on one radial motion guide rail, and the rolling head rotating component and the angle adjustment component are arranged on the axial motion frame arranged transversely on the axial motion guide rail. Similarly, the second axial motion guide rail 22 is divided into two axial motion guide rails from the middle, which are respectively arranged on two radial motion frames on another radial motion guide rail, and the rolling head rotating component and the angle adjustment component are arranged on the axial motion frame arranged transversely on the axial motion guide rail.

[0097] In such Figure 1 In the embodiment shown, the infrared temperature measuring probe 47 is arranged on one side of the first axial motion guide rail 3 and the second radial motion guide rail 14, and can detect the online temperature of the preform 42. The position setting of the infrared temperature measuring probe 47 is not limited to the method shown in the embodiment of this application, and this application does not make specific restrictions here.

[0098] in addition, Figure 1 The M shown a 1 is the motor identifier that drives the first axial motion electric cylinder 1, M a 2 is the motor identifier for driving the second axial motion electric cylinder 20, M a 3 is the motor identifier for driving the third axial motion electric cylinder 11, M a 4 is the motor identifier for driving the fourth axial motion electric cylinder 30; M r 1 is the motor identifier for driving the first radial motion electric cylinder 4, M r 2 is the motor identifier for driving the second radial motion electric cylinder 13, M r 3 is the motor identifier for driving the third radial motion electric cylinder 23, M r 4 is the motor identifier for driving the fourth radial motion electric cylinder 32; M s 1 is the motor identifier for driving the first angle adjustment electric cylinder 6, M s 2 is the motor identifier for driving the second angle adjustment electric cylinder 15, M s 3 is the motor identifier for driving the third angle adjustment electric cylinder 25, Ms 4 is the identifier of the motor that drives the fourth angle adjustment electric cylinder 34 to operate.

[0099] The present application also provides a method for rolling and forming an integral disc-shaft component, which uses any of the above-mentioned integral disc-shaft component rolling and forming equipment to roll and form the disc surface portion and the shaft portion of a prefabricated blank in a single heating process to form an integral disc-shaft component with spokes of a specific shape and a stepped shaft, comprising:

[0100] In the preparation stage, the preform is clamped and rotated by a clamping device;

[0101] In the induction heating stage, the induction heating device is started to heat the preform to a predetermined temperature;

[0102] In the rolling forming stage, the disc part and the shaft part of the prefabricated blank are rolled and formed by controlling the axial feed, radial feed and tilt angle of the forming rolling head in the rolling head movement device.

[0103] Specifically, first, the preform is clamped using the clamping head in the clamping device, the induction heating device is covered on both sides of the preform, and the rotary drive motor in the clamping device is used to drive the clamping head to rotate the preform, then the induction heating device is started, and the infrared temperature probe is used to detect online whether the preform reaches the predetermined temperature. When the preform is heated to the predetermined temperature, the starting inclination angle of the forming rolling head in the rolling head movement device is adjusted so that the forming rolling head busbar is parallel to the radial direction of the preform, the axial feeding and radial movement are completed by the rolling head movement component, and the rolling movement is completed by the rolling head rotating component to complete the forming of the disk spoke part of the preform, and then the forming rolling head leaves the preform axially and is swung by the angle adjustment component to an inclination angle so that the forming rolling head busbar is parallel to the axial direction of the preform, and then the radial feeding, axial movement and rolling movement of the rolling head are performed by the rolling head movement component and the rolling head rotating component to complete the forming of the shaft part of the preform.

[0104] In a specific embodiment of the present application, the preform 42 is first clamped using the first clamping head 41 and the second clamping head 46 of the clamping device. Then, the upper and lower induction heaters 43 are placed on the upper and lower sides of the preform 42, respectively. The first rotary drive motor 39 and the second rotary drive motor 44 simultaneously drive the two clamping heads to rotate the preform 42 and activate the induction heaters 43 to heat the preform 42. After the infrared temperature probe 47 detects that the preform 42 has been heated to a predetermined temperature, the initial tilt angles of the four forming rollers are adjusted using the first angle adjustment electric cylinder 6, the second angle adjustment electric cylinder 15, the third angle adjustment electric cylinder 25, and the fourth angle adjustment electric cylinder 34, respectively, so that the conical generatrix of the forming rollers is parallel to the radial direction of the integral disc shaft component (i.e., the preform 42). Axial feed is achieved using the four axial motion frames and four axial motion electric cylinders on the two axial motion guides. Radial motion and rolling motion of the rollers are achieved using the radial motion frames and radial motion electric cylinders on each radial motion guide, completing the forming of the disc surface spoke portion of the integral disc shaft component. Then, after the four forming rolling heads axially leave the preform, the first forming rolling head 10 and the third forming rolling head 29 are swung and tilted by the first angle adjustment electric cylinder 6 and the third angle adjustment electric cylinder 25 respectively, so that the conical generatrix of the forming rolling head is parallel to the axial direction of the integral disc shaft component, and then the axial movement is realized by the axial movement frame and the axial movement electric cylinder on the axial movement guide rail, and the radial feeding and rolling movement of the rolling head are realized by the radial movement frame and the radial movement electric cylinder on the radial movement guide rail, and finally the forming of the shaft part of the integral disc shaft component is completed.

[0105] In the embodiment shown in this application, the forming roller head is generally conical in shape, and the head of the forming roller head is in the form of a frustum. The forming roller head style described in this application only refers to the integral disc-shaft arrangement mentioned herein. In addition, the shape of the forming roller head can be set according to the shape of the finished product, and no other specific limitations are imposed herein.

[0106] In such Figure 2a-2b In the relationship between the induction heater, the preform and the forming rolling head, two induction heaters 43 are provided, and the induction heater 43 contains a heating wire, such as Figure 2a As shown in the cross section at the corresponding position; Figure 2b This is a view of the integral disc shaft rolling forming equipment from the first forming rolling head 10 and the third forming rolling head 29. The middle small circle represents the clamping head, the next circle represents the preform, and the upper and lower semi-arcs represent induction heaters.

[0107] exist Figure 3 In the embodiment shown, the disk portion of the preform 42 is formed by rolling as follows:

[0108] The first rotary drive motor 39 and the second rotary drive motor 44 operate to drive the first clamping head 41 and the second clamping head 46 to rotate, thereby driving the preform 42 to rotate under the heating state of the two induction heaters 43 .

[0109] The first radial motion electric cylinder 4 drives the first radial motion frame 7 to move a certain distance along the first radial motion guide rail 5 in the direction of deviating from the preformed blank 42. At the same time, the second radial motion electric cylinder 13 drives the second radial motion frame 16 to move a certain distance along the second radial motion guide rail 14 in the direction of deviating from the preformed blank 42. The third radial motion electric cylinder 23 drives the third radial motion frame 26 to move a certain distance along the third radial motion guide rail 24 in the direction of deviating from the preformed blank 42. The fourth radial motion electric cylinder 32 drives the fourth radial motion frame 35 to move a certain distance along the fourth radial motion guide rail 33 in the direction of deviating from the preformed blank 42, so that the four forming rolling heads roll the disk surface of the preformed blank 42 into a specific spoke shape. An axial motion electric cylinder 1 drives the first axial motion frame 2 to move a certain distance along the first axial motion guide rail 3 toward the direction close to the preform 42, and the second axial motion electric cylinder 11 drives the second axial motion frame 12 to move a certain distance along the first axial motion guide rail 3 toward the disk part close to the preform 42, so that the first forming rolling head 10 and the second forming rolling head 19 can contact the disk part of the preform 42; similarly, the third axial motion electric cylinder 20 and the fourth axial motion electric cylinder 30 drive the third axial motion frame 21 and the fourth axial motion frame 31 to move a certain distance toward the disk part close to the preform 42, so that the third forming rolling head 29 and the fourth forming rolling head 38 can contact the disk part of the preform 42.

[0110] exist Figure 4 In the embodiment shown, when the rolling of the disk portion of the preform 42 is completed and the shaft portion of the preform 42 is ready to be rolled, the position of the forming rolling head is shown as follows:

[0111] The second axial motion electric cylinder 11 drives the second axial motion frame 12 to move along the first axial motion guide rail 3 in the direction away from the preform 42, and the fourth axial motion electric cylinder 30 drives the fourth axial motion frame 31 to move away from the preform 42, so that the second forming rolling head 19 and the fourth forming rolling head 38 are away from the preform 42; at the same time, the first axial motion electric cylinder 1 drives the first axial motion frame 2 to move along the first axial motion guide rail 3 toward the shaft part close to the preform 42, and the third axial motion electric cylinder 20 drives the third axial motion frame 21 to move toward the shaft part close to the preform 42, so that the first forming rolling head 10 and the third forming rolling head 29 can contact the shaft part of the preform 42.

[0112] Furthermore, the first angle adjustment electric cylinder 6 operates to push the first rolling head seat 9, so that the angle between the first angle adjustment electric cylinder 6 and the first rolling head seat 9 becomes smaller, and the third angle adjustment electric cylinder 25 operates to push the third rolling head seat 28, so that the angle between the third angle adjustment electric cylinder 25 and the third rolling head seat 28 becomes smaller, so as to prepare for the first forming rolling head 10 and the third forming rolling head 29 to roll the shaft portion of the preform 42. Figure 5 As shown, the first forming rolling head 10 and the third forming rolling head 29 perform step-shaped rolling on the shaft portion of the preform 42 .

[0113] After the disk surface portion and the shaft portion of the prefabricated blank 42 are rolled and formed, an integral disk shaft component with a specific shape of spokes and a stepped shaft is obtained, such as Figure 6 shown.

[0114] To sum up, the integral disc shaft part rolling forming equipment and method provided in this application belongs to the dieless rolling forming technology, which is a flexible forming technology that can use local continuous plastic deformation to finally form larger parts. It has unique advantages in saving forming molds, reducing the tonnage of forming equipment, and facilitating digital flexible production. Based on the dieless rolling forming process, the equipment can realize the precise adjustment of the movement position of multiple groups of forming rolling heads through axial feeding, radial feeding and angular swinging of multiple groups of forming rolling heads in one heating, with high forming accuracy.

[0115] Unless otherwise defined, all technical and scientific terms used in this application are the same as those commonly understood by those skilled in the art to which this application belongs. In the event of any inconsistency, the meaning described in the full text of this application or the meaning derived from the content recorded in the full text of this application shall prevail. In addition, the terms used in this description are only for the purpose of describing the embodiments of the present application and are not intended to limit this application.

[0116] It should be noted that, in the description herein, the terms "front", "left front", "right rear", "up", "down", "left rear", "right rear", "horizontal", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they should not be understood as limitations on this application.

[0117] Furthermore, the terms "installed," "disposed," "provided with," "connected," "connected," "socketed," and the like should be interpreted broadly. For example, they may refer to fixed connections, removable connections, or integral structures; they may refer to mechanical connections; they may refer to direct connections, indirect connections through an intermediary, or internal communication between two devices, elements, or components. Those skilled in the art will understand the specific meanings of these terms in the present invention based on the specific circumstances.

[0118] Note that the above are only preferred embodiments of the present application and the technical principles employed. Those skilled in the art will understand that the present application is not limited to the specific embodiments described herein, and that various obvious changes, readjustments, and substitutions can be made by those skilled in the art without departing from the scope of protection of the present application. Therefore, although the present application has been described in more detail through the above embodiments, the present application is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the technical concept of the present application, all of which fall within the scope of protection of the present application.

[0119] The above description is merely an embodiment of the present application and does not limit the patent scope of the present application. Any equivalent structural transformation made using the contents of the present application specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. An integral disc shaft rolling forming device, characterized in that: include: A clamping device that clamps on the end of the preform; An induction heating device is arranged on both sides of the periphery of the preform; A rolling head movement device comprises a rolling head movement component, a rolling head rotation component and an angle adjustment component, wherein the rolling head movement component comprises an axial movement component and a radial movement component, the rolling head rotation component and the angle adjustment component are assembled above the rolling head movement component, the angle adjustment component is connected to the rolling head rotation component, and the forming rolling head in the rolling head rotation component passes through the induction heating device to roll and form the disk surface part and the shaft rod part of the preform, so as to form an integral disk-shaft component with a specific spoke shape and a stepped shaft rod.

2. The integral disk shaft component rolling forming equipment according to claim 1 is characterized in that: The clamping device comprises two clamping assemblies, which are clamped at two ends of the preform, wherein each group of the clamping assemblies comprises: A clamping head, the front end of which is protruding and inserted into the center hole at one end of the preform; A clamping head seat, one end of which is mounted with the clamping head tail end, and an opposite end of the clamping head seat is mounted with a rotation drive motor; The driving shaft of the rotary driving motor passes through the clamping head seat and is connected with the rear end of the clamping head.

3. The integral disc shaft component rolling forming equipment according to claim 1 or 2, characterized in that: The induction heating device comprises two induction heaters, and the two induction heaters are symmetrically arranged on both sides of a horizontal plane where a central axis of the preform is located.

4. The integral disc shaft component rolling forming equipment according to claim 3 is characterized in that: The distance between the two induction heaters is determined according to the space required for the movement of the forming rolling head.

5. The integral disc shaft component rolling forming equipment according to claim 3, characterized in that: In the rolling head moving component, the axial moving component is arranged below the radial moving component, and the axial moving component is perpendicular to the radial moving component.

6. The integral disc shaft component rolling forming equipment according to claim 5, characterized in that: The axial motion component comprises an axial motion guide rail, an axial motion frame and an axial motion electric cylinder, wherein the axial motion electric cylinder is connected to one end of the axial motion frame, and the axial motion guide rail is equipped with the axial motion electric cylinder connected to the axial motion frame; The radial motion component includes a radial motion guide rail, a radial motion frame and a radial motion electric cylinder, wherein the radial motion electric cylinder is connected to one end of the radial motion frame, the radial motion guide rail is equipped with the radial motion electric cylinder connected to the radial motion frame, and the radial motion guide rail is arranged on the axial motion frame.

7. The integral disc shaft component rolling forming equipment according to claim 6, characterized in that: The rolling head rotating component comprises: A rolling head seat, which is arranged on the upper surface of the radial motion frame; a forming rolling head supported on the rolling head seat; The rolling head rotating motor is arranged on the upper surface of the radial motion frame, and the rotating shaft of the rolling head rotating motor passes through the inside of the rolling head seat and is connected to the forming rolling head.

8. The integral disk shaft component rolling forming equipment according to claim 1, characterized in that: The angle adjustment component includes an angle adjustment electric cylinder.

9. The integral disk shaft component rolling forming equipment according to claim 1, characterized in that: It also includes an infrared temperature measuring probe for online detection of the temperature of the preform during the rolling process of the preform.

10. A method for rolling an integral disc shaft, characterized in that: The integral disk-shaft component rolling forming device according to any one of claims 1 to 9 is used to roll and form the disk surface part and the shaft rod part of the prefabricated blank in one heating to form an integral disk-shaft component with a spoke and a stepped shaft rod of a specific shape, which comprises: In the preparation stage, the preform is clamped and rotated by a clamping device; In the induction heating stage, the induction heating device is started to heat the preform to a predetermined temperature; In the rolling forming stage, the disk portion and the shaft portion of the preform are rolled and formed by controlling the axial feed, radial feed and tilt angle of the forming rolling head in the rolling head movement device.

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