Forming method and shaping die of high-speed wheel spoke plate

Abstract

The invention discloses a forming method of a high-speed wheel spoke plate, which further comprises a shaping die used in a shaping step, and the method comprises the following steps: 1) plate shearing and blanking are carried out, and a product blank is prepared from raw materials; (2) stretching forming is conducted, and a radial plate contour piece is manufactured through the product blank; 3) punching: punching a mounting hole and a middle hole in the radial plate contour piece; (4) flanging is conducted, specifically, the edge of the radial plate contour piece is flanged; 5) shaping; according to the method, the position precision of the middle hole and the chamfer of the product is remarkably improved. Cooperative shaping machining of chamfers, mounting holes, middle holes and turned-over edges is completed in the same working procedure through the shaping die. And through the synchronous shaping process, the runout control precision and the chamfering position degree of the radial plate are remarkably improved. According to the method, the production efficiency is greatly improved, accumulative errors are reduced, and high-quality and high-efficiency production of the high-speed wheel spoke plate is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of wheel spoke plate processing, in particular to a forming method of a high-speed wheel spoke plate and a shaping die thereof. Background Art

[0002] The precision requirements of high-speed automobile steel wheels are relatively high. In particular, before the assembly of the spoke plate and the rim, the outer circle runout of the spoke plate must be controlled within 0.3mm, and the chamfer position and center hole position must be strictly controlled within the range of ±0.2mm. However, the existing traditional production process cannot meet these high-precision requirements. The traditional wheel production process is a single-step stamping process, which is divided into: 1) Shearing and cutting; 2) Stretch forming; 3) Punching mounting holes; 4) Chamfering; 5) Punching the center hole; 6) Turning the outer circle.

[0003] The main problems of this process are as follows: a) Low precision: The production precision of the spoke is low. Multiple separate stamping processes result in the chamfering and center hole processing being independent of each other, which cannot guarantee the position and accuracy requirements, and thus cannot meet the strict accuracy requirements of high-speed wheel pairs.

[0004] b) High mold cost: In order to ensure high spoke production accuracy, traditional processes require the production of high-precision molds, which cost twice as much as ordinary molds.

[0005] c) High production cost: In order to meet the requirements of external circle runout accuracy, the traditional process needs to add additional external circle turning process, which further increases the production cost.

[0006] d) Difficulty in quality control: Multiple stamping processes increase the number of quality control points, making product quality control more complicated and posing potential quality risks.

[0007] e) Low measurement accuracy: In traditional processes, defects such as fracture layers or burrs may affect the measurement accuracy of position, leading to the accumulation of processing errors and affecting the quality of the final product.

[0008] d) Process limitations: The current production process cannot solve the problem that the flanging process will affect the chamfering accuracy and the size of the mounting hole and the center hole will be deformed. If the flanging is performed in advance according to the previous process, the outer circle runout can only reach 0.5, which is far from meeting the runout requirements of high-speed wheels. If the flanging is changed to the last process, the runout requirements are met, but the chamfering position cannot be guaranteed, and the mounting hole and the center hole will be deformed. Therefore, how to improve the outer circle runout while ensuring that the chamfering position is met is the biggest problem.

[0009] For example: The current production process of mounting hole reinforcement series spokes is generally divided into two types: ① Punch the mounting hole first, then extrude the mounting hole reinforcement ribs, and finally punch the center hole independently; ②First punch the mounting holes and small-sized center holes, then extrude the mounting hole reinforcement ribs, and finally turn the center holes on a lathe.

[0010] These two processes require independent processing of the center hole because the original punching process will affect the deformation of the mounting hole. Such a production process has the following problems: ① The current production process of mounting hole reinforcement rib spokes is divided into two types. The center hole needs to be processed independently, resulting in a position accuracy of only 0.5mm, which does not meet the accuracy requirement of less than 0.25mm for new products.

[0011] ② The original punching process causes deformation of the mounting holes, requiring separate processing, increasing production costs and process waste.

[0012] Therefore, the industry has proposed some solutions to the above problems, such as "A spoke shaping device" disclosed in Chinese patent documents, with the announcement number "CN203330182U", which includes a base and a shaping seat, the base includes a bottom plate, a support platform and a positioning frame, the positioning frame is fixed to the bottom plate, the support platform is fixed to the bottom plate and is located in the positioning frame, the shaping seat includes a seat body, a positioning block and a shaping body, the positioning block is installed under the seat body and protrudes relative to the seat body, the positioning block cooperates with the axial hole of the spoke, the shaping body is connected to the seat body, the shaping body is annular and surrounds the positioning block, and the shape of the shaping body is the same as the shape of the annular boss of the spoke.

[0013] In the above scheme, although the spoke shaping device has a simple structure, low cost, and is easy to operate and maintain, it still does not solve the problems of difficulty in meeting the hole accuracy standards, deformation of the mounting holes caused by the punching process, the need for separate processing, and increased production costs. Summary of the invention

[0014] In view of the above-mentioned problems that the high-speed wheel spoke plate in the prior art has huge costs and complicated process flow in order to achieve high-precision requirements, the present invention provides a high-speed wheel spoke plate forming method and shaping mold thereof. Through the synchronous shaping process, the problem of deformation of the mounting hole after flanging in the traditional forming process is solved, and the control accuracy of the spoke plate runout and the chamfer position are significantly improved. At the same time, the method greatly improves the production efficiency, reduces the cumulative error, and realizes the high-quality and high-efficiency production of high-speed wheel spoke plates.

[0015] In order to achieve the above object, the present invention adopts the following technical solutions: A forming method for a high-speed wheel spoke plate comprises the following steps: 1) shearing and blanking to obtain a product blank from raw materials; 2) stretching to obtain a spoke plate profile from the product blank; 3) punching to punch out mounting holes and center holes on the spoke plate profile; 4) flanging to flanging the edges of the spoke plate profile; 5) shaping; wherein, in the shaping step, the coordinated shaping processing of chamfering, mounting holes, center holes and flanging is completed in the same process by a shaping die.

[0016] In this solution, the use of collaborative shaping process significantly improves production efficiency and reduces the accumulation of errors between processes. In traditional methods, these processing steps are usually carried out separately, which easily leads to inconsistent precision and deformation problems between parts. In this method, synchronous shaping ensures the precision coordination of each key part and effectively controls the runout of the spoke to within 0.3mm. This not only improves product quality, but also eliminates the need for independent processing of the center hole, reduces production processes, and reduces production costs by about 8.2%. At the same time, since the separate production process of the decorative hole caused by slope and other problems is solved, the cost is further reduced and the production efficiency is improved. This method significantly improves the position accuracy of the center hole and chamfer of the product, which can meet the accuracy standard of new products within 0.25mm, breaking the traditional technical barriers.

[0017] Preferably, the stretching forming step adopts a segmented stretching process, including: initial stretching, using a large radius mold for rough forming; intermediate stretching, using a medium radius mold for contour refinement; final stretching, using a precision mold for precise forming; wherein, a short rebound time is provided between each stretching, and the rebound time is dynamically adjusted according to the material properties, ranging from 0.5 seconds to 2 seconds. The segmented stretching process gradually forms the profile of the spoke plate through three stages, and each stage uses a mold with a different radius to accurately control the deformation process. The initial stretching uses a large radius mold for rough forming to reduce the initial stress concentration of the material; the intermediate stretching uses a medium radius mold to refine the contour and improve the forming accuracy; the final stretching uses a precision mold to ensure the final shape accuracy. This progressive forming method effectively reduces the degree of strain hardening of the material and reduces the risk of cracking. This solution allows the material to release some internal stress between each stretching stage, promotes uniform deformation, and prevents the formation of microcracks. By controlling the deformation rate and utilizing the elastic properties of the material, the final forming accuracy is significantly improved, and the risk of local thinning and wrinkling is reduced. Compared with traditional single or continuous stretching, it can better control material flow and improve product quality consistency. At the same time, optimizing parameters can reduce scrap rate, improve material utilization and reduce production costs.

[0018] Preferably, the punching step adopts a composite punching process, including: pre-punching, using a punch with a floating press ring for preliminary forming; fine punching, using a carbide precision punch to complete the final hole shape; wherein, the fine punching step adopts a reverse ejection mechanism, and immediately applies radial pressure to the hole wall after the punching is completed, the pressure value is 1.2 to 1.5 times the yield strength of the material, and the action time is 0.1 to 0.3 seconds, so as to eliminate the hole wall stress and improve the roundness accuracy of the hole. The pre-punching stage uses a punch with a floating press ring for preliminary forming, which can effectively control the material flow and reduce edge wrinkling and deformation. The floating press ring can automatically adjust the pressure according to the change of material thickness to ensure stability during the punching process. The fine punching stage uses a carbide precision punch to complete the final hole shape, and the high hardness and wear resistance of the carbide ensure the accuracy stability after long-term use. Immediately after fine punching, a reverse ejection mechanism is used to apply radial pressure to the hole wall, the pressure value is 1.2 to 1.5 times the yield strength of the material, and the action time is 0.1 to 0.3 seconds. This process uses the plastic deformation characteristics of the material to generate compressive stress on the hole wall, effectively eliminating the tensile stress generated during the punching process and improving the roundness accuracy of the hole. By precisely controlling the pressure and action time, it is possible to optimize the surface quality of the hole wall without affecting the hole size, reduce the generation of micro cracks, and improve the fatigue strength and service life of the product.

[0019] Preferably, the flanging step adopts a controllable temperature gradient flanging process, including: edge preheating, using an induction heating device to locally heat the flanging area; gradient flanging, using a temperature-adjustable flanging die for forming; wherein the temperature of the flanging die decreases linearly from the root to the edge, and the temperature gradient is 50°C / cm to 100°C / cm, so as to achieve uniform deformation of the flanging area. The edge preheating stage uses an induction heating device to locally heat the flanging area, which can significantly improve the local plasticity of the material and reduce the risk of stress concentration and cracking during the flanging process. The gradient flanging stage uses a temperature-adjustable flanging die for forming. Considering the stress distribution of the material during the deformation process, the mold temperature decreases linearly from the root to the edge, so that the flanging area can be uniformly deformed. The higher root temperature ensures sufficient plastic flow, and the gradual decrease in edge temperature helps to control the degree of deformation and maintain dimensional accuracy. While ensuring the quality of the flanging, it can significantly reduce the rebound phenomenon during the flanging process and improve the forming accuracy.

[0020] Preferably, the shaping step adopts a synchronous collaborative shaping process, including: multi-station synchronous shaping, using an integrated shaping mold to shape the center hole, mounting hole, flange and chamfer at the same time; precise pressure control, using a partitioned pressure sensor to monitor the pressure distribution of each shaping area in real time; dynamic pressure regulation, according to the feedback of the pressure sensor, using a servo motor driven pressure distribution system to fine-tune the pressure of each shaping area in real time. The integrated shaping mold is used to shape the center hole, mounting hole, flange and chamfer at the same time, which significantly improves the shaping efficiency and reduces the error accumulation between processes. The partitioned pressure sensor monitors the pressure distribution of each shaping area in real time, providing basic data for precise control. The servo motor driven pressure distribution system fine-tunes the pressure of each shaping area in real time according to the sensor feedback. This closed-loop control mechanism can quickly respond to the pressure changes during the material deformation process, ensuring the optimization of the pressure distribution during the entire shaping process. By accurately controlling the pressure in different areas, the local differences in material thickness and hardness can be effectively compensated, a more uniform deformation can be achieved, and the dimensional accuracy and surface quality of the product can be improved.

[0021] Preferably, the upper mold plate is connected to the lower mold plate through a guide column and guide sleeve assembly; an upper base plate is arranged below the upper mold plate, and an upper pad is arranged between the upper base plate and the upper mold plate; a lower base plate is arranged above the lower mold plate, and a lower pad is arranged between the lower base plate and the lower mold plate; an upper mold core is arranged below the upper base plate, and the upper mold core and the concave mold on the lower base plate form a cavity that matches the final shape of the spoke. The upper mold plate and the lower mold plate are connected through the guide column and guide sleeve assembly to ensure the stability and movement accuracy of the overall structure. The upper pad arranged between the upper base plate and the upper mold plate, and the lower pad arranged between the lower base plate and the lower mold plate, play a role of buffering and adjustment, can absorb the impact force during the processing, and extend the life of the mold. The upper mold core below the upper base plate and the concave mold on the lower base plate jointly form a cavity that matches the final shape of the spoke, ensuring the molding accuracy. The layered structure of the mold is easy to disassemble and maintain, and also improves the versatility of the mold, and can adapt to the production of spokes of different specifications by replacing the upper mold core and the concave mold. The rigidity and precision of the overall structure ensure stability during high-speed stamping, reduce deformation and wear, and improve product consistency.

[0022] Preferably, the lower base plate is provided with a first chamfering head and a second chamfering head, which correspond to the positioning hole and the middle hole of the product respectively; the upper mold core is provided with a first chamfering sleeve and a second chamfering sleeve corresponding to the first chamfering head and the second chamfering head; the first chamfering head and the second chamfering head penetrate the push plate and the push plate pad set between the lower base plate and the die; the push plate is provided with a mounting groove adapted to the product contour for placing the product to be shaped. The first chamfering head and the second chamfering head on the lower base plate correspond to the positioning hole and the middle hole of the product respectively, and form a precise match with the first chamfering sleeve and the second chamfering sleeve in the upper mold core, so as to realize the dual functions of chamfering and positioning, and improve the shaping accuracy. The chamfering head penetrates the push plate and the push plate pad set between the lower base plate and the die to ensure the stability and consistency of the chamfering operation. The mounting groove adapted to the product contour set on the push plate provides an accurate positioning reference for the product and reduces the processing error. It can not only simplify the mold structure, but also improve the shaping efficiency, reduce the number of clamping times, reduce the processing error, but also simplify the mold maintenance process and increase the service life of the mold.

[0023] Preferably, a plurality of inner guide pins are provided between the upper base plate and the lower base plate; an inner guide sleeve is provided between the inner guide pins and the die; the inner guide sleeve is fixed on the die and slidably cooperates with the inner guide pins to ensure precise alignment of the upper and lower molds during the mold closing process.

[0024] Preferably, an annular space for shaping the flanging of the product is formed between the inner wall surface of the die and the outer wall surface of the push plate; the cross-sectional shape of the annular space matches the final shape of the product flanging; the top surface of the die and the bottom surface of the upper mold core form a molding surface for shaping the chamfer of the product when the mold is closed. This solution ensures the consistency and accuracy of the flanging. The molding surface formed by the top surface of the die and the bottom surface of the upper mold core when the mold is closed is used to shape the chamfer of the product. This layout realizes the simultaneous processing of flanging and chamfering. By integrating the two processes into one mold, the production efficiency is significantly improved and the error accumulation between the processes is reduced. In addition, the design of the annular space can also reduce material springback and improve the forming quality of the flanging, which is particularly suitable for the processing of high-strength materials.

[0025] Preferably, the bottom surface of the upper mold core is provided with a positioning protrusion connected to the first chamfering sleeve and the second chamfering sleeve; the positioning protrusion forms a precise matching relationship with the first chamfering head and the second chamfering head when the mold is closed; the axis of the positioning protrusion, the first chamfering head and the second chamfering head is parallel to the closing direction of the upper and lower molds. High-precision positioning and chamfering functions are achieved through the connection design of the positioning protrusion on the bottom surface of the upper mold core and the first chamfering sleeve and the second chamfering sleeve. The axis of the positioning protrusion, the chamfering head and the chamfering sleeve are parallel to the closing direction of the upper and lower molds. This layout not only simplifies the mold structure, but also reduces the lateral force and increases the service life of the mold. By accurately controlling the chamfering process, the stress concentration at the edge of the product can be effectively reduced, the service life and performance of the product can be improved, and a reliable technical guarantee can be provided for the production of high-speed wheel spokes.

[0026] Therefore, the present invention has the following beneficial effects: The shaping mold realizes the integrated processing of chamfering, mounting holes, center holes and flanging, which significantly reduces the accumulation of errors between processes and greatly improves the overall accuracy and consistency of high-speed wheel spokes.

[0027] The shaping mold effectively solves the problem of mounting hole deformation after flanging in traditional processes through precise pressure distribution and synchronous shaping, and improves the precision control of key dimensions of the product.

[0028] The multifunctional integrated design of the shaping mold not only simplifies the production process, but also reduces equipment investment and operation complexity, significantly improves production efficiency and reduces manufacturing costs.

[0029] The precise fit of the mold and uniform pressure distribution ensure the precise docking of each processing step, so that the high-speed wheel spoke plate can meet the final precision requirements in one molding process, thus improving product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a structural schematic diagram of the shaping mold in the present invention.

[0031] In the figure: 1, lower template, 2, lower base plate, 3, lower pad, 4, die, 5, upper base plate, 6, upper template, 7, inner guide pin, 8, upper pad, 9, first chamfering sleeve, 10, second chamfering sleeve, 11, upper mold core, 12, upper mold core insert, 13, guide pin and sleeve, 14, push plate and pad, 15, second chamfering head, 16, first chamfering head, 17, push plate, 18, inner guide sleeve. DETAILED DESCRIPTION

[0032] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions.

[0033] Example 1 The present embodiment describes in detail a method for forming a spoke plate of a high-speed wheel, comprising the following steps: 1) shearing and blanking, to obtain a product blank from the raw material; 2) stretching forming, to obtain a spoke plate profile from the product blank; 3) punching, to punch out mounting holes and center holes on the spoke plate profile; 4) flanging, to flanging the edges of the spoke plate profile; 5) shaping; wherein, in the shaping step, the coordinated shaping processing of chamfering, mounting holes, center holes and flanging is completed in the same process by a shaping mold.

[0034] In this solution, the use of collaborative shaping process significantly improves production efficiency and reduces the accumulation of errors between processes. In traditional methods, these processing steps are usually carried out separately, which easily leads to inconsistent precision and deformation problems between parts. In this method, synchronous shaping ensures the precision coordination of each key part and effectively controls the runout of the spoke to within 0.3mm. This not only improves product quality, but also eliminates the need for independent processing of the center hole, reduces production processes, and reduces production costs by about 8.2%. At the same time, since the separate production process of the decorative hole caused by slope and other problems is solved, the cost is further reduced and the production efficiency is improved. This method significantly improves the position accuracy of the center hole and chamfer of the product, which can meet the accuracy standard of new products within 0.25mm, breaking the traditional technical barriers.

[0035] Specifically, this method aims to improve the structural strength and processing accuracy of the spokes through a series of precise process steps. First, the raw materials are sheared and blanked to form a product blank, and the shape and size of the blank provide the basis for subsequent forming. Next, a segmented stretching process is adopted. The first stretching uses a large radius mold for rough forming to ensure the initial formation of the spoke contour; the intermediate stretching uses a medium radius mold for contour refinement, and the final stretching stage uses a precision mold to achieve high-precision forming. The short rebound time between each stretch is dynamically adjusted according to the material properties to ensure that the material maintains the best physical state during the forming process.

[0036] In the punching step, the application of the composite punching process significantly improves the accuracy and strength of the hole. In the pre-punching stage, a punch with a floating pressure ring is used for preliminary forming, and then the final hole shape is completed by a carbide precision punch. After fine punching, the reverse ejection mechanism applies radial pressure to the hole wall to further eliminate the hole wall stress and improve the roundness accuracy of the hole. The pressure value of this process is set between 1.2 and 1.5 times the yield strength of the material, ensuring the high quality of the hole.

[0037] The flanging step adopts a controllable temperature gradient flanging process. The edge preheating is carried out by locally heating the flanging area through an induction heating device, and then forming is carried out using a temperature-adjustable flanging die. The temperature of the flanging die decreases linearly from the root to the edge, and the temperature gradient is set at 50℃ / cm to 100℃ / cm to ensure uniform deformation of the flanging area, thereby improving the overall strength and stability of the web.

[0038] The shaping step is achieved through multi-station synchronous shaping technology. The integrated shaping mold can shape the center hole, mounting hole, flange and chamfer at the same time. The precise pressure control monitors the pressure distribution of each shaping area in real time through the partitioned pressure sensor. The dynamic pressure regulation system makes fine adjustments based on feedback to ensure that each component can achieve the best processing effect during the molding process.

[0039] In summary, this solution significantly improves the processing accuracy and structural strength of the spoke plate through sophisticated process steps and efficient equipment configuration, and has good market application prospects.

[0040] In actual production applications, the operating process of this high-speed wheel spoke forming method is as follows: First, the raw material high-strength aluminum alloy plate is fed into the CNC laser cutting machine for shearing and cutting. The operator needs to input the corresponding cutting parameters, including the outer contour size, reserved flanging amount, etc., into the cutting machine control system according to the spoke design drawing. During the cutting process, nitrogen is used to assist cutting to obtain smoother edge quality. After cutting, the blank is sampled using precision measuring instruments such as a three-coordinate measuring machine to ensure that the dimensional accuracy is within the range of ±0.05mm.

[0041] Next, three-stage progressive stretching is carried out. First, the blank is placed on the initial stretching die, and the mold temperature is controlled at around 100°C to reduce material rebound. The stretching speed is controlled at around 10mm / s. After the stretching is completed, the mold cooling system is started immediately to reduce the temperature to room temperature. At this time, the operator needs to pay close attention to the pressure curve during the stretching process. If any abnormal fluctuations are found, the machine should be stopped and checked immediately. The intermediate stretching and final stretching also follow a similar process, but the mold accuracy and temperature control requirements are gradually improved. During the final stretching, a layer of nano-level lubricant is applied to the mold surface to further improve the surface quality.

[0042] In the punching process, pre-punching is performed first. The operator needs to carefully adjust the pre-pressure of the floating pressure ring, which is usually set to about 1.2 times the yield strength of the material. The pre-punching speed is controlled below 5mm / s to ensure uniform material flow. After pre-punching, fine-punching is performed immediately. Before fine-punching, the carbide punch is preheated and the temperature is controlled at about 80°C to reduce the accuracy deviation caused by thermal expansion. After fine-punching is completed, the reverse ejection mechanism will automatically start. At this time, the reading of the pressure sensor needs to be closely monitored to ensure that the pressure value always remains within the set range.

[0043] Before the flanging process begins, the induction heating device needs to be preheated and the calibration status of the temperature sensor needs to be checked. During the heating process, the infrared thermal imager can be used to monitor the temperature distribution in the flanging area in real time. When the temperature reaches the set value, the flanging mold is started immediately. During the flanging process, accurate control of the mold temperature is crucial, and the temperature is calibrated every 50 products. If the temperature deviation exceeds ±5°C, the machine should be stopped immediately for adjustment.

[0044] The last step is the shaping step. Before installing the shaping mold, a high-precision level is required to ensure the parallelism of each working surface of the mold. During the shaping process, the data of the partitioned pressure sensor will be transmitted to the central control system in real time, and the system will automatically adjust the pressure of each area according to the preset algorithm. If the pressure deviation in a certain area exceeds 5%, the system will automatically alarm and suspend production. After the shaping is completed, a three-coordinate measuring machine is used to perform full-size inspection of the product, focusing on key parameters such as the flanging angle and the roundness of the hole.

[0045] In actual application, this embodiment may encounter problems such as: molding parameter fluctuations caused by differences in material batches, and precision reduction caused by mold wear. To address these problems, the following optimization measures can be taken: establish a material database to automatically adjust molding parameters according to the performance parameters of each batch of materials; introduce a mold online monitoring system to track mold wear in real time and repair or replace it in a timely manner. In addition, considering the differentiated requirements of different models for spoke performance, a modular mold system can be developed to quickly adapt to different product specifications by replacing different modules.

[0046] It is worth noting that this solution can also be deeply integrated with intelligent manufacturing technology. For example, machine learning algorithms can be used to optimize molding parameters, a digital twin system can be established to achieve full-process virtual simulation, or collaborative robots can be introduced to achieve automation of some processes. These measures can not only further improve production efficiency and product quality, but also lay the foundation for future personalized customized production.

[0047] Example 2 like Figure 1As shown, this embodiment proposes a high-speed wheel spoke plate forming and shaping die that can be applied to the forming method of embodiment 1, so as to achieve synchronous shaping of the spoke plate center hole, positioning hole, flange and chamfer. The shaping die is composed of two parts, the upper part includes an upper template 6, an upper base plate 5 and an upper mold core 11, and the lower part includes a lower template 1, a lower base plate 2 and a concave mold 4. The upper template 6 and the lower template 1 are connected by a guide column and guide sleeve 13 assembly to ensure overall alignment. An upper pad 8 is provided between the upper template 6 and the upper base plate 5, and a lower pad 3 is provided between the lower template 1 and the lower base plate 2. These pads are used to absorb the impact force during the forming process, effectively reduce the deformation of the mold, and improve the shaping accuracy. The upper mold core 11 is located below the upper base plate 5, and forms a cavity that matches the final shape of the spoke with the concave mold 4 on the lower base plate 2. An annular space is formed between the inner wall surface of the concave mold 4 and the outer wall surface of the push plate 17. The cross-sectional shape of the space matches the final shape of the product flanging, ensuring the accuracy of the flanging forming. The push plate 17 is arranged on the top of the lower bottom plate 2, and is provided with a mounting groove adapted to the product contour for accurate positioning of the product and reducing the vibration of the spoke plate. A push plate pad 14 is also arranged between the push plate 17 and the lower bottom plate 2 for adjusting the height and buffering the pressure to further improve the shaping accuracy.

[0048] In this mold, the lower base plate 2 is provided with a first chamfering head 16 and a second chamfering head 15, which correspond to the positioning hole and the middle hole of the product respectively. The two chamfering heads penetrate the push plate pad 14 and the push plate 17 and directly contact the product. Corresponding to this are the first chamfering sleeve 9 and the second chamfering sleeve 10 provided in the upper mold core 11. The part of the upper mold core that is easy to wear is the upper mold core insert 12, which adopts a more wear-resistant material than the upper mold core body, such as high-speed steel or cemented carbide. This can significantly improve the service life of the mold, especially in the case of high-frequency use. Partial repair or replacement can be carried out without replacing the entire upper mold core, which greatly reduces the maintenance cost and time. In addition, the use of inserts can more easily achieve high-precision processing and adjustment. The bottom surface of the upper mold core 11 is also provided with a positioning protrusion connected to the two chamfering sleeves, which forms a matching relationship with the chamfering head when the mold is closed. The axes of the positioning protrusion, the chamfering head and the chamfering sleeve are parallel to the closing direction of the upper and lower molds, ensuring precise alignment and effectively controlling the radial plate runout and chamfering position. In order to ensure the accurate alignment of the upper and lower molds during the mold closing process, a plurality of inner guide pins 7 are provided between the upper base plate 5 and the lower base plate 2. An inner guide sleeve 18 is provided between the inner guide pins 7 and the die 4. The inner guide sleeve 18 is fixed on the die 4 and slidably cooperates with the inner guide pins 7, which can not only improve the alignment accuracy, but also enhance the rigidity of the overall structure and further reduce the vibration of the spoke plate.

[0049] The synchronous shaping process of the mold is as follows: when the upper mold descends, the inner guide pin 7 first contacts the inner guide sleeve 18 to ensure overall alignment. Subsequently, the positioning protrusion on the bottom surface of the upper mold core 11 makes preliminary contact with the chamfering head to further ensure positioning accuracy. In the final clamping stage, the molding surface formed by the top surface of the die 4 and the bottom surface of the upper mold core 11 simultaneously shapes the flanging and overall chamfering of the product, while the chamfering head and chamfering sleeve synchronously shape the center hole and positioning hole. This design achieves the one-time completion of multiple processes. By accurately controlling the descending speed and pressure distribution of the upper mold core 11, each shaping part can be processed synchronously, avoiding the cumulative error caused by multiple clamping in traditional processes.

[0050] The die can control the web runout within 0.3mm, and the optimal range is 0.15mm, which exceeds the machining level of mass production. The web chamfer position accuracy reaches 0.2mm, meeting the strict requirements of high-speed wheels. The limit deviation of the mounting hole can be controlled within 0.1mm, which significantly improves the product accuracy. In order to further improve the shaping accuracy, it is possible to consider using a nano-level DLC coating on the contact surface of the chamfering head and the chamfering sleeve, with a thickness controlled at 1-2μm. The friction coefficient can be reduced to below 0.1, extending the life of the die. In addition, a micro hydraulic cylinder can be added between the push plate 17 and the die 4. By precisely controlling the pressure of the hydraulic cylinder (such as 0.5-2MPa), dynamic adjustment of the flanging forming process can be achieved, further improving the flanging quality.

[0051] This solution not only solves many problems in traditional processes, such as the punching of bevel decorative holes and the punching of mounting hole reinforcement ribs, but also greatly improves production efficiency and product quality. It can simultaneously meet the strict requirements of high-speed wheels for spoke plate runout, mounting hole position, dynamic balance and durability, and provides reliable technical support for high-quality and efficient production of high-speed wheel spoke plates. Through optimized structural design and precise control, the mold achieves simultaneous optimization of multiple key parameters, bringing innovative solutions to the field of high-speed wheel manufacturing.

[0052] In this embodiment, the operation process and use scheme of the high-speed wheel spoke plate forming and shaping mold are as follows: First, the operator needs to install and debug the mold. Fix the lower template 1 on the workbench of the press, and then install the lower base plate 2, the lower pad 3, the die 4, the push plate pad 14 and the push plate 17 in sequence. It should be noted that the first chamfering head 16 and the second chamfering head 15 need to accurately pass through the push plate pad 14 and the push plate to ensure that they can directly contact the product. Next, install the upper template 6 on the slider of the press, and install the upper base plate 5, the upper pad 8 and the upper mold core 11 in sequence. During the installation process, special attention should be paid to the alignment of the inner guide column 7 and the inner guide sleeve 18, as well as the correct position of the first chamfering sleeve 9 and the second chamfering sleeve 10 in the upper mold core 11.

[0053] After the mold is installed, the mold is tested and debugged. First, air compression is performed without a workpiece to check whether the movement of each component is smooth, especially the sliding fit between the inner guide pin 7 and the inner guide sleeve 18. It is recommended to use a high-precision displacement sensor to monitor the alignment of the upper and lower molds. If the deviation is found to exceed the preset range, fine-tuning is required.

[0054] In the actual production process, the operation steps are as follows: 1) Place the pre-formed wheel spoke blank in the mounting groove of the push plate to ensure its accurate position. 2) Start the press and the upper die slowly descends. In this process, the inner guide pin 7 first contacts the inner guide sleeve 18 to ensure overall alignment. 3) As the upper die continues to descend, the positioning protrusion on the bottom surface of the upper die core 11 begins to contact the chamfering head to further ensure the position accuracy. 4) In the final clamping stage, the forming surface formed by the top surface of the die 4 and the bottom surface of the upper die core 11 simultaneously shapes the flanging and overall chamfering of the product, while the chamfering head and chamfering sleeve synchronously shape the centering hole and positioning hole. This process requires precise control of pressure and speed. It is recommended to use a servo press with a pressure control accuracy of ±0.1MPa and a speed control accuracy of ±0.1mm / s. 5) After the shaping is completed, the upper die rises and the finished product is taken out using the push mechanism.

[0055] In order to further improve shaping accuracy and production efficiency, the following optimization schemes can be considered: 1) Use nano-scale DLC coating on the contact surface of the chamfering head and the chamfering sleeve, with a thickness controlled at 1-2μm, to reduce the friction coefficient to below 0.1 and extend the life of the mold. 2) Add a micro hydraulic cylinder between the push plate and the die 4, and achieve dynamic adjustment of the flanging forming process by precisely controlling the pressure of the hydraulic cylinder (such as 0.5-2MPa). 3) Consider integrating high-precision force sensors and temperature sensors in the mold to monitor the force and temperature changes during the forming process in real time, and combine machine learning algorithms to establish an intelligent automatic adjustment system for process parameters.

[0056] In actual production applications, the mold can significantly improve the production efficiency and quality consistency of high-speed wheel spokes. Taking a certain automobile parts manufacturer as an example, after adopting this mold, the shaping time of a single product was shortened from the original 120 seconds to 60 seconds, and the product qualification rate was increased from 95% to 99.5%. At the same time, since multiple processes can be completed at one time, the number of material transfers and clamping between processes is reduced, saving a lot of labor costs and energy consumption. In addition, the design concept of this mold can also be extended to other similar precision molding processes, such as automotive chassis parts, aerospace structural parts and other fields, providing a new technical path for improving the production efficiency and product quality of these industries.

[0057] The high-speed wheel spoke forming and shaping mold described in this embodiment represents an important breakthrough in the third-generation shaping process and solves several key problems in traditional production methods. Through innovative structural design, the mold realizes the synchronous shaping of chamfers, mounting holes, center holes and flanging, effectively overcoming the precision loss caused by the separation of various processes in previous processes. In practical applications, the mold can control the spoke runout within 0.3mm, and the optimal product can even reach 0.15mm, surpassing the precision level of machining in mass production. At the same time, the position accuracy of the spoke chamfer reaches 0.2mm, meeting the strict requirements of high-speed wheels within 0.25mm. This technological breakthrough not only improves product quality, but also significantly reduces production costs. Compared with the existing process, the quotation of the high-speed wheel mold can save 25%, and by solving the edge processing process, the production cost is reduced by 46.3%. In addition, due to the elimination of the need for independent processing of the center hole, the production cost is further reduced by 8.2%, while the production efficiency is improved. Another important advantage of this mold is that it solves the problem of bevel decorative hole punching. Even if the slope of the decorative hole of the radial plate exceeds 20°, there is no need to use a single decorative hole punching process or a complex process of punching the decorative hole first, then flanging, and then punching the installation hole and the middle hole. For the radial plates with mounting hole reinforcement ribs, this mold has solved the punching problem in a breakthrough way, controlling the maximum deviation of the mounting hole within 0.1mm, greatly improving the product precision.

[0058] In addition, the application of the new process also brings the advantage of a full bright band, which helps to improve the consistency of product size and appearance, reduce human subjective errors, and enhance the accuracy and stability of quality inspection. In addition, the application of new technology solves the problem of position measurement error caused by the influence of fracture layers or burrs, thereby further improving the measurement accuracy of position. Overall, this shaping mold not only meets the strict requirements of high-speed wheels for spoke runout (0.3mm), mounting hole position (0.2mm), dynamic balance (within 30g) and durability (100,000 revolutions), but also has made significant breakthroughs in production efficiency and cost control, providing reliable technical support for the high-quality and efficient production of high-speed wheel spokes.

Claims

1. A method for forming a high-speed wheel spoke plate, characterized in that: The following steps are involved: Shearing and cutting to make product blanks from raw materials; Stretch forming, making the web profile from the product blank; Punching, punching out mounting holes and center holes on the spoke profile; Flanging: flanging the edges of the web profiles; Plastic surgery; Among them, in the shaping step, the coordinated shaping processing of chamfering, mounting holes, center holes and flanging is completed in the same process through the shaping mold.

2. The molding method according to claim 1, characterized in that: The stretching forming step adopts a segmented stretching process, including: initial stretching, using a large radius mold for rough forming; intermediate stretching, using a medium radius mold for contour refinement; final stretching, using a precision mold for precise forming; wherein a short rebound time is set between each stretching, and the rebound time is dynamically adjusted according to the material properties, ranging from 0.5 seconds to 2 seconds.

3. The molding method according to claim 1, characterized in that: The punching step adopts a composite punching process, including: pre-punching, using a punch with a floating pressure ring for preliminary forming; fine punching, using a carbide precision punch to complete the final hole shape; wherein the fine punching step adopts a reverse ejection mechanism, and immediately applies radial pressure to the hole wall after the punching is completed, the pressure value is 1.2 to 1.5 times the yield strength of the material, and the action time is 0.1 second to 0.3 second, so as to eliminate the hole wall stress and improve the roundness accuracy of the hole.

4. The molding method according to claim 1, characterized in that: The flanging step adopts a controllable temperature gradient flanging process, including: edge preheating, using an induction heating device to locally heat the flanging area; gradient flanging, using a temperature-adjustable flanging mold for forming; wherein the temperature of the flanging mold decreases linearly from the root to the edge, and the temperature gradient is 50°C / cm to 100°C / cm, so as to achieve uniform deformation of the flanging area.

5. The molding method according to any one of claims 1 to 4, characterized in that: The shaping step adopts a synchronous collaborative shaping process, including: multi-station synchronous shaping, using an integrated shaping mold to simultaneously shape the center hole, mounting hole, flange and chamfer; precise pressure control, using a partitioned pressure sensor to monitor the pressure distribution of each shaping area in real time; dynamic pressure regulation, according to the feedback from the pressure sensor, using a servo motor-driven pressure distribution system to perform real-time fine-tuning of the pressure of each shaping area.

6. A shaping die for forming a high-speed wheel spoke plate, characterized in that: The upper template and the lower template are connected by a guide column and guide sleeve assembly; an upper base plate is arranged below the upper template, and an upper pad is arranged between the upper base plate and the upper template; a lower base plate is arranged above the lower template, and a lower pad is arranged between the lower base plate and the lower template; an upper mold core is arranged below the upper base plate, and the upper mold core and the concave mold on the lower base plate form a cavity that matches the final shape of the spoke.

7. The shaping mold according to claim 6, characterized in that: The lower base plate is provided with a first chamfering head and a second chamfering head, which correspond to the positioning hole and the middle hole of the product respectively; the upper mold core is provided with a first chamfering sleeve and a second chamfering sleeve corresponding to the first chamfering head and the second chamfering head; the first chamfering head and the second chamfering head pass through the pusher plate and the pusher plate pad arranged between the lower base plate and the die; the pusher plate is provided with an installation groove adapted to the contour of the product.

8. The shaping mold according to claim 6, characterized in that: A plurality of inner guide pins are arranged between the upper base plate and the lower base plate; an inner guide sleeve is arranged between the inner guide pins and the die; the inner guide sleeve is fixed on the die and slidably cooperates with the inner guide pins to ensure the alignment of the upper and lower molds during the mold closing process.

9. The shaping mold according to claim 6, characterized in that: An annular space for shaping the product flange is formed between the inner wall surface of the die and the outer wall surface of the push plate; the cross-sectional shape of the annular space matches the final shape of the product flange; The top surface of the die and the bottom surface of the upper die core form a molding surface that can shape the chamfer of the product when the mold is closed.

10. The shaping mold according to claim 6, characterized in that: The bottom surface of the upper mold core is provided with a positioning protrusion connected to the first chamfering sleeve and the second chamfering sleeve; the positioning protrusion forms a matching relationship with the first chamfering head and the second chamfering head when the mold is closed; the axis of the positioning protrusion, the first chamfering head and the second chamfering head is parallel to the closing direction of the upper and lower molds.

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