A double-ear wedge-shaped wire clamp forging die and manufacturing method

Abstract

A double-wedge ear wire clamp forging die and manufacturing method, belonging to the field of electrified railway contact network parts manufacturing technology, aims to solve the problem that the metallographic structure of the existing electrified railway contact network double-ear wedge-shaped wire clamp products is loose, and the manufacturing method still has room for improvement and innovation. The double-wedge ear wire clamp forging die used in the forging die is a primary forging die, a final forging die, and a final forging die. The primary forging die is a left-right symmetrical movable fit installed in the concave hole of the fixed lower base, and the upper die is inserted and forged into the round bar material segment clamped between the left-right dies and the right-right dies in the concave hole of the fixed lower base, and an automatic push rod is installed at the bottom of the fixed lower base; the manufacturing method includes the first process of blanking the bar into segments to the eighth process of treating the preservative layer. The forging die is new and practical, and the manufacturing method is reasonable and feasible, which is suitable for the anchoring and fixing of the load-bearing wire terminal of the electrified railway contact network.

Description

Technical Field

[0001] The invention belongs to the technical field of manufacturing parts for electrified railway contact network and relates to a forging die and manufacturing process method of a double-ear wedge-shaped wire clamp. Technical Background

[0002] The double-ear wedge-shaped wire clamp is a kind of wire clamp used to fix the flexible wire ends such as load-bearing cables or contact wires in the field of electrified railway contact network and rail transportation. In the known technology, the existing double-ear wedge-shaped wire clamp mainly adopts the casting process. Due to the loose metallographic structure inside the casting, it is easy to produce defects such as pores and cracks. For the double-ear wedge-shaped wire clamp used for anchoring the load-bearing wire terminal, its internal defects will be fatal, and the flaw detection requirements are very high. Therefore, the existing double-ear wedge-shaped wire clamp products manufactured by casting technology have many flaw detection defects and low pass rate. Especially in cold areas, cast steel products are prone to low-temperature brittleness and cold cracking. With the continuous increase in the operating speed of electrified railways, as an important anchoring component on electrified railways, cast double-ear wedge-shaped wire clamps have become a hidden safety hazard for anchoring the load-bearing wire terminal of electrified railways. In addition, the casting of double-ear wedge-shaped wire clamps External defects such as appearance deformation will also affect product quality. The product's internal quality and external structure have certain defects, which makes it difficult for the double-ear wedge-shaped wire clamp to meet performance and use requirements. The double-ear wedge-shaped wire clamp parts casting process method is processed, and customized molds and supporting die-casting equipment are required, resulting in high manufacturing costs. For example, Chinese patent application publication number CN104385941A discloses a technical solution of "die-forged load-bearing cable double-ear wedge-shaped wire clamp", which is characterized by being made of symmetrically arranged two ears and a wedge cavity at the bottom, and double-ear reinforcement ribs are made on the outside of the two ears, the connection between the two ears and the wedge cavity is made into a circular arc transition, and connecting reinforcement ribs are made on the outside of the connection between the two ears and the wedge cavity, and wedge cavity reinforcement ribs are made at the bottom of the wedge cavity. However, its specific forging process preparation method lacks specific forging technical measures. It can be inferred that if the double-ear wedge-shaped wire clamp forging molding process method is applied to this solution, it will be limited. Therefore, limited by the existing double-ear wedge-shaped wire clamp manufacturing process method, there is still room for further improvement and research and development in the actual application of electrified railway contact network.

[0003] In view of this, in order to adapt to the development and technological progress of electrified railway contact network, it is necessary to further improve and develop a new forming mold and manufacturing method of double-ear wedge-shaped wire clamp. Summary of the invention

[0004] In order to overcome the shortcomings of the prior art, solve the problem that the metallographic structure of the existing double-ear wedge-shaped wire clamp products for the contact network of electrified railways is loose, and the manufacturing method still has room for improvement and innovation. The purpose of the present invention is to provide a forging mold and manufacturing process method of a new type of contact network double-ear wedge-shaped wire clamp that can make the overall metallographic structure of the double-ear wedge-shaped wire clamp dense, and only the double-ear hole processing is performed after the product is manufactured and formed, and the processing time is short, which can not only improve the production and processing efficiency and the product qualification rate, but also enhance the product structural performance. The internal and external structures of the product are novel and practical, and the manufacturing process method is reasonable and feasible.

[0005] The technical solution adopted by the present invention to solve the above problems is:

[0006] A double wedge ear wire clamp forging die, comprising: a primary forging die, a final forging die, and a final forging die, wherein the primary forging die comprises an initial forging top die, an initial forging left die, an initial forging right die, a fixed lower base, and an automatic push rod, wherein the initial forging left die and the initial forging right die are symmetrically and movably connected to the concave hole of the fixed lower base, and the top die is inserted and forged into the concave hole of the fixed lower base to clamp the round bar material segment between the initial forging left die and the initial forging right die, and An automatic push rod is installed in the concave hole at the bottom of the fixed lower base to dynamically connect the initial forging left die and the initial forging right die; the final forging die is composed of the final forging upper flattening die and the final forging lower flattening die; the final forging die is composed of a positive die punch head, a positive left die seat and a positive right die seat, the positive left die seat and the positive right die seat are symmetrical on the left and right, and the positive die punch head is dynamically connected to forge the flattened semi-finished product clamped between the positive left die seat and the positive right die seat.

[0007] The double-wedge ear wire clamp forging die mentioned above comprises a primary forging die, a final forging die, and a final forging die, and each corner of the inner cavity of each component in the forging die is an arc chamfer.

[0008] The double wedge ear wire clamp forging die is characterized in that, based on the double wedge ear wire clamp forging die, the double wedge ear wire clamp forging manufacturing method is as follows:

[0009] 1) The first process is to forge the round bar material into round bar segments;

[0010] 2) The second process is to heat treat the round bar segments according to the set initial forging temperature and final forging temperature;

[0011] 3) The third process is to carry out the first primary forging, which is to segment the round bar into a tapered round tube-shaped initial product with a larger top and a smaller bottom;

[0012] 4) The fourth process is the second final forging, which flattens the conical cylindrical primary product material formed by the first primary forging into a flattened semi-finished product material of a set thickness;

[0013] 5) The fifth process is to transport the flattened semi-finished product to the shaping die for shaping and forging into a shaped product;

[0014] 6) The sixth process uses a CNC drilling machine to drill holes in both ears of the shaped product to make a double wedge ear wire clamp shaped product;

[0015] 7) The seventh process is to inspect the double wedge ear wire clamp formed product manufactured in the sixth process according to national product standards and enterprise product standards. Those that pass the inspection become the double wedge ear wire clamp products of this application.

[0016] The forging manufacturing method of the double wedge ear wire clamp further includes an eighth process, namely:

[0017] 8) The eighth process is to galvanize or spray the anti-corrosion agent layer on the manufactured double wedge ear wire clamp products according to actual needs and design requirements.

[0018] The above-mentioned method of forging a double-wedge ear wire clamp product using a forging forming die, the first primary forging setting temperature in the third process is 1150±50℃, and the second final forming forging setting temperature in the fourth process is 850±50℃.

[0019] The above-mentioned double wedge ear wire clamp forging manufacturing method, the process equipment and instruments used in the manufacturing method, which include a programmable industrial computer, a bar blanking table, an automatic feeder, a material heater, a mechanical gripper, a forging press, a CNC drilling machine, a conveyor track, a product assembly inspection table, and a product container 25, wherein the mechanical gripper includes a first mechanical gripper to a fifth mechanical gripper, a total of 5 units, and the forging press includes a first forging press to a third forging press, a total of 3 units, and the programmable industrial computer is respectively connected by electrical wires and controls the bar blanking table, the automatic feeder, the material heater, the first mechanical gripper to the third mechanical gripper. Five mechanical grippers, the first to third forging presses, a CNC drilling machine, and a conveying track. The bar blanking table is connected to the automatic loader and then to the material heater. The rear of the material heater is connected to the first forging press by the first mechanical gripper. The rear of the first forging press is connected to the second forging press by the second mechanical gripper. The rear of the second forging press is connected to the third forging press by the third mechanical gripper. The rear of the third forging press is connected to the CNC drilling machine by the fourth mechanical gripper. The rear of the CNC drilling machine is connected to the conveying track and the product inspection table by the fifth mechanical gripper. The rear of the conveying track is connected to the product container.

[0020] When the present invention is used, the invented forged structure contact network double wedge ear wire clamp product is assembled to various types of contact networks of electrified railways according to design requirements and actual needs. The specific manufacturing process is as follows: the initial forging left die and the initial forging right die are fixed in a fixed lower base to prevent the initial forging left die and the initial forging right die from being separated when the upper push die is stressed. After forging and forming, the automatic push rod pushes the initial forging left die and the initial forging right die upward, the initial forging left die and the initial forging right die are separated, and the forged part is taken out. Specifically: according to the design requirements, the programmable industrial computer is controlled and set, and the initial forging temperature and final forging temperature of the material are set. After the raw materials are dropped from the bar blanking table, they are connected to the automatic feeder and then to the material heater to heat the materials to the initial forging temperature of 1150±50℃ for heat treatment. Then, they are transported to the first forging press by the first mechanical gripper for stretching and initial forging of the raw materials into a tapered circular tube-shaped initial product material with a larger upper part and a smaller lower part. Then, they are transported to the second forging press by the second mechanical gripper for the second final forging to flatten the tapered circular tube-shaped initial product material to a set thickness of the flattened semi-finished product. Then, they are transported to the shaping die of the third forging press by the third mechanical gripper for shaping and forging into a shaped product. The fourth mechanical gripper transports the shaped product to the CNC drilling machine precision machine to perform double-ear drilling to manufacture a double-wedge ear wire clamp product. The fifth mechanical gripper transports the shaped product to the conveying track and the product assembly inspection table. After the qualified products are inspected according to national standards and enterprise standards, they are transported to the qualified product container by the conveying track.

[0021] Since the design of the present invention adopts the above technical solution, it effectively solves the problem that the metallographic structure of the existing double-ear wedge-shaped wire clamp products of the electrified railway contact network is loose, and the manufacturing method still has room for improvement and innovation. The actual test results also show that it has a new and practical mold structure, a reasonable and feasible manufacturing method, and only double-ear hole processing is performed after the product is manufactured and formed, and the processing time is short. The overall metallographic structure of the double-ear wedge-shaped wire clamp product is dense, and the production and processing efficiency and product qualification rate are greatly improved, and the structural performance of product stability and safety is enhanced. It is suitable for anchoring and fixing the stressed wire terminal of the electrified railway contact network.

[0022] Other features and advantages of the present invention will be described in the following description, and partly become obvious from the description, or be understood by implementing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures pointed out in the description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0024] Figure 1 It is a schematic diagram of the specific structure of the primary forging die of this application.

[0025] Figure 2 yes Figure 1 Schematic diagram of the application process flow of the double wedge ear wire clamp forging die in which the primary forging die is connected in sequence to the final forging die, the forming forging die, and the CNC drilling machine to form the double wedge ear wire clamp.

[0026] Figure 3 The invention discloses a process flow chart for applying for manufacturing a double-wedge ear wire clamp.

[0027] Figure 4 It is a picture Figure 3 A process flow chart of the equipment and instruments used in the process method embodiment to manufacture the double wedge ear wire clamp product.

[0028] The numbers in the attached drawings are: A-primary forging die; B-final forging die; C-forming forging die; 1-upper die; 2-primary forging left die; 3-primary forging right die; 4-fixed lower base; 5-automatic push rod; 6-final forging upper flattening die; 7-final forging lower flattening die; 8-positive die punch; 9-positive left die seat; 10-positive right die seat; 11-bar blanking table; 12-automatic loader; 13-material heater; 14-14-first mechanical gripper ~ fifth mechanical gripper; 15-17-first forging press ~ third forging press; 18-CNC drilling machine; 19-transmission track; 20-product inspection table; 24-product container; 25-26-programmable industrial computer; 27-conical tubular primary product material; 28-flattened semi-finished product material; 29-forming product; 30-double wedge ear wire clamp product. DETAILED DESCRIPTION

[0029] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] In the description of the present invention, it should be noted that the terms "upper", "lower", "left", "right", "inside", "outside", "top", "bottom", "front end", "rear end", "head", "tail", etc. indicate orientations or positional relationships based on the orientations 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 orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limiting the present invention.

[0031] like Figure 1-Figure 4 As shown, this embodiment includes: a primary forging die A, a final forging die B, and a final forging die C. The primary forging die A includes a primary forging top die 1, a primary forging left die 2, a primary forging right die 3, a fixed lower base 4, and an automatic push rod 5. The primary forging left die 2 and the primary forging right die 3 are symmetrically and dynamically connected in the concave hole of the fixed lower base 4. The top die 1 is inserted and forged into the concave hole of the fixed lower base 4 to fit the round bar material segment clamped between the primary forging left die 2 and the primary forging right die 3, and is fixed in the lower base. An automatic push rod 5 is installed in the concave hole at the bottom of the seat 4, which is dynamically connected to the initial forging left die 2 and the initial forging right die 3; the final forging die B is composed of the final forging upper flattening die 6 and the final forging lower flattening die 7; the final forging die C is composed of a positive die punch head 8, a positive left die seat 9 and a positive right die seat 10, the positive left die seat 9 and the positive right die seat 10 are symmetrical, and the positive die punch head 8 is dynamically connected to forge the flattened semi-finished product clamped between the positive left die seat 9 and the positive right die seat 10.

[0032] For example, see the attached Figure 2 The application process flow of the double wedge ear wire clamp forging die described in this embodiment is: the primary forging die A segments the round bar material into a tapered circular tubular primary product material 27 with a larger upper portion and a smaller lower portion, and the rear portion is connected to the final forging die B. After the tapered circular tubular primary product material 27 is forged and flattened to a flattened semi-finished product material 28 of a set thickness, the rear portion is connected to the final forging die C, and the flattened semi-finished product material 28 is sent into the finalizing die for finalizing forging to be finalized and forged into a finalized product 29, and then the finalized product is drilled with double ears by a precision drilling machine to manufacture a double wedge ear wire clamp product.

[0033] For details, see the attached Figure 1-Figure 2 The double wedge ear wire clamp forging die includes the primary forging die A, the final forging die B, and the final forging die C, and the inner corners of each component are all arc chamfered.

[0034] Preferably, see the attached Figure 2-Figure 4 The forging process of the double wedge ear wire clamp product in this embodiment is as follows:

[0035] 1) The first process is to forge the round bar material into round bar segments;

[0036] 2) The second process is to heat treat the round bar segments according to the set initial forging temperature and final forging temperature;

[0037] 3) The third process is to carry out the first primary forging. The setting temperature of the first primary forging is 1150±50℃, and the round bar material is segmented into a tapered round tube-shaped initial product with a larger top and a smaller bottom;

[0038] 4) The fourth process is the second final forging. The setting temperature of the second final forming forging is 850±50℃. The conical round tube primary product material formed by the first primary forging is forged and flattened to a flattened semi-finished product of a set thickness;

[0039] 5) The fifth process is to transport the flattened semi-finished product to the shaping die for shaping and forging into a shaped product;

[0040] 6) The sixth process uses a CNC drilling machine to drill holes in both ears of the shaped product to make a double wedge ear wire clamp shaped product;

[0041] 7) The seventh process is to inspect the double wedge ear wire clamp formed product manufactured in the sixth process according to national product standards and enterprise product standards. Those that pass the inspection become the double wedge ear wire clamp products of this application.

[0042] For further details, see the attached Figure 3 This embodiment also includes an eighth process, which is to treat the manufactured double wedge ear wire clamp shaped product with a galvanized anti-corrosion agent layer according to actual needs and design requirements.

[0043] Preferably, see the attached Figure 4 The process equipment and instruments used in the forging process of the double wedge ear wire clamp described in this embodiment include: a programmable industrial computer 26, a bar blanking table 11, an automatic feeder 12, a material heater 13, a mechanical gripper, a forging press, a CNC drilling machine 22, a conveying track 24, a product assembly inspection table 23, and a product container 25. The mechanical gripper includes a first mechanical gripper to a fifth mechanical gripper 14-18, a total of 5 units, and the forging press includes a first forging press to a third forging press 19-21, a total of 3 units. The programmable industrial computer 26 is respectively connected by electrical wires and controls the bar blanking table 11, the automatic feeder 12, the material heater 13, the first mechanical gripper to the fifth mechanical gripper 14-18, the first mechanical gripper to the fifth mechanical gripper 19-21, and the third mechanical gripper 19-21. The first forging press to the third forging press 19-21, the CNC drilling machine 22, and the conveying track 24, the bar blanking table 11 is connected to the automatic feeder 12 and then connected to the material heater 13, the rear of the material heater 13 is connected to the first forging press 19 by the first mechanical gripper 14, the rear of the first forging press 19 is connected to the second forging press 20 by the second mechanical gripper 15, the rear of the second forging press 20 is connected to the third forging press 21 by the third mechanical gripper 16, the rear of the third forging press 21 is connected to the CNC drilling machine 22 by the fourth mechanical gripper 17, the rear of the CNC drilling machine 22 is connected to the conveying track 24 and the product inspection table 23 by the fifth mechanical gripper 18, and the rear of the conveying track 24 is connected to the product container 25. The forging press described in this embodiment is an intelligent J58K series CNC electric screw forging press of Henan Anduan Intelligent Equipment Co., Ltd.

[0044] The above is only one embodiment. On this basis, other technical features and technical solutions derived by adding components, equivalent substitutions and local improvements without creative work by technicians in this field are all within the scope of protection of the patent of this invention.

Claims

1. A double wedge ear wire clamp forging die, characterized in that: It comprises a primary forging die (A), a final forging die (B), and a final forging die (C). The primary forging die (A) comprises a primary forging top die (1), a primary forging left die (2), a primary forging right die (3), a fixed lower base (4), and an automatic push rod (5). The primary forging left die (2) and the primary forging right die (3) are symmetrically and dynamically connected in a concave hole of the fixed lower base (4). The top die (1) is inserted and forged into a round bar material segment sandwiched between the primary forging left die (2) and the primary forging right die (3) in the concave hole of the fixed lower base (4), and is disposed at the bottom of the fixed lower base (4). An automatic push rod (5) is installed in the concave hole to dynamically connect the initial forging left die (2) and the initial forging right die (3); the final forging die (B) is composed of the final forging upper flattening die (6) and the final forging lower flattening die (7) that are connected in a coordinated manner; the final forging die (C) is composed of a positive die punch head (8), a positive left die seat (9) and a positive right die seat (10), the positive left die seat (9) and the positive right die seat (10) being left-right symmetrical devices, and the positive die punch head (8) is dynamically connected to forge the flattened semi-finished product clamped between the positive left die seat (9) and the positive right die seat (10).

2. The double wedge ear wire clamp forging die according to claim 1, characterized in that: The double-wedge ear wire clamp forging die comprises a primary forging die (A), a final forging die (B), and a final forging die (C), and each corner of the inner cavity of each component is a circular arc chamfer.

3. The double wedge ear wire clamp forging die according to claim 1, characterized in that: Based on the above double wedge ear wire clamp forging die, the double wedge ear wire clamp forging manufacturing method is as follows: 1) The first process is to forge the round bar material into round bar segments; 2) The second process is to heat treat the round bar segments according to the set initial forging temperature and final forging temperature; 3) The third process is to carry out the first primary forging, which is to segment the round bar into a tapered round tube-shaped initial product with a larger top and a smaller bottom; 4) The fourth process is the second final forging, which flattens the conical cylindrical primary product material formed by the first primary forging into a flattened semi-finished product material of a set thickness; 5) The fifth process is to transport the flattened semi-finished product to the shaping die for shaping and forging into a shaped product; 6) The sixth process uses a CNC drilling machine to drill holes in both ears of the shaped product to make a double wedge ear wire clamp shaped product; 7) The seventh process is to inspect the double wedge ear wire clamp formed product manufactured in the sixth process according to national product standards and enterprise product standards. Those that pass the inspection become the double wedge ear wire clamp products of this application.

4. The forging manufacturing method of the double wedge ear wire clamp according to claim 3, characterized in that: It also includes an eighth process, namely: 8) The eighth process is to galvanize or spray the anti-corrosion agent layer on the manufactured double wedge ear wire clamp products according to actual needs and design requirements.

5. The forging manufacturing method of the double wedge ear wire clamp according to claim 3, characterized in that: The setting temperature of the first primary forging in the third process is 1150±50°C, and the setting temperature of the second final forming forging in the fourth process is 850±50°C.

6. The forging manufacturing method of the double wedge ear wire clamp according to claim 3, characterized in that: The process equipment and instruments used in the manufacturing method include a programmable industrial control computer (26), a bar blanking table (11), an automatic feeder (12), a material heater (13), a mechanical gripper, a forging press, a numerically controlled drilling machine (22), a conveying track (24), a product assembly inspection table (23), and a product container (25). The mechanical grippers include a first mechanical gripper to a fifth mechanical gripper (14-18), a total of five, and the forging presses include a first forging press to a third forging press (19-21), a total of three. The programmable industrial control computer (26) is respectively connected by electrical wires to control the bar blanking table (11), the automatic feeder (12), the material heater (13), the first mechanical gripper to the fifth mechanical gripper (14-18), the first forging press to the third forging press (19-21). 21), a CNC drilling machine (22), and a conveying track (24); the bar material blanking platform (11) is connected to an automatic material loader (12) and then to a material heater (13); the rear of the material heater (13) is connected to a first forging press (19) by a first mechanical gripper (14); the rear of the first forging press (19) is connected to a second forging press (20) by a second mechanical gripper (15); the rear of the second forging press (20) is connected to a third forging press (21) by a third mechanical gripper (16); the rear of the third forging press (21) is connected to a CNC drilling machine (22) by a fourth mechanical gripper (17); the rear of the CNC drilling machine (22) is connected to a conveying track (24) and a product inspection table (23) by a fifth mechanical gripper (18); the rear of the conveying track (24) is connected to a product container (25).

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