A convex closed-end wave spring and a method for manufacturing the same

Abstract

The application provides a convex closed wave spring and a preparation method thereof. The spring sheet of the convex closed wave spring is in a closed circular shape and has a plurality of wave crests and troughs connected in sequence, and a spherical convex structure is further arranged on the wave crest and trough. The preparation method of the convex closed wave spring comprises the following steps: a) material selection and preparation, b) blanking, c) cutting, d) wave forming, e) boss forming, f) turning inner and outer circles, and g) aging and shaping. The application adopts linear cutting or laser cutting for blanking, reserves a shrinkage allowance for subsequent forming, ensures compensation of the diameter size of the inner and outer circles, forms the wave shape and the convex structure in two steps through a mold, ensures the radial position accuracy of the bulge, avoids changes of the convex position caused by the material flowing to the radial center direction when the convex size is formed into a wave shape, and avoids cracking phenomena at the convex position, shrinkage defects and bulge deviation phenomena near the convex position caused by poor material fluidity.

Description

Technical Field

[0001] This invention relates to the field of springs, and more particularly to a closed-end wave spring with protrusions and a method for manufacturing the same. Background Technology

[0002] A wave spring is a special type of spring, often simply called a wave spring. It is a thin, ring-shaped elastic metal element composed of several wave crests and troughs. It has good elasticity and is widely used in industries such as aerospace parts, motors, textile machinery, hydraulic equipment, and automobiles. It is mainly installed in bearing housings or holes of suitable specifications, requiring very little installation space. It has the special functions of reducing noise and vibration.

[0003] Traditional single-layer closed-loop wave springs generally employ a direct die-forming and heat-treatment process. First, a metal sheet is stamped into a ring-shaped blank. Then, a wave shape is stamped along the ring direction using a die. Finally, heat treatment is performed to give it elastic properties. This forming process has several main problems: 1) Single-layer closed-loop wave springs generally require internal hole positioning during forming. Due to springback during forming, the die wave height needs to be compensated for relative to the spring wave height. Radial flow occurs during material forming, making it difficult to accurately calculate and compensate for protrusion positions during die design. Figure 1 The diagram shows a comparison before and after springback during one-time molding. 2) Waveform and bulge molding will result in significant material flow, requiring compensation. However, one-time molding of waveforms and bulges will lead to more irregular material flow, making accurate compensation calculation more difficult. Furthermore, for materials with poor plasticity, cracking may occur at the bulges (e.g., Figure 2 As shown), and during the final molding process, shrinkage, insufficient material, and bulging / displacement phenomena will occur near the protrusions (such as...). Figure 3 (As shown).

[0004] Therefore, there is an urgent need for a closed-end wave spring with protrusions and its manufacturing method to overcome the above-mentioned technical defects. Summary of the Invention

[0005] To solve the above-mentioned technical problems, this patent provides a closed-end wave spring with protrusions and its preparation method. This high-precision, high-quality, and low-processing-difficulty molding method can accurately control the position of the protrusions, avoid cracking at the protrusions, and also avoid shrinkage, missing material, bulging, and displacement near the protrusions.

[0006] To achieve the above objectives, this application provides the following technical solution: a closed-circuit wave spring with raised sections, comprising: a spring sheet, wherein the spring sheet is in the shape of a closed circular ring, the spring sheet has a plurality of wave crests and troughs connected in sequence, and a spherical raised structure is further provided on the wave crests and troughs.

[0007] On the other hand, this application also provides a technical solution, a method for preparing a closed wave spring with a raised end, the preparation method including the following steps: a) material selection and preparation, b) blanking, c) cutting, d) wave forming, e) boss forming, f) machining inner and outer circles, g) aging and shaping.

[0008] Optionally, in step a), the raw material for the wave spring is an alloy spring steel plate with a thickness of 0.3-0.5mm. The main components of the steel plate are: C, Mn, Cr, Ni, Si, Cu, Al, Mo, Ti, Pd, Ce and Fe; the content of impurity P is controlled below 0.03%, and the content of impurity S is controlled below 0.03%.

[0009] Optionally, in step c), the spring steel plate after cutting in step b) is processed into a ring-shaped blank by wire cutting or laser cutting. The inner and outer diameters of the blank need to retain a preset allowance, which can be calculated by simulation or experience.

[0010] Optionally, in step d), the annular blank in step c) is shaped into a waveform using a first mold to form a closed waveform spring, and the forming surface of the first mold is shaped into a waveform.

[0011] Optionally, in step d), the waveform quantity of the first mold adopts a sine and cosine formula corresponding to the waveform spring with raised closed opening, and the waveform height of the first mold is set with height compensation.

[0012] Optionally, in step d), the first mold is provided with a positioning gap between the inner hole and the annular blank. The positioning gap can be obtained by simulation or empirical calculation. A fixed gap is retained in the first mold to facilitate material flow and final molding limitation.

[0013] Optionally, in step d), the first mold is designed with an inner hole limiting block to position the inner hole of the annular blank in step b). This ensures that the inner hole of the annular blank is limited to prevent shrinkage after molding, while also preventing cracking of the annular blank during molding.

[0014] Optionally, in step e), a second mold is used to shape the closed wave spring in step d) into a raised form, forming a closed wave spring with raised sections. The forming surface of the second mold consists of raised sections spaced vertically.

[0015] Optionally, in step e), the convex hull position of the second mold is designed at the theoretical position.

[0016] Optionally, in step e), the second mold is provided with a positioning gap between the inner hole of the closed wave spring and the positioning gap of the inner hole can be obtained by simulation or empirical calculation. A fixed gap is retained in the second mold to facilitate material flow and final molding limit.

[0017] Optionally, in step e), the second mold is designed with an inner hole limiting block to position the inner hole of the closed-end wave spring in step d). This ensures that the inner hole of the closed-end wave spring is limited to prevent shrinkage after molding, but also prevents the closed-end wave spring from cracking during molding.

[0018] Optionally, in step f), protrusions and profiles are used for positioning, and the multiple closed-type wave springs from step e) are stacked and machined to form inner and outer circles. This method can effectively ensure the relative positional relationship between the bulge and the inner and outer circles.

[0019] Optionally, in step g), protrusions and profiles are used for positioning, and multiple closed-circle wave springs with machined inner and outer circles in step f) are stacked and put into the furnace for heat treatment and shaping.

[0020] Optionally, the method for preparing the protruding closed wave spring further includes the following steps: h) loading and aging, i) deburring, j) fatigue strength test, k) elasticity test, l) marking, m) final inspection, n) cleaning and packaging.

[0021] Beneficial effects

[0022] The wave spring with protrusion and closed opening in this application is blanked by wire cutting or laser cutting, with a shrinkage allowance reserved for subsequent forming to ensure compensation of the inner and outer diameter dimensions. The wave and protrusion are formed in two steps by mold, which can effectively ensure the radial position accuracy of the bulge compared with the traditional one-step forming. It can avoid the change of the bulge position caused by the material flowing towards the radial center direction when forming the wave, and avoid the cracking phenomenon that may occur at the bulge when the material has poor fluidity. It can also avoid shrinkage and bulge displacement near the bulge.

[0023] This method involves clamping the upper and lower surfaces of the machining fixture against the surface of the part to achieve protrusion positioning, and simultaneously machining the inner and outer circles. It allows for the stacking and machining of multiple parts, with the quantity adjusted appropriately according to the size of the wave spring. This method can effectively ensure the relative positional relationship between the protrusion and the inner and outer circles.

[0024] This method has low processing difficulty and high protrusion forming accuracy, and is suitable for forming various single-layer closed waveform springs with different waveforms and protrusions. Attached Figure Description

[0025] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a comparative schematic diagram of a one-piece molded closed wave spring before its rebound, provided by existing technology.

[0027] Figure 2 This is a schematic diagram of the convex flow of a one-piece molded closed wave spring provided by existing technology;

[0028] Figure 3 This is a schematic diagram of the machining protrusion offset of a one-piece molded closed wave spring provided by existing technology;

[0029] Figure 4 This is a schematic diagram of a two-dimensional structure of a closed-end wave spring with a raised end provided in an embodiment of this application;

[0030] Figure 5 This is a schematic diagram of a three-dimensional structure of a closed-end wave spring with a raised end provided in an embodiment of this application;

[0031] Figure 6 This is a schematic diagram of a three-dimensional structure of a closed waveform spring after waveform shaping, provided in an embodiment of this application.

[0032] Figure 7 This is a schematic diagram of a three-dimensional structure of a closed-end wave spring with a protrusion after being formed according to an embodiment of this application.

[0033] Figure 8 This is a schematic diagram of the lower mold structure of a closed-end wave spring mold with a raised boss after the boss is formed, provided in an embodiment of this application. Detailed Implementation

[0034] The present application will be further described in detail below with reference to the accompanying drawings and embodiments. However, it should be noted that these embodiments are not intended to limit the present application. Equivalent transformations or substitutions in function, method, or structure made by those skilled in the art based on these embodiments are all within the protection scope of the present application.

[0035] In the description of the embodiments of this application, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the creation of this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the creation of this application.

[0036] Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0037] The terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0038] like Figure 4-5 As shown, a closed-loop wave spring with protrusions is provided, comprising: a spring sheet, the spring sheet being a closed-loop ring shape, the spring sheet having a plurality of sequentially connected peaks and troughs, and a spherical protrusion structure being provided on the peaks and troughs.

[0039] The aforementioned protruding closed wave spring is often welded and fixed with a base to form an elastic element. The protrusion can be spot welded to the corresponding accessories for fixation. It is mainly used in the field of aero-engine sealing to provide axial elastic force with uniform temperature.

[0040] like Figure 6-8 As shown, a method for manufacturing a closed-circuit spring with a raised section is provided. The method includes the following steps: a) material selection and preparation, b) blanking, c) cutting, d) wave forming, e) boss forming, f) machining the inner and outer circles, and g) aging and shaping.

[0041] In some embodiments, in step a), the raw material for the wave spring is an alloy spring steel plate with a thickness of 0.3-0.5mm. The main components of the steel plate are: C, Mn, Cr, Ni, Si, Cu, Al, Mo, Ti, Pd, Ce and Fe; the content of impurity P is controlled below 0.03%, and the content of impurity S is controlled below 0.03%.

[0042] In some embodiments, step b) specifically includes combining the alloy spring steel plates from step a), drilling holes, and cutting materials, which can improve production efficiency.

[0043] In some embodiments, in step c), the spring steel plate after cutting in step b) is processed into a ring-shaped blank by wire cutting or laser cutting. The inner and outer diameters of the blank need to retain a preset allowance, which can be calculated by simulation or experience.

[0044] In some embodiments, in step d), a first mold is used to form the annular blank in step c) into a waveform to form a closed waveform spring, and the forming surface of the first mold is closed in a waveform shape.

[0045] In some embodiments, in step d), the waveform quantity of the first mold adopts a sine and cosine formula corresponding to the waveform spring with raised closed opening, and the waveform height of the first mold is set with height compensation.

[0046] In some embodiments, in step d), the first mold is provided with a positioning gap between the inner hole and the annular blank. The positioning gap can be obtained by simulation or empirical calculation. A fixed gap is retained in the first mold to facilitate material flow and final molding limitation.

[0047] In some embodiments, in step d), the first mold is designed with an inner hole limiting block to position the inner hole of the annular blank in step b). This ensures that the inner hole of the annular blank is limited to prevent shrinkage after molding, while also preventing cracking of the annular blank during molding.

[0048] In some embodiments, in step e), a second mold is used to shape the closed wave spring in step d) into a raised form, forming a closed wave spring with raised sections. The forming surface of the second mold consists of raised sections spaced vertically.

[0049] In some embodiments, in step e), the convex hull position of the second mold is designed at the theoretical position.

[0050] In some embodiments, in step e), the second mold is provided with a positioning gap between the inner hole of the closed wave spring and the positioning gap of the inner hole. The positioning gap of the inner hole can be obtained by simulation or empirical calculation. A fixed gap is retained in the second mold to facilitate material flow and final molding limit.

[0051] In some embodiments, in step e), the second mold is designed with an inner hole limiting block to position the inner hole of the closed-end wave spring in step d). This ensures that the inner hole of the closed-end wave spring is limited to prevent shrinkage after molding, but also prevents the closed-end wave spring from cracking during molding.

[0052] In some embodiments, in step f), protrusions and profiles are used for positioning, and the multiple closed-end wave springs in step e) are stacked and machined to form inner and outer circles. This method can effectively ensure the relative positional relationship between the bulge and the inner and outer circles.

[0053] In some embodiments, in step g), protrusions and profiles are used for positioning, and multiple closed wave springs with machined inner and outer circles in step f) are stacked and put into the furnace for heat treatment and shaping.

[0054] In some embodiments, the method for preparing the corrugated closed-face wave spring further includes the following steps: h) loading and aging, i) deburring, j) fatigue strength test, k) elasticity test, l) marking, m) final inspection, and n) cleaning and packaging. The corrugated closed-face wave spring of this application is prepared by wire cutting or laser cutting, with a shrinkage allowance reserved for subsequent forming to ensure compensation of the inner and outer diameter dimensions. The wave and the corrugation are formed in two steps using a mold. Compared to traditional one-step forming, this effectively ensures the radial position accuracy of the bulge, avoids changes in the bulge position caused by material flowing towards the radial center during wave forming, and avoids cracking at the bulge that may occur due to poor material flow. It also avoids shrinkage and bulge misalignment near the bulge.

[0055] This method involves clamping the upper and lower surfaces of the machining fixture against the surface of the part to achieve protrusion positioning, and simultaneously machining the inner and outer circles. It allows for the stacking and machining of multiple parts, with the quantity adjusted appropriately according to the size of the wave spring. This method can effectively ensure the relative positional relationship between the protrusion and the inner and outer circles.

[0056] This method has low processing difficulty and high protrusion forming accuracy, and is suitable for forming various single-layer closed waveform springs with different waveforms and protrusions.

[0057] This preparation method is fully applicable to the processing of single-layer closed wave springs with protrusions. For those skilled in the art, similar modifications can be easily implemented. Therefore, without departing from the claims and the general concept defined by their equivalents, this invention is not limited to the established process flow, processing details and the illustrations described herein.

[0058] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application. The above description is merely a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of this application, and these improvements and modifications should also be considered within the protection scope of this application.

Claims

1. A method for manufacturing a closed-end wave spring with raised sections, characterized in that, The spring includes: a spring sheet, which is a closed circular ring shape, and has a plurality of sequentially connected crests and troughs, with spherical protrusions further provided on the crests and troughs. The preparation method includes the following steps: a) material selection and preparation, b) blanking, c) cutting, d) wave forming, e) boss forming, f) machining inner and outer circles, and g) aging and setting. In step c), the spring steel plate cut in step b) is processed into a ring-shaped blank by wire cutting or laser cutting. The inner and outer diameters of the blank retain a preset allowance, which can be calculated by simulation or empirical methods. In step d), the annular blank from step c) is shaped into a waveform using a first mold to form a closed-loop wave spring. The molded surface of the first mold is then closed in a wave pattern. The waveform quantity of the first mold adopts a sine and cosine formula corresponding to the part to be processed, and the waveform height of the first mold is set with height compensation; the first mold is provided with a positioning gap between itself and the inner hole of the annular blank, which can be obtained through simulation or empirical calculation, and a fixed gap is maintained inside the first mold; the first mold is designed with an inner hole limiting block to position the annular blank in step b). The closed-face wave spring in step d) is shaped into a raised form using a second mold, wherein the forming surface of the second mold consists of raised sections spaced vertically. Using protrusions and profiles for positioning, the multiple closed-end wave springs in step e) are stacked and machined to form inner and outer circles.

2. The method for preparing a closed-end wave spring with protrusions as described in claim 1, characterized in that, In step a), the raw material for the wave spring is an alloy spring steel plate with a thickness of 0.3-0.5mm. The main components of the steel plate are: C, Mn, Cr, Ni, Si, Cu, Al, Mo, Ti, Pd, Ce and Fe; the content of impurity P is controlled below 0.03%, and the content of impurity S is controlled below 0.03%.

3. The method for preparing a closed-end wave spring with protrusions as described in claim 1, characterized in that, Using protrusions and profiles for positioning, the multiple closed-circle wave springs with machined inner and outer circles in step f) are stacked and put into the furnace for heat treatment and shaping.

4. The method for manufacturing a closed-end wave spring with protrusions as described in claim 1, characterized in that, The method for preparing the protruding closed wave spring further includes the following steps: h) loading and aging, i) deburring, j) fatigue strength test, k) elasticity test, l) marking, m) final inspection, n) cleaning and packaging.

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