Technological method for casting and forging integrated forming of complex part

Abstract

The invention relates to the field of machining, and provides a casting and forging integrated process method for forming a complex part. The process method for casting and forging integrated forming of the complex part comprises the steps that mold locking force is applied to an upper mold and a lower mold through a pressurizing piece; a molten medium is injected into a casting and forging cavity defined by the upper die and the lower die; performing die-casting molding on the molten medium through the pressurizing piece to form an initial blank, and driving the upper die through the pressurizing piece to perform die forging on the initial blank to form a final forge piece. According to the casting and forging integrated process method for forming the complex part, the die casting process and the die forging process are combined, the characteristics that the die casting process is few in defect and excellent in casting structure and the die forging process is high in strength can be fully utilized, and a final forging piece has better mechanical performance and surface quality. A casting primary blank with relatively few defects is obtained by using a die-casting process, and has obvious advantages compared with a primary blank obtained by common casting; a part initial blank obtained through die casting is subjected to die forging forming immediately, and the defects that a casting structure is not compact, the mechanical property and impact resistance are low, and air holes are many are overcome.

Description

Technical Field

[0001] The invention relates to the field of machining and provides a process method for forming complex parts by integrating casting and forging. Background Art

[0002] Castings and forgings each have their own unique advantages. Castings excel in shape complexity and machinability, and are particularly suitable for complex one-piece parts, such as new energy vehicle bodies. This process allows the molten metal to flow freely in the cavity and cool and solidify, making it easy to produce parts with complex geometries.

[0003] However, the casting process can lead to higher internal stresses, cracks, and grain structure inhomogeneities, which can affect mechanical properties and reliability.

[0004] Forgings usually exhibit excellent mechanical properties, including high tensile strength, impact resistance and fatigue strength. The forging process can significantly improve the grain structure inside the metal, decompose and redistribute dislocation components, thereby improving the uniformity and consistency of the material.

[0005] However, the forging process is mainly suitable for simple shapes and sizes. For parts with complex shapes, especially those that require precise cavity design, forging is difficult to achieve the desired effect.

[0006] There is great potential in combining the advantages of casting and forging to improve the mechanical properties and manufacturing efficiency of complex alloy parts. However, there are still some problems that need to be solved in the existing casting and forging technology. On the one hand, the traditional integrated casting and forging device tends to achieve one-time forming and forging of liquid metal through a simple pressurization method, but this method often makes it difficult to ensure sufficient filling of the cavity, resulting in unstable product quality and a high defective rate. On the other hand, the existing technology often requires two independent molds and equipment to achieve casting and forging respectively, which increases production costs and reduces production efficiency. Summary of the invention

[0007] The embodiment of the present invention provides a process method for forming complex parts by integrated casting and forging, so as to solve the defects of poor product quality and low production efficiency in the related technology.

[0008] The embodiment of the present invention provides a process for forming a complex part by integrated casting and forging, comprising: Apply clamping force to the upper and lower dies through the pressure piece; Injecting molten medium into a casting and forging chamber formed by the upper die and the lower die; The molten medium is die-casted by the pressure member to form a preliminary blank, and the upper die is driven by the pressure member to die-forge the preliminary blank to form a final forging.

[0009] According to one embodiment of the present invention, the upper die further includes an injection punch, and the step of applying a clamping force to the upper die and the lower die through the pressure member further includes: The injection punch is connected via the pressure member.

[0010] According to one embodiment of the present invention, the lower die further comprises a counter-punch movably disposed in the lower die, and the step of injecting the molten medium into the casting and forging chamber formed by the upper die and the lower die further comprises: The injection punch and the counter-material punch are inserted into the upper die, and the molten medium is injected into the casting and forging chamber formed by the upper die, the injection punch and the counter-material punch.

[0011] According to one embodiment of the present invention, the step of die-casting the molten medium into a preform by the pressure member comprises: The injection punch is driven by the pressure member to press the molten medium into the casting and forging chamber to die-cast the preform.

[0012] According to one embodiment of the present invention, the step of pressing the molten medium into the casting and forging chamber to die-cast the preform comprises: The preform is maintained under pressure by the injection punch and the upper die until the preform is cooled to the die forging temperature.

[0013] According to one embodiment of the present invention, a pad is provided between the upper die and the lower die; After the step of die-casting the molten medium into a preform by the pressure member, the method comprises: The clamping force applied to the upper mold and the lower mold is cancelled and the backing plate is taken out.

[0014] According to one embodiment of the present invention, after the step of removing the backing plate, the method further comprises: The pressure member drives the injection punch to move upward to cancel the pressure applied by the injection punch to the preform.

[0015] According to one embodiment of the present invention, the step of die-casting the molten medium into a preform by the pressure member further includes: A locking force is applied to the backing plate.

[0016] According to one embodiment of the present invention, a perforating rod is movably provided in the upper die, and in the step of driving the upper die by the pressure member to forge the rough blank into a final forging, the upper die, the lower die and the perforating rod form the casting and forging chamber.

[0017] According to one embodiment of the present invention, after the step of driving the upper die by the pressure member to forge the preform into a final forging, the method includes: The perforated rod is removed and demoulding is completed.

[0018] According to the process method for forming complex parts by integrated casting and forging provided by the embodiment of the present invention, the filling and forming process of the molten medium can be accurately controlled through the die casting process, thereby improving the quality of the blank and the shape of the blank with a relatively complex structure. Combining the two processes of die casting and die forging, the defects of the die casting process, excellent casting structure and high strength characteristics of the die forging process can be fully utilized, so that the final forging has better mechanical properties and surface quality. The die casting process is used to obtain a casting blank with relatively few defects, which has obvious advantages over the blank obtained by ordinary casting; the blank of the part obtained by die casting is immediately die forged, which can improve the shortcomings of the die casting structure being not dense enough, the mechanical properties being low, the impact resistance being low, and the pore defects being many. Compared with the traditional casting or die forging process, the method of the present invention closely combines the two steps of die casting and die forging, reduces the intermediate links and waiting time, and thus shortens the production cycle. More importantly, by continuously performing the die casting and die forging processes in the same set of molds, production is facilitated. Due to the improved material utilization rate and shortened production cycle, the method of the present invention helps to reduce production costs and improve production efficiency. The method is suitable for the production of a variety of materials and complex-shaped products, and has strong flexibility and adaptability. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0020] Figure 1 It is a schematic stereoscopic diagram of the device for forming complex parts by integrated casting and forging provided by the present invention.

[0021] Figure 2 It is a schematic cross-sectional view of the device for forming complex parts by integrated casting and forging provided by the present invention.

[0022] Figure 3 It is a schematic cross-sectional view of the device for forming complex parts by integrated casting and forging provided by the present invention before casting and forging.

[0023] Figure 4 It is a schematic cross-sectional view of a complex part formed by integrated casting and forging provided by the present invention during casting and forging.

[0024] Figure 5It is a schematic cross-sectional view of the device for forming complex parts by integrated casting and forging provided by the present invention after casting and forging.

[0025] Figure 6 It is a schematic flow chart of the process method for forming complex parts by integrated casting and forging provided by the present invention.

[0026] Reference numerals: 100, upper die; 102, lower die; 104, molten medium; 106, initial blank; 108, final forging; 110, injection punch; 112, counter punch; 114, pad; 116, piercing rod. DETAILED DESCRIPTION

[0027] The following embodiments of the present invention are described in further detail in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0028] like Figures 1 to 6 As shown, an embodiment of the present invention provides a process for forming complex parts by integrated casting and forging, comprising: Step 10, applying a clamping force to the upper mold 100 and the lower mold 102 through a pressure member; Step 20, injecting molten medium 104 into the casting and forging chamber formed by the upper die 100 and the lower die 102; Step 30 , the molten medium 104 is die-casted by a pressure member to form a preliminary blank 106 , and the upper die 100 is driven by the pressure member to die-forge the preliminary blank 106 to form a final forging 108 .

[0029] According to the process method for forming complex parts by integrated casting and forging provided by the embodiment of the present invention, the filling and forming process of the molten medium 104 can be accurately controlled through the die casting process, thereby improving the quality of the blank and the shape of the blank with a relatively complex structure. Combining the two processes of die casting and die forging, the high precision of the die casting process and the high strength characteristics of the die forging process can be fully utilized, so that the final forging 108 has better mechanical properties and surface quality. The die casting process is used to obtain a relatively small number of defects in the casting blank 106, which has obvious advantages over the blank 106 obtained by ordinary casting; the blank 106 of the part obtained by die casting is immediately die forged, which can improve the shortcomings of the die casting part, such as insufficient density, low mechanical properties, low impact resistance, and many pore defects. Compared with the traditional casting or die forging process, the method of the present invention closely combines the two steps of die casting and die forging, reduces the intermediate links and waiting time, and thus shortens the production cycle. More importantly, by continuously performing the die casting and die forging processes in the same set of molds, production is facilitated. Due to the improved material utilization rate and shortened production cycle, the method of the present invention helps to reduce production costs and improve production efficiency. This method is suitable for the production of products of various materials and complex shapes, and has strong flexibility and adaptability.

[0030] Please continue to see Figures 1 to 6 The process method for forming complex parts by integrated casting and forging provided in the embodiment of the present invention is a new metal forming method that combines die casting and die forging. The method mainly includes the following steps: Step 10, applying clamping force: First, a sufficient clamping force is applied to the upper mold 100 and the lower mold 102 through a pressure-applying member (such as a hydraulic cylinder, a pneumatic cylinder, etc.) to ensure that the mold is tightly closed during the subsequent process to prevent the molten medium 104 from leaking.

[0031] Step 20, injecting molten medium 104: injecting molten metal or other suitable medium into the casting and forging chamber formed by the upper die 100 and the lower die 102. The selection of the molten medium 104 depends on the material requirements of the final product.

[0032] Step 30, die-casting the blank 106: After the molten medium 104 is injected, the pressure is continued to be applied to the molten medium 104 in the mold through the pressure piece, so that it fills the mold cavity at a high speed and high pressure state and die-casts the blank 106. In this step, it is necessary to continue to apply pressure until it cools to the die forging temperature. Cooling and die forging: When the blank 106 is cooled to a temperature suitable for die forging (i.e., die forging temperature), the blank 106 has a certain strength and shape stability. Then, the upper die 100 (or lower die 102) is driven by the pressure piece (or a special die forging device) to die forge the blank 106, further improve its internal structure and mechanical properties, and finally obtain the final forging 108. In this process, different forging ratio requirements can be met to ensure that the expected forging ratio can be obtained through one forging.

[0033] According to one embodiment of the present invention, the upper die 100 further includes an injection punch 110, and the step of applying a clamping force to the upper die 100 and the lower die 102 through a pressure member further includes: The injection punch 110 is connected via a press member.

[0034] In one embodiment of the present invention, the design of the upper die 100 is further optimized, including a key component, the injection punch 110. In the step of applying a clamping force to the upper die 100 and the lower die 102 through a pressure member, the embodiment also specifically includes an operation of connecting and driving the injection punch 110 through a pressure member.

[0035] Specifically, an injection punch 110 is added to the upper mold 100, and this design enables the molten medium 104 to be injected into the mold cavity more accurately and efficiently. The injection punch 110 is usually designed to be connected to a pressure member (such as a piston rod of a hydraulic cylinder) so that the molten medium 104 can be injected while applying a clamping force.

[0036] In the process of applying the clamping force, the pressure member not only applies pressure to the upper mold 100 and the lower mold 102 to ensure that the mold is tightly closed, but is also connected to the injection punch 110 through a connecting mechanism (such as a connecting rod, a piston rod, etc.) to drive it to perform the injection operation.

[0037] In order to ensure the coordinated injection and clamping processes, the embodiment may further include a corresponding control system or sensor for monitoring the mold state, the filling of the molten medium 104 and the working state of the pressurizing part, so as to achieve precise injection and clamping control.

[0038] The introduction of the injection punch 110 enables the molten medium 104 to be injected into the mold cavity more quickly and accurately, thereby improving the injection efficiency. The design of the injection punch 110 helps the molten medium 104 to be evenly distributed in the mold cavity, reducing the generation of bubbles and defects, thereby optimizing the filling effect. Since the injection punch 110 can accurately control the injection amount and speed of the molten medium 104, it helps to improve the dimensional accuracy and shape stability of the product. Integrating the injection and clamping functions on the pressure piece simplifies the operating process and reduces the difficulty and cost of operation. The design of this embodiment allows the injection amount and speed of the molten medium 104 to be adjusted according to specific product requirements, thereby improving the flexibility and adaptability of production.

[0039] According to one embodiment of the present invention, the lower die 102 further includes a counter punch 112 movably disposed in the lower die 102, and the step of injecting the molten medium 104 into the casting and forging chamber formed by the upper die 100 and the lower die 102 further includes: The injection punch 110 and the counter punch 112 are inserted into the upper die 100 , and the molten medium 104 is injected into the casting and forging chamber surrounded by the upper die 100 , the injection punch 110 and the counter punch 112 .

[0040] In one embodiment of the present invention, the design of the lower die 102 is further innovated, including a counter-punch 112 movably inserted into the lower die 102. In the step of injecting the molten medium 104 into the casting and forging chamber surrounded by the upper die 100 and the lower die 102, the embodiment particularly adopts a method of inserting the injection punch 110 and the counter-punch 112 into the upper die 100, and injecting the molten medium 104 into the new casting and forging chamber surrounded by the upper die 100, the injection punch 110 and the counter-punch 112.

[0041] Specifically, a movable counter-punch 112 is added to the lower die 102, and this design allows for more flexible control of the injection and molding process of the molten medium 104. The counter-punch 112 is generally designed to be able to move up and down in the lower die 102 so as to be inserted into the upper die 100 to form a new casting and forging chamber when needed.

[0042] After the injection punch 110 and the counter punch 112 are inserted into the upper die 100, a new casting and forging chamber is formed by the upper die 100, the injection punch 110 and the counter punch 112. The newly formed casting and forging chamber can be designed according to the requirements of specific products to achieve a more complex or precise molding effect.

[0043] After the new casting and forging cavity is formed, the molten medium 104 is injected into it through a specific injection device. Due to the presence of the counter-material punch 112, the flow and distribution of the molten medium 104 can be more accurately controlled during the injection process.

[0044] In order to ensure that the injection punch 110 and the counter-punch 112 can be accurately inserted into the upper die 100 and form a new casting and forging chamber, the embodiment may also include a corresponding control system or drive mechanism. These systems or mechanisms are responsible for monitoring the position, speed and movement trajectory of the injection punch 110 and the counter-punch 112, and adjusting them as needed.

[0045] The introduction of the counter-material punch 112 makes the design of the casting and forging chamber more flexible and diverse, and can be customized according to the needs of specific products. This helps to improve the molding accuracy and dimensional stability of the product. By controlling the position and movement trajectory of the counter-material punch 112, the distribution of the molten medium 104 in the casting and forging chamber can be more accurately controlled. This helps to reduce material waste and the generation of internal defects. Since the counter-material punch 112 can form a more complex casting and forging chamber structure, products with higher strength and more complex shapes can be produced. These products are generally superior to products produced by traditional methods in performance. The design of this embodiment enables the process method of casting and forging integrated forming of complex parts to be applied to the production of products of more types and shapes. This helps to expand the scope of application and market prospects of this method.

[0046] According to one embodiment of the present invention, the step of die-casting the molten medium 104 into the preform 106 by a pressure member includes: The injection punch 110 is driven by the pressure member to press the molten medium 104 into the casting and forging chamber to die-cast a preform 106 .

[0047] In one embodiment of the present invention, the step of die-casting the molten medium 104 to form the blank 106 by a pressure member is further clarified and optimized. This step specifically includes the process of driving the injection punch 110 by the pressure member to press the molten medium 104 into the casting and forging chamber formed by the upper die 100 and the lower die 102 (or the upper die 100 and the counter-material punch 112, according to the above embodiment) to die-cast the blank 106.

[0048] Specifically, before or at the same time as the molten medium 104 is injected into the casting and forging chamber, the injection punch 110 is ready to be used. It is usually connected to a pressurizing member (such as a hydraulic cylinder, a pneumatic cylinder, etc.) and can reciprocate through the driving force of the pressurizing member.

[0049] When the molten medium 104 is injected into the casting chamber, the pressure member starts to work, driving the injection punch 110 to move forward. The movement of the injection punch 110 further presses the molten medium 104 into every corner of the casting chamber to ensure that the medium is fully filled and closely fits the inner wall of the mold.

[0050] After the molten medium 104 is fully injected, it will cool and solidify in the casting chamber to form a preform 106. The shape and size of the preform 106 will be determined by the design of the casting chamber and the filling of the molten medium 104.

[0051] After the forming of the blank 106 is completed, the pressure member will drive the injection punch 110 to return to its original position to prepare for the next die-casting operation.

[0052] The use of the injection punch 110 can ensure that the molten medium 104 is fully filled and compacted in the casting and forging chamber, thereby reducing the generation of internal defects and bubbles. This helps to improve the density and strength of the preform 106, laying a solid foundation for the subsequent die forging operation. Since the injection punch 110 can accurately control the filling amount and speed of the molten medium 104, products with higher dimensional accuracy can be produced. This is particularly important for products that require high-precision molding. The rapid movement and return operation of the injection punch 110 can shorten the time cycle of die casting, thereby improving the efficiency of the entire production process. By accurately controlling the filling amount and distribution of the molten medium 104, material waste and overuse can be reduced. This helps to reduce production costs and improve material utilization. The design of the injection punch 110 makes the die casting process more flexible and controllable. According to different product requirements and mold designs, parameters such as the movement speed and filling pressure of the injection punch 110 can be adjusted to adapt to different production scenarios.

[0053] According to one embodiment of the present invention, the step of pressing the molten medium 104 into the casting and forging chamber to die-cast the preform 106 includes: The preform 106 is maintained under pressure by the injection punch 110 and the upper die 100 until the preform 106 is cooled to the die forging temperature.

[0054] In one embodiment of the present invention, the step of cooling the blank 106 to the die forging temperature is further optimized, which specifically includes maintaining the pressure of the blank 106 by the injection punch 110 and the upper die 100 until the blank 106 is cooled to the die forging temperature.

[0055] Specifically, after the blank 106 is die-cast, the injection punch 110 does not return immediately, but remains in place or slightly retreats a distance, so as to maintain pressure on the blank 106 together with the upper die 100. At the same time, the upper die 100 also maintains a tight state on the blank 106 to ensure that the blank 106 will not deform or shift during the cooling process.

[0056] Under the pressure holding state, the blank 106 begins to cool gradually. In order to ensure that the blank 106 can be cooled evenly and quickly to the die forging temperature, additional cooling measures may be taken, such as using cooling water, cooling fans or natural cooling. The selection and application of these cooling measures will depend on the specific production environment and product requirements.

[0057] During the cooling process, the holding pressure of the injection punch 110 and the upper die 100 needs to be kept constant or gradually reduced to avoid excessive pressure on the preform 106, which may cause deformation or damage. At the same time, the coordination of the cooling speed and the holding time is also very important to ensure that the preform 106 can be cooled to the die forging temperature under the best condition.

[0058] When the blank 106 is cooled to the die forging temperature, the pressure holding device of the injection punch 110 and the upper die 100 will gradually release the pressure and allow the blank 106 to be removed from the die for subsequent die forging operations.

[0059] By applying continuous pressure to the blank 106 through the pressure-holding device, it can be ensured that the blank 106 will not be deformed or displaced during the cooling process, thereby improving the dimensional accuracy and shape stability of the blank 106. The pressure-holding effect of the injection punch 110 and the upper mold 100 can also promote the uniform dissipation of heat inside the blank 106, thereby accelerating the cooling speed and improving the cooling efficiency. This helps to reduce the production cycle and improve production efficiency. Since the blank 106 is fully pressure-held and uniformly cooled during the cooling process, its internal structure will be denser and more uniform, thereby improving the mechanical properties and durability of the product. By optimizing the design of the cooling process and the pressure-holding device, the need for additional cooling equipment and energy consumption can be reduced, thereby reducing production costs and improving economic benefits.

[0060] According to one embodiment of the present invention, a backing plate 114 is provided between the upper die 100 and the lower die 102; After the step of die-casting the molten medium 104 into a preform 106 by a pressurizing member, the method includes: The clamping force applied to the upper mold 100 and the lower mold 102 is cancelled and the backing plate 114 is removed.

[0061] In one embodiment of the present invention, a pad 114 is innovatively provided between the upper mold 100 and the lower mold 102, and after the step of die-casting the molten medium 104 into a preliminary blank 106 by a pressure member, an operation of canceling the clamping force applied to the upper mold 100 and the lower mold 102 and removing the pad 114 is performed.

[0062] Specifically, during the die casting process, the backing plate 114 is placed between the upper die 100 and the lower die 102. The main function of the backing plate 114 is to provide additional support and cushioning to prevent the upper die 100 and the lower die 102 from directly contacting and causing wear or damage under the clamping force. At the same time, the backing plate 114 can also be replaced or adjusted according to production requirements to adapt to preforms 106 of different thicknesses or shapes.

[0063] When the blank 106 is cooled to the die forging temperature, the clamping force applied to the upper die 100 and the lower die 102 needs to be removed. This step is usually achieved by controlling the driving force of a pressurizing member (such as a hydraulic cylinder, a pneumatic cylinder, etc.). After the clamping force is removed, the upper die 100 and the lower die 102 will gradually separate, preparing for taking out the blank 106 and the backing plate 114.

[0064] After the clamping force is released, the backing plate 114 can be easily removed. The removal of the backing plate 114 is usually completed manually or automatically, depending on the degree of automation and ease of operation of the production line. After the backing plate 114 is removed, its wear can be checked and replaced or maintained as needed.

[0065] By adjusting the pads 114 of different sizes, it is possible to adapt to different die forging ratio requirements, ensuring that the expected die forging ratio can be obtained through one forging. In addition, the pads 114 can provide additional support and cushioning, which helps to ensure that the blank 106 is fully filled and compacted during the die casting process. This helps to increase the density and strength of the blank 106 and reduce the generation of internal defects and bubbles. The setting and removal of the pads 114 are relatively simple and convenient, which helps to reduce the difficulty and cost of operation. At the same time, the pads 114 can also be replaced or adjusted according to production requirements to adapt to blanks 106 of different thicknesses or shapes.

[0066] According to one embodiment of the present invention, after the step of removing the backing plate 114, the method further includes: The injection punch 110 is driven upward by the pressure member to cancel the pressure applied by the injection punch 110 to the preform 106 .

[0067] In one embodiment of the present invention, after the backing plate 114 is removed, a key step is further included: the pressure member drives the injection punch 110 to move upward to cancel the pressure applied by the injection punch 110 to the preform 106. This step ensures that the preform 106 will not be affected by additional pressure during removal and subsequent processing, thereby ensuring the quality and integrity of the product.

[0068] Specifically, after the backing plate 114 is removed, the pressure member (such as a hydraulic cylinder, a pneumatic cylinder, etc.) is ready to be used. The pressure member is connected to the injection punch 110 through a connecting rod or a transmission mechanism, and can accurately control the up and down movement of the injection punch 110.

[0069] By controlling the driving force of the pressure member, the injection punch 110 is driven to move upward. The moving speed and stability of the injection punch 110 can be achieved by adjusting the parameters of the pressure member to ensure that the preform 106 is not impacted or damaged.

[0070] As the injection punch 110 moves upward, it gradually separates from the preform 106, thereby canceling the pressure applied to the preform 106. This step ensures that the preform 106 can be deformed or moved freely during subsequent processing without being restricted by the injection punch 110.

[0071] After the pressure on the blank 106 is removed, the injection punch 110 will continue to move upward until it returns to its original position. The injection punch 110 after returning to its original position is ready for the next die-casting operation.

[0072] Removing the pressure applied by the injection punch 110 to the blank 106 helps to prevent the blank 106 from being affected by additional pressure during removal and subsequent processing, thereby ensuring the quality and integrity of the product. By accurately controlling the driving force of the pressure-applying member and the moving speed of the injection punch 110, the process of removing the pressure can be ensured to be smooth and efficient. This helps to shorten the production cycle and improve production efficiency. The operation of removing the pressure of the injection punch 110 is an important link in the die casting process. By optimizing this step, the stability and controllability of the entire process can be further improved. The operation of removing the pressure of the injection punch 110 is relatively simple and easy to implement, without the need for additional equipment and manpower. This helps to reduce production costs and improve economic benefits.

[0073] According to one embodiment of the present invention, the step of die-casting the molten medium 104 into the preform 106 by the pressure piece further includes: A locking force is applied to the backing plate 114 .

[0074] In one embodiment of the present invention, the step of die-casting the molten medium 104 to form the blank 106 by a pressure member is further improved. This step not only includes the traditional die-casting operation, but also innovatively adds a step of applying a locking force to the backing plate 114. The addition of this step is intended to improve the stability and reliability of the die-casting process and ensure the quality of the blank 106.

[0075] Specifically, Before die casting, the pad 114 is precisely placed between the upper die 100 and the lower die 102. The main function of the pad 114 is to provide additional support and cushioning to prevent the upper die 100 and the lower die 102 from deformation or damage due to excessive force during the die casting process.

[0076] Before or at the same time as the molten medium 104 is injected into the casting and forging chamber, a locking force is applied to the backing plate 114 by the pressure member. The magnitude and direction of the locking force need to be determined according to specific production requirements and mold design to ensure that the backing plate 114 can be firmly fixed between the upper mold 100 and the lower mold 102.

[0077] After the backing plate 114 is firmly locked, the die casting operation begins. The pressure-applying member (such as a hydraulic cylinder, a pneumatic cylinder, etc.) drives the injection punch 110 to move forward through a connecting rod or a transmission mechanism, and presses the molten medium 104 into the casting and forging chamber. During the die casting process, the backing plate 114 will withstand huge pressure from the upper die 100 and the lower die 102, but because it has been firmly locked, it can remain stable and not deformed.

[0078] When the blank 106 is die-cast and cooled to a certain temperature, it is necessary to release the locking force applied to the backing plate 114. This step is usually achieved by controlling the action of the locking mechanism. After the locking force is released, the backing plate 114 can be separated from the upper mold 100 and the lower mold 102, preparing for taking out the blank 106 and the backing plate 114.

[0079] The locking effect of the backing plate 114 can effectively prevent the upper die 100 and the lower die 102 from being deformed or damaged due to excessive force during the die casting process. This helps to extend the service life of the mold and reduce production costs. Since the backing plate 114 is firmly locked, it can remain stable and not deformed during the die casting process. This helps to ensure the dimensional accuracy and shape stability of the preform 106, thereby improving the overall quality of the product.

[0080] According to one embodiment of the present invention, a perforating rod 116 is movably provided in the upper die 100. In the step of driving the upper die 100 by a pressure member to forge the blank 106 into a final forging 108, the upper die 100, the lower die 102 and the perforating rod 116 form a casting and forging chamber.

[0081] In one embodiment of the present invention, a movable punching rod 116 is innovatively provided in the die. In the step of driving the upper die 100 by the pressure member to forge the blank 106 into the final forging 108, the upper die 100, the lower die 102 and the punching rod 116 together form a casting and forging chamber. This design not only optimizes the structure of the casting and forging chamber, but also improves the accuracy and efficiency of the die forging.

[0082] Specifically, the punching rod 116 is movably disposed in the upper die 100, and its position and quantity can be determined according to specific production requirements and die design. The main function of the punching rod 116 is to help form the casting and forging chamber and provide additional support and guidance during the die forging process.

[0083] Before die forging, the upper die 100 and the lower die 102 are precisely closed, and the punch rod 116 is inserted into a predetermined position. In this way, the upper die 100, the lower die 102 and the punch rod 116 together form a closed casting and forging chamber. This chamber provides sufficient space and shape support for the molten medium 104 or the preform 106 to ensure the smooth progress of the die forging process.

[0084] After the casting and forging chamber is formed, the pressurizing member (such as a hydraulic cylinder, a pneumatic cylinder, etc.) starts to drive the upper die 100 to move downward, applying pressure to the preform 106 for die forging. In this process, the perforating rod 116 not only plays a supporting and guiding role, but also can adjust its position or shape as needed to meet different die forging requirements.

[0085] When die forging is completed, the upper die 100 and the lower die 102 are separated, and the punch rod 116 is also extracted. In this way, the final forging 108 can be easily taken out from the casting and forging chamber for subsequent processing or detection.

[0086] The provision of the perforating rod 116 can help to more accurately control the shape and size of the casting and forging chamber, thereby improving the accuracy of the die forging. This helps to ensure the dimensional accuracy and shape stability of the final forging 108, meeting the requirements of high-quality products. The perforating rod 116 plays a supporting and guiding role in the die forging process, helping to ensure that the molten medium 104 or the preform 106 can evenly fill the entire casting and forging chamber. This helps to reduce the generation of internal defects and bubbles, and improve the quality and reliability of the final forging 108.

[0087] According to one embodiment of the present invention, after the step of driving the upper die 100 by the pressure member to forge the preform 106 into the final forging 108, the following steps are included: The perforating rod 116 is removed and demoulding is completed.

[0088] In one embodiment of the present invention, after the die forging step, the important operation of removing the punch rod 116 and completing the demoulding is followed. This step ensures that the final forging 108 can be smoothly removed from the die while maintaining its integrity and quality.

[0089] Specifically, after the die forging is completed, the driving force of the pressure member on the upper die 100 needs to be stopped first, so that the upper die 100 and the lower die 102 are gradually separated. Then, the piercing rod 116 is taken out of the casting and forging chamber by a special taking-out mechanism or manual operation. This step needs to ensure that the piercing rod 116 does not cause any damage to the final forging 108 during the taking-out process.

[0090] After the punch rod 116 is removed, the demoulding operation is performed. Demolding is usually achieved by an ejector mechanism, which can push the final forging 108 to separate from the lower die 102. The design of the ejector mechanism needs to ensure that the force can be applied evenly to avoid deformation or damage of the final forging 108 during the demoulding process.

[0091] After the demoulding operation is completed, the final forging 108 can be easily removed. After removal, the final forging 108 needs to be fully inspected, including size, shape, surface quality, etc., to ensure that it meets the design requirements and quality standards.

[0092] By precisely controlling the removal and demolding operations of the punch rod 116, it can be ensured that the final forging 108 will not be damaged during the removal process. This helps to maintain the integrity and quality of the final forging 108 and meet the needs of high-quality products. The operations of removing the punch rod 116 and completing the demolding are relatively simple and efficient, which helps to shorten the production cycle and improve production efficiency. This helps to meet the market demand for high-efficiency products and reduce production costs. Since the punch rod 116 is movable and can be easily removed after die forging, the die forging method of this embodiment can be applied to a wider variety of products and production scenarios. This enhances the adaptability and flexibility of the mold, making production more flexible and efficient.

[0093] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A process for forming complex parts by integrated casting and forging, characterized in that: include: Applying a clamping force to the upper mold (100) and the lower mold (102) through a pressure member; Injecting a molten medium (104) into a casting and forging chamber formed by the upper die (100) and the lower die (102); The molten medium (104) is die-casted by the pressurizing member to form a preliminary blank (106), and the upper die (100) is driven by the pressurizing member to die-forge the preliminary blank (106) to form a final forging (108).

2. The process for forming complex parts by integrated casting and forging according to claim 1 is characterized in that: The upper die (100) further comprises an injection punch (110), and the step of applying a clamping force to the upper die (100) and the lower die (102) through a pressure member further comprises: The injection punch (110) is connected via the pressure member.

3. The process for forming complex parts by integrated casting and forging according to claim 2 is characterized in that: The lower die (102) further comprises a counter punch (112) movably disposed in the lower die (102), and the step of injecting a molten medium (104) into a casting and forging chamber formed by the upper die (100) and the lower die (102) further comprises: The injection punch (110) and the counter-material punch (112) are inserted into the upper die (100), and the molten medium (104) is injected into the casting and forging chamber formed by the upper die (100), the injection punch (110) and the counter-material punch (112).

4. The process for forming complex parts by integrated casting and forging according to claim 2 is characterized in that: The step of die-casting the molten medium (104) to form a preform (106) by the pressure member comprises: The pressure member drives the injection punch (110) to press the molten medium (104) into the casting and forging chamber to die-cast the blank (106).

5. The process for forming complex parts by integrated casting and forging according to claim 4 is characterized in that: The step of pressing the molten medium (104) into the casting and forging chamber to die-cast the preform (106) comprises: The preform (106) is pressurized by the injection punch (110) and the upper die (100) until the preform (106) is cooled to a die forging temperature.

6. The process for forming complex parts by integrated casting and forging according to claim 5 is characterized in that: A pad (114) is provided between the upper die (100) and the lower die (102); After the step of die-casting the molten medium (104) into a preform (106) by the pressure member, the method comprises: The clamping force applied to the upper mold (100) and the lower mold (102) is cancelled and the backing plate (114) is removed.

7. The process for forming complex parts by integrated casting and forging according to claim 6 is characterized in that: After the step of removing the backing plate (114), the method further comprises: The pressure member drives the injection punch (110) to move upward to cancel the pressure applied by the injection punch (110) to the preform (106).

8. The process for forming complex parts by integrated casting and forging according to claim 6 is characterized in that: The step of die-casting the molten medium (104) into a preform (106) by the pressure member further comprises: A locking force is applied to the backing plate (114).

9. The process for forming complex parts by integrated casting and forging according to any one of claims 1 to 8, characterized in that: A punching rod (116) is movably provided in the upper die (100), and in the step of driving the upper die (100) by the pressure member to forge the rough blank (106) into a final forging (108), the upper die (100), the lower die (102) and the punching rod (116) form the casting and forging chamber.

10. The process for forming complex parts by integrated casting and forging according to claim 9, characterized in that: After the step of driving the upper die (100) by the pressure member to perform die forging on the blank (106) to form a final forging (108), the method comprises: The perforating rod (116) is removed and demoulding is completed.

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