Manufacturing process of rust-proof shock absorber

Abstract

The invention relates to a manufacturing process of a rust-proof shock absorber. The manufacturing process comprises the steps of material preparation, machining and forming, rust-proof treatment, assembly and performance detection. By selecting a high-strength, high-toughness and corrosion-resistant metal material and a high-temperature-resistant and wear-resistant rubber or alloy material, anti-rust treatment such as precision machining, electroplating, chemical plating or spraying is carried out, strict assembly is carried out, and multiple performance tests are carried out, so that the damping, sealing and anti-rust performance of the shock absorber in a severe environment is ensured. The shock absorber manufactured through the technology is high in corrosion resistance, high in machining precision, reliable in assembly, excellent in comprehensive performance, wide in application range, capable of remarkably reducing the maintenance cost, suitable for different environment conditions, high in product quality consistency and capable of promoting industry technology progress.

Description

Technical Field

[0001] The invention relates to the technical field of new energy automobile parts processing, in particular to a manufacturing process of a rust-proof shock absorber. Background Art

[0002] In the field of modern machinery and transportation, shock absorbers, as key components, play an indispensable role in improving operational stability and riding comfort. Shock absorbers are widely used in land transportation such as cars and motorcycles, as well as industrial machinery and equipment, to effectively buffer and absorb impact and vibration during operation. In harsh environmental conditions, the corrosion resistance and comprehensive performance of shock absorbers are particularly important.

[0003] At present, the common shock absorbers on the market have taken rust prevention and shock absorption performance into consideration to a certain extent during the design and manufacturing process, but there are still some obvious shortcomings. For example, Chinese patent CN201820367221.6 discloses a rust-proof shock-absorbing spring for electric vehicles, which mainly realizes the rust prevention function by setting a protective paint on the outer surface of the spring. However, in actual use, when the vehicle speed is too fast and rushing downhill, the shock absorber is easy to hit the base of the vehicle, causing damage to the base, thereby affecting the overall performance and service life of the vehicle. In addition, some other shock absorbers also have similar problems in rust prevention treatment, such as the anti-rust layer is not strong and uniform, and it is easy to peel off and peel during use, thereby reducing the anti-rust performance of the shock absorber and shortening its service life.

[0004] Therefore, developing a more advanced and reliable anti-rust shock absorber manufacturing process has become an inevitable trend in the development of the industry. The new process needs to be optimized and innovated in multiple links such as raw material selection, processing accuracy, anti-rust treatment, assembly process and performance testing to overcome the shortcomings of the existing technology, improve the overall performance and service life of the shock absorber, and better adapt to the use requirements in various harsh environments. Summary of the invention

[0005] In order to solve the above problems, the present invention provides a manufacturing process of a rust-proof shock absorber to solve the technical problems raised in the above background technology.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A manufacturing process of a rust-proof shock absorber comprises the following steps:

[0008] S1. Select metal materials with high strength, high toughness and good corrosion resistance as the raw materials for the piston rod and cylinder of the shock absorber, and select rubber or alloy materials with high temperature resistance, wear resistance and excellent anti-rust performance as the raw materials for the seals and dust covers of the shock absorber.

[0009] S2. Use precision processing equipment to process the piston rod and cylinder body to ensure that their dimensional accuracy and surface roughness meet the design requirements. At the same time, use injection molding or compression molding technology to process the seals and dust covers so that their shapes and sizes match the corresponding parts of the shock absorber.

[0010] S3. Anti-rust treatment is performed on the surface of the piston rod and the cylinder body. The specific method includes spraying a layer of galvanized layer to form a dense and strong anti-rust layer to prevent the metal surface from rusting due to contact with the external environment.

[0011] S4. Assemble the rust-proofed piston rod and cylinder body with the processed seals, dust covers and other parts. During the assembly process, strictly control the assembly torque and assembly sequence to ensure a close fit between the components. At the same time, apply an appropriate amount of grease to the assembly parts to reduce friction and wear, and further improve the rust-proof performance and service life of the shock absorber.

[0012] S5. Conduct multiple performance tests on the assembled shock absorber, including but not limited to shock absorption performance test, performance test, and anti-rust performance test, to ensure that the various performance indicators of the shock absorber meet the design requirements and relevant standards.

[0013] Furthermore, in the material preparation step, the metal material is alloy steel, stainless steel or aluminum alloy, the carbon content of the alloy is not more than 0.5%, the chromium content of the stainless steel is not less than 12%, the aluminum content of the aluminum alloy is not less than 90%, and the metal material also contains an appropriate amount of trace elements to further improve its corrosion resistance and mechanical properties.

[0014] Furthermore, in the processing and forming step, the precision processing equipment is a CNC lathe, a machining center or a precision grinder, the dimensional accuracy is ±0.02mm, the surface roughness is Ra0.4μm, and coolant is used for cooling during the processing to prevent the heat generated during the processing from causing changes in material properties.

[0015] Furthermore, in the anti-rust treatment step, the thickness of the sprayed galvanized layer is 10-20 μm, and the anti-rust layer should evenly cover the entire metal surface without defects such as missing plating, missing coating, peeling, and falling off.

[0016] Furthermore, in the assembly step, the assembly torque is ±10% of the specified torque, the assembly order is to first install the seal and dust cover on the piston rod, then install the piston rod into the cylinder body, and finally install other parts on the cylinder body, and the grease is lithium-based grease or molybdenum disulfide grease, and the application amount is 1 / 3-1 / 2 of the gap of the assembly part.

[0017] Furthermore, in the performance testing step, the shock absorption performance test adopts a vibration test bench that simulates vehicle driving, with a test frequency of 1-3 Hz, an amplitude of ±2.5 mm, and a test time of 24 hours. The pressure of the sealing performance test is 1.5 times the working pressure, and the pressure holding time is 30 minutes. The anti-rust performance test adopts a salt spray test, and the test time is 48 hours. The performance test also includes an inspection of the appearance, size, and weight of the shock absorber to ensure that the appearance of the shock absorber is free of scratches, deformations, and cracks, the size meets the requirements of the design drawings, and the weight deviation does not exceed ±5%.

[0018] Furthermore, in the anti-rust treatment step, the anti-rust treatment also includes polishing the surface of the piston rod and the cylinder body, and the surface roughness after polishing is Ra0.2μm, so as to further improve the surface finish and enhance the adhesion and protective effect of the anti-rust layer.

[0019] Furthermore, in the assembly step, the seals and dust covers need to be pretreated before assembly, including preheating them at a certain temperature (the preheating temperature is 50-80°C) to increase their flexibility and sealing. At the same time, special assembly tools are used during the assembly process to ensure that the seals and dust covers can be installed accurately and correctly to avoid damage to them during the assembly process.

[0020] Furthermore, in the performance testing step, the shock absorbing performance test also includes testing the shock absorbing effect of the shock absorber under different temperature environments. The test temperature range is -40°C to 80°C to ensure that the shock absorber can maintain stable shock absorbing performance under various extreme climatic conditions. The test time at each temperature point is not less than 2 hours. Data is recorded every 30 minutes during the test to analyze the performance changes of the shock absorber in detail.

[0021] Furthermore, in the material preparation step, the rubber or alloy material needs to be subjected to performance testing before processing, including testing of tensile strength, tear strength, and hardness indicators, to ensure that its performance meets the design requirements, and the tensile strength of the rubber material is not less than 15MPa, the tear strength is not less than 50kN / m, and the hardness is Shore A6-070; the tensile strength of the alloy material is not less than 30MPa, and the hardness is Shore A80-90, to ensure that the seals and dust covers can withstand certain mechanical stress and friction during use without cracking, deformation or wear.

[0022] The beneficial effects of the present invention are as follows:

[0023] The rust-proof shock absorber manufacturing process strictly selects metal materials with high strength, high toughness and strong corrosion resistance as the raw materials of the piston rod and cylinder body, and performs anti-rust treatment by electroplating and spraying zinc layer to form a dense and firm anti-rust layer, which effectively isolates the metal surface from the external corrosive environment, significantly improves the corrosion resistance of the shock absorber, enables it to maintain a good working condition under harsh environmental conditions, and prolongs the service life of the shock absorber. The piston rod and cylinder body are processed using precision processing equipment to ensure that their dimensional accuracy reaches ±0.02mm and the surface roughness reaches Ra0.4μm. At the same time, the processing process is strictly controlled, such as using coolant cooling to prevent processing heat from causing material performance changes, thereby ensuring the processing accuracy and surface quality of the key components of the shock absorber, providing a solid foundation for subsequent assembly and performance, and improving the overall performance and reliability of the shock absorber. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a complete process flow chart of the present invention. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present invention will be described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0026] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present invention, so the present invention is not limited by the specific implementation disclosed below.

[0027] In the description of the present invention, it is necessary to understand that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0028] Combination Figure 1, the metal materials used for piston rods and cylinder bodies must have high strength, high toughness and good corrosion resistance. For example, alloy steel with a carbon content not exceeding 0.5%, stainless steel with a chromium content not less than 12%, or aluminum alloy with an aluminum content not less than 90%, and containing appropriate trace elements to enhance performance. The rubber or alloy materials used to make seals and dust covers must have the characteristics of high temperature resistance, wear resistance and excellent rust resistance. The tensile strength of rubber materials shall not be less than 15MPa, the tear strength shall not be less than 50kN / m, and the hardness shall be Shore A60-70; the tensile strength of alloy materials shall not be less than 30MPa, and the hardness shall be Shore A80-90. The selected raw materials shall be strictly inspected to ensure that their chemical composition, mechanical properties and other indicators meet the design requirements and relevant standards, and to avoid the use of unqualified materials. The piston rod and cylinder body shall be processed using precision processing equipment such as CNC lathes, machining centers or precision grinders to achieve a dimensional accuracy of ±0.02mm and a surface roughness of Ra0.4μm. During the processing, coolant is used for cooling to prevent the processing heat from causing changes in material properties. The seals and dust boots are processed by injection molding or compression molding to make their shapes and sizes accurately match the corresponding parts of the shock absorber. Strictly control the molding process parameters, such as temperature, pressure, time, etc., to ensure the quality and performance of non-metallic parts. When spraying, spray a layer of zinc with a thickness of 10-20μm. Select high-quality anti-rust zinc and spray the operation strictly in accordance with the process requirements to ensure that the paint film evenly covers the entire metal surface and has good adhesion and protective performance. Before assembly, clean and inspect the piston rod and cylinder body that have been treated with anti-rust, as well as the processed seals, dust boots and other parts to ensure that there are no defects such as oil stains, impurities, damage, etc. At the same time, prepare the assembly tools to ensure that the tools are complete and intact. The assembly is carried out in the order of installing the seals and dust boots on the piston rod first, then installing the piston rod into the cylinder body, and finally installing other parts on the cylinder body. During assembly, the assembly torque is strictly controlled to be within the range of ±10% of the specified torque to ensure a close fit between the components. Apply an appropriate amount of lithium-based grease or molybdenum disulfide grease or other grease to the assembly part, the amount of which is 1 / 3-1 / 2 of the gap of the assembly part to reduce friction and wear and improve the anti-rust performance and service life of the shock absorber. After assembly, the shock absorber is inspected for appearance and preliminary performance test to check that there are no scratches, deformations, cracks and other defects on the appearance, and that all parts are installed in place without looseness or falling off, to initially ensure the assembly quality of the shock absorber. A vibration test bench simulating vehicle driving is used, with the test frequency set to 1-3Hz, the amplitude to ±2.5mm, and the test time to 24 hours, to detect the shock absorption effect of the shock absorber during simulated driving. At the same time, the shock absorption performance of the shock absorber is tested under different temperature environments (-40℃ to 80℃), and the test time at each temperature point is not less than 2 hours. The data is recorded to analyze the performance changes of the shock absorber to ensure that it can stably perform the shock absorption function under various working conditions.

[0029] Sealing performance test: Place the assembled shock absorber under a certain pressure (1.5 times the working pressure) for 30 minutes, and observe whether there is oil leakage or oil seepage to ensure that the shock absorber has good sealing performance and prevent oil leakage from affecting the normal operation and service life of the shock absorber. Place the shock absorber in a salt spray environment or other corrosive environment for 48 hours, and then check whether there is rust on its surface. Through this strict anti-rust performance test, it is ensured that the shock absorber can still maintain good anti-rust performance under harsh environmental conditions and meet the reliability requirements for long-term use. The appearance, size, weight and other items of the shock absorber are checked to ensure that there are no defects in the appearance, the size meets the requirements of the design drawings, and the weight deviation does not exceed ±5%. At the same time, the shock absorber is subjected to a balance test to ensure its balance at high speed operation to avoid vibration and noise caused by imbalance, which affects the driving stability and comfort of the vehicle.

[0030] The basic principles and main features of the present invention and the advantages of the present invention are shown and described above. For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention; therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is limited by the attached claims rather than the above description. Therefore, it is intended to include all changes within the meaning and scope of the equivalent elements of the claims in the present invention, and any figure marks in the claims should not be regarded as limiting the claims involved.

[0031] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A process for manufacturing a rust-proof shock absorber, characterized in that: The steps include: S1. Select metal materials with high strength, high toughness and good corrosion resistance as the raw materials for the piston rod and cylinder of the shock absorber, and select rubber or alloy materials with high temperature resistance, wear resistance and excellent anti-rust performance as the raw materials for the seals and dust covers of the shock absorber. S2. Use precision processing equipment to process the piston rod and cylinder body to ensure that their dimensional accuracy and surface roughness meet the design requirements. At the same time, use injection molding or compression molding technology to process the seals and dust covers so that their shapes and sizes match the corresponding parts of the shock absorber. S3. Anti-rust treatment is performed on the surface of the piston rod and the cylinder body. The specific method includes spraying a layer of galvanized layer to form a dense and strong anti-rust layer to prevent the metal surface from rusting due to contact with the external environment. S4. Assemble the rust-proofed piston rod and cylinder body with the processed seals, dust covers and other parts. During the assembly process, strictly control the assembly torque and assembly sequence to ensure a close fit between the components. At the same time, apply an appropriate amount of grease to the assembly parts to reduce friction and wear, and further improve the rust-proof performance and service life of the shock absorber. S5. Conduct multiple performance tests on the assembled shock absorber, including but not limited to shock absorption performance test, performance test, and anti-rust performance test, to ensure that the various performance indicators of the shock absorber meet the design requirements and relevant standards.

2. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the material preparation step, the metal material is alloy steel, stainless steel or aluminum alloy, the steel carbon content of the alloy does not exceed 0.5%, the chromium content of the stainless steel is not less than 12%, the aluminum content of the aluminum alloy is not less than 90%, and the metal material also contains an appropriate amount of trace elements to further improve its corrosion resistance and mechanical properties.

3. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the processing and forming step, the precision processing equipment is a CNC lathe, a machining center or a precision grinder, the dimensional accuracy is ±0.02mm, the surface roughness is Ra0.4μm, and coolant is used for cooling during the processing to prevent the heat generated during the processing from causing changes in material properties.

4. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the anti-rust treatment step, the thickness of the sprayed zinc coating is 10-20 μm, and the anti-rust layer should evenly cover the entire metal surface without defects such as missing plating, missing coating, peeling, and falling off.

5. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the assembly steps, the assembly torque is ±10% of the specified torque, the assembly order is to first install the seal and dust cover on the piston rod, then install the piston rod into the cylinder body, and finally install other parts on the cylinder body, and the grease is lithium-based grease or molybdenum disulfide grease, and the amount of grease applied is 1 / 3-1 / 2 of the gap of the assembly part.

6. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the performance testing step, the shock absorption performance test adopts a vibration test bench that simulates vehicle driving, with a test frequency of 1-3Hz, an amplitude of ±2.5mm, and a test time of 24 hours. The pressure of the sealing performance test is 1.5 times the working pressure, and the pressure holding time is 30 minutes. The anti-rust performance test adopts a salt spray test, and the test time is 48 hours. The performance test also includes an inspection of the appearance, size, and weight of the shock absorber to ensure that the appearance of the shock absorber has no scratches, deformations, cracks, and defects, the size meets the requirements of the design drawings, and the weight deviation does not exceed ±5%.

7. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the rust-proofing step, the rust-proofing also includes polishing the surface of the piston rod and the cylinder body, and the surface roughness after polishing is Ra0.2μm, so as to further improve the surface finish and enhance the adhesion and protective effect of the rust-proof layer.

8. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the assembly step, the seals and dust covers need to be pretreated before assembly, including preheating them at a certain temperature (the preheating temperature is 50-80°C) to increase their flexibility and sealing. At the same time, special assembly tools are used during the assembly process to ensure that the seals and dust covers can be installed accurately and correctly to avoid damage to them during the assembly process.

9. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the performance testing step, the shock absorption performance test also includes testing the shock absorption effect of the shock absorber under different temperature environments. The test temperature range is -40°C to 80°C to ensure that the shock absorber can maintain stable shock absorption performance under various extreme climatic conditions. The test time at each temperature point is not less than 2 hours. Data is recorded every 30 minutes during the test to analyze the performance changes of the shock absorber in detail.

10. The manufacturing process of a rust-proof shock absorber according to claim 1, characterized in that: In the material preparation step, the rubber or alloy material needs to be tested for performance before processing, including the detection of tensile strength, tear strength, and hardness indicators, to ensure that its performance meets the design requirements, and the tensile strength of the rubber material is not less than 15MPa, the tear strength is not less than 50kN / m, and the hardness is Shore A6-070. The tensile strength of the alloy material is not less than 30MPa, and the hardness is Shore A80-90, to ensure that the seals and dust covers can withstand certain mechanical stress and friction during use without cracking, deformation or wear.

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