Rudder ball structure machining device and machining process thereof

Abstract

According to the processing device and the processing technology of the rudder ball structure, the rudder ball structure is divided into a rudder body and a rudder ball cover plate, a rudder body outer plate is processed and pressed by adopting a rudder body upper mold and a rudder body lower mold, and the rudder ball cover plate is processed and pressed by adopting a rudder ball cover plate upper mold and a rudder ball cover plate lower mold; the rudder body upper mold, the rudder body lower mold, the rudder ball cover plate upper mold and the rudder ball cover plate lower mold are all arranged on the oil press; the oil press comprises a stamping table and a pressure applying mechanism, when the rudder body is manufactured, the pressure applying mechanism is connected with the rudder body upper die, and the stamping table is provided with the rudder body lower die; when the rudder ball cover plate is manufactured, the pressure applying mechanism is connected with the rudder ball cover plate upper die, and the stamping table is provided with the rudder ball cover plate lower die. By designing the split type mold and combining the cold press molding and flame heating correction technology, efficient machining of the complex curved surface rudder ball is achieved, the production period is remarkably shortened, the defect rate is reduced, and the structural strength is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of shipbuilding, and particularly relates to a processing device and a processing technology for a rudder bulb structure, which are particularly suitable for the forming and manufacturing of a complex space curved surface rudder bulb. Background Art

[0002] With the development of the ship and ocean engineering fields, various ship types have emerged in the transportation demand for bulk commodities. The hull plates of these ship types are usually composed of complex non-developable space curved surfaces, requiring a smooth overall hull line. This is not only for visual perception but also affects the shipbuilding quality and overall performance. The rudder bulb is a key component of the ship's rudder system, and its structure needs to meet the requirements of high strength, high precision, and complex curved surface forming. Due to the large size and high processing difficulty of the rudder bulb, traditional processing methods mainly rely on cast steel parts for the rudder bulb, but there are the following significant defects: (1) Insufficient material properties: The toughness of cast steel parts is poor, and cracks or even fractures are likely to occur under complex sea conditions, threatening the safety of the ship.

[0003] (2) Process defects are difficult to avoid: Defects such as porosity, sand holes, and shrinkage porosity are likely to occur during the casting process, resulting in a decrease in the density of the finished product and a shortening of the fatigue life.

[0004] (3) Long production cycle: It needs to go through multiple processes such as mold manufacturing, casting, heat treatment, and machining. The production process of ship cast steel parts has many steps, and each link requires a certain amount of time, resulting in a long overall production cycle and seriously affecting the shipbuilding progress.

[0005] In addition, some existing solutions use forging processes instead, but forging processes: are difficult to form complex curved surfaces, require a large investment in equipment, and are difficult to adapt to the spherical structure of rudder bulbs.

[0006] Therefore, there is an urgent need for a processing device and a processing technology for a rudder bulb structure that are efficient, low-cost, and high-precision to overcome the deficiencies of the existing technology. Summary of the Invention

[0007] The purpose of the present invention is to overcome the above deficiencies and provide a processing device and a processing technology for a rudder bulb structure, which solve the problems of long production cycle and many defects of traditional cast steel parts through the design of special molds and a combination of cold and hot processing methods.

[0008] The purpose of the present invention is achieved as follows: A processing device for a rudder bulb structure, the rudder bulb structure is divided into a rudder body and a rudder bulb cover plate. The rudder bulb cover plate is the head plate of the rudder bulb spherical structure. A dividing line is defined between the rudder body and the rudder bulb cover plate. A plurality of evenly distributed dividing lines parallel to this dividing line are provided on the rudder body. A plurality of dividing lines are evenly divided horizontally on the rudder bulb structure, separating the rudder body into a plurality of rudder body outer plates and separating the entire rudder bulb cover plate into a plurality of rudder bulb cover plates; The outer plate of the rudder body is processed and pressed by the upper die of the rudder body and the lower die of the rudder body, and the cover plate of the rudder ball is processed and pressed by the upper die of the rudder ball cover plate and the lower die of the rudder ball cover plate; the upper die of the rudder body, the lower die of the rudder body, the upper die of the rudder ball cover plate and the lower die of the rudder ball cover plate are all arranged on the hydraulic press; The hydraulic press includes a stamping table and a pressing mechanism. When making the rudder body, the pressing mechanism of the hydraulic press is connected to the upper die of the rudder body, and the lower die of the rudder body is arranged on the stamping table, and the upper die of the rudder body and the lower die of the rudder body are correspondingly matched up and down; when making the cover plate of the rudder ball, the pressing mechanism of the hydraulic press is connected to the upper die of the rudder ball cover plate, and the lower die of the rudder ball cover plate is arranged on the stamping table, and the upper die of the rudder ball cover plate and the lower die of the rudder ball cover plate are correspondingly matched up and down; The upper die of the rudder body includes a fixed upper plate and a linear web. The fixed upper plate is used to connect with the pressing mechanism of the hydraulic press. The fixed upper plate is a rectangular plate, and a linear web is vertically arranged on its horizontal central axis. One side of the linear web connected to the fixed upper plate is a plane, and the other side facing the side of the lower die of the rudder body is a curved surface with a radian; The lower die of the rudder body includes a bottom plate, two sealing plates and two longitudinal side plates to form a box body with an open top. The left and right ends of the bottom plate are respectively vertically connected to the sealing plates, and the front and back sides of the bottom plate are respectively vertically connected to the longitudinal side plates. The heights of the sealing plates and the longitudinal side plates are the same. A waist-drum-shaped groove is provided on the open top surface of the box body of the lower die of the rudder body through a double-sided panel; The upper die of the rudder ball cover plate includes a fixed panel, an extended round tube and a curved die for the rudder ball. The fixed panel is used to connect with the pressing mechanism of the hydraulic press. The fixed panel is a rectangular plate, and an extended round tube is vertically connected to its center. The top end of the extended round tube is arranged on the fixed panel, and the end of the extended round tube is connected to the curved die for the rudder ball. The curved die for the rudder ball is made according to the curve radian of the cover plate of the rudder ball; The lower die of the rudder ball cover plate includes a curved lower die for the rudder ball. The curved lower die for the rudder ball is disc-shaped, and an equal-curve groove is provided at the center of the top surface of the curved lower die for the rudder ball. The equal-curve groove is matched with the curved die for the rudder ball, which is convenient for pressing the curve of the cover plate of the rudder ball.

[0009] Furthermore, a double-sided panel is arranged above each longitudinal side plate, and the front and back double-sided panels are symmetrically arranged on the open surface of the box body. The two ends of the double-sided panel are respectively arranged on the left and right sealing plates; the opposite sides of the two double-sided panels are set as concave arc surfaces to form a waist-drum-shaped groove.

[0010] Furthermore, the width of the double-sided panel is not greater than 1 / 3 of the width of the sealing plate, so that a waist-drum-shaped through hole is formed between the two double-sided panels, which is convenient for pressing the curve of the outer plate of the rudder body.

[0011] Further, a circle of evenly distributed reinforcing gussets is provided on the outer wall of the top of the extended circular pipe. One right-angled side of the reinforcing gusset is welded to the fixed panel, and the other right-angled side is welded to the outer wall of the extended circular pipe.

[0012] Further, a plurality of longitudinal circular pipe reinforcing ribs and transverse circular pipe reinforcing ribs are provided inside the extended circular pipe to increase the strength of the extended circular pipe.

[0013] A processing technology for a rudder bulb structure, based on the above-mentioned processing device for a rudder bulb structure, includes the following contents: S1. Inspection and pretreatment of raw materials: S1.1. Conduct mechanical property tests and appearance inspections on the rudder body and rudder bulb cover plate materials, and eliminate defective materials with cracks and pitting. S1.2. Mark the processing reference line to ensure accurate positioning in subsequent processes. S2. Divide the rudder body and rudder bulb cover plate: The rudder bulb cover plate is the head plate of the rudder bulb spherical structure. The rudder bulb structure is vertically and equally divided into four dividing lines in sequence. The fourth dividing line is the dividing line between the rudder body and the rudder bulb cover plate. The rudder bulb structure is horizontally and equally divided into four dividing lines in sequence. Thus, the rudder body is divided into multiple rudder outer plates, and the rudder bulb cover plate is divided into multiple rudder bulb cover plates. S3. Cold processing and forming: S3.1. Cold processing of the rudder body; S3.11. Inspection before operation; S3.12. Mark the center line on the plate, and mark the lines at both ends according to equal division on both sides in the head and tail directions. S3.13. Find the corresponding wooden template according to the sample box line type. S3.14. Press the edge of the outer plate of the rudder body structure. During the edge pressing process, use a general wooden template for the edge of the plate to conduct a duplicate sample, strictly control the forming degree of the plate edge, and make it smooth without hair edges. Mark the processing line at the originally marked position. S3.15. Lift the rudder outer plate onto the lower die of the rudder body, and start processing from the position behind the plate edge, and cold press it into shape in stages. S3.16. After each stage of processing, use the wooden template for duplicate sampling, mark the unqualified areas and correct them, and repeat until the line type is smooth. S3.17. When the operation of the first batch of processing lines is completed, lift out the die and use the sample box for duplicate sampling. During the duplicate sampling process, pay attention to the placement position, mark the areas where the processing is not in place, and then carry out the processing operation according to the original processing method. S3.18. After the processing of the rudder outer plate is completed, mark the surplus line according to the sample box size and mark the quality identification. S3.2. Cold processing of the rudder bulb cover plate; S3.21. Pre-operation inspection; S3.22. Welder's assistant by means of a hand-pull; Before processing, weld a hand-pull assistant at the three sharp-corner positions of each rudder bulb cover plate; After the rudder bulb mold is installed, place the rudder bulb cover plate on the lower mold of the rudder bulb and other curves, and observe and mark the processing lines according to the matching wooden sample box; S3.24. Cold press in sections along the processing lines, and the processing method is to press repeatedly from the middle to both sides; During this period, continuously change the processing orientation along the processing lines to make the forging more uniform; during the processing, detect the forming quality in real time, and revise the deviation by combining with the sample box to ensure a smooth surface transition; After the rudder bulb cover plate is processed, mark the surplus line and quality identification according to the dimensions of the sample box; S4. Hot processing correction: S4.1. Fix the cold-formed rudder bulb cover plate on the multi-hole working platform, use the sample box to re-sample the plate, observe the places where the line shape is not in place, and mark the processing lines; S4.2. After the rudder bulb cover plate is stabilized, carry out hot work and heat it with a flame; S4.3. After the first batch of processing lines are completed, re-sample them. According to the law of thermal deformation, heat and correct them in 2 to 3 times to eliminate residual stress and optimize the surface accuracy; after 2 to 3 times of re-sampling and processing, the rudder bulb cover plate is processed; S4.4. Then carry out surface grinding, repair and anti-rust treatment; S4.5. Finally, mark the processing surplus line and various processing information.

[0014] S5. Overall assembly and inspection.

[0015] Furthermore, the following content is also included in step S2: S2.1. The rudder body is composed of the outer plate of the rudder body. Description of the division of the outer plate of the rudder body: The overall shape of the outer plate of the rudder body is a cone. After division according to the mold parameters, lofting and nesting are carried out; The nesting width of the division of the outer plate of the rudder body is one-fourth of a circle; The nesting length of the division of the outer plate of the rudder body is within 2.5 meters; The thickness and material of the outer plate of the rudder body are not limited; The curvature of the outer plate of the rudder body is not limited; S2.2. The rudder bulb cover plate is the head plate of the rudder bulb spherical structure, and the overall shape is a semi-spherical. Description of the division of the rudder bulb cover plate: The overall shape of the rudder bulb cover plate is a semi-circle with the same curvature or a semi-circle with different curvatures. Lofting and nesting are carried out according to the mold parameters; The nesting width of the rudder bulb cover plate is a quarter circle; The nesting length of the rudder bulb cover plate is within 2.5 meters; The thickness and material of the rudder bulb cover plate are not limited; The curvature of the rudder bulb cover plate is not limited.

[0016] Furthermore, for the edge pressing process in step S3.14: the machining width per cut is maintained at 5 mm, and the machining width in the upper and lower mouth directions is maintained at 200 mm.

[0017] Furthermore, in step S3.24, cold pressing is performed in segments along the machining line, controlling the indentation depth ≤ 2 mm. During machining, first move down 10 mm, wait until the surroundings are smooth, and then gradually machine according to the above steps.

[0018] Furthermore, in step S4.2, the temperature control for the hot work operation is 800 - 1000 °C, the width of the heating line ≤ 10 mm, and the water - fire distance is controlled at 90 - 110 mm.

[0019] Compared with the prior art, the beneficial effects of the present invention are: The present invention provides a processing device and a processing technology for a rudder bulb structure. Through the design of special molds and the combination of cold and hot processing technologies, the efficient forming of complex - curved rudder bulbs is realized, significantly shortening the production cycle, reducing the defect rate, and enhancing the structural strength. It has the following specific advantages: (1) Improved production efficiency: The production cycle is greatly shortened, from 1 month in the traditional process to 3 days, and the production efficiency is greatly improved; (2) Significantly reduced costs: The costs of mold development and rework are reduced, and the unit manufacturing cost is decreased by 40%; (3) Quality optimization: The combination of cold and hot processes reduces internal defects in materials, and the finished product rate is greatly improved; The forming accuracy of the curved surface is improved, the overall error is small, and the hydrodynamic performance of the ship is enhanced; (4) Enhanced process adaptability: The split - mold design supports the efficient processing of complex spherical - like rudder bulbs; It can be extended to high - end fields such as new - energy ships, promoting the technological progress of the industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic structural diagram of the upper mold of the rudder body of the present invention.

[0021] Figure 2 It is the front view of the upper mold of the rudder body of the present invention.

[0022] Figure 3 It is the top view of the upper mold of the rudder body of the present invention.

[0023] Figure 4 It is a schematic structural diagram of the lower mold of the rudder body of the present invention.

[0024] Figure 5This is the front view of the lower die of the rudder body of the present invention.

[0025] Figure 6 This is the side view of the lower die of the rudder body of the present invention.

[0026] Figure 7 This is the schematic structural diagram of the upper die of the rudder ball cover plate of the present invention.

[0027] Figure 8 This is the front view of the upper die of the rudder ball cover plate of the present invention.

[0028] Figure 9 This is the bottom view of the upper die of the rudder ball cover plate of the present invention.

[0029] Figure 10 This is the schematic structural diagram of the lower die of the rudder ball cover plate of the present invention.

[0030] Figure 11 This is the front view of the lower die of the rudder ball cover plate of the present invention.

[0031] Figure 12 This is the schematic diagram of the rudder ball structure division of the present invention.

[0032] Figure 13 This is the nesting drawing of the division of the outer plate of the rudder ball and rudder body of the present invention.

[0033] Figure 14 This is the nesting drawing of the division of the rudder ball cover plate of the present invention.

[0034] Wherein: The upper die of the rudder body 1, the fixed upper plate 1.1, the linear web 1.2, the lower die of the rudder body 2, the bottom plate 2.1, the sealing plate 2.2, the longitudinal side plate 2.3, the double-sided panel 2.4, the upper die of the rudder ball cover plate 3, the fixed panel 3.1, the extended round tube 3.2, the equal-curve die of the rudder ball 3.3, the reinforcing gusset 3.4, the longitudinal reinforcing rib of the round tube 3.5, the transverse reinforcing rib of the round tube 3.6, the lower die of the rudder ball cover plate 4, the equal-curve lower die of the rudder ball 4.1, the equal-curve groove 4.2. Specific embodiments

[0035] To better understand the technical solution of the present invention, the following will be described in detail in combination with relevant drawings. It should be understood that the following specific embodiments are not intended to limit the specific implementation forms of the technical solution of the present invention, and they are only the implementation forms that the technical solution of the present invention can adopt. It should be noted first that the expressions regarding the positional relationships of the components herein, such as component A is located above component B, are based on the relative positions of the components in the drawings and are not intended to limit the actual positional relationships of the components. Embodiment 1

[0036] See Figures 1 - 14 , Figure 1Draw a schematic structural diagram of the upper die of the rudder body of the present invention. As shown in the figure, a processing device for a rudder ball structure of the present invention divides the rudder ball structure into a rudder body and a rudder ball cover plate. Refer to Figure 12 , since the rudder ball structure is in the shape of a baseball bat, a smooth round rod, with one end converging linearly and the other end being a semi-spherical cover, the rudder ball structure is divided into a rudder body and a rudder ball cover plate. The rudder ball structure is vertically and equally divided into four dividing lines in sequence, and the fourth dividing line is the dividing line between the rudder body and the rudder ball cover plate. The rudder ball structure is horizontally and equally divided into four dividing lines in sequence, thereby dividing the rudder body into multiple rudder outer plates and dividing the rudder ball cover plate as a whole into multiple rudder ball cover plates.

[0037] The said rudder outer plates are processed and pressed by the upper die 1 of the rudder body and the lower die 2 of the rudder body, and the rudder ball cover plate is processed and pressed by the upper die 3 of the rudder ball cover plate and the lower die 4 of the rudder ball cover plate; the upper die 1 of the rudder body, the lower die 2 of the rudder body, the upper die 3 of the rudder ball cover plate and the lower die 4 of the rudder ball cover plate are all arranged on the hydraulic press; The said hydraulic press includes a stamping table and a pressing mechanism. When making the rudder body, the pressing mechanism of the hydraulic press is connected to the upper die 1 of the rudder body, and the lower die 2 of the rudder body is arranged on the stamping table, and the upper die 1 of the rudder body and the lower die 2 of the rudder body are vertically corresponding and matching; when making the rudder ball cover plate, the pressing mechanism of the hydraulic press is connected to the upper die 3 of the rudder ball cover plate, and the lower die 4 of the rudder ball cover plate is arranged on the stamping table, and the upper die 3 of the rudder ball cover plate and the lower die 4 of the rudder ball cover plate are vertically corresponding and matching.

[0038] The upper die 1 of the rudder body includes a fixed upper plate 1.1 and a linear web 1.2. The fixed upper plate 1.1 is used to connect with the pressing mechanism of the hydraulic press. The fixed upper plate 1.1 is a rectangular plate, and a linear web 1.2 is vertically arranged on its horizontal central axis. One side of the linear web 1.2 connected to the fixed upper plate 1.1 is a plane, and the other side facing the side of the lower die 2 of the rudder body is a curved surface with a radian.

[0039] The lower die 2 of the rudder body includes a box body with an open top composed of a bottom plate 2.1, two sealing plates 2.2 and two longitudinal side plates 2.3. The left and right ends of the bottom plate 2.1 are respectively vertically connected to the sealing plates 2.2, and the front and back sides of the bottom plate 2.1 are respectively vertically connected to the longitudinal side plates 2.3. The sealing plates 2.2 and the longitudinal side plates 2.3 have the same height. A two-way panel 2.4 is arranged above each longitudinal side plate 2.3. The front and back two-way panels 2.4 are symmetrically arranged on the opening surface of the box body. The two ends of the two-way panel 2.4 are respectively arranged on the left and right two sealing plates 2.2; The opposite sides of the two two-way panels 2.4 are set as concave arc surfaces. The width of the two-way panel 2.4 is not greater than 1 / 3 of the width of the sealing plate 2.2. Thus, a waist-drum-shaped through hole is formed between the two two-way panels 2.4, which is convenient for pressing the curve of the rudder outer plate.

[0040] The upper die 3 for the rudder bulb cover plate includes a fixed panel 3.1, an extended circular tube 3.2, and a rudder bulb contour die 3.3. The fixed panel 3.1 is used to connect with the pressing mechanism of the hydraulic press. The fixed panel 3.1 is in the shape of a rectangular plate, and a vertical extended circular tube 3.2 is connected at its center. The top end of the extended circular tube 3.2 is disposed on the fixed panel 3.1, and the end of the extended circular tube 3.2 is connected to the rudder bulb contour die 3.3. The rudder bulb contour die 3.3 is fabricated according to the curve radian of the rudder bulb cover plate. A circle of evenly distributed strengthening gussets 3.4 is provided on the outer wall of the top of the extended circular tube 3.2. One right-angle side of the strengthening gusset 3.4 is welded to the fixed panel 3.1, and the other right-angle side is welded to the outer wall of the extended circular tube 3.2. A plurality of longitudinal circular tube strengthening ribs 3.5 and transverse circular tube strengthening ribs 3.6 are provided inside the extended circular tube 3.2 to increase the strength of the extended circular tube 3.2.

[0041] The lower die 4 for the rudder bulb cover plate includes a rudder bulb contour lower die 4.1. The rudder bulb contour lower die 4.1 is in the shape of a disc. An isometric curve groove 4.2 is provided at the center of the top surface of the rudder bulb contour lower die 4.1. The isometric curve groove 4.2 is matched and corresponding to the rudder bulb contour die 3.3, which is convenient for pressing the curve of the rudder bulb cover plate.

[0042] See Figures 1 - 12 , Figure 1 Draw the structural schematic diagram of the upper die of the rudder body of the present invention. As shown in the figure, a processing technology for a rudder bulb structure of the present invention, based on the above-mentioned processing device for the rudder bulb structure, includes the following content: S1. Raw material inspection and preprocessing: S1.1. Conduct mechanical property tests (tensile strength ≥ 450 MPa, elongation ≥ 20%) and appearance inspections on the rudder body and cover plate plates, and eliminate defective materials with cracks and pitting. S1.2. Mark the processing reference line with an error ≤ 0.5 mm to ensure accurate positioning in subsequent processes.

[0043] S2. Divide the rudder body and the rudder bulb cover plate: See Figure 12 , the rudder bulb cover plate is the head plate of the rudder bulb spherical structure. Vertically and equally divide the rudder bulb structure into four dividing lines in sequence. The fourth dividing line is the dividing line between the rudder body and the rudder bulb cover plate. Horizontally and equally divide the rudder bulb structure into four dividing lines in sequence. Thus, the rudder body is divided into a plurality of rudder body outer plates, and the rudder bulb cover plate is divided into a plurality of rudder bulb cover plates. S2.1. The rudder body is composed of rudder body outer plates. See Figure 13 , the description of the division of the rudder body outer plates: The overall shape of the rudder body outer plate is a cone, and lofting and nesting are carried out after division according to the die parameters. The nesting width of the rudder body outer plate is a quarter circle; The nesting length of the rudder body outer plate is within 2.5 meters; The thickness and material of the rudder body outer plate are not limited; The curvature of the rudder body outer plate is not limited; S2.2. The rudder bulb cover plate, i.e., the head plate of the rudder bulb spherical structure, is integrally semi-spherical, see Figure 14 , Instructions for dividing the rudder bulb cover plate: The overall shape of the rudder bulb cover plate is a co-curved semi-circle or a non-co-curved semi-circle, and lofting and nesting are carried out according to the die parameters; The nesting width of the rudder bulb cover plate is a quarter circle; The nesting length of the rudder bulb cover plate is within 2.5 meters; The thickness and material of the rudder bulb cover plate are not limited; The curvature of the rudder bulb cover plate is not limited.

[0044] S3. Cold forming: S3.1. Rudder body cold processing; S3.11. Pre-operation inspection; (1) Check the hydraulic press: Connect the main power supply of the hydraulic press control panel, and perform pre-operation inspections of rising, falling, and pressing down using the hand control for equipment operation; (2) Check the lifting appliance; (3) Check the matching of the plate part number and the sample box, and whether the part numbers match; S3.12. Mark the center line on the plate, and draw lines according to equal division on both sides in the head and tail directions; S3.13. Find the corresponding wooden template according to the sample box line type; S3.14. Edge pressing; First, perform edge pressing on the outer plate of the rudder body structure. The processing width of each cut is kept at 5 mm, and the processing width in the up and down mouth directions is kept at 200 mm; During edge pressing, use a general plate edge wooden template for a re-sample, strictly control the forming degree of the plate edge, and make it smooth without hairy edges; Mark the processing line at the original marked position; S3.15. Lift the rudder body outer plate onto the lower die of the rudder body, and start processing from the position behind the plate edge. Adopt the strategy of "less pressing and more closing", and perform cold pressing forming in stages; After each stage of processing, use a wooden template for re-sampling, mark the unqualified areas and correct them, and repeat until the line type is smooth (surface error ≤ 1.5 mm); After processing to 300 MM, re-sample and correct the plate line type; After synchronous processing on both sides, check with a template; S3.17. After the operation of the first batch of processing lines is completed, lift out the mold and use the sample box for re-sampling. Pay attention to the placement position during re-sampling, mark the areas where processing is not in place, and then carry out processing operations according to the original processing method; S3.18. After the processing of the rudder outer plate is completed, draw the allowance line according to the size of the sample box and mark the quality identification; S3.19. After on-site splicing, observe whether the line shape is smooth. If it is not smooth, repeat the correction; if it is smooth, the operation ends; S3.110. End of operation: The operator operates the equipment, and when the upper mold descends onto the lower mold and cuts off the main power switch, the operation ends.

[0045] S3.2. Cold processing of the rudder ball cover plate; S3.21. Pre-operation inspection; (1) Check the hydraulic press: Connect the main power supply of the hydraulic press control panel, and use the hand control of the equipment operator to perform pre-operation inspections of rising, descending, and pressing down; (2) Check the lifting appliance; (3) Check the matching of the plate part number and the sample box to see if the part numbers match; S3.22. Weld and assist with a hand-pull; Since the plate cannot be lifted and transported after processing and needs to be manually moved, a hand-pull is welded at the three sharp corners of each rudder ball cover plate before processing; S3.23. After the rudder ball mold is installed, place the rudder ball cover plate on the lower mold of the rudder ball and other curves, and observe and draw the processing line according to the matching wooden sample box; S3.24. Cold press in segments along the processing line, adopt the strategy of "less pressing and more closing", control the indentation depth ≤ 2 mm, and the processing method is to press repeatedly from the middle to both sides (when processing, first press down 10 mm and then gradually process according to the above steps after the surrounding is smooth); S3.25. Continuously change the processing orientation along the processing line during the period to make the forging more uniform; during the processing, the forming quality is detected in real time through "seeing with the eyes and feeling with the hands", and the deviation is corrected by combining the re-sampling with the sample box to ensure smooth surface transition; S3.26. After the processing of the rudder ball cover plate is completed, draw the allowance line according to the size of the sample box and mark the quality identification; S3.27. After segmented splicing, observe whether the overall line shape is smooth. If it is not smooth, repeat the correction; if it is smooth, the operation ends; S3.28. End of operation: The operator operates the equipment, and when the upper mold descends onto the lower mold and cuts off the main power switch, the operation ends.

[0046] S4. Hot processing correction: S4.1. Fix the cold-formed rudder ball cover plate on the multi-hole operation platform, use the sample box to re-sample the plate, observe the areas where the line shape is not in place, and draw the processing line; S4.2. After stabilizing the rudder bulb cover plate, carry out hot working operations, using flame heating (the temperature is controlled at 800 - 1000 °C, the width of the heating line is ≤ 10 mm, and the water - fire distance is controlled at about 100 mm); S4.3. After the operation of the first - batch processing line is completed, conduct a duplicate sample inspection. According to the law of thermal deformation, carry out heating correction in 2 - 3 times to eliminate residual stress and optimize the surface accuracy (local error ≤ 0.8 mm); After 2 - 3 times of duplicate sample inspection and processing, the rudder bulb cover plate is processed; S4.4. Then carry out surface grinding, repair and anti - rust treatment; S4.5. Finally, mark the machining allowance line and various machining information.

[0047] S5. Overall assembly and inspection: S5.1. Weld and assemble the rudder body and the cover plate, and use ultrasonic flaw detection to detect the weld quality (defect rate ≤ 0.5%); S5.2. Use a 3D scanner to compare with the design model to ensure that the overall line - type error ≤ 2 mm.

[0048] Specific implementation cases: Take the machining of the rudder bulb of a new - energy - powered ship as an example: 1. Die installation: Install the outer - plate die of the rudder body and the cover - plate die of the rudder bulb according to the design parameters, and calibrate the positioning accuracy ≤ 0.5 mm; 2. Cold processing: The outer - plate of the rudder body undergoes 3 rounds of edge pressing and duplicate sample inspection, and the cover plate undergoes 2 times of cold pressing correction, with the line - type error ≤ 1.5 mm; 3. Hot processing: Carry out flame heating correction 2 times to eliminate local stress concentration (the temperature is controlled at 900 °C, and the water - fire distance is 100 mm); 4. Inspection: 3D scanning shows that the overall error is 1.2 mm, and there are no defects in ultrasonic flaw detection, and it passes the acceptance at one time.

[0049] Working principle: The present invention provides a processing device for a rudder - bulb structure, which has the following technical contents: (1) Machining die for the outer - plate of the rudder body Upper die: Adopt an R6000 mm arc structure to accurately match the double - curvature line - type of the upper part of the rudder body; Lower die: Designed as a composite structure with a double - curvature arch height of 20 mm in the up - down and left - right directions, adapting to the complex curved surface of the lower part of the rudder body; (2) Machining die for the rudder - bulb cover plate Modular multi - curved - surface design: According to the spherical - like characteristics of the rudder - bulb cover plate, design a segmented adjustable die to support cold - pressing for uniform forming.

[0050] The above are only specific application examples of the present invention and do not constitute any limitation to the protection scope of the present invention. Any technical solutions formed by equivalent transformation or equivalent substitution fall within the scope of the protection of the present invention.

Claims

1. A processing device for a rudder bulb structure, characterized in that: The rudder bulb structure is divided into a rudder body and a rudder bulb cover plate. The rudder bulb cover plate is the head plate of the rudder bulb spherical structure. A dividing line is defined between the rudder body and the rudder bulb cover plate. Multiple evenly distributed dividing lines parallel to this dividing line are provided on the rudder body. The rudder bulb structure is horizontally and evenly divided by multiple dividing lines, separating the rudder body into multiple rudder body outer plates and the entire rudder bulb cover plate into multiple rudder bulb cover plates; The said rudder body outer plates are processed and pressed by the upper die (1) and the lower die (2) of the rudder body on the oil press, and the rudder bulb cover plate is processed and pressed by the upper die (3) and the lower die (4) of the rudder bulb cover plate; The upper die (1) of the rudder body, the lower die (2) of the rudder body, the upper die (3) of the rudder bulb cover plate and the lower die (4) of the rudder bulb cover plate are all arranged on the oil press; The said oil press includes a stamping table and a pressing mechanism. When making the rudder body, the pressing mechanism of the oil press is connected to the upper die (1) of the rudder body, and the lower die (2) of the rudder body is arranged on the stamping table. The upper die (1) of the rudder body and the lower die (2) of the rudder body are vertically corresponding and matching; When making the rudder bulb cover plate, the pressing mechanism of the oil press is connected to the upper die (3) of the rudder bulb cover plate, and the lower die (4) of the rudder bulb cover plate is arranged on the stamping table. The upper die (3) of the rudder bulb cover plate and the lower die (4) of the rudder bulb cover plate are vertically corresponding and matching; The upper die (1) of the rudder body includes a fixed upper plate (1.1) and a linear web (1.2). The fixed upper plate (1.1) is used to connect to the pressing mechanism of the oil press. The fixed upper plate (1.1) is a rectangular plate, and a linear web (1.2) is vertically arranged on its horizontal central axis. One side of the linear web (1.2) connected to the fixed upper plate (1.1) is a plane, and the other side facing the side of the lower die (2) of the rudder body is a curved surface with a radian; The lower die (2) of the rudder body includes a bottom plate (2.1), two sealing plates (2.2) and two longitudinal side plates (2.3) to form a box body with an open top. The left and right ends of the bottom plate (2.1) are respectively vertically connected to the sealing plates (2.2), and the front and back sides of the bottom plate (2.1) are respectively vertically connected to the longitudinal side plates (2.3). The sealing plates (2.2) and the longitudinal side plates (2.3) have the same height. A waist-shaped groove is provided on the open top surface of the box body of the lower die (2) of the rudder body through a two-way panel (2.4); The upper die (3) of the rudder bulb cover plate includes a fixed panel (3.1), an extended circular tube (3.2) and a rudder bulb equal-curve die (3.3). The fixed panel (3.1) is used to connect to the pressing mechanism of the oil press. The fixed panel (3.1) is a rectangular plate, and a vertical extended circular tube (3.2) is connected to its center. The top end of the extended circular tube (3.2) is arranged on the fixed panel (3.1), and the end of the extended circular tube (3.2) is connected to the rudder bulb equal-curve die (3.3). The rudder bulb equal-curve die (3.3) is made according to the curve radian of the rudder bulb cover plate; The lower die (4) of the rudder bulb cover plate includes a lower die (4.1) for the rudder bulb and other curved parts. The lower die (4.1) for the rudder bulb and other curved parts is disc-shaped. A curved groove (4.2) is provided at the center of the top surface of the lower die (4.1) for the rudder bulb and other curved parts. The curved groove (4.2) corresponds to the die (3.3) for the rudder bulb and other curved parts, facilitating the pressing of the curve of the rudder bulb cover plate.

2. The processing device for a rudder bulb structure according to claim 1, characterized in that: A two-way panel (2.4) is provided above each longitudinal side plate (2.3). The front and rear two-way panels (2.4) are symmetrically arranged on the opening surface of the box body. The two ends of the two-way panel (2.4) are respectively arranged on the left and right sealing plates (2.2). The opposite sides of the two two-way panels (2.4) are concave arc surfaces, forming a waist-shaped groove.

3. The processing device for a rudder bulb structure according to claim 2, characterized in that: The width of the two-way panel (2.4) is not greater than 1 / 3 of the width of the sealing plate (2.2). Thus, a waist-shaped through hole is formed between the two two-way panels (2.4), facilitating the pressing of the curve of the outer plate of the rudder body.

4. The processing device for a rudder bulb structure according to claim 1, characterized in that: A circle of evenly distributed strengthening gussets (3.4) is provided on the outer wall of the top of the extended circular tube (3.2). One right-angled side of the strengthening gusset (3.4) is welded to the fixed panel (3.1), and the other right-angled side is welded to the outer wall of the extended circular tube (3.2).

5. The processing device for a rudder bulb structure according to claim 1, characterized in that: A plurality of longitudinal circular tube stiffeners (3.5) and transverse circular tube stiffeners (3.6) are provided inside the extended circular tube (3.2) to increase the strength of the extended circular tube (3.2).

6. A processing technology for a rudder bulb structure, based on the processing device for a rudder bulb structure described in claim 1, characterized in that, Including the following content: S1. Raw material inspection and pretreatment: S1.

1. Conduct mechanical property testing and appearance inspection on the plates of the rudder body and the rudder bulb cover plate, and eliminate defective materials with cracks and pitting. S1.

2. Mark the processing reference line to ensure accurate positioning in subsequent processes. S2. Divide the rudder body and the rudder bulb cover plate: The rudder bulb cover plate is the head plate of the rudder bulb spherical structure. Four equally spaced dividing lines are vertically and equally divided on the rudder bulb structure. The fourth dividing line is the dividing line between the rudder body and the rudder bulb cover plate. Four equally spaced dividing lines are horizontally and equally divided on the rudder bulb structure. Thus, the rudder body is divided into multiple outer plates of the rudder body, and the rudder bulb cover plate is integrally divided into multiple rudder bulb cover plates. S3. Cold processing and forming: S3.

1. Cold processing of the rudder body S3.

11. Inspection before operation S3.

12. Mark the center line on the plate, and mark the lines according to equal division on both sides in the head and tail directions. S3.

13. Find the corresponding wooden template according to the line type of the sample box. S3.

14. Press the edge of the outer plate of the rudder body structure. During the edge pressing process, a general edge wooden template is used for a duplicate sample, strictly controlling the forming degree of the edge of the plate to be smooth and without hairy edges. Mark the processing line at the original marked position. S3.

15. Lift the outer plate of the rudder body onto the lower die of the rudder body, and start processing from the position behind the edge of the plate, and cold press and form in stages. S3.

16. After each stage of processing, use the wooden template for duplicate sampling, mark the unqualified areas and correct them, and repeat until the line type is smooth. S3.

17. When the operation of the first batch of processing lines is completed, lift out the die and use the sample box for duplicate sampling. Pay attention to the placement position during the duplicate sampling process, mark the areas where the processing is not in place, and then carry out the processing operation according to the original processing method. S3.18 After the rudder outer plate machining is completed, mark the surplus line according to the size of the sample box and label the quality identification; S3.2 Cold machining of the rudder ball cover plate; S3.21 Inspection before operation; S3.22 Welding for auxiliary handling; Before machining, weld auxiliary handling at the three sharp corners of each rudder ball cover plate; After the rudder ball mold is installed, place the rudder ball cover plate on the lower mold of the rudder ball and observe and mark the machining line according to the matching wooden sample box; S3.24 Cold press in segments along the machining line, and the machining method is to press repeatedly from the middle to both sides; During this period, continuously change the machining orientation along the machining line to make the forging more uniform; during the machining process, detect the forming quality in real time, combine with the sample box to recheck and correct the deviation to ensure a smooth surface transition; S3.26 After the rudder ball cover plate machining is completed, mark the surplus line according to the size of the sample box and label the quality identification; S4. Hot working correction: S4.1 Fix the cold-formed rudder ball cover plate on the multi-hole working platform, recheck the plate with the sample box, observe the places where the line shape is not in place, and mark the machining line; S4.2 After the rudder ball cover plate is fixed firmly, carry out the fire working operation; S4.3 After the first batch of machining line operations are completed, recheck it, and according to the thermal deformation law, heat and correct it in 2 - 3 times to eliminate the residual stress and optimize the surface accuracy; after 2 - 3 times of rechecking and machining, the rudder ball cover plate machining is completed; S4.4 Then carry out surface grinding, repair and rust prevention treatment; S4.5 Finally, mark the machining surplus line and label various machining information; S5. Overall assembly and inspection.

7. The processing technology of a rudder bulb structure according to claim 6, characterized in that: The following content is also included in step S2: S2.1 The rudder body is composed of the rudder outer plate, and the division description of the rudder outer plate: The overall shape of the rudder outer plate is a cone, and after division according to the mold parameters, lofting and nesting are carried out; The nesting width of the divided rudder outer plate is one-fourth of a circle; The nesting length of the divided rudder outer plate is within 2.5 meters; The thickness and material of the rudder outer plate are not limited; The curvature of the rudder outer plate is not limited; S2.2 The rudder ball cover plate is the head plate of the rudder ball spherical structure, and the overall shape is a semi-sphere. The division description of the rudder ball cover plate: The overall shape of the rudder ball cover plate is a semi-circle with the same curvature or a semi-circle with different curvatures, and lofting and nesting are carried out according to the mold parameters; The nesting width of the rudder ball cover plate is one-fourth of a circle; The nesting length of the rudder ball cover plate is within 2.5 meters; The thickness and material of the rudder ball cover plate are not limited; The curvature of the rudder ball cover plate is not limited.

8. The processing technology of a rudder bulb structure according to claim 6, characterized in that: The edge pressing process in step S3.14: The machining width of each cut is kept at 5 mm, and the machining width in the upper and lower mouth directions is kept at 200 mm.

9. The processing technology of a rudder bulb structure according to claim 6, characterized in that: In step S3.24, cold press in segments along the machining line, control the indentation depth ≤ 2 mm, first press down 10 mm during machining, and then gradually machine according to the above steps after the surrounding is smooth.

10. The processing technology of a rudder bulb structure according to claim 6, characterized in that: In step S4.2, the temperature control of the fire working operation is 800 - 1000 °C, the heating line width ≤ 10 mm, and the water-fire distance is controlled at 90 - 110 mm.

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