Special-shaped terminal production process and terminal

Abstract

The invention discloses a special-shaped terminal production process, which comprises the following steps of: straightening a cylindrical copper material through a straightening bending machine, upsetting two ends of the cylindrical copper material to form fillets by using an automatic machine, bending and forming the fillets, and finally finishing a final finished product in a mode of integrating flattening, shaping and cutting into one die. According to the improved process, the production efficiency and the product quality are remarkably improved by simplifying procedures, optimizing material utilization, reducing energy consumption and die cost, improving the yield and achieving continuous production. And meanwhile, the flexibility and adaptability of the process are higher (a straightening-upsetting-bending three-step forming system), and diversified production requirements can be met.

Description

Technical Field

[0001] The present invention relates to the technical field of part processing, and particularly to a production process and a terminal for special-shaped terminals. Background Art

[0002] The existing production process for special-shaped cold forging parts is relatively complex, involving multiple steps and dies. The specific process is as follows: First, the material is formed into a cylindrical shape and a sheet shape; second, the taper of the cylindrical head and the diameter expansion of the sheet are formed; then, the diameter reduction of the cylinder and the diameter expansion of the lower part are carried out; then, the offset part is formed; subsequently, a flattening operation is performed; finally, precise forming is carried out. This process requires the use of multiple sets of dies. Such a multi-step and multi-die process not only increases the production cost but also affects the production efficiency. Summary of the Invention

[0003] The purpose of this part is to outline some aspects of the embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this part, as well as in the abstract and the title of the present application, to avoid obscuring the purpose of this part, the abstract, and the title. However, such simplifications or omissions shall not be used to limit the scope of the present invention.

[0004] To solve the above-mentioned problems, the present invention provides the following technical solutions: Including the following steps; S1: Put the cylindrical raw material into a straightening and bending machine for straightening; S2: Use an automatic machine to upset both ends of the material straightened in S1 to form rounded corners; S3: Bend the material with rounded corners in S2 to form the required bending shape; S4: Flatten, shape, and cut the material bent in S3 to complete the final forming.

[0005] Preferably, the material in the above steps is made of brass.

[0006] Preferably, in the step of S1, the straightening is completed by the straightening and bending machine in a continuous feeding manner.

[0007] Preferably, the method further includes the step of performing surface passivation treatment on the special-shaped terminal after cutting in step S4.

[0008] Preferably, the whole process of the process adopts a continuous die forging method, and only one set of stamping dies and one bending machine are required.

[0009] Preferably, it includes a bridging block, the bridging block has a first extension end and a second extension end, the first extension end is a column terminal or a flat terminal, and the second extension end is a column terminal or a flat terminal.

[0010] Preferably, the first extended end is a column terminal, and the second extended end is a flat terminal.

[0011] Preferably, the first extended end is a flat terminal, and the second extended end is a column terminal.

[0012] Preferably, both the first extended end and the second extended end are column terminals or both are flat terminals.

[0013] Preferably, the bridging block can completely coincide after rotating 180° along the center point.

[0014] The beneficial effects of the present invention are as follows: The improved process simplifies the process, optimizes material utilization, reduces energy consumption and mold costs, increases the yield rate, and realizes continuous production, significantly improving production efficiency and product quality. At the same time, the process has stronger flexibility and adaptability (the "straightening-upsetting-bending" three-stage forming system), and can meet diverse production requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts. Among them: Figure 1 It is a structural diagram of the terminal of this embodiment.

[0016] Figure 2 It is a structural diagram of the connecting block of this embodiment.

[0017] Figure 3 It is a schematic diagram of the terminal forming process steps S2 to S3 of this embodiment.

[0018] Figure 4 It is a schematic diagram of the terminal forming process steps S2 to S3 of this embodiment.

[0019] Figure 5 It is a three-dimensional diagram of various shaped terminals of this embodiment.

[0020] Figure 6 It is a three-dimensional diagram of the production process of special-shaped terminals of this embodiment.

[0021] In the figure: bridging block 100, first extended end 101, second extended end 102, center point 103, first terminal 200, second terminal 300; First connection end 100-1, first bending end 100-1a, first diameter-expanded end 200-1, first pre-treatment end 200-1a, first non-diameter-expanded end 300-1, first fixed end 300-1a; The second connection end 100-2, the second bent end 100-2a, the second non-expanded diameter end 200-2, the second fixed end 200-2a, the second expanded diameter end 300-2, the second pre-treatment end 300-2a, the column terminal 400, and the flat terminal 500. Detailed implementation manners

[0022] To make the above objects, features, and advantages of the present invention more obvious and understandable, the following will describe the detailed implementation manners of the present invention with reference to the accompanying drawings of the specification.

[0023] In the following description, many specific details are set forth to facilitate a thorough understanding of the present invention. However, the present invention may be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0024] Secondly, the so-called "one embodiment" or "embodiment" herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation manner of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it an individual or alternative embodiment that is mutually exclusive with other embodiments.

[0025] Embodiment Refer to Figure 6 , which is an embodiment of the present invention. This embodiment provides a production process for special-shaped terminals; S1; Place the cylindrical raw material (copper material) into a straightening and bending machine for straightening treatment; S2; Use an automatic machine to upset both ends of the straightened material to form rounded corners; S3; Bend the material after locking the rounded corners to form the required bending shape; S4; Flatten, shape, and cut the bent material to complete the final forming; Furthermore, the straightening treatment in S1 is completed by the straightening and bending machine in a continuous feeding manner to improve the production efficiency of the initial processing; The special-shaped terminals after cutting in step S4 are subjected to surface passivation treatment to achieve an anti-corrosion effect and improve the service life of the terminals; A specific implementation manner given in combination with this process; Step S1: Straightening pre-treatment Place copper cylindrical raw materials (material: C1100 or C5191, diameter Φ2mm - Φ8mm, etc.) into a straightening and bending machine, and perform dynamic straightening through multiple groups of straightening wheel sets (material: SKD11 die steel, hardness HRC58 - 60, etc.). Among them, the straightening wheel pressure is 10 - 50kN, and the straightening speed is 20 - 30m / min, so that the straightness error of the material is ≤0.1mm / m; Step S2: Double - end rounded upset forming Feed the straightened material into a multi - station automatic cold heading machine (number of stations ≥3). At the first station, apply a heading pressure of 50 - 150T to both ends of the material through a pre - heading die (material: Cr12MoV, surface TD treatment) to form an R0.5 - R2 rounded corner matrix; at the second station, use a final heading die to shape the rounded corner profile, and control the rounded corner size tolerance to be ±0.05mm; at the third station, eliminate the cold heading springback through a sizing die; Step S3: Special - shaped bending forming Transfer the material with rounded corners formed to a CNC hydraulic bending machine, and use a bending die made of DC53 steel (bending radius R0.5 - R5mm) for bending processing. The bending force is 10 - 60T. At the same time, use a laser angle sensor to monitor the bending angle in real - time, and dynamically compensate for the springback error based on the feedback data, so that the bending angle deviation is ≤±0.1°; Step S4: Integrated flattening - shaping - cutting Place the bent workpiece in a progressive die high - speed punch (punching frequency 200 - 400SPM), and complete the following steps in sequence through a three - station compound die: Flattening station: Locally flatten the workpiece using upper and lower dies made of YG15 cemented carbide (gap 0.05 - 0.1mm), and the thickness reduction rate is 30% - 50%; Shaping station: Correct the contour deformation of the workpiece through a V - shaped positioning groove and an elastic ejecting mechanism (nitrogen spring pressure 5 - 10MPa); Cutting station: Use an inclined - edge shearing blade (blade gap 0.01 - 0.03mm) to cut off the surplus material, and the burr height of the cut surface is ≤0.03mm; Finally, obtain a special - shaped terminal finished product with a dimensional tolerance of ±0.1mm; Compared with the traditional process, this process simplifies the original 6 processes into 4 processes, eliminates the "diameter expansion - diameter reduction" repeated forming link, uses a single cylindrical raw material to replace the original cylindrical + sheet - like dual - material system, and introduces a combined processing system of a straightening and bending machine + automatic machine to achieve continuous production. For this reason, the number of processes is reduced by 33%, the production cycle is shortened by about 40%, eliminates 3 material form conversion links in the traditional process, and the number of equipment switches is reduced from 5 times to 2 times; During the production of terminals, the material utilization rate has been improved compared with the traditional process. Due to the shortening of the process flow and the reduction of equipment application, the energy consumption has been reduced, and the cost of the molds used has been reduced. Different from the traditional process, the "three-stage forming system" of straightening-upsetting-bending not only improves the production efficiency but also solves the problem of low yield rate of the existing process. Finally, a multi-process composite mold (flattening+shaping+cutting integrated module) is developed. This step is not related to any previous step. Therefore, on the premise that multiple S1-S3 steps can be carried out simultaneously, it will still not affect the production efficiency of the S4 step. The improved process has more deformable ways, mainly the changes in the S1-S3 steps. At the same time, after the changed new process is combined with the S4 process, compared with S1-S4, it can significantly improve the production efficiency of terminals, and has the advantages of simple process and high yield rate; Refer to Figures 1 to 5 , which is an embodiment of the present invention. This embodiment provides a terminal, including a bridging block 100. The bridging block 100 has a first extension end 101 and a second extension end 102. The first extension end 101 is a column terminal 400 or a flat terminal 500, and the second extension end 102 is a column terminal 400 or a flat terminal 500; Such as Figure 1 The dissimilar terminals are reflected in the specific shapes of the two extension ends of the bridging block 100. According to needs, the following dissimilar terminals can be produced through the above process; Such as Figure 5 As shown, the first extension end 101 is a column terminal 400, and the second extension end 102 is a flat terminal 500, which is a type of terminal; Such as Figure 5 As shown, the first extension end 101 is a flat terminal 500, and the second extension end 102 is a column terminal 400, which is a type of terminal; Such as Figure 5 As shown, both the first extension end 101 and the second extension end 102 are column terminals 400, or both are flat terminals 500, which are two different types of terminals respectively; All four types of terminals can be manufactured through the S1-S4 steps, and there is no need to add any steps during the process. However, in the existing process during production, especially when producing four types of terminals simultaneously, the order of the steps will change and more steps will be added. At the same time, the tolerances and yield rates caused by mixed production will be further reduced. Therefore, the limitations of the existing process are obvious; Specifically, when manufacturing terminals of different shapes, the material needs to be converted between cylindrical and sheet-like forms multiple times (such as diameter expansion, diameter reduction, flattening, etc.), increasing the number of material form conversions. Specifically, the conversion of material forms results in a decrease in material utilization rate, an increase in waste, and frequent form conversions increase the equipment load and energy consumption. When mixing and producing four types of terminals, the equipment needs to be frequently switched to adapt to the processing requirements of different shapes (such as diameter expansion, diameter reduction, flattening, etc.). The number of equipment switches increases from 2 times to 5 times or more. Specifically, equipment switching leads to production interruptions, affects continuous production, increases the error rate in the process manufacturing, and when mixing and producing four types of terminals, due to complex processes and frequent equipment switching, it is easy to cause tolerance accumulation, affecting product accuracy. Specifically, the processing steps of terminals of different shapes are different, and it is difficult to control tolerances. When mixing and producing, the change in the sequence of processes before and after leads to error superposition, further reducing the yield rate. The change in the sequence of processes before and after disrupts the production rhythm, further reducing efficiency, etc.; Furthermore, the bridging block 100 can rotate 180° along the center point 103 and completely coincide. In this way, for one type of terminal, the first extension end 101 is a cylindrical terminal 400, and the second extension end 102 is a flat terminal 500. For another type of terminal, the first extension end 101 is a flat terminal 500, and the second extension end 102 is a cylindrical terminal 400. The two opposite-sex terminals of one shape of the terminal can be exactly the same. By improving the bending method, the production efficiency of this process can be further improved and the yield rate can be increased; In another embodiment; such as Figure 5 when it comes to the second terminal from top to bottom in the figure, such as Figure 1 、 Figure 3 From the corresponding positions of the unformed terminals in the S1-S2 stage; specifically, the bridging block 100 corresponds to the first connection end 100-1, the first terminal 200 corresponds to the first diameter-expanded end 200-1, and the second terminal 300 corresponds to the first un-expanded end 300-1; from the corresponding positions of the unformed terminals in the S2-S3 stage; specifically, the first connection end 100-1 corresponds to the first bent end 100-1a, the first diameter-expanded end 200-1 corresponds to the first pre-treatment end 200-1a, and the first un-expanded end 300-1 corresponds to the first fixed end 300-1a, and finally forms a terminal with the first extension end 101 being a flat terminal 500 and the second extension end 102 being a cylindrical terminal 400; Such as Figure 5 when it comes to the first terminal from top to bottom in the figure, such as Figure 1 、 Figure 4The corresponding positions of the unformed terminals from the S1-S2 stage; specifically, the bridging block 100 corresponds to the second connection end 100-2, the first terminal 200 corresponds to the second non-expanded end 200-2, and the second terminal 300 corresponds to the second expanded end 300-2; the corresponding positions of the unformed terminals from the S2-S3 stage; specifically, the second connection end 100-2 corresponds to the second bent end 100-2a, the second non-expanded end 200-2 corresponds to the second fixed end 200-2a, and the second expanded end 300-2 corresponds to the second pre-treatment end 300-2a, and finally formed into a terminal with the first extension end 101 being the column terminal 400 and the second extension end 102 being the flat terminal 500; It is worth mentioning that if the lengths of the first terminal 200 and the second terminal 300 are different, and the shapes of the connecting blocks 100 are different, separate operations of the existing process are required. However, the existing process can switch between the S1-S2 stage and the S2-S3 stage at any time to complete the preliminary forming of the two types of terminals. Subsequently, S4 can finally form the two types of terminals. From a process perspective, there is no additional item. Similarly, as Figure 5 The third and fourth terminals also have the same manufacturing principle, so it will not be elaborated here, but the existing process still needs to be realized separately; What is even more worth mentioning is that if the bridging block 100 can rotate 180° along the center point 103 and completely coincide, that is, to achieve complete rotational symmetry of the "bent end" shape in the S2 step, the faster production of the first and second or multiple terminals can be completed simultaneously. Combining this with the improved S1-S4 steps can further improve production efficiency. As for the final shape of the bent end, it only exists in the S2 step and does not affect other steps.

[0026] Importantly, it should be noted that the construction and arrangement of the present application shown in multiple different exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those who refer to this disclosure should easily understand that many modifications are possible without substantially departing from the novel teachings and advantages of the subject matter described in this application (e.g., changes in the dimensions, scales, structures, shapes and proportions of various elements, as well as parameter values (such as temperature, pressure, etc.), installation arrangements, use of materials, colors, orientations, etc.). For example, an element shown as integrally formed may be composed of multiple parts or elements, the position of the element may be inverted or otherwise changed, and the nature or number or position of discrete elements may be altered or changed. Accordingly, all such modifications are intended to be included within the scope of the present invention. The order or sequence of any process or method steps may be changed or reordered according to alternative embodiments. In the claims, any "means plus function" clauses are intended to cover the structures that perform the recited functions described herein, and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments, but extends to various modifications that still fall within the scope of the appended claims.

[0027] In addition, in order to provide a concise description of the exemplary embodiments, all features of the actual embodiments may not be described (i.e., those features that are not relevant to the currently contemplated best mode of carrying out the present invention, or those features that are not relevant to the implementation of the present invention).

[0028] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention may be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered by the scope of the claims of the present invention.

Claims

1. A production process for special-shaped terminals, characterized in that: Including the following steps; S1: Put the cylindrical raw material into a straightening and bending machine for straightening; S2: Use an automatic machine to upset the two ends of the material straightened in S1 to form rounded corners; S3: Bend the material with rounded corners in S2 to form the required bending shape; S4: Flatten, shape and cut the material bent in S3 to complete the final forming.

2. The special-shaped terminal production process according to claim 1, characterized in that: The material in step S1 is made of brass.

3. The special-shaped terminal production process according to claim 1, wherein: In step S1, the straightening process is completed by the straightening and bending machine in a continuous feeding manner.

4. The special-shaped terminal production process according to claim 1, characterized in that: It further includes step S5: Perform surface passivation treatment on the shaped terminals after cutting in step S4.

5. The special-shaped terminal production process according to claim 1, characterized in that: The whole process of this process adopts a continuous die forging method, and only one set of stamping die and one bending machine are required.

6. A terminal, characterized in that: Adopt the production process of the shaped terminal according to any one of claims 1-4; Including a bridging block (100), the bridging block (100) has a first extension end (101) and a second extension end (102), the first extension end (101) is a column terminal (400) or a flat terminal (500), and the second extension end (102) is a column terminal (400) or a flat terminal (500).

7. The terminal according to claim 6, characterized in that: The first extension end (101) is a column terminal (400), and the second extension end (102) is a flat terminal (500).

8. The terminal according to claim 7, characterized in that: The first extension end (101) is a flat terminal (500), and the second extension end (102) is a column terminal (400).

9. The terminal according to claim 7 or 8, characterized in that: Both the first extension end (101) and the second extension end (102) are column terminals (400), or both are flat terminals (500).

10. The terminal according to claim 1, characterized in that: The bridging block (100) can rotate 180° along the center point (103) and completely coincide.

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