Forming production process of integrated rear axle housing

Abstract

The invention discloses a forming production process of an integrated rear axle housing, which comprises the following steps of: 1, selecting a seamless steel tube as a raw material, and placing a driving coil in the seamless steel tube to provide electromagnetic force for forming; secondly, the seamless steel pipe with the drive coil is placed in a mold, and the drive coil is connected with electric appliance control equipment for electromagnetic forming; thirdly, the mold is started, primary electromagnetic forming is conducted after the upper mold and the lower mold are closed, and then a semi-finished product is obtained; according to the forming production process of the integrated rear axle housing, the electromagnetic forming technology is used for replacing an internal high-pressure forming mode, the investment cost for producing the integrated rear axle housing is effectively reduced, the production benefit is improved, meanwhile, only the forming procedure is needed for electromagnetic forming, and therefore the investment cost of equipment and molds is effectively reduced, and the production efficiency is improved. And electromagnetic forming also belongs to a high-strain forming process scheme, so that the formability of the material can be greatly improved, and the cracking problem of the integrated rear axle housing is effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile parts processing, in particular to a forming production process for an integrated rear axle housing. Background Art

[0002] As we all know, the rear axle housing is a protective cover on the rear axle of a car. Its main function is to support and protect the rear axle and its internal parts, such as the main reducer, differential, half-axles, etc.; the rear axle housing also plays a role in dustproof, waterproof and noise reduction. At the same time, it is also a supporting and containing part for components such as the main reducer, differential, half-axles, etc. The shell is filled with lubricating oil to lubricate gears, bearings, etc. The sealed shell can prevent dirt from invading and damaging the working environment of the internal components of the shell; in addition, the rear axle housing also bears the reaction force and reaction torque of the traction, braking force, lateral force, vertical force transmitted by the wheels, and transmits them to the frame or body through the suspension.

[0003] The current rear axle housings on the market are made of multiple pieces welded together, which are commonly prone to problems such as weld cracking and oil leakage. They also have disadvantages such as heavy weight and high cost. In the past two years, the market has introduced a new one-piece rear axle housing that solves the problems of weld cracking and oil leakage. Compared with traditional rear axle housings, it has the advantages of low part cost, low weight, and high strength. However, the one-piece rear axle housing adopts the internal high pressure forming process, and there are still many difficulties to overcome in the production process. The main difficulties are as follows:

[0004] 1. The depth of the shape forming far exceeds the material limit, which makes it easy to crack and extremely difficult to form;

[0005] 2. The forming process is complicated and requires multiple forming and annealing;

[0006] 3. The equipment investment cost is high.

[0007] To this end, we propose a forming production process for an integrated rear axle housing.

[0008] The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art. Summary of the Invention

[0009] The purpose of the present invention is to provide a forming production process for an integrated rear axle housing to solve the problems raised in the above background technology.

[0010] To achieve the above-mentioned object, the present invention provides the following technical solution: a forming production process of an integrated rear axle housing, comprising the following steps:

[0011] Step 1: Select seamless steel pipe as raw material and place a driving coil inside the seamless steel pipe to provide electromagnetic force for forming;

[0012] Step 2: Place the seamless steel pipe with the driving coil into the mold, and connect the driving coil to the electrical control device of the electromagnetic forming;

[0013] Step 3: Start the mold, close the upper mold and the lower mold, and then perform the first electromagnetic forming to obtain a semi-finished product;

[0014] Step 4: Take out the semi-finished driving coil obtained in step 3, cut a hole in the semi-finished product by laser, and rearrange the driving coil;

[0015] Step 5: Place the first-order semi-finished product into another mold, connect the drive coil to the electrical control device of electromagnetic forming, and perform a second electromagnetic forming after the upper and lower molds are closed to obtain the final semi-finished product.

[0016] Preferably, in steps 1 to 5, the essence of the electromagnetic forming system is a production application of Lenz's law and Faraday's law of electromagnetic induction, which mainly utilizes the high-speed movement of a current-carrying conductor under the action of the Lorentz force in a magnetic field to perform forming.

[0017] Preferably, the electromagnetic forming system is mainly composed of a high-voltage power supply system, an energy storage system, a discharge circuit and a control system.

[0018] Preferably, in steps one to five, the main principle of electromagnetic forming is that the high-voltage power supply system charges the capacitor, and disconnects the charging switch after charging is completed; the discharge circuit switch is instantaneously closed, and the energy storage system will instantly release electrical energy to the discharge circuit, and a high-frequency and high-intensity pulse current will be generated in the working coil in the discharge circuit. The high-frequency and high-intensity pulse current generates a strong magnetic field. According to Faraday's law of electromagnetic induction, the metal blank will move at a high speed away from the coil under the action of the strong magnetic field force given by the induced magnetic field and undergo plastic forming.

[0019] Preferably, the instantaneous speed of electromagnetic forming of the sheet material can reach over 100 meters per second, and the entire forming process can be completed within milliseconds.

[0020] Preferably, in step five, the final semi-finished product needs to be cut, cleaned, and subjected to rust prevention treatment to obtain the final integrated rear axle housing.

[0021] In summary, this application includes at least one of the following beneficial technical effects:

[0022] The forming production process of this integrated rear axle housing uses electromagnetic forming technology instead of internal high-pressure forming, which effectively reduces the investment cost of producing the integrated rear axle housing and improves production efficiency. At the same time, electromagnetic forming not only only requires a forming process, thereby effectively reducing the investment cost of equipment and molds, but also electromagnetic forming is also a high-strain forming process solution, which can greatly improve the formability of the material, thereby effectively solving the cracking problem of the integrated rear axle housing and improving its production yield. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 Schematic diagram of the principle of the forming production process of the integrated rear axle housing of the present invention;

[0024] Figure 2 Schematic diagram of the electromagnetic forming process in the forming production process of the integrated rear axle housing of the present invention;

[0025] Figure 3 Schematic diagram of a seamless steel tube and a drive coil in the forming and production process of an integrated rear axle housing of the present invention;

[0026] Figure 4 Schematic diagram of the upper mold and the lower mold in the forming production process of the integrated rear axle housing of the present invention;

[0027] Figure 5 Schematic diagram of the first electromagnetic forming in the forming production process of the integrated rear axle housing of the present invention;

[0028] Figure 6 Schematic diagram of laser cutting holes and drive coils in the forming and production process of the integrated rear axle housing of the present invention;

[0029] Figure 7 A schematic diagram of an electrical control device in the forming and production process of an integrated rear axle housing of the present invention;

[0030] Figure 8 Schematic diagram of the second electromagnetic forming in the forming production process of the integrated rear axle housing of the present invention.

[0031] In the figure: 1. Driving coil and current; 2. Strong magnetic field; 3. Induced current; 4. Induced magnetic field; 5. Magnetic field force; 6. Metal conductor blank. DETAILED DESCRIPTION

[0032] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not 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 efforts are within the scope of protection of the present invention.

[0033] See also Figures 1-8 The present invention provides a technical solution: a forming production process of an integrated rear axle housing, characterized in that it includes the following steps:

[0034] Step 1: Select seamless steel pipe as raw material and place a driving coil inside the seamless steel pipe to provide electromagnetic force for forming;

[0035] Step 2: Place the seamless steel pipe with the driving coil into the mold, and connect the driving coil to the electrical control device of the electromagnetic forming;

[0036] Step 3: Start the mold, close the upper mold and the lower mold, and then perform the first electromagnetic forming to obtain a semi-finished product;

[0037] Step 4: Take out the semi-finished driving coil obtained in step 3, cut a hole in the semi-finished product by laser, and rearrange the driving coil;

[0038] Step 5: Place the first-order semi-finished product into another mold, connect the drive coil to the electrical control device of electromagnetic forming, and perform a second electromagnetic forming after the upper and lower molds are closed to obtain the final semi-finished product.

[0039] In one embodiment, the essence of the electromagnetic forming system is a production application of Lenz's law and Faraday's law of electromagnetic induction. It mainly uses the high-speed movement of current-carrying conductors under the action of the Lorentz force in a magnetic field to perform forming. The electromagnetic forming system is mainly composed of a high-voltage power supply system, an energy storage system, a discharge circuit and a control system.

[0040] In one embodiment, the main principle of electromagnetic forming is that the high-voltage power supply system charges the capacitor, and after charging is completed, the charging switch is disconnected; the discharge circuit switch is instantaneously closed, and the energy storage system will instantly release electrical energy to the discharge circuit. A high-frequency, high-intensity pulse current 1 will be generated in the working coil in the discharge circuit. The high-frequency, high-intensity pulse current 1 generates a strong magnetic field 2. According to Faraday's law of electromagnetic induction, at this time, the metal blank 6 will move at high speed away from the coil under the action of the strong magnetic field force 5 given by the induced magnetic field 4 and undergo plastic forming.

[0041] In one embodiment, the instantaneous speed of electromagnetic forming of the sheet material can reach over 100 meters per second, and the entire forming process can be completed within milliseconds.

[0042] It should be noted that in step five, the final semi-finished product needs to be cut, cleaned, and subjected to rust-proofing treatment to obtain the final integrated rear axle housing.

[0043] In summary: The forming production process of the integrated rear axle housing uses electromagnetic forming technology instead of internal high-pressure forming, which effectively reduces the investment cost of producing the integrated rear axle housing and improves production efficiency. At the same time, electromagnetic forming not only only requires a forming process, thereby effectively reducing the investment cost of equipment and molds, but also electromagnetic forming is also a high-strain forming process solution, which can greatly improve the formability of the material, thereby effectively solving the cracking problem of the integrated rear axle housing and improving its production yield.

[0044] Parts not described in the present invention are the same as those in the prior art or can be implemented using the prior art. Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. The forming production process of the integrated rear axle housing is characterized by: The following steps are involved: Step 1: Select seamless steel pipe as raw material and place a driving coil inside the seamless steel pipe to provide electromagnetic force for forming; Step 2: Place the seamless steel pipe with the driving coil into the mold, and connect the driving coil to the electrical control device of the electromagnetic forming; Step 3: Start the mold, close the upper mold and the lower mold, and then perform the first electromagnetic forming to obtain a semi-finished product; Step 4: Take out the semi-finished driving coil obtained in step 3, cut a hole in the semi-finished product by laser, and rearrange the driving coil; Step 5: Place the first-order semi-finished product into another mold, connect the drive coil to the electrical control device of electromagnetic forming, and perform a second electromagnetic forming after the upper and lower molds are closed to obtain the final semi-finished product.

2. The forming and production process of the integrated rear axle housing according to claim 1, characterized in that: In steps one to five, the essence of the electromagnetic forming system is a production application of Lenz's law and Faraday's law of electromagnetic induction, which mainly utilizes the high-speed movement of current-carrying conductors under the action of the Lorentz force in a magnetic field to achieve forming.

3. The forming and production process of the integrated rear axle housing according to claim 2, characterized in that: The electromagnetic forming system mainly consists of a high-voltage power supply system, an energy storage system, a discharge circuit and a control system.

4. The forming and production process of the integrated rear axle housing according to claim 1, characterized in that: In steps 1 to 5, the main principle of electromagnetic forming is that the high-voltage power supply system charges the capacitor, and after charging is completed, the charging switch is disconnected; the discharge circuit switch is instantly closed, and the energy storage system will instantly release electrical energy to the discharge circuit. A high-frequency, high-intensity pulse current (1) will be generated in the working coil in the discharge circuit. The high-frequency, high-intensity pulse current (1) generates a strong magnetic field (2). According to Faraday's law of electromagnetic induction, at this time, the metal blank (6) will move at high speed away from the coil under the action of the strong magnetic field force (5) given by the induced magnetic field (4) to undergo plastic forming.

5. The forming and production process of the integrated rear axle housing according to claim 4, characterized in that: The instantaneous speed of electromagnetic forming of sheet metal can reach over 100 meters per second, and the entire forming process can be completed within milliseconds.

6. The forming and production process of the integrated rear axle housing according to claim 1, characterized in that: In step five, the final semi-finished product needs to be cut, cleaned, and subjected to rust prevention treatment to obtain the final integrated rear axle housing.

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