Driving gear precision cold extrusion tool and forming process

Abstract

The invention relates to the technical field of gear manufacturing, in particular to a precise cold extrusion tool and forming process for a driving gear, after a blank is in place, a cooperative control module issues optimal parameters, and a lubrication module instantaneously sprays a water-based lubricant in a pulse mode to cover a cavity; and the synchronous compensation module samples temperature and displacement at 1kHz, and corrects servo feed within 20ms when the deviation exceeds a threshold value. The cooling module circulates the nano medium, maintains the temperature difference of the die cavity to be less than or equal to 3 DEG C and transmits temperature data back to the compensation module in real time to correct thermal expansion. And after extrusion is completed, hydraulic buffering and constant-speed demolding are conducted, and the noise reduction and dust suppression module absorbs impact noise smaller than or equal to 75 dB and recovers 98% of atomized lubricant. And the whole-process data uploading process optimization module performs self-learning to update parameters, so that a closed loop is formed, and high-precision, long-life, low-noise and dust-free cold extrusion continuous production of the driving gear is realized. Therefore, the problem that tooth profile filling is incomplete due to uneven lubrication, temperature control lag and compensation deficiency in an existing cold extrusion process is solved.

Description

Technical Field

[0001] This invention relates to the field of gear manufacturing technology, and in particular to a precision cold extrusion tooling and forming process for drive gears. Background Technology

[0002] The high power density transmission system of new energy vehicles requires the drive gear to be "net-shape, cutting-free, and JIS2 level precision". The traditional hot forging-machining route has a material utilization rate of less than 65%, and the tooth profile accuracy depends on subsequent shaving and grinding, which results in high energy consumption and high dust and noise.

[0003] Existing cold extrusion tooling still uses graphite lubrication, linear cooling, and rigid integral molds, resulting in insufficient tooth root filling, large temperature gradient in the mold cavity, early tooth breakage in the mold, and graphite dust and 100dB noise seriously restrict green manufacturing. Summary of the Invention

[0004] The purpose of this invention is to provide a precision cold extrusion tooling and forming process for drive gears, which aims to solve the problem of incomplete tooth profile filling caused by uneven lubrication, delayed temperature control, and lack of compensation in existing cold extrusion processes.

[0005] To achieve the above objectives, in a first aspect, the present invention provides a precision cold extrusion fixture for active gears, comprising a lubrication module, a compensation module, a cooling module, a noise reduction and dust suppression module, a die module, a collaborative control module, and a process optimization module; the die module and the collaborative control module are respectively connected to the lubrication module and respectively connected to the compensation module; the cooling module is respectively connected to the die module and the compensation module; the collaborative control module is respectively connected to the cooling module, the die module, and the process optimization module; The lubrication module is used to improve the friction between the die and the material during cold extrusion. The compensation module is used to monitor the mold cavity temperature and billet compression displacement in real time, and dynamically adjust the extrusion parameters based on the monitoring data. The cooling module is used to precisely control the temperature field distribution of the mold and suppress thermal expansion; The noise reduction and dust suppression module is used to reduce noise in the production environment and control dust pollution. The mold module is used to provide a high-rigidity support and wear-resistant extrusion molding base; The collaborative control module is used to realize information interaction and efficient linkage between various modules; The process optimization module is used for data-driven real-time process parameter optimization.

[0006] The lubrication module includes a lubricant storage unit, a pulse injection unit, and an injection control unit. The lubricant storage unit is used to store water-based polymeric lubricants; The pulse injection unit is used to precisely inject lubricating microdroplets before extrusion; The injection control unit adjusts the injection timing and dosage in real time based on the extrusion process.

[0007] The compensation module includes a temperature monitoring unit, a displacement monitoring unit, a fuzzy PID control unit, and a servo adjustment unit. The temperature monitoring unit is used to collect mold cavity temperature data in real time; The displacement monitoring unit is used to measure the compression of the billet using a laser displacement sensor; The fuzzy PID control unit is used to perform calculations and processing on the monitoring data; The drive servo adjustment unit is used to dynamically control the feed speed of the extrusion cylinder.

[0008] The cooling module includes a cooling channel unit, a cooling circulation unit, and a temperature gradient control unit. The cooling channel unit is used to conform to the mold cavity to construct a cooling channel; The cooling circulation unit is responsible for efficiently delivering the cooling medium; The temperature gradient control unit is used to ensure that the surface temperature of the mold cavity fluctuates within ±3℃.

[0009] The noise reduction and dust suppression module includes a composite sound-absorbing material unit, a hydraulic buffer unit, a water-based lubrication unit, and an atomization recovery unit. The composite sound-absorbing material unit is used to absorb high-frequency noise generated by internal impact and mechanical friction of the press. The hydraulic buffer unit is used to provide reverse damping force at the moment of demolding, reduce the impact of gear-mold separation, suppress secondary noise and prevent tooth surface damage; The water-based lubrication unit is used to replace traditional graphite lubricants and reduce the coefficient of friction between the mold and the workpiece. The atomization recovery unit is used to capture and circulate water-based lubricating microdroplets.

[0010] The mold module includes a base unit, a toothed insert unit, and a hydraulic interference fit assembly unit. The base unit is used to provide high rigidity support; The tooth-shaped insert unit is used to directly form the tooth profile of the drive gear, ensuring the stability of the tooth surface dimensions and roughness.

[0011] The hydraulic interference fit assembly unit is used to assemble the toothed insert unit onto the base through hydraulic interference fit.

[0012] Secondly, a forming process for a precision cold extrusion tooling for a drive gear, used in the precision cold extrusion tooling for a drive gear described in the first aspect, includes the following steps: The pre-treated gear blank is heated to a set temperature range; The lubrication module precisely sprays lubricating microdroplets at key locations within the mold cavity; After the blank is placed into the mold, the compensation module monitors the mold cavity temperature and blank compression displacement in real time, and dynamically adjusts the extrusion parameters based on the fuzzy PID control algorithm. Start the cold extrusion equipment and extrude the material using the optimized process parameters, while simultaneously activating the cooling module; After molding, the gears are demolded in a noise-reducing and dust-suppressing environment, and an automatic collection system recovers the atomized lubricant. The finished gears are subjected to dimensional inspection and performance testing, and the process parameters are further optimized based on the data feedback.

[0013] This invention discloses a precision cold extrusion fixture for active gears. After the blank is positioned, the collaborative control module issues optimal parameters, and the lubrication module instantaneously pulses and sprays water-based lubricant to cover the cavity. The synchronous compensation module samples temperature and displacement at 1kHz, correcting the servo feed within 20ms if the deviation exceeds a threshold. The cooling module circulates nano-medium to maintain a cavity temperature difference ≤3℃ and transmits the temperature data back to the compensation module in real time to correct for thermal expansion. After extrusion, hydraulic buffering and uniform demolding occur, and the noise reduction and dust suppression module absorbs impact noise ≤75dB and recovers 98% of the atomized lubricant. The entire process data is uploaded to the process optimization module for self-learning and parameter updates, forming a closed loop to achieve high-precision, long-life, low-noise, and dust-free continuous production of active gear cold extrusion. This solves the problems of incomplete tooth filling caused by uneven lubrication, delayed temperature control, and lack of compensation in existing cold extrusion processes. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of a precision cold extrusion fixture for drive gears provided by the present invention.

[0016] Figure 2 This is a schematic diagram of the lubrication module.

[0017] Figure 3 This is a schematic diagram of the compensation module.

[0018] Figure 4 This is a schematic diagram of the cooling module.

[0019] Figure 5 This is a schematic diagram of the noise reduction and dust suppression module.

[0020] Figure 6 This is a schematic diagram of the mold module.

[0021] Figure 7 This is a schematic diagram of the collaborative control module.

[0022] Figure 8 This is a schematic diagram of the process optimization module.

[0023] Figure 9 This is a flowchart of the forming process of a precision cold extrusion tooling for active gears provided by the present invention.

[0024] In the diagram: 1-Lubrication module, 2-Compensation module, 3-Cooling module, 4-Noise reduction and dust suppression module, 5-Mold module, 6-Collaborative control module, 7-Process optimization module, 11-Lubricant storage unit, 12-Pulse injection unit, 13-Injection control unit, 21-Temperature monitoring unit, 22-Displacement monitoring unit, 23-Fuzzy PID control unit, 24-Servo adjustment unit, 31-Cooling channel unit, 32-Cooling circulation unit, 33-Temperature gradient control unit, 41-Composite sound-absorbing material unit, 42-Hydraulic buffer unit, 43-Water-based lubrication unit, 44-Atomization recovery unit, 51-Base unit, 52-Toothed insert unit, 53-Hydraulic interference fit assembly unit, 61-Control unit, 62-Sensor network unit, 63-Modular software unit, 71-Predictive model unit, 72-Parameter optimization unit, 73-Adjustment execution unit. Detailed Implementation

[0025] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0026] Please see Figures 1 to 8 In a first aspect, the present invention provides a precision cold extrusion fixture for active gears, comprising a lubrication module 1, a compensation module 2, a cooling module 3, a noise reduction and dust suppression module 4, a mold module 5, a collaborative control module 6, and a process optimization module 7; the mold module 5 and the collaborative control module 6 are respectively connected to the lubrication module 1 and the compensation module 2; the cooling module 3 is respectively connected to the mold module 5 and the compensation module 2; the collaborative control module 6 is respectively connected to the cooling module 3, the mold module 5, and the process optimization module 7. The lubrication module 1 is used to improve the friction between the die and the material during cold extrusion. The compensation module 2 is used to monitor the mold cavity temperature and billet compression displacement in real time, and dynamically adjust the extrusion parameters based on the monitoring data; The cooling module 3 is used to precisely control the temperature field distribution of the mold and suppress thermal expansion; The noise reduction and dust suppression module 4 is used to reduce noise in the production environment and control dust pollution. The mold module 5 is used to provide a high-rigidity support and wear-resistant extrusion molding base; The collaborative control module 6 is used to realize information interaction and efficient linkage between various modules; The process optimization module 7 is used for data-driven real-time process parameter optimization.

[0027] In this embodiment, after the blank is positioned, the collaborative control module 6 issues optimal parameters, and the lubrication module 1 instantaneously pulses and sprays water-based lubricant to cover the cavity; the synchronous compensation module 2 samples temperature and displacement at 1kHz, and corrects the servo feed within 20ms when the deviation exceeds the threshold. The cooling module 3 circulates nano-medium to maintain the temperature difference in the mold cavity ≤3℃ and transmits the temperature data back to the compensation module 2 in real time to correct for thermal expansion. After extrusion, hydraulic buffering and uniform demolding are performed, and the noise reduction and dust suppression module 4 operates independently, absorbing impact noise ≤75dB and recovering 98% of the atomized lubricant. The entire process data is uploaded to the process optimization module 7, which self-learns and updates parameters to form a closed loop, realizing high-precision, long-life, low-noise, and dust-free continuous production of active gear cold extrusion. This solves the problem of incomplete tooth filling caused by uneven lubrication, delayed temperature control, and lack of compensation in existing cold extrusion processes.

[0028] Furthermore, the lubrication module 1 includes a lubricant storage unit 11, a pulse injection unit 12, and an injection control unit 13; The lubricant storage unit 11 is used to store water-based polymer lubricant; The pulse injection unit 12 is used to precisely inject lubricating microdroplets before extrusion; The injection control unit 13 adjusts the injection timing and dosage in real time based on the extrusion process.

[0029] In this embodiment, the lubricant storage unit 11 is used to store water-based polymer lubricant. The tank is made of 316L stainless steel and is equipped with a 0.2μm filter and nitrogen pressure stabilization at 0.3MPa to prevent lubricant stratification and oxidation. The pulse injection unit 12 is used to precisely inject lubricant droplets into the tooth root and tooth tip in a pulse format of 0.1-0.3mL and 50ms before extrusion via a piezoelectric microvalve. The injection angle is 30° and the coverage area is ≥95%. The injection control unit 13 is used to read the "extrusion start" signal from the collaborative control module 6 in real time, trigger the microvalve 80ms in advance, and automatically correct the injection volume by ±10% based on the mold temperature feedback to ensure a lubricant film thickness of 0.8-1.2μm.

[0030] Furthermore, the compensation module 2 includes a temperature monitoring unit 21, a displacement monitoring unit 22, a fuzzy PID control unit 23, and a servo adjustment unit 24; The temperature monitoring unit 21 is used to collect mold cavity temperature data in real time; The displacement monitoring unit 22 is used to measure the compression amount of the billet using a laser displacement sensor; The fuzzy PID control unit 23 is used to perform calculations on the monitoring data; The drive servo adjustment unit 24 is used to dynamically control the feed speed of the extrusion cylinder.

[0031] In this embodiment, the temperature monitoring unit 21 is used to collect the mold cavity temperature at a frequency of 1kHz using a K-type thermocouple embedded 1mm into the toothed insert. The data is then converted by a 24-bit ADC and uploaded in real time via RS-485. The displacement monitoring unit 22 is used to measure the axial compression of the billet using a laser displacement sensor (±0.5μm repeatability accuracy) at a sampling frequency of 2kHz. The data is then sent to the fuzzy PID control unit 23 after being aligned with the temperature timestamp. The fuzzy PID control unit 23 is used to input the temperature-displacement two-dimensional error into the membership function and output the extrusion speed correction Δv. The proportional, integral, and differential factors are self-tuned online with a calculation cycle of 10ms. The servo adjustment unit 24 is used to receive Δv and drive the press servo motor to continuously change speed within the range of ±5mm / s, so that the dimensional deviation is kept within ±0.01mm and the closed-loop response time is ≤20ms.

[0032] Furthermore, the cooling module 3 includes a cooling channel unit 31, a cooling circulation unit 32, and a temperature gradient control unit 33; The cooling channel unit 31 is used to conform to the mold cavity to construct a cooling channel; The cooling circulation unit 32 is responsible for efficiently transporting the cooling medium; The temperature gradient control unit 33 is used to ensure that the surface temperature of the mold cavity fluctuates within ±3℃.

[0033] In this embodiment, the cooling channel unit 31 is used to create conformal channels inside the mold using 3D printing SLM technology. The channel is 3-5 mm from the cavity surface, with a cross-sectional diameter of 3 mm and a curvature that follows the tooth shape, reducing the hot spot temperature by 10-15℃. The cooling circulation unit 32 is used to deliver a nano-Al2O3-ethylene glycol aqueous solution (10wt%) at a flow rate of 4L / min via a magnetically coupled gear pump. The inlet temperature is set to 20℃, and the outlet temperature is ≤30℃. The circulation loop is equipped with a 0.1mm online filter. The temperature gradient control unit 33 is used to compare the measured temperature of the thermocouple array with the set value and change the coolant flow rate by adjusting the opening of the proportional valve through PID control, so that the temperature gradient of the mold cavity surface is ±3℃, suppressing tooth pitch drift caused by thermal expansion.

[0034] Furthermore, the noise reduction and dust suppression module 4 includes a composite sound-absorbing material unit 41, a hydraulic buffer unit 42, a water-based lubrication unit 43, and an atomization recovery unit 44; The composite sound-absorbing material unit 41 is used to absorb high-frequency noise generated by internal impact and mechanical friction of the press. The hydraulic buffer unit 42 is used to provide reverse damping force at the moment of demolding, reduce the impact of gear-mold separation, suppress secondary noise and prevent tooth surface damage; The water-based lubrication unit 43 is used to replace traditional graphite lubricant and reduce the friction coefficient between the mold and the workpiece. The atomization recovery unit 44 is used to capture and circulate water-based lubricating microdroplets.

[0035] In this embodiment, the composite sound-absorbing material unit 41 is used to attach a polyester fiber-aluminum honeycomb three-layer structure (thickness 30mm) to the inner wall of the housing, with a sound absorption coefficient ≥0.85 in the 500-2000Hz frequency band, reducing airborne noise by 8-10dB; the hydraulic buffer unit 42 is used to connect a proportional overflow valve in the return oil line of the demolding cylinder, releasing oil pressure according to a preset ramp curve, reducing the ejection speed from 0.5m / s to 0.1m / s, reducing impact noise and the risk of tooth surface damage; the water-based lubrication unit 43 is used to supply water-based lubricant to the pulse jet unit 12 at a pressure of 0.2MPa through a diaphragm pump, with a flow rate adjustable from 0-10mL / min, completely eliminating the graphite dust source; the atomization recovery unit 44 is used to form a -200Pa negative pressure zone below the nozzle, and after two-stage recovery by cyclone separation and electrostatic collection, the 0.3μm particle collection efficiency is ≥98%, the lubricant reuse rate is ≥95%, and zero external discharge is achieved.

[0036] Furthermore, the mold module 5 includes a base unit 51, a toothed insert unit 52, and a hydraulic interference fit assembly unit 53; The base unit 51 is used to provide high rigidity support; The tooth-shaped insert unit 52 is used to directly form the tooth profile of the drive gear, ensuring the stability of the tooth surface dimensions and roughness.

[0037] The hydraulic interference fit assembly unit 53 is used to assemble the toothed insert unit 52 onto the base through hydraulic interference fit.

[0038] In this embodiment, the base unit 51 is made of pre-hardened H13 steel (HRC48-52) and integrally quenched. The bottom is machined with a cooling channel interface and a sensor wiring groove. It can withstand an extrusion pressure ≥2000kN and a deformation ≤0.02mm. The toothed insert unit 52 is made of WC-Co hard alloy powder metallurgy. After the tooth surface is finely ground, it is coated with TiAlN. The hardness is HV1200-1400 and the roughness Ra≤0.2μm to ensure the gear tooth profile accuracy and wear resistance. The hydraulic interference fitting unit 53 is used to inject high-pressure oil (pressure 30-50MPa) into the sealed oil cavity between the outer wall of the insert and the hole wall of the base through a manual pump. This causes the base to expand elastically by 0.05-0.08mm. After the insert slides into place easily, the pressure is released, forming an interference of 0.04mm. The assembly time is shortened from 30min to 3min, and it can be repeatedly disassembled and assembled without damaging the mating surfaces.

[0039] Furthermore, the collaborative control module 6 includes a control unit 61, a sensor network unit 62, and a modular software unit 63; The control unit 61 is used to summarize the sensor data of each module in real time and issue the calculated control commands. The sensor network unit 62 is used to deploy thermocouples, pressure and displacement sensors at key points of lubrication, mold and cooling, collect temperature-load-position signals and transmit them back to the control unit 61. The modular software unit 63 is used to encapsulate various functional algorithms to achieve data exchange between cooling and compensation, linkage between lubrication and process parameters, and rapid iterative upgrades.

[0040] In this embodiment, the control unit 61 uses a TwinCAT real-time PLC with a cycle of 1ms. It aggregates temperature, pressure, displacement, and liquid level signals via the EtherCAT bus and sends out PID / fuzzy calculation results to achieve microsecond-level synchronization among modules. The sensor network unit 62 is used to arrange 20 thermocouples, 4 pressure sensors, and 2 laser displacement sensors at key locations such as lubrication nozzles, cooling channel inlets and outlets, and mold cavities, forming a star topology. The sampling frequency is uniformly 2kHz, and the data packet loss rate is <0.01%. The modular software unit 63 uses an object-oriented approach to encapsulate lubrication, cooling, compensation, and optimization algorithms into independent FB function blocks, supports online hot updates, and interfaces with MES via OPCUA to achieve rapid iteration and remote maintenance of process versions.

[0041] Furthermore, the process optimization module 7 includes a prediction model unit 71, a parameter optimization unit 72, and an adjustment execution unit 73; The prediction model unit 71 is used to train a machine learning model based on historical extrusion data and output predicted values ​​of size deviation and load fluctuation in advance. The parameter optimization unit 72 is used to receive the predicted values ​​and calculate the optimal combination of extrusion speed, lubricant dosage, and die preheating temperature using the response surface methodology. The adjustment execution unit 73 is used to write the optimized parameters into the collaborative control module 6 in real time, drive the servo press, lubrication nozzle and cooling pump to adjust synchronously, and complete the closed-loop optimization.

[0042] In this embodiment, the prediction model unit 71 is used to build an LSTM network based on Python-TensorFlow. Inputting the temperature, pressure, displacement, and lubrication data of the first 50 pieces, it predicts the pitch deviation and maximum extrusion force of the next piece after training, with a prediction accuracy R² ≥ 0.92. The parameter optimization unit 72 uses the Box-Behnken response surface methodology, with the prediction deviation as a constraint and extrusion speed, lubrication dosage, and die preheating temperature as variables, to solve for the optimal parameter combination that minimizes the deviation and shortens the cycle time, with optimization time < 2 seconds. The adjustment execution unit 73 writes the optimization results to the collaborative control module 6 in real time via the EtherCAT bus, automatically updating the lubrication pulse width, servo speed setpoint, and cooling PID parameters. After closed-loop adjustment, the first piece dimension enters the tolerance zone, reducing trial production scrap by 90%. Please see Figure 9 Secondly, a forming process for a precision cold extrusion tooling for an active gear, used in the precision cold extrusion tooling for an active gear described in the first aspect, includes the following steps: S1 heats the pre-treated gear blank to a set temperature range; Specifically, an electromagnetic induction heating coil is used to rapidly heat the 20CrMnTi blank at a power of 50kHz / 30kW. An infrared thermometer is used for closed-loop temperature control. The target temperature is 180±5℃, and the heating time is 35s. After reaching the temperature, the blank is transferred to the mold within 3s to prevent sudden changes in flow stress caused by temperature drop.

[0043] S2 lubrication module 1 precisely sprays lubricating microdroplets at key locations in the mold cavity; Specifically, after receiving the "blank in place" signal, the injection control unit 13 drives the piezoelectric microvalve to spray water-based lubricant in a 30° fan shape with 0.15mL and 60ms pulses to the tooth root and tooth tip, covering an area of ​​≥95%. Within 50ms after spraying, the mold is installed to ensure that the lubricating film thickness is 0.8-1.2μm and is not dry.

[0044] After the S3 blank is placed into the mold, the compensation module 2 monitors the mold cavity temperature and blank compression displacement in real time, and dynamically adjusts the extrusion parameters based on the fuzzy PID control algorithm. Specifically, the K-type thermocouple and the laser displacement sensor collect temperature and compression at 1kHz and 2kHz respectively. The data is sent to the PLC for fuzzy PID calculation, and the speed correction amount Δv is output every 10ms. The servo motor is steplessly adjusted within the range of ±5mm / s according to Δv, so that the dimensional deviation is always ≤0.01mm.

[0045] S4 starts the cold extrusion equipment and performs extrusion molding with optimized process parameters, while cooling module 3 is turned on simultaneously; Specifically, the collaborative control module 6 calls upon the process optimization results: extrusion speed 15mm / s, pressure 1200kN, magnetic coupling pump delivers 20℃ nano-cooling liquid at 4L / min, conformal flow channel maintains a temperature gradient of ±3℃ on the mold cavity surface, coolant outlet temperature ≤30℃, and the entire extrusion cycle is completed within 2.5s.

[0046] After S5 molding, the gears are demolded in a noise-reducing and dust-suppressing environment, and the automatic collection system recovers the atomized lubricant. Specifically, the hydraulic buffer cylinder pushes out at a uniform speed of 0.1 m / s, and the composite sound-absorbing lining reduces the noise to 78 dB; the annular negative pressure hood starts immediately, with a wind speed of 12 m / s, and 98% of the atomized droplets are recovered in two stages of cyclone + electrostatic, and then pumped back to the lubricant storage tank after being filtered by a 0.1 μm filter element, achieving zero external discharge.

[0047] S6 performs dimensional inspection and performance testing on the finished gears, and further optimizes process parameters based on data feedback.

[0048] Specifically, the coordinate measuring machine randomly checks the tooth pitch and tooth profile errors, and the data is automatically uploaded to the MES; the LSTM model is retrained with the measured deviation, the response surface methodology refreshes the optimal parameters within 2 seconds and sends them to the PLC via EtherCAT, and the updated values ​​are used in the next cycle to continuously compress the tolerance zone, reducing the scrap rate of the trial production by 90%.

[0049] The above-disclosed embodiments are merely preferred embodiments of the precision cold extrusion tooling and forming process for drive gears according to the present invention. Of course, they should not be construed as limiting the scope of the present invention. Those skilled in the art can understand that all or part of the processes of the above embodiments can be implemented, and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A precision cold extrusion fixture for a drive gear, characterized in that, It includes a lubrication module, a compensation module, a cooling module, a noise reduction and dust suppression module, a mold module, a collaborative control module, and a process optimization module; the mold module and the collaborative control module are respectively connected to the lubrication module and the compensation module; the cooling module is connected to both the mold module and the compensation module; the collaborative control module is connected to the cooling module, the mold module, and the process optimization module. The lubrication module is used to improve the friction between the die and the material during cold extrusion. The compensation module is used to monitor the mold cavity temperature and billet compression displacement in real time, and dynamically adjust the extrusion parameters based on the monitoring data. The cooling module is used to precisely control the temperature field distribution of the mold and suppress thermal expansion; The noise reduction and dust suppression module is used to reduce noise in the production environment and control dust pollution. The mold module is used to provide a high-rigidity support and wear-resistant extrusion molding base; The collaborative control module is used to realize information interaction and efficient linkage between various modules; The process optimization module is used for data-driven real-time process parameter optimization.

2. The precision cold extrusion tooling for the drive gear as described in claim 1, characterized in that, The lubrication module includes a lubricant storage unit, a pulse injection unit, and an injection control unit; The lubricant storage unit is used to store water-based polymeric lubricants; The pulse injection unit is used to precisely inject lubricating microdroplets before extrusion; The injection control unit adjusts the injection timing and dosage in real time based on the extrusion process.

3. The precision cold extrusion tooling for the drive gear as described in claim 1, characterized in that, The compensation module includes a temperature monitoring unit, a displacement monitoring unit, a fuzzy PID control unit, and a servo adjustment unit; The temperature monitoring unit is used to collect mold cavity temperature data in real time; The displacement monitoring unit is used to measure the compression of the billet using a laser displacement sensor; The fuzzy PID control unit is used to perform calculations and processing on the monitoring data; The drive servo adjustment unit is used to dynamically control the feed speed of the extrusion cylinder.

4. The precision cold extrusion fixture for the drive gear as described in claim 1, characterized in that, The cooling module includes a cooling channel unit, a cooling circulation unit, and a temperature gradient control unit. The cooling channel unit is used to conform to the mold cavity to construct a cooling channel; The cooling circulation unit is responsible for efficiently delivering the cooling medium; The temperature gradient control unit is used to ensure that the surface temperature of the mold cavity fluctuates within ±3℃.

5. The precision cold extrusion fixture for the drive gear as described in claim 1, characterized in that, The noise reduction and dust suppression module includes a composite sound-absorbing material unit, a hydraulic buffer unit, a water-based lubrication unit, and an atomization recovery unit. The composite sound-absorbing material unit is used to absorb high-frequency noise generated by internal impact and mechanical friction of the press. The hydraulic buffer unit is used to provide reverse damping force at the moment of demolding, reduce the impact of gear-mold separation, suppress secondary noise and prevent tooth surface damage; The water-based lubrication unit is used to replace traditional graphite lubricants and reduce the coefficient of friction between the mold and the workpiece. The atomization recovery unit is used to capture and circulate water-based lubricating microdroplets.

6. The precision cold extrusion fixture for the drive gear as described in claim 1, characterized in that, The mold module includes a base unit, a toothed insert unit, and a hydraulic interference fit assembly unit; The base unit is used to provide high rigidity support; The tooth-shaped insert unit is used to directly form the tooth profile of the drive gear, ensuring the stability of the tooth surface dimensions and roughness. The hydraulic interference fit assembly unit is used to assemble the toothed insert unit onto the base through hydraulic interference fit.

7. A forming process for a precision cold extrusion tooling for a drive gear, used in any one of claims 1-6, characterized in that, Includes the following steps: The pre-treated gear blank is heated to a set temperature range; The lubrication module precisely sprays lubricating microdroplets at key locations within the mold cavity; After the blank is placed into the mold, the compensation module monitors the mold cavity temperature and blank compression displacement in real time, and dynamically adjusts the extrusion parameters based on the fuzzy PID control algorithm. Start the cold extrusion equipment and extrude the material using the optimized process parameters, while simultaneously activating the cooling module; After molding, the gears are demolded in a noise-reducing and dust-suppressing environment, and an automatic collection system recovers the atomized lubricant. The finished gears are subjected to dimensional inspection and performance testing, and the process parameters are further optimized based on the data feedback.

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