Gear machining forging device with temperature monitoring function

Abstract

The invention relates to the technical field of gear machining forging and pressing equipment, in particular to a forging device with a temperature monitoring function for gear machining, the forging device comprises a first forging machine, a second forging machine, a manipulator and a test board, the first forging machine is used for machining a hollow cylindrical raw material block into an intermediate, and the second forging machine is placed beside the first forging machine; the secondary forging machine processes the intermediate into a gear-shaped forming body, the test board is placed beside the secondary forging machine and tests the tooth root toughness of the forming body in the meshing process, and the manipulator is arranged among the primary forging machine, the secondary forging machine and the test board and used for transferring workpieces. The raw material block is heated to a forging and pressing point in a resistance heating mode, electrodes for resistance heating are arranged in a first forging machine and a second forging machine, and infrared probes are arranged in the first forging machine and the second forging machine to recognize the temperature of the raw material block and the intermediate in the heating process. And after the intermediate is obtained, the outer edge of the intermediate is heated, so that the material which finally becomes the tooth surface in the second forging and pressing process is mostly based on the original outer edge material.

Description

TECHNICAL FIELD

[0001] The present application relates to gear processing forging equipment technical field, specifically a kind of temperature monitoring function's gear processing is forged device. BACKGROUND

[0002] Gear is a widely used transmission component, for the occasion of precision transmission, all adopt gear transmission, good stability, rigid transmission, large load range.

[0003] In prior art, the blank of large gear is generally produced by forging, and then the gear surface is processed by the way of gear shaping and gear expanding, while small gear is generally directly processed by gear shaping using metal block, in this case, the metal block is generally cast ingot, and the mechanical strength is general, the processed gear can only be used in general occasions, for the working condition of large load fluctuation range, higher grade material needs to be used to manufacture, which increases cost, under the same material selection, producing small gear by forging is the main means to improve the mechanical properties of gear, for small gear with diameter less than 50mm, generally, the raw material block is heated to forging point and then forged once, the deformation is large, and the material between teeth is not very precise, the metallographic structure is seriously decoupled, which affects the overall strength, and occasionally, the single tooth strength is not high and the gear is broken, so the forging process needs to be improved to obtain the gear with uniform strength. SUMMARY

[0004] The present application aims to provide a kind of to solve the problems raised in prior art.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical scheme: A kind of temperature monitoring function's gear processing is forged device, the forging device includes first forging machine, second forging machine, manipulator, test table, first forging machine processes hollow cylindrical raw material block into intermediate body, second forging machine is placed beside first forging machine, second forging machine processes intermediate body into gear-shaped forming body, test table is placed beside second forging machine, test table tests the tooth root toughness during meshing process, manipulator is arranged between first forging machine, second forging machine and test table for transferring workpiece.

[0006] The raw material block is processed into a shaped body in steps to avoid large deformation and metallographic defects and surface defects in the one-time forging process, the shape of the intermediate body and the shaped body is changed and adapted through the forming cavity in the first forging machine and the second forging machine, and the continuous forging production is carried out through multi-step continuous operation, so that the small gear forging production can obtain higher strength, the test bench is an auxiliary equipment of the device, the shaped body obtained after the forging process has basically become the shape of the final gear, and only heat treatment, gear surface grinding, key groove processing and other steps are needed, before these steps, the gear tooth root toughness can be checked first to avoid wasting subsequent process effort due to mechanical defects of part of the forged parts, the test bench fixes the shaped body and then uses a gear meshing with the shaped body to apply transmission force, and the tooth root is simply checked whether it is stressed well, it should be noted that the shaped body has not been heat treated, and the mechanical properties have not been fully improved, therefore, the gear operating force is not needed for detection.

[0007] The raw material block is heated to the forging point by resistance heating, the resistance heating electrode is arranged in the first forging machine and the second forging machine, and the infrared probe in the first forging machine and the second forging machine identifies the temperature of the raw material block and the intermediate body in the heating process.

[0008] The electric heating method is convenient to implement in most workshop environments, and the flame furnace heating form can cause the temperature of the workshop to be too high, affect the surrounding machines, and cause heat loss.

[0009] The first forging machine includes a machine body, a flywheel, an upper die, a lower die and an electric box, the flywheel is arranged on the side of the machine body, the upper die and the lower die are oppositely arranged in the machine body, the upper die is vertically slidably installed, the electric box is arranged on the side of the machine body, the electric box supplies power to the electrodes in contact with the raw material block and resistance heating, and the flywheel accumulates kinetic energy by mechanical or electric drive and transmits the kinetic energy to the upper die when the upper die is downwardly forging the raw material block.

[0010] The flywheel can continue to accumulate kinetic energy, and the accumulated low-power power input can be used for the downward movement of the upper die to forge the workpiece, replacing the relatively complex hydraulic drive with powerful power. The raw material block is placed in the main cavity of the lower die, and then the upper die moves downward to press the raw material block, the electrodes arranged on the upper die and the lower die are powered to heat the raw material block to the forging temperature point, then the upper die is lifted again, and the raw material block is forged downward with a large kinetic energy to become an intermediate body, and the shape of the intermediate body fits the shape of the main cavity. The structure of the second forging machine is the same as that of the first forging machine, except that the cavity shape of the upper and lower dies needs to be replaced by the shape of the shaped body, which can be changed by detachable upper and lower dies.

[0011] The forging device further includes a top electrode and a bottom electrode, the top electrode is arranged at the central position of the lower surface of the upper die, and the bottom electrode is arranged at the central bottom surface of the main cavity of the lower die, and the top electrode and the bottom electrode are electrically connected with the electric box.

[0012] The top electrode and the bottom electrode are in contact with the raw material block from top to bottom and are powered to heat until the raw material block is heated to an appropriate temperature through the infrared probe.

[0013] The forging device further comprises outer edge electrodes, which are provided at the tip ends of the plurality of radial main die cavities and are electrically connected to the electric box.

[0014] After the raw material block is forged into an intermediate body, the metal organization position of the intermediate body needs to be deformed to form a shaped body, which is concentrated at the outer edge. Compared with the casting process, the forging process improves the mechanical properties of the workpiece mainly because the metallographic structure is stretched during the forging process. In a large range of metallographic structure, the material is continuous and uniform, and the materials are intertwined with each other in a large range, which is not easy to be broken locally, causing macroscopic fracture. In the scenario, the gear inner ring only supports and connects the gear tooth top and tooth root, and the material is forged and continuously distributed on the tooth top and tooth root. The tooth top and tooth root have a so-called "trace" in the metallographic structure, which improves the fracture strength of the tooth root. In the present application, the outer edge electrode is used for regionally controlled resistance heating of the intermediate body. If only two adjacent outer edge electrodes are powered, the current will mostly flow between the two teeth along the outer contour of the intermediate body. At this point, the temperature in this area is higher than that in other areas. Similarly, the core of the intermediate body is heated to a lower temperature, and the outer contour is heated to a higher temperature. Therefore, when the intermediate body is transferred to the second forging machine for forging, the metal part of the core of the intermediate body deforms less, the outer edge increases the forging deformation, the material migrates in the circumferential direction, and the outer surface of the shaped body becomes an integral part, thereby improving the local strength of the tooth root.

[0015] The shaped shape of the main die cavity is a sawtooth gear with a recess in the middle. When the intermediate body is forged from the raw material block, the intermediate position is extruded to become a recessed area, and the outer edge position is relatively thick. When heated by the outer edge electrode, the position with a thicker thickness is the desired heating position for more deformation. Then, the intermediate body is forged into a shaped body with uniform thickness in the second forging machine.

[0016] The forging device further comprises an electric module, which supplies short-time high-voltage current to the electric box.

[0017] Industrial electricity 220V or 380V is directly used for the electric heating effect of the workpiece, which needs to be adjusted for power supply.

[0018] The electric module includes a transformer and a capacitor box. The transformer is connected to the power supply and charges the capacitor box. The capacitor box supplies short-time high-voltage current to the top electrode, the bottom electrode, and the outer edge electrode through the electric box.

[0019] After the capacitor box is charged, it maintains a high voltage state, and then releases it to the raw material block or the intermediate body for heating when needed, and then is charged by the transformer again.

[0020] The top electrode uses a corrugated tube wire harness in the process of leading out from the upper die and entering the electric box, and the bottom electrode and the outer edge electrode use a hard tube wire in the process of leading out from the lower die and entering the electric box. The corrugated tube wire harness maintains high wire harness strength and prevents ordinary cables from sagging down to affect the lifting action of the upper die.

[0021] The test table uses a variable-diameter shaft to penetrate into the to-be-tested molded body, and the variable-diameter shaft is tightly driven with the molded body and used for testing.

[0022] The inner ring of the molded body is circular and has not yet been processed with a key groove for transmission, so that a relatively convenient transmission mode of the test table is that a variable-diameter shaft is in interference fit with the inner ring of the molded body and simply transmits power.

[0023] Compared with the prior art, the beneficial effects of the present application are that the small raw material block is deformed in multiple steps to prevent defects caused by excessive deformation at one time, the outer edge of the intermediate body is heated after the intermediate body is obtained, the material that becomes the tooth surface in the second forging process is mainly based on the material at the original outer edge, the connection between the metallographic structures is precise, the tooth root strength is high, tooth breakage is prevented in the subsequent use of the gear, the heating of the intermediate body is realized through the outer edge electrode of the forming die cavity, the heating position is adjusted purposefully, the expected material deformation direction is obtained, the heating process is monitored through an infrared probe to prevent the temperature from deviating from the expected value, the gear obtained by forging is subjected to strength detection, unqualified products are picked out in time, and waste of subsequent heat treatment and inner hole processing time is prevented. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 It is a front view arrangement schematic diagram of the present application; Figure 2 It is an outline structure schematic diagram of the present application; Figure 3 It is a cross-sectional structure schematic diagram of the first forging machine of the present application; Figure 4 It is Figure 3 A partial view in the figure; Figure 5 It is a representative shape schematic diagram of the raw material block, the intermediate body and the molded body processed by the present application; Figure 6 It is a top view schematic diagram of the main die cavity of the present application; In the figure: 1, first forging machine; 11, machine body; 12, flywheel; 13, upper die; 14, lower die; 141, main die cavity; 15, electric box; 2, second forging machine; 3, mechanical hand; 4, electric die group; 41, transformer; 42, capacitor box; 51, top electrode; 52, bottom electrode; 53, outer edge electrode; 54, corrugated tube wire harness; 6, test table; 91, raw material block; 92, intermediate body; 93, molded body. DETAILED DESCRIPTION

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] A forging apparatus for gear processing with temperature monitoring function. The forging apparatus includes a first forging machine 1, a second forging machine 2, a robot arm 3, and a test table 6. The first forging machine 1 processes a hollow cylindrical raw material block 91 into an intermediate body 92. The second forging machine 2 is placed next to the first forging machine 1 and processes the intermediate body 92 into a gear-shaped formed body 93. The test table 6 is placed next to the second forging machine 2 and tests the root toughness of the gear 93 during the meshing process. The robot arm 3 is set between the first forging machine 1, the second forging machine 2, and the test table 6 for transferring workpieces.

[0027] like Figure 1 , 2 As shown in Figure 5, the raw material block 91 is processed into the shaped body 93 in steps to avoid large deformation in a single forging process, which could lead to metallographic and surface defects. The shapes of the intermediate body 92 and the shaped body 93 are adapted by modifying the forming cavities in the first forging machine 1 and the second forging machine 2. Continuous forging production is carried out through multi-step continuous operation. Small gear forging production achieves higher strength. The test bench is an auxiliary device of this apparatus. After the forging process, the shaped body 93 obtained has basically become the shape of the final gear, requiring only heat treatment, tooth surface grinding, and keyway machining. Before these steps, the tooth root toughness of the gear can be checked to avoid mechanical defects in some forging parts, which would waste subsequent process effort. The test bench fixes the shaped body 93 and then uses a gear meshing with it to apply power to simply check whether the tooth root is under good stress. It should be noted that the shaped body 93 has not yet been heat treated, and its mechanical properties have not been fully improved. Therefore, it is not necessary to test it using the force of the gear's operating conditions.

[0028] The raw material block 91 is heated to the forging point by resistance heating. The electrodes for resistance heating are set in the first forging machine 1 and the second forging machine 2. The first forging machine 1 and the second forging machine 2 are equipped with infrared probes to identify the temperature of the raw material block 91 and the intermediate 92 during the heating process.

[0029] Electric heating is convenient to implement in most workshop environments, while flame furnace heating can cause the workshop temperature to become too high, affecting surrounding machines and resulting in heat loss.

[0030] The first forging machine 1 includes a machine body 11, a flywheel 12, an upper die 13, a lower die 14, and an electrical box 15. The flywheel 12 is installed on the side of the machine body 11. The upper die 13 and the lower die 14 are arranged opposite each other inside the machine body 11. The upper die 13 is slidably installed in the vertical direction. The electrical box 15 is located on the side of the machine body 11. The electrical box 15 supplies power to the electrodes on the upper die 13 and the lower die 14 that are in contact with the raw material block 91 and are subjected to resistance heating. The flywheel 12 accumulates kinetic energy through mechanical or electric drive and transfers it to the upper die 13 when the upper die 13 forges the raw material block 91 downward.

[0031] like Figure 2 , 3 As shown in Figure 4, the flywheel 12 can continue to generate kinetic energy. The small power input can be used to move the upper die 13 downward to forge the workpiece, replacing the relatively complex but powerful hydraulic drive. The raw material block 91 is placed into the main die cavity 141 in the lower die 14. Then, the upper die 13 moves downward to press the raw material block 91. The electrodes set on the upper die 13 and lower die 14 energize the raw material block 91 to heat it to the forging temperature point. Then, the upper die 13 is raised again and forges the raw material block 91 downward with greater kinetic energy, making it into an intermediate body 92. The shape of the intermediate body 92 fits the shape of the main die cavity 141. The internal structure of the second forging machine 2 is the same as that of the first forging machine 1, except that the shape of the die cavity when the upper and lower dies are aligned needs to be replaced with the shape of the formed body 93. This can be changed by using the detachable upper die 13 and lower die 14.

[0032] The forging device also includes a top electrode 51 and a bottom electrode 52. The top electrode 51 is located at the center of the lower surface of the upper die 13, and the bottom electrode 52 is located at the center of the bottom surface of the main die cavity 141 inside the lower die 14. Both the top electrode 51 and the bottom electrode 52 are electrically connected to the electrical box 15.

[0033] like Figure 3 , 4 As shown in Figure 5, the top electrode 51 and the bottom electrode 52 contact the raw material block 91 from the top and bottom directions and are heated by electricity until the infrared probe detects that the raw material block 91 has been heated to a suitable temperature.

[0034] The forging device also includes an outer electrode 53, which has several parts and is respectively disposed at multiple pointed ends in the radial direction of the main die cavity 141. The outer electrode 53 is electrically connected to the electrical box 15.

[0035] like Figure 4 , 5As shown in Figure 6, after the raw material block 91 is forged into an intermediate body 92, the metal structure that needs to be deformed in the forging process of the intermediate body 92 into the formed body 93 is concentrated at the outer edge. This is because, compared with the casting process, the improvement of the mechanical properties of the workpiece by forging is mainly due to the fact that the metallographic structure is stretched during the forging process, and there is continuous uniformity of the material within a large metallographic structure range. The materials are interlocked and tightly bound together over a large area, making it difficult to be broken locally and cause macroscopic fracture. In this case, the inner ring of the gear only serves as a support and connection. The forging and continuous distribution on the material of the gear tooth tip and tooth root allows the tooth tip and tooth root to have so-called "traces" in the metallographic structure, which improves the fracture strength of the tooth root. In this application, the outer electrode 53 is used to perform regionally controlled resistance heating of the intermediate body 92, such as... Figure 6 As shown, if only two adjacent outer edge electrodes 53 are energized, then most of the current will flow along the outer contour of the intermediate body 92 between the two teeth. The temperature rises more in this area and less in other areas. Similarly, this means that the core of the intermediate body 92 will have a smaller temperature rise and the outer contour will have a higher temperature rise. Thus, when the intermediate body 92 is transferred to the second forging machine 2 for forging, the deformation of the metal part of the core of the intermediate body 92 will be reduced, while the forging deformation at the outer edge will be increased. This increases the migration of material in the circumferential direction, making the outer surface of the formed body 93 a single unit and improving the local strength at the tooth root.

[0036] The main mold cavity 141 is molded in the shape of a sawtooth with a central recess. For example... Figure 5 As shown, when the intermediate body 92 is forged from the raw material block 91, the middle position is squeezed more to become a concave area, and the outer edge position is relatively thicker. When heated by the outer edge electrode 53, the thicker position is the heating position where more deformation is expected. Then, the intermediate body 92 is forged in the second forging machine 2 to form a shaped body 93 with uniform thickness.

[0037] The forging apparatus also includes an electric module 4, which supplies short-term high-voltage current to the electrical box 15.

[0038] Industrial electricity of 220V or 380V is not effective for direct electric heating of workpieces and requires adjustment of the power supply.

[0039] The electrical module 4 includes a transformer 41 and a capacitor box 42. The transformer 41 is energized and charges the capacitor box 42. The capacitor box 42, after being distributed by the electrical box 15, supplies short-term high-voltage current to the top electrode 51, bottom electrode 52 and outer electrode 53.

[0040] like Figure 2 As shown, after the capacitor box 42 is charged, it maintains a high voltage state, and then briefly releases it onto the raw material block 91 or intermediate 92 to achieve heating when needed, and then is charged again by the transformer 41.

[0041] The top electrode 51 uses a corrugated conduit harness as it is led out from the upper mold 13 and enters the electrical box 15. The bottom electrode 52 and the outer edge electrode 53 use rigid conduit harnesses as they are led out from the lower mold 14 and enter the electrical box 15. The corrugated conduit harness maintains high harness strength to prevent ordinary cables from drooping down and affecting the lifting and lowering movement of the upper mold 13.

[0042] The test bench 6 uses a variable diameter shaft that is inserted into the molded body 93 to be tested. The variable diameter shaft and the molded body 93 are tightened and driven together for testing.

[0043] The inner ring of the molded body 93 is circular and has not yet been machined with a keyway for transmission. Therefore, a relatively convenient transmission method for the test bench 6 is to use a variable diameter shaft that forms an interference fit with the inner ring of the molded body 93 to simply transmit power.

[0044] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A forging apparatus for gear processing with temperature monitoring function, characterized in that: The forging apparatus includes a first forging machine (1), a second forging machine (2), a robot (3), and a test bench (6). The first forging machine (1) processes a hollow cylindrical raw material block (91) into an intermediate body (92). The second forging machine (2) is placed next to the first forging machine (1) and processes the intermediate body (92) into a gear-shaped formed body (93). The test bench (6) is placed next to the second forging machine (2) and tests the tooth root toughness of the formed body (93) during the meshing process. The robot (3) is set between the first forging machine (1), the second forging machine (2), and the test bench (6) for transferring workpieces. The raw material block (91) is heated to the forging point by resistance heating, and the resistance heating electrodes are set in the first forging machine (1) and the second forging machine (2); The first forging machine (1) includes a machine body (11), an upper die (13), a lower die (14), and an electrical box (15). The upper die (13) and the lower die (14) are arranged opposite each other inside the machine body (11). The upper die (13) is slidably installed in the vertical direction. The electrical box (15) is located on the side of the machine body (11). The electrical box (15) supplies power to the electrodes on the upper die (13) and the lower die (14) that are in contact with the raw material block (91) and perform resistance heating. The forging device also includes a top electrode (51) and a bottom electrode (52). The top electrode (51) is located at the center of the lower surface of the upper die (13), and the bottom electrode (52) is located at the center of the bottom surface of the main die cavity (141) inside the lower die (14). Both the top electrode (51) and the bottom electrode (52) are electrically connected to the electrical box (15). The forging device also includes an outer electrode (53), which has a plurality of electrodes and is respectively disposed at multiple pointed ends in the radial direction of the main die cavity (141). The outer electrode (53) is electrically connected to the electrical box (15).

2. The forging apparatus for gear processing with temperature monitoring function according to claim 1, characterized in that: The first forging machine (1) and the second forging machine (2) are equipped with infrared probes to identify the temperature of the raw material block (91) and intermediate (92) during the heating process.

3. A forging apparatus for gear processing with temperature monitoring function according to claim 2, characterized in that: The first forging machine (1) also includes a flywheel (12). The flywheel (12) is provided on the side of the machine body (11). The flywheel (12) accumulates kinetic energy through mechanical or electric drive and transmits it to the upper die (13) when the upper die (13) forges the raw material block (91) downward.

4. The forging apparatus for gear processing with temperature monitoring function according to claim 1, characterized in that: The main mold cavity (141) is molded into a saw gear with a central depression.

5. A forging apparatus for gear processing with temperature monitoring function according to claim 1, characterized in that: The forging device also includes an electric module (4), which supplies short-term high-voltage current to the electrical box (15).

6. A forging apparatus for gear processing with temperature monitoring function according to claim 5, characterized in that: The electrical module (4) includes a transformer (41) and a capacitor box (42). The transformer (41) is connected to the power supply and charges the capacitor box (42). The capacitor box (42) supplies short-term high-voltage current to the top electrode (51), bottom electrode (52) and outer electrode (53) after being distributed by the power box (15).

7. A forging apparatus for gear processing with temperature monitoring function according to claim 1, characterized in that: The top electrode (51) is led out from the upper mold (13) and enters the electrical box (15) using a corrugated wire harness, while the bottom electrode (52) and outer edge electrode (53) are led out from the lower mold (14) and enter the electrical box (15) using a rigid conduit.

8. A forging apparatus for gear processing with temperature monitoring function according to claim 1, characterized in that: The test bench (6) uses a variable diameter shaft to pass through the molded body (93) to be tested. The variable diameter shaft and the molded body (93) are tightened and driven together for testing.

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