Method and system for upsetting large crankshaft forged piece smooth blank through TR method

Abstract

The invention discloses an upsetting method and system for a TR-method large crankshaft forged piece smooth blank. The upsetting method comprises the following steps that a front fixing device and a rear fixing device are arranged in an upsetting die; the method comprises the following steps: putting a polished blank into an upsetting die, contacting with the end face of one end of the polished blank through a front fixing device, and contacting with the end face of one end of the polished blank through a rear fixing device so as to transfer horizontal upsetting force; and under the combined action of the horizontal upsetting force and the vertical bending force, upsetting of the crank throw is completed.

Description

Technical Field

[0001] This invention relates to the field of materials processing technology, specifically to a method and system for upsetting large crankshaft forging blanks using the TR method. Background Technology

[0002] The crankshaft is a key component of medium- and high-speed diesel engines. To improve its fatigue performance, it is formed by upsetting with continuous fiber flow lines. TR upsetting is a typical continuous fiber flow line upsetting method.

[0003] Traditional TR upsetting involves stepped billet upsetting, meaning that a billet is prepared before crankshaft upsetting, machining a stepped billet with annular grooves for the main journals and connecting rod journals, such as... Figure 1 As shown. Figure 2 This is a schematic diagram of the TR upsetting process. Figure 2 (a) The state of the locally heated billet before upsetting when the mold is closed. Figure 2 (b) shows the finished state of the billet upsetting. 1 is the crankshaft billet, 2 is the upper bending die, 3 is the lower bending die, 4 is the TR upper die holder (symmetrical on the left and right), 5 is the upper clamping die, 6 is the lower clamping die, and 7 is the TR lower die holder (symmetrical on the left and right). The step between the connecting rod neck groove of billet 1 and the crank arm billet forms an annular surface. During upsetting, the annular surface formed by the step contacts the surfaces of the upper clamping die 5 and the lower clamping die 6, bearing and transmitting the horizontal upsetting force to upset the billet. Simultaneously, under the action of bending force, one crank upsetting is completed.

[0004] The raw material specifications for the above upsetting process are designed based on the diameter of the crank arm blank. The diameter of the raw material is larger than that of the main journal, resulting in low raw material utilization. A blank needs to be prepared before upsetting, resulting in low forging production efficiency. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a method and system for upsetting large crankshaft forging blanks using the TR method, which aims to overcome at least one related technical problem existing in the background art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, this application provides a method for upsetting large crankshaft forging blanks using the TR method, comprising the following steps: A front fixing device and a rear fixing device are configured in the upsetting die; The blank is placed into the upsetting die, and the front fixing device contacts one end face of the blank, and the rear fixing device contacts one end face of the blank to transmit the horizontal upsetting force. Under the combined action of the horizontal upsetting force and the vertical bending force, the upsetting of the crank is completed.

[0007] In order to solve the positioning accuracy problem of the crankshaft multi-crank continuous upsetting, in an alternative embodiment, the front positioning device includes a first set of positioning device and a continuous positioning device, the first set of positioning device is used for limiting the position of the blank when the first crank is made; the continuous positioning device is used for limiting the position of the blank when the second crank and subsequent cranks are made. The first set of positioning device is used for initial positioning when the first crank is made; the continuous positioning device is switched to when the subsequent cranks are made, and the formed cranks are used as a reference for positioning.

[0008] By setting the first set of positioning device and the continuous positioning device, accurate positioning at different processing stages is realized, and the position accuracy and size consistency between the cranks are ensured.

[0009] In order to ensure the accurate positioning of the blank when the first crank is upset, in an alternative embodiment, the first set of positioning device includes a left clamping upper die and a left clamping lower die that cooperate with each other and have plugs, and the left clamping upper die with plug and the left clamping lower die with plug limit the position of the blank after cooperation.

[0010] In order to solve the positioning reference conversion problem during multi-crank continuous forming, in an alternative embodiment, the continuous positioning device includes a left clamping upper die and a left clamping lower die that cooperate with each other and have protrusions, and the left clamping upper die with protrusion and the left clamping lower die with protrusion limit the position of the cranks on the blank after cooperation.

[0011] In order to establish a stable upsetting force transmission path and adapt to the structure of the blank, in an alternative embodiment, the rear positioning device includes a right clamping upper baffle, a right clamping lower baffle, a clamping insert, a rear top die seat, a rear positioning lower die seat, and a rear positioning tool; the right clamping upper baffle, the right clamping lower baffle, and the clamping insert are used for radially clamping and limiting the blank, and the rear positioning tool is used for contacting the end face of the blank; the rear top die seat is installed on the TR upper die seat; the rear positioning lower die seat is installed on the TR lower die seat.

[0012] In order to solve the equipment universality problem in the production of different specifications of crankshafts, in an alternative embodiment, the rear positioning tool can be adjusted or replaced according to the length of the blank.

[0013] In order to enhance the connection rigidity and stability of the rear positioning tool, in an alternative embodiment, the rear positioning device further includes a connecting sleeve for connecting the rear positioning tool. In order to realize accurate fine adjustment of the position of the rear positioning device, in an alternative embodiment, the rear positioning device further includes an adjusting handle; by operating the adjusting handle, the axial position of the rear positioning tool can be adjusted.

[0014] In order to improve the adjustment accuracy and prevent thread wear, in an alternative embodiment, the rear positioning device further comprises a positioning pad arranged between the rear positioning tool and the adjustment handle.

[0015] In a second aspect, the application also provides a crankshaft upsetting system for implementing the method, comprising an upsetting die configured with a front positioning device and a rear positioning device, the front positioning device being configured to contact an end face of one end of the blank to limit the blank, and the rear positioning device being configured to contact an end face of the other end of the blank to transmit the horizontal upsetting force.

[0016] The front positioning device and the rear positioning device are respectively integrated at the two ends of the upsetting die and connected with the main machine control system. By integrating the front positioning device and the rear positioning device in the upsetting system, the reliable implementation of the blank upsetting process is ensured, and the production efficiency and the product quality stability are improved.

[0017] When the system is working, the front positioning device and the rear positioning device work cooperatively to limit the positions of the two ends of the blank, forming a stable force flow path during the upsetting process and ensuring the forming quality.

[0018] The TR method for large crankshaft forging blank upsetting method and system disclosed in the application can bring the following beneficial effects, but not limited to: 1. The production efficiency is significantly improved Since the blank making process before upsetting is completely eliminated, the original multi-process flow of "blanking → blank making (turning ring groove) → upsetting" is simplified into a single process flow of "blanking → upsetting", and the production cycle is greatly shortened. Practice has proved that the method can improve the forging production efficiency by more than 20%, and is particularly suitable for mass production.

[0019] 2. The material utilization rate is greatly improved In the traditional process, the diameter of the blank needs to be designed according to the size of the crank arm, while in the present application, the diameter of the blank is designed according to the smaller size of the main journal, which reduces the original material specifications from the source. At the same time, the material reserved for forming the step is cancelled, and the material utilization rate is improved by more than 10%. For large crankshafts, which are expensive forgings, the saving of material cost is particularly significant.

[0020] 3. The product quality is guaranteed and optimized Fiber continuity: inherits the advantage of forming continuous fiber flow lines in TR method, ensuring the fatigue performance of the crankshaft; Dense structure: direct forming of the blank reduces the cutting of metal flow lines by mechanical processing, which helps to improve the integrity and mechanical properties of the forging; Dimensional consistency: the precise positioning mechanism of the front and rear positioning devices ensures the positional accuracy and dimensional stability between the crank webs.

[0021] 4. The equipment versatility and production line flexibility are enhanced Fast changeover: The modular rear positioning tooling and front positioning device enable the same equipment to quickly adapt to the production of different specifications of products; Process flexibility: The adjustable positioning system can adapt to normal fluctuations in the length of the blank, improving process stability; Automation compatibility: The system structure facilitates integration with automated loading and unloading systems and intelligent control systems, laying the foundation for digital workshop construction.

[0022] 5. Significant reduction in overall cost Direct cost: Material cost savings and production efficiency improvements directly reduce the cost of individual pieces Indirect cost: Reduced equipment investment (eliminating blanking equipment), reduced mold wear, and reduced energy consumption Maintenance cost: The system structure is relatively simple, maintenance is convenient, and the service life is long 6. Clear technology upgrade path The present invention innovates on the basis of maintaining the technical advantages of the TR method, and existing production lines can be upgraded to realize the application of new technology. The upgrade cost is low, the effect is quick, and it has good promotional value.

[0023] In summary, through the technical innovation of "light blank + front and rear positioning device", the present invention successfully solves the long-standing problems of material waste and complex process in traditional TR upsetting, while maintaining product quality, achieving quality improvement, efficiency increase, and cost reduction, providing a new solution for the technical upgrade of large-scale crankshaft manufacturing. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 A schematic diagram of the existing technology upsetting front step blank.

[0025] Figure 2 A schematic diagram of the initial and final state of the existing technology TR upsetting.

[0026] Figure 3 A schematic diagram of the upsetting front light blank of the present application.

[0027] Figure 4 A schematic diagram of the upsetting front blank die assembly state of the present application (first set of positioning device).

[0028] Figure 5 A schematic diagram of the upsetting front blank die assembly state of the present application (continuous positioning device).

[0029] Figure 6 A schematic diagram of the rear positioning device of the present application.

[0030] Explanation of reference signs in the figure: 1 - crankshaft blank, 2 - bending upper die, 3 - bending lower die, 4 - TR upper die holder, 5 - clamping upper die, 6 - clamping lower die, 7 - TR lower die holder, 8 - right clamping lower baffle, 9 - clamping insert, 10 - right clamping upper baffle, 11 - rear positioning device, 11.1 - rear top die holder, 11.2 - rear lower die holder, 11.3 - rear positioning tool, 11.4 - connecting sleeve, 11.5 - positioning pad, 11.6 - adjusting handle. DETAILED DESCRIPTION

[0031] Various exemplary embodiments, features, and aspects of the present application will be described in detail below with reference to the accompanying drawings. The same reference numbers in the drawings represent functionally the same or similar elements. Although various aspects of the embodiments are illustrated in the drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

[0032] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connection", and "linking" should be understood in a broad sense, for example, it can be fixed connection, or indirect connection through an intermediate medium, or internal communication of two elements, or interaction relationship between two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0033] As shown in Figures 3-6 The present application provides a first aspect, which provides a TR method for large crankshaft forging blank upsetting method, comprising the following steps: A front positioning device and a rear positioning device 11 are arranged in the upsetting die; The blank is placed in the upsetting die, the front positioning device contacts one end surface of the blank, and the rear positioning device 11 contacts the other end surface of the blank to transmit the horizontal upsetting force; Under the combined action of the horizontal upsetting force and the vertical bending force, the crank web is completed.

[0034] In order to solve the problems of low production efficiency and material waste caused by the need for pre-manufacturing ring groove in the traditional TR method, the front positioning device and the rear positioning device 11 are arranged to contact the two end surfaces of the blank respectively, the direct upsetting forming of the blank is realized, the blank manufacturing process is cancelled, the production efficiency is improved by more than 20%, and the material utilization rate is improved by more than 10%.

[0035] Specifically, the blank is placed in the die, the front positioning device and the rear positioning device 11 clamp the blank from both ends, and the horizontal upsetting force is transmitted during the upsetting process. At the same time, the die applies a vertical bending force, so that the blank completes plastic forming under three-dimensional stress state.

[0036] To solve the positioning accuracy problem of the crankshaft multi-crank continuous upsetting, in some embodiments, the front positioning device includes a first set of positioning device and a continuous positioning device, the first set of positioning device is used for limiting the position of the blank when the first crank is made; the continuous positioning device is used for limiting the position of the blank when the second crank and subsequent cranks are made. The first set of positioning device is used for initial positioning when the first crank is made; the continuous positioning device is switched to when the subsequent cranks are made, and the formed crank is used as a reference for positioning.

[0037] By setting the first set of positioning device and the continuous positioning device, accurate positioning at different processing stages is realized, and the position accuracy and size consistency between the cranks are ensured.

[0038] To ensure the accurate positioning of the blank when the first crank is upset, in some embodiments, the first set of positioning device includes a left clamping upper die 5 and a left clamping lower die 6 that cooperate with each other and have plugs, the left clamping upper die 5 with plugs and the left clamping lower die 6 with plugs cooperate to limit the position of the blank, see Figure 4 .

[0039] When the upper and lower clamping dies are closed, the plug structure is in full contact with the end face of the blank, providing a stable support surface to withstand the upsetting reaction force. By setting the clamping die with plugs, a reliable end face limiting structure is formed to prevent the blank from moving axially during upsetting.

[0040] To solve the positioning reference conversion problem during multi-crank continuous forming, in some embodiments, the continuous positioning device includes a left clamping upper die 5 and a left clamping lower die 6 that cooperate with each other and have protrusions, the left clamping upper die 5 with protrusions and the left clamping lower die 6 with protrusions cooperate to limit the position of the cranks on the blank.

[0041] The clamping die with protrusions is installed at the position of the traditional clamping die and works in coordination with the front and rear process dies. The protrusion structure cooperates with the specific part (such as the crank arm) of the formed crank to form mechanical interlocking, accurately positioning the upsetting position of the next crank, see Figure 5 .

[0042] The present application uses the geometric features of the formed crank for positioning by setting the clamping die with protrusions, ensuring the relative position accuracy between the cranks.

[0043] See Figure 6In order to establish a stable upsetting force transmission path and adapt to the structure of the optical blank, in some embodiments, the rear positioning device 11 includes a right clamping upper stop plate 10, a right clamping lower stop plate 8, a clamping insert 9, a rear top upper die seat 11.1, a rear positioning lower die seat 11.2, and a rear positioning tool 11.3; the right clamping upper stop plate 10, the right clamping lower stop plate 8, and the clamping insert 9 are used for radially clamping and limiting the optical blank, and the rear positioning tool 11.3 is used for contacting the end face of the optical blank; the rear top upper die seat 11.1 is installed on the TR upper die seat 4; and the rear positioning lower die seat 11.2 is installed on the TR lower die seat 7.

[0044] It should be noted that the clamping insert 9 is a pair of upper and lower molds, and one end of the rear top upper die seat 11.1 and the rear positioning lower die seat 11.2 is respectively clamped on the upper and lower sides of the clamping insert 9. The rear top upper die seat 11.1 and the rear positioning lower die seat 11.2 provide a mounting base, and the rear positioning tool 11.3 directly contacts the end face of the blank and bears and transmits the axial force during the upsetting process. Specifically, the rear top upper die seat 11.1 is connected with the TR upper die seat 4, the rear positioning lower die seat 11.2 is connected with the TR lower die seat 7, and the rear positioning tool 11.3 is installed between the two die seats.

[0045] By arranging the rear positioning device 11, an adjustable end face support is provided, and the reliability and stability of force transmission are ensured.

[0046] In order to solve the problem of equipment universality in the production of different specifications of crankshafts, in some embodiments, the rear positioning tool 11.3 can be adjusted or replaced according to the length of the optical blank. By making the rear positioning tool 11.3 adjustable and replaceable, rapid production change of the equipment is realized, and the flexibility of the production line is improved.

[0047] Specifically, according to the length specification of the blank, a positioning tool with a suitable length is selected or its position is adjusted to ensure optimal contact with the end face of the blank.

[0048] In order to enhance the connection rigidity and stability of the rear positioning tool 11.3, in some embodiments, the rear positioning device 11 further includes a connecting sleeve 11.4 for connecting the rear positioning tool 11.3. The connecting sleeve 11.4 serves as a transition member to firmly connect the positioning tool to the die seat, ensuring that it does not deform or loosen under high pressure. By arranging the connecting sleeve 11.4, a reliable force transmission interface is provided, and stress concentration at the connection site is reduced.

[0049] In order to realize the accurate fine adjustment of the position of the rear positioning device 11, in some embodiments, the rear positioning device 11 further comprises an adjusting handle 11.6; by operating the adjusting handle 11.6, the axial position of the rear positioning tool 11.3 can be adjusted. The adjusting handle 11.6 is arranged in a large rotating sleeve, and the inner wall has threads matched with the adjusting handle 11.6. By rotating the adjusting handle 11.6, the positioning tool can be driven to move axially through the threaded transmission, and the accurate position fine adjustment can be realized. By arranging the adjusting handle 11.6, a convenient manual adjustment mode is provided, and the positioning accuracy of the blank is ensured.

[0050] In order to improve the adjustment accuracy and prevent thread wear, in some embodiments, the rear positioning device 11 further comprises a positioning pad 11.5 arranged between the rear positioning tool 11.3 and the adjusting handle 11.6. By arranging the positioning pad 11.5, a stable supporting surface is provided, and the stability and repeatability of the adjustment position are ensured.

[0051] In a second aspect, the application also provides a crankshaft upsetting system for implementing the method, comprising an upsetting die configured with a front positioning device and a rear positioning device 11. The front positioning device is configured to be in contact with one end surface of the blank to limit the position of the blank; and the rear positioning device 11 is configured to be in contact with the other end surface of the blank to transmit the horizontal upsetting force.

[0052] The front positioning device and the rear positioning device 11 are respectively integrated at both ends of the upsetting die and connected with the main control system. By integrating the front positioning device and the rear positioning device 11 in the upsetting system, the reliable implementation of the blank upsetting process is ensured, and the production efficiency and product quality stability are improved.

[0053] When the system is working, the front positioning device and the rear positioning device 11 work cooperatively to limit the positions of the two ends of the blank, form a stable force flow path during the upsetting process, and ensure the forming quality.

[0054] The TR method large crankshaft forging blank upsetting method and system provided by the application has the core working principle that the front positioning device and the rear positioning device 11 work cooperatively to build a complete and reliable force transmission system, realize the direct upsetting forming of the blank, and completely abandon the blank making process necessary in the traditional process. Specifically as follows: 1. Double device cooperatively building force transmission path The traditional TR method relies on the contact between the ring groove structure of the stepped blank and the clamping die to transmit the horizontal upsetting force. After the adoption of the blank in the application, this force transmission mechanism no longer exists. Therefore, the system is provided with front and rear symmetrical positioning devices: Front positioning device: Located at the feeding side of the die, it is divided into the first positioning device and the continuous positioning device according to the processing stage. The first positioning device is in full contact with the original billet end face through the clamping die with a plug; the continuous positioning device is matched with the specific structure of the shaped crank handle through the clamping die with a convex head, providing accurate positioning for the subsequent crank handle upsetting.

[0055] Rear positioning device 11: Located at the end of the die, it is in contact with the other end face of the billet through the adjustable rear positioning tool 11.3, forming a complete force-closed system.

[0056] 2. Three-stage force flow transmission mechanism In the upsetting process, the transmission of the horizontal upsetting force follows a clear path: Starting end: the front positioning device (the first or continuous positioning device) is in contact with the billet or the shaped crank handle; Transmission medium: the billet body; Termination end: the end face of the positioning tool of the rear positioning device 11; This force flow path ensures that after the step structure is cancelled, the huge horizontal upsetting force can still be stably and uniformly transmitted to the billet heating area.

[0057] 3. Multi-dimensional stress plastic forming After the horizontal upsetting force is established through the front and rear positioning devices 11, the system enters the forming stage: Axial compression: under the cooperation of the two end positioning devices, the billet is axially compressed, and the metal material flows axially; Radial expansion: under the restriction of the die cavity, the metal fills the die cavity in the radial direction Bending forming: at the same time, the bending upper die 2 and the lower die exert a vertical bending force on the billet, so that the metal is formed in the shape of a crank handle; The synergistic effect of three-dimensional stress ensures that the metal fibers are continuously distributed along the shape of the crank handle, maintaining the fiber flow line advantage of the TR method.

[0058] The above has described the embodiments of the present application, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and changes are obvious to those skilled in the art without departing from the scope and spirit of the described embodiments.

Claims

1. A method of upsetting a TR-method large crankshaft forging bloom, characterized by, The method comprises the following steps: configure front and rear positioning devices in the upsetting die; put the light blank into the upsetting die, contact one end face of the light blank with the front positioning device, and contact the other end face of the light blank with the rear positioning device to transmit the horizontal upsetting force; complete the upsetting of the crank handle under the combined action of the horizontal upsetting force and the vertical bending force.

2. The method according to claim 1, wherein the method is characterized by, The front positioning device comprises a first set of positioning devices and a continuous positioning device, the first set of positioning devices are used for limiting the light blank when the first crank handle is made, and the continuous positioning device is used for limiting the light blank when the second crank handle and subsequent crank handles are made.

3. The method according to claim 2, wherein the TR method large crank forging bloom upsetting method is characterized by, The first set of positioning devices comprises a left clamping upper die and a left clamping lower die which are matched and provided with plugs, and the left clamping upper die and the left clamping lower die provided with plugs are matched to limit the light blank.

4. The method of claim 2, wherein the method is characterized by, The continuous positioning device comprises a left clamping upper die and a left clamping lower die which are matched and provided with protrusions, and the left clamping upper die and the left clamping lower die provided with protrusions are matched to limit the crank handle on the light blank.

5. The method of claim 1, wherein the method is characterized by: The rear positioning device comprises a right clamping upper baffle, a right clamping lower baffle, a clamping insert, a rear top die holder, a rear positioning lower die holder and a rear positioning tool; the right clamping upper baffle, the right clamping lower baffle and the clamping insert are used for radially clamping and limiting the light blank, the rear positioning tool is used for contacting the end face of the light blank, the rear top die holder is installed on the TR upper die holder, and the rear positioning lower die holder is installed on the TR lower die holder.

6. The method of claim 5, wherein, The rear positioning tool can be adjusted or replaced according to the length of the light blank.

7. The method of claim 5, wherein, The rear positioning device further comprises a connecting sleeve for connecting the rear positioning tool.

8. The method of claim 5, wherein, The rear positioning device further comprises an adjusting handle, and the axial position of the rear positioning tool can be adjusted by operating the adjusting handle.

9. The method of claim 8, wherein, The rear positioning device further comprises a positioning pad arranged between the rear positioning tool and the adjusting handle.

10. A crankshaft upsetting system for implementing the method of any one of claims 1 to 9, characterized in that The method comprises configuring front and rear positioning devices in the upsetting die, the front positioning device is configured to contact one end face of the light blank to limit the light blank, and the rear positioning device is configured to contact the other end face of the light blank to transmit the horizontal upsetting force.

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