Z-shaped thin-walled battery pack support forging, forming die and forming method

Abstract

This invention relates to the field of metal parts forming and manufacturing technology, and in particular to a Z-shaped thin-walled battery pack bracket forging, forming mold, and forming method. The forging process involves placing the forged part into a pre-forging cavity in the forming mold for forging; placing the pre-forged part into a precision forging cavity in the forming mold, and restarting the press for precision forging; placing the precision forging part into a cutting die frame for trimming; sawing the left and right symmetrical brackets to obtain two symmetrical forgings; magnetically inspecting and cleaning the forging before storage; pre-forging guidance and distribution; and final precision forging. This process allows the metal to flow more smoothly and evenly from the central region to the asymmetrical thin-walled wings on both sides, minimizing flow resistance. The pre-forging and precision forging cavities are integrated into the same mold module and equipped with a high-strength anti-eccentric load guiding component. The layout of two parts in one mold and the parallel integrated design of the pre-forging and precision forging cavities result in high-precision forgings, improving production efficiency and material utilization, reducing manufacturing costs, and simplifying the design and manufacturing difficulty of the trimming mold.

Description

Technical Field

[0001] This invention relates to the field of metal parts forming and manufacturing technology, and in particular to a Z-shaped thin-walled battery pack bracket forging, forming mold and forming method. Background Technology

[0002] Thin-walled brackets are key components of battery packs in new energy vehicles, and their materials and manufacturing processes directly affect the system's safety, sealing, and service life. This particular bracket is a thin-walled component, ranging from 3mm to 60mm in thickness; its forging shape has a complexity coefficient of S4. To ensure the safety performance of the battery pack assembly, the bracket needs to achieve a certain level of strength; therefore, forging is employed.

[0003] However, existing forging methods have the following problems: 1. The complex asymmetric three-dimensional configuration makes the flow path of metal in the mold cavity tortuous and the resistance distribution extremely uneven, which can easily lead to defects such as incomplete filling, folding, and disordered flow lines, seriously affecting the internal quality and load-bearing capacity of the forging. 2. Asymmetric deformation generates enormous off-center loads on the mold and equipment, directly causing abnormal mold misalignment, uneven wear, and even cracking, seriously threatening mold life, production stability, and economy. Simultaneously, this is also a direct cause of uneven forging thickness and out-of-tolerance contour accuracy. 3. If traditional molds and processes with separate pre-forging and precision forging are used, not only will there be energy consumption and oxidation losses due to multiple heating processes, but also cumulative errors introduced by the conversion of positioning references, making it difficult to guarantee the consistency of product precision. In addition, the dispersed processes also restrict production cycle time and efficiency, and increase manufacturing costs; 4. An unreasonable pre-forging shape design will increase the difficulty of subsequent trimming processes, resulting in uneven trimming force, poor contour quality, and even the need to design more complex trimming dies, affecting the smoothness and cost of the overall process chain. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a Z-shaped thin-walled battery pack bracket forging, forming mold and forming method that reduces the eccentric load of precision forging, ensures uniform thickness of the two wings of the forging, high yield, and facilitates subsequent edge trimming without being affected, in order to solve the problems existing in the prior art mentioned above.

[0005] The technical solution adopted by this invention to solve its technical problem is: a Z-shaped thin-walled battery pack bracket forging, including a forging body, wherein the forging body is an integrally forged structure with a Z-shaped forging structure. The forging design fully considers the forming deflection angle and the magnitude of the eccentric load, maximizing the convenience of metal flow and forming, reducing the deformation resistance of the forging, thereby indirectly ensuring the mold life. The forging body includes... The middle section is divided into a first inclined section and a second inclined section. The first inclined section and the second inclined section are connected by an arc section, and there is a first spatial angle between the first inclined section and the second inclined section. The first side wing extends outward from the first inclined section and bends along the first direction, and the extension surface of the first side wing forms a second spatial angle with the extension surface of the first inclined section. The second wing extends outward from the second inclined section and bends along a second direction opposite to the first direction, and the extension surface of the second wing forms a third spatial angle with the extension surface of the second inclined section. The bottom wing extends laterally from the bottom of the middle section and connects with either side wing.

[0006] Furthermore, one end of the forging body is the large end, and the other end is the small end, with the small end located near the bottom wing; The angle α between the first inclined segment and the horizontal baseline is 1° to 5°. The angle β between the second inclined segment and the horizontal baseline is 5° to 10°. The first wing is set parallel to the horizontal baseline; The angle γ between the second flank and the horizontal baseline is 15° to 18°.

[0007] Furthermore, the arc segment is provided with an integrally formed cylindrical part, and the first inclined segment and the second inclined segment are thin-walled plate-like structures extending from both sides of the cylindrical part, with the local column of the cylindrical part protruding outward relative to the thin-walled plate-like structure.

[0008] A forming die for preparing a Z-shaped thin-walled battery pack bracket forging as described in any one of the above claims, comprising a die body, the die body including... upper mold, The lower die is set opposite to the upper die. After the lower die and the upper die are closed, they form a pre-forging cavity and a precision forging cavity set in parallel. The pre-forging and precision forging are placed on a single module, which improves the overall strength of the die. At the same time, the upper and lower dies have their own guides to resist the eccentric load of the forging itself. They also correct the misalignment of the forging and ensure the uniformity and consistency of the forging thickness. A guide component is located on the contact surface between the upper and lower molds and is used to position and guide the upper and lower molds during the mold closing process. Both the pre-forging cavity and the precision forging cavity are designed with a two-piece structure in one mold. This ensures the yield of forgings while further improving the utilization rate of forging materials and reducing the manufacturing cost of bracket forgings.

[0009] Furthermore, the guiding components include The first guide pair is composed of protrusions on the lower front and lower rear surfaces of the upper mold and corresponding grooves on the upper surfaces of both ends of the lower mold. The second guide pair is composed of a first groove on the lower right surface of the upper mold and a first protrusion on the upper left surface of the lower mold. The third guide pair is composed of a second groove on the upper left surface of the upper mold and a second protrusion on the upper right surface of the lower mold.

[0010] Furthermore, the inclination angle between at least one sidewall segment in the pre-forging cavity and the horizontal reference surface is greater than the inclination angle between the corresponding sidewall segment and the horizontal reference surface in the precision forging cavity. Furthermore, the inclination angle of each sidewall segment in the pre-forging cavity and the precision forging cavity is different.

[0011] Furthermore, a mold closing and positioning assembly is provided between the pre-forging cavity and the precision forging cavity. The mold closing and positioning assembly includes positioning protrusions and positioning grooves respectively provided on the upper mold and the lower mold and capable of fitting into each other.

[0012] A molding method, comprising a molding die as described in any of the preceding claims, including the following process steps: Step 1: Blanking: Obtain round bars of the corresponding diameter and length; Step 2: Heating: Medium frequency heating; Step 3: Pre-forging: Remove the surface oxide scale from the heated bar stock, place it into the pre-forging cavity of the forming die, and forge it using a press. Step 4: Precision forging: After the pre-forging is completed, the pre-forged part is placed into the precision forging cavity in the forming die, and the press is started again to perform precision forging. Step 5: Trimming: Place the precision forging into the cutting die frame and trim the edges; Step 6: Temperature Controlled Cooling: The precision forgings after edge trimming are subjected to temperature controlled cooling to ensure their mechanical properties and hardness. Step 7: Shot blasting: Perform surface shot blasting on the forgings to remove surface oxide scale; Step 8: Shaping: Cold finish the symmetrical precision forgings, and shape and precision forge the machining positioning surfaces and control the thickness uniformity. Step 9: Sawing: Sawing the left and right symmetrical brackets to obtain two types of forgings that are symmetrical on the left and right; Step 10: Magnetic detector cleaning and storage.

[0013] Furthermore, the cutting mold frame in step 5 includes... The upper template has a connecting block installed at its lower end, an upper mold base installed at the lower end of the connecting block, a trimming die installed below the upper mold base, a trimming die floating core located in the middle of the trimming die, a spring connecting plate installed in the middle of the upper mold base, a nitrogen spring installed between the connecting block and the spring connecting plate, and the trimming die floating core connected to the spring connecting plate. The lower end of the spring connecting plate is equipped with The lower template has a trimming punch fixing plate installed in the middle position, and the trimming punch fixing plate is equipped with a trimming punch; Cylinders are installed on both sides of the lower template. A floating positioning plate is installed on the extended end of the cylinder. The floating positioning plate has a through hole for the trimming punch to pass through. The forged part is placed on the floating positioning plate and is directly opposite the trimming punch. The upper template is equipped with a guide sleeve, and the lower template is equipped with a guide post that inserts into and cooperates with the guide sleeve.

[0014] Furthermore, the single-sided clearance fit between the trimming die and the trimming punch is d1, and the single-sided clearance fit between the floating core of the trimming die and the inclined punch is d2, and d1≤0.3mm, 0.3mm≤d2≤0.6mm; The deviation of the peripheral profile of the forging after trimming from its reference surface is Δ≤1.2mm, and the deviation of the peripheral profile of the finished thin-walled part from its reference surface is Δ≤2mm.

[0015] The beneficial effects of this invention are: 1. The gradient design of pre-forging guidance distribution and final shaping of precision forging allows the metal to flow more smoothly and evenly from the central area to the asymmetrical thin-walled wings on both sides, minimizing flow resistance and effectively avoiding internal defects such as incomplete filling, folding and flow line disorder. Thus, while obtaining an extremely lightweight shape, it ensures the dense internal structure and excellent load-bearing capacity of the forging. 2. The pre-forging and precision forging cavities are integrated into the same mold module and equipped with a high-strength anti-eccentric load guiding component, which directly suppresses the harm of eccentric load from the structure, significantly extends the service life of the mold, reduces maintenance costs, and ensures the stable operation of equipment such as presses; 3. The layout of two parts in one mold and the parallel integrated design of pre-forging and precision forging cavities completely eliminate the reference conversion error, multiple heating energy consumption and oxidation loss caused by traditional multi-process and multi-mold processes. It ensures ultra-high repeatability positioning accuracy from pre-forging to precision forging, thereby stably obtaining high-precision forgings with uniform thickness and consistent contour, which greatly improves production efficiency and material utilization and reduces the manufacturing cost per piece. 4. The forgings have a reasonable flash distribution and contour transition, which significantly simplifies the design and manufacturing difficulty of the trimming die, avoids trimming difficulties, secondary defects or additional shaping processes caused by poor forging shape, and makes the entire forging-trimming process chain smooth, efficient and cost-controllable. Attached Figure Description

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0017] Figure 1 This is a schematic diagram of the structure of the Z-shaped thin-walled battery pack support forging of the present invention; Figure 2 This is the present invention. Figure 1 A structural diagram from another direction; Figure 3 This is a front view of the Z-shaped thin-walled battery pack support forging of the present invention; Figure 4 This is a top view of the Z-shaped thin-walled battery pack support forging of the present invention; Figure 5 This is a schematic diagram of the molding die of the present invention; Figure 6 This is a schematic diagram of the upper mold in the molding die of this invention; Figure 7 This is a schematic diagram of the lower mold in the molding die of this invention; Figure 8 This is a picture of the finished product forged using the present invention; Figure 9 This is a process flow diagram of the present invention; Figure 10 This is a cross-sectional view of the cutting mold frame of the present invention; In the diagram: 1. Upper mold, 101. Protrusion, 102. First groove, 103. Second groove. 2. Lower mold, 201. Inner groove, 202. Second protrusion, 203. First protrusion, 3. Pre-forging cavity; 4. Precision forging cavity. 501. Floating core of trimming die, 502. Trimming die, 503. Upper die base, 504. Spring connecting plate, 505. Floating positioning plate, 506. Trimming punch, 507. Trimming punch fixing plate, 508. Cylinder, 509. Connecting block, 510. Nitrogen spring, 511. Lower template, 512. Upper template, 513. Guide post, 514. Guide sleeve, 6. Lower push rod, 71. Middle section, 711. Cylindrical section, 712. Arc section, 714. First inclined section, 715. Second inclined section, 72. First side wing, 73. Second side wing, 74. Bottom wing, 75. Reinforcing rib, 76. Thinning zone. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0019] like Figures 1-4As shown, a Z-shaped thin-walled battery pack bracket forging includes a forging body, which is a monolithic forging structure without any welding or splicing seams, thus ensuring the continuity of the material's metal flow lines and the overall high strength and high reliability. The forging body exhibits a complex three-dimensional "Z"-shaped spatial configuration. The forging body includes... The middle section 71 is divided into a first inclined section 714 and a second inclined section 715. The first inclined section 714 and the second inclined section 715 are connected by an arc section 712. The first inclined section 714 and the second inclined section 715 have a first spatial angle. The first side wing 72 extends outward from the first inclined section 714 and bends along the first direction, and the extension surface of the first side wing 72 forms a second spatial angle with the extension surface of the first inclined section. The second side wing 73 extends outward from the second inclined section 715 and bends along a second direction opposite to the first direction, and the extension surface of the second side wing 73 forms a third spatial angle with the extension surface of the second inclined section 715. This layout, with its two wings extending in opposite directions, is key to creating the Z-shaped feature and achieving spatial avoidance and multi-directional connectivity. The bottom wing 74 extends laterally from the bottom of the middle section 71 and connects with either side wing. The bottom wing 4 is a plate-like structure that extends horizontally outward from the bottom of the middle section 71. Together, they form a stable triangular support area, providing the main installation reference for the entire bracket.

[0020] like Figure 3 As shown, one end of the forging body is the large end, and the other end is the small end, with the small end located near the bottom wing 74. The angle α between the first inclined segment 714 and the horizontal baseline is 1° to 5°. The angle β between the second inclined segment 715 and the horizontal baseline is 5° to 10°. The first wing 72 is positioned parallel to the horizontal baseline; The angle γ between the second flank 73 and the horizontal baseline is 15° to 18°.

[0021] This series of precise, asymmetrical angle designs serves two purposes: firstly, functionally, they precisely define the final spatial orientation of the forging within the battery pack, ensuring a perfect fit with surrounding components; secondly, in terms of process, these optimized gradient angles (α<β<γ) effectively guide the metal to flow smoothly and orderly from the middle section to the two side wings during forging, significantly reducing the resistance of metal filling thin walls and far ends, which is key to ensuring that complex components are forged in one go with full shape and good internal quality.

[0022] like Figure 2As shown, the outer contours of the first side wing 72 and the second side wing 73 are both inclined surfaces, which not only serve as the draft angle necessary for forging demolding, making it easy for the parts to be taken out of the mold smoothly, but also achieve further weight reduction through the gradual thinning of the edge material.

[0023] like Figure 1 As shown, a reinforcing rib 75 is provided at the connection between the cylindrical part 711 and the bottom wing 74. The addition of the reinforcing rib can greatly improve the local stiffness and resistance to deformation, and ensure the reliability of the connection.

[0024] The connections between the middle section 71 and the first side wing 72, the second side wing 73, and the bottom wing 74 are all made with arc surfaces, thereby reducing stress concentration and extending service life. Figure 2 and Figure 4 As shown, an integrally formed cylindrical portion 711 is provided at the arc segment 712. The first inclined segment 714 and the second inclined segment 715 are thin-walled plate-like structures extending from both sides of the cylindrical portion 711. The local columnar part of the cylindrical portion 711 protrudes outward relative to the thin-walled plate-like structure, achieving an optimal combination of local reinforcement and overall lightweight, while the smooth transition avoids stress concentration. The axial length of the cylindrical portion 711 is less than the length of the plate-like structure of the first inclined segment 714 or the second inclined segment 715, and the connection between the cylindrical portion 711 and the first inclined segment 714 and the second inclined segment 715 is through an arc segment transition.

[0025] Thinning zones 76 are provided on the surfaces of the first side wing 72, the second side wing 73, and the bottom wing 74.

[0026] like Figure 3 As shown, the side profiles of the first wing 72 and the second wing 73 are wavy. The side profile at the junction of one wing and bottom wing 74 is the first concave arc segment; The contour between two adjacent thinning zones 76 located on the first wing 72 and the second wing 73 is a second concave arc segment; The radius of curvature of the first concave arc segment is greater than the radius of curvature of the second concave arc segment.

[0027] Usage process: When the bracket forging is installed and operates in the battery pack, its bottom wing 74 is fixed to the lower shell of the battery pack with bolts, while the side wings are used to support and fix the battery modules or pipelines. Its one-piece forged Z-shaped three-dimensional frame can efficiently decompose and transmit forces through its continuous metal streamlines and optimized geometry when subjected to multi-dimensional loads from vehicle vibration, impact and other factors. It provides extremely high structural integrity with extremely light weight, perfectly meeting the stringent requirements of new energy vehicle battery packs for high safety and long range.

[0028] like Figures 5-8As shown, a forming die for preparing a Z-shaped thin-walled battery pack bracket forging as described in any of the above claims includes a die body, the die body comprising... Upper mold 1, The lower mold 2 is set opposite to the upper mold 1. After the lower mold 2 and the upper mold 1 are closed, they form a pre-forging cavity 3 and a precision forging cavity 4 arranged side by side. That is, the pre-forging cavity 3 and the precision forging cavity 4 are placed on one mold, thereby improving the overall strength of the mold. The guide assembly is located on the contact surface between the upper die 1 and the lower die 2. It is used to position and guide the upper die 1 and the lower die 2 during the die closing process. In particular, it is used to resist the off-center load moment generated when the forging is formed by the Z-shaped asymmetric structure. It also corrects the misalignment of the forging and ensures the uniformity and consistency of the forging thickness. Both the pre-forging cavity 3 and the precision forging cavity 4 are laid out as a two-piece structure in one die, and the final forging is as follows: Figure 8 As shown, the final forging is machined to divide the forging into two support forgings, which ensures the thickness of the bottom wing of the support forging and improves the yield.

[0029] At the same time, to achieve better forging, a symmetrical structure is adopted, with the thickest part of the forging in the middle and the thinnest part on both sides. Following the characteristic that the deformation is small in the middle and large on both sides, the material is evenly distributed to further improve the material utilization rate of the forging. A cavity positioning assembly for improving mold closing accuracy is provided at the middle position of the pre-forging cavity 3 and the precision forging cavity 4.

[0030] The guide components include The first guide pair is composed of protrusions 101 provided on the lower front surface and the lower rear surface of the upper mold 1 and inner grooves 201 provided on the upper surfaces of the two ends of the lower mold 2. The second guide pair is composed of a first groove 102 disposed on the lower right surface of the upper mold 1 and a first protrusion 203 disposed on the upper left surface of the lower mold 2. The third guide pair is composed of a second groove 103 disposed on the upper left surface of the upper mold 1 and a second protrusion 202 disposed on the upper right surface of the lower mold 2.

[0031] The lower surface refers to the side of the upper mold 1 facing the mold closing direction; the upper surface refers to the side of the lower mold 1 facing the mold closing direction.

[0032] The first guide pair, the second guide pair, and the third guide pair constitute a complete guide pair on the upper mold 1 and the lower mold 2. The three sets of guide pairs are asymmetrically distributed in space, forming a constraint system that can effectively resist complex variable load moments.

[0033] like Figure 6 or Figure 7As shown, the height of the first protrusion 203 is greater than the height of the second protrusion 202; The height of the first protrusion 203 is less than the depth of the second groove 103. After the first protrusion 203 and the second groove 103 are molded together, a gap is formed. This gap is directly opposite the pouring port of the pre-forging cavity 3, providing a small amount of allowance space for the huge radial pressure generated when the metal begins to fill the cavity violently. This avoids the hard jamming and wear of the guide pair at this point, and is also conducive to the stability of the initial flow of metal. It is a precise pressure release and dynamic compensation mechanism.

[0034] The inclination angle between at least one sidewall segment in the pre-forging cavity 3 and the horizontal reference surface is greater than the inclination angle between the corresponding sidewall segment in the precision forging cavity 4 and the horizontal reference surface. Furthermore, the inclination angle of each sidewall segment in the pre-forging cavity 3 and the precision forging cavity 4 is different.

[0035] A larger pre-forging cavity angle allows for a more open cavity, reducing metal flow resistance and facilitating initial material distribution during the pre-forging stage. A smaller finish-forging cavity angle, however, more closely approximates the final part shape, enabling precision forming. This gradient angle design, guiding pre-forging and shaping finish-forging, combined with asymmetrical guide components, fundamentally optimizes the metal flow path and homogenizes deformation resistance, significantly reducing the eccentric load in the finish-forging process and ensuring uniform thickness on both sides and overall. Furthermore, a well-designed pre-forging shape lays a solid foundation for subsequent trimming processes, ensuring uniform trimming force, easy removal of flash, and simplifying die design.

[0036] 7. A forming mold according to claim 1, characterized in that: the projected area of ​​the pre-forging cavity 3 is larger than the projected area of ​​the precision forging cavity 4, ensuring that there is sufficient metal material to complete the forming from pre-forging to precision forging.

[0037] At the same time, thickness compensation is performed. In areas where the flow is not obvious in the internal region, the thickness is designed to be slightly lower; in areas where the flow is relatively fast in the external region, the thickness is designed to be slightly higher, so as to ensure that the overall thickness of the forging is within the dimensional range.

[0038] A mold closing and positioning assembly is provided between the pre-forging cavity 3 and the precision forging cavity 4. The mold closing and positioning assembly includes positioning protrusions and positioning grooves respectively provided on the upper mold 1 and the lower mold 2 and capable of fitting together, in order to further enhance the local rigidity and centering accuracy of this area. like Figure 5 As shown, the upper mold 1 is provided with multiple ejector pins 6 that penetrate its body and point toward the lower mold 2.

[0039] It also includes a drive mechanism for driving the lower ejector rod 6 to move along the mold opening direction, for removing the forging from the upper mold 1.

[0040] like Figure 9As shown, a molding method includes a molding die as described in any of the above claims, comprising the following process steps: Step 1: Blanking: Obtain round bars of the corresponding diameter and length; Step 2: Heating: Medium frequency heating, heating to 1100℃~1300℃, and after heating, it is transported to the press station by conveyor belt; Step 3: Pre-forging: Use an air gun to remove the surface oxide scale from the heated bar stock, place it into the pre-forging cavity 3 of the forming die, and forge it using a press. Pre-forging facilitates the pre-forming and material distribution of the Z-shaped part, but generates a large eccentric load, resulting in permissible thickness deviations. Specifically: Step 31: Preparation and Mold Closure: Place the heated billet into the pre-forging cavity 3 of the lower die 2. The press drives the upper die 1 downward, and the guide components (first, second, and third guide pairs) begin to function, guiding the upper die 1 and the lower die 2 to achieve precise and stable centering and mold closure under high off-center load conditions; Step 32: Pre-forging: The upper die 1 continues to descend, and the billet undergoes plastic deformation within the pre-forging cavity 3. Guided by the optimized cavity angle, the metal flows from the center to the asymmetrical wings on both sides. At this time, the guide gap plays a dynamic adjustment role at the metal flow inlet. Step 4: Precision Forging: After pre-forging, place the pre-forged part into the precision forging cavity 4 of the forming die, and restart the press for precision forging. The precision forging cavity 4 is designed to rotate at a certain angle based on the pre-forging process, minimizing the eccentric load on the equipment and maintaining uniform thickness of the forging. The pre-forged part has a smaller profile than the precision forging part, which facilitates stable placement into the precision forging cavity 4. Specifically: Step 41: Transfer and Precision Forging: After pre-forging is completed, the mold is opened, and the operating equipment or robot quickly transfers the pre-forged part to the adjacent precision forging cavity 4. The upper mold 1 descends again, and the mold closing accuracy is ensured by the cavity positioning components. The pre-forged part completes the final precision forming in the precision forging cavity 4. Since the pre-forged shape has greatly improved the metal distribution, the eccentric load during precision forging is effectively reduced. Step 42: Ejection and Demolding: After precision forging is completed, the mold is opened, and the drive mechanism (such as the pneumatic or hydraulic ejection device at the bottom of the press) is activated, pushing the lower ejector rod 6 downward to smoothly eject the precision forging that may have adhered to the upper mold 1, completing one forging cycle. The final product image is shown below. Figure 8 As shown.

[0041] Step 5: Trimming: The precision forging is conveyed to the trimming station via a conveyor belt. The forging is placed in the trimming die for trimming. The trimmed edge shape differs from that of normal forging; it is a 45° bevel cut. Therefore, a trimming gap of ≤0.3 mm is required to ensure no burrs or burrs on the edge. The specific steps for trimming in Step 5 are as follows: Step 51: Install the trimming die 502 on the slide of the press. Its inner cavity shape is completely consistent with the contour of the parting surface of the forging, and it has a sharp cutting edge on the lower end face. Step 52: Fix the trimming punch 506 on the worktable of the press. The shape of its working part matches the shape of the corresponding part of the forging. It serves to position and support the forging. Step 53: The operator uses clamps to accurately place the precision forging with flash onto the trimming punch 506. The shape of the trimming punch 506 ensures that the forging can be stably and correctly positioned. Step 54: The press slide moves the trimming die 502 downwards; Step 55: The cutting edge of the trimming die 502 first contacts the flash of the forging and continues to move downward; Step 56: Under the combined action of the cutting edge of the trimming die 502 and the fixed trimming punch 506 as the lower support, the flash is subjected to a strong shearing force. Step 57: As the cutting die 502 continues to descend, the shearing action starts from one point of the flash and quickly expands to the entire contour circumference, eventually cutting off the entire flash completely. At this point, the forging body has completely entered the inner cavity of the die, and the shearing is complete. Step 58: The press drives the trimming die 502 to start the upward return stroke, and the flash falls off; when the return stroke reaches a certain position, the cylinder 508 pushes the floating positioning plate 505 to smoothly push the forging out of the punch, and the trimmed forging and the trimmed flash enter the next process respectively. Step 6: Temperature Controlled Cooling: The precision forgings after edge trimming are subjected to temperature controlled cooling to ensure their mechanical properties and hardness. Step 7: Shot blasting: Perform surface shot blasting on the forgings to remove surface oxide scale; Step 8: Shaping: Shape the symmetrical precision forgings (such as...) Figure 8 (As shown) cold finishing is performed, and the machining positioning surfaces are shaped, precision forged, and thickness uniformity is controlled. Step 9: Sawing: Sawing the left and right symmetrical brackets to obtain two types of forgings that are symmetrical on the left and right; Step 10: Magnetic detector cleaning and storage.

[0042] Among them, such as Figure 10 As shown, the cutting mold frame in step 5 includes The upper template 512 has a connecting block 509 installed at its lower end. The lower end of the connecting block 509 is equipped with an upper mold base 503. A trimming die 502 is installed below the upper mold base 503. A trimming die floating core 501 is provided in the middle of the trimming die 502. A spring connecting plate 504 is installed in the middle of the upper mold base 503. A nitrogen spring 510 is installed between the connecting block 509 and the spring connecting plate 504. The trimming die floating core 501 is connected to the spring connecting plate 504. The lower end of the spring connecting plate 504 is equipped with The lower template 511 has a trimming punch fixing plate 507 installed in the middle position, and the trimming punch fixing plate 507 is provided with a trimming punch 506. Cylinders 508 are installed on both sides of the lower template 511. A floating positioning plate 505 is installed on the extended end of the cylinder 508. A through hole is opened on the floating positioning plate 505 for the trimming punch 506 to pass through. The forged flash is placed on the floating positioning plate 505 and is directly facing the trimming punch 506. A guide sleeve 514 is installed on the upper template 512, and a guide post 13 is installed on the lower template 511 to insert into and cooperate with the guide sleeve 514.

[0043] The single-sided clearance fit between the trimming die 502 and the trimming punch 506 is d1, and the single-sided clearance fit between the floating core 501 of the trimming die and the inclined punch 506 is d2, and d1≤0.3mm, 0.3mm≤d2≤0.6mm; d1 directly determines the quality of the sheared surface and the cut edge, preventing excessive burrs, rough cross-sections, and contour deformation caused by excessive clearance; it also prevents excessively small clearance from causing mold wear or even abnormal shearing. d1≤0.3mm yields a clean, perpendicular sheared contour with minimal deformation, thus ensuring the accuracy of the forging's peripheral contour after shearing.

[0044] d2 determines the positioning and support accuracy of the forging body during the trimming process. Its lower limit ensures that the gap cannot be too small, so as to avoid jamming or severe scratching due to small positive deviations in the size of the forging or misalignment of the mold, which could scratch the surface of the forging or even cause contour deformation. The upper limit ensures that the gap is not too large, so as to ensure that the forging has a stable and accurate radial positioning during edge trimming, preventing it from shaking or tipping in the mold, and thus preventing the profile from exceeding the tolerance after trimming.

[0045] After trimming, the deviation of the peripheral profile of the forging relative to its reference surface is Δ≤1.2mm. In order to ensure that the final product can meet the requirement of 2mm, a smaller inner hole standard is set in the earlier trimming process to leave a margin for subsequent processes. The deviation of the peripheral contour of the finished thin-walled part from the reference surface is Δ≤2mm, that is, 2mm is the maximum allowable deviation. The smaller the value, the higher the precision requirement.

[0046] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A Z-shaped thin-walled battery pack support forging, characterized in that: Includes a forging body, which is an integral structure formed by one-piece forging. The forging body includes... The middle section (71) is divided into a first inclined section (714) and a second inclined section (715). The first inclined section (714) and the second inclined section (715) are connected by an arc section (712). The first inclined section (714) and the second inclined section (715) have a first spatial angle. The first side wing extends outward from the first inclined section (714) and bends along the first direction, and the extension surface of the first side wing forms a second spatial angle with the extension surface of the first inclined section. The second wing extends outward from the second inclined section (715) and bends in a second direction opposite to the first direction, and the extension surface of the second wing forms a third spatial angle with the extension surface of the second inclined section (715). Bottom wing (74), which extends laterally from the bottom of the middle section (71) and connects to either side wing; One end of the forging body is the large end, and the other end is the small end, with the small end located near the bottom wing (74); The angle α between the first inclined segment (714) and the horizontal baseline is 1° to 5°; The angle β between the second inclined segment (715) and the horizontal baseline is 5° to 10°; The first wing is set parallel to the horizontal baseline; The angle γ between the second flank and the horizontal baseline is 15° to 18°.

2. The Z-shaped thin-walled battery pack support forging according to claim 1, characterized in that: The arc segment (712) is provided with an integrally formed cylindrical part (711), the first inclined segment (714) and the second inclined segment (715) are thin-walled plate-like structures extending from both sides of the cylindrical part (711), and the local column of the cylindrical part (711) protrudes outward relative to the thin-walled plate-like structure.

3. A forming mold for preparing a Z-shaped thin-walled battery pack support forging as described in any one of claims 1 to 2, characterized in that: Includes a mold body, the mold body comprising Upper mold (1), The lower die (2) is set opposite to the upper die (1). After the lower die (2) and the upper die (1) are closed, they form a pre-forging cavity (3) and a precision forging cavity (4) arranged in parallel. A guide component is provided on the contact surface between the upper mold (1) and the lower mold (2) for positioning and guiding the upper mold (1) and the lower mold (2) during the mold closing process; Both the pre-forging cavity (3) and the precision forging cavity (4) are laid out as a two-piece structure in one mold; The guiding component includes The first guide pair is composed of a protrusion (101) on the lower front surface and the lower rear surface of the upper mold (1) and an inner groove (201) on the upper surface of both ends of the lower mold (2); The second guide pair is composed of a first groove (102) disposed on the lower right side surface of the upper mold (1) and a first protrusion (203) disposed on the upper left side surface of the lower mold (2); The third guide pair is composed of a second groove (103) provided on the left upper surface of the upper mold (1) and a second protrusion (202) provided on the right upper surface of the lower mold (2); The inclination angle between at least one side wall segment of the pre-forging cavity (3) and the horizontal reference surface is greater than the inclination angle between the corresponding side wall segment and the horizontal reference surface of the precision forging cavity (4); Furthermore, the inclination angles of each sidewall segment in the pre-forging cavity (3) and the precision forging cavity (4) are different.

4. A molding die according to claim 3, characterized in that: A mold closing and positioning assembly is provided between the pre-forging cavity (3) and the precision forging cavity (4). The mold closing and positioning assembly includes positioning protrusions and positioning grooves respectively provided on the upper mold (1) and the lower mold (2) and capable of fitting together.

5. A molding method, comprising a molding die as described in any one of claims 3 to 4, characterized in that: The process includes the following steps: Step 1: Blanking: Obtain round bars of the corresponding diameter and length; Step 2: Heating: Medium frequency heating; Step 3: Pre-forging: Remove the surface oxide scale from the heated bar stock, place it into the pre-forging cavity (3) in the forming mold, and forge it using a press. Step 4: Precision forging: After the pre-forging is completed, the pre-forged part is placed into the precision forging cavity (4) in the forming mold, and the press is started again to perform precision forging; Step 5: Trimming: Place the precision forging into the cutting die frame and trim the edges; Step 6: Temperature Controlled Cooling: The precision forgings after edge trimming are subjected to temperature controlled cooling to ensure their mechanical properties and hardness. Step 7: Shot blasting: Perform surface shot blasting on the forgings to remove surface oxide scale; Step 8: Shaping: Cold finishing is performed on the symmetrical precision forging parts, and the machining positioning surfaces are shaped and precision forged, and the thickness uniformity is controlled. Step 9: Sawing: Sawing the left and right symmetrical brackets to obtain two types of forgings that are symmetrical on the left and right; Step 10: Magnetic detector cleaning and storage.

6. The molding method according to claim 5, characterized in that: The cutting mold frame in step 5 includes The upper template (512) has a connecting block (509) installed at its lower end. The upper mold base (503) is installed at the lower end of the connecting block (509). The trimming die (502) is installed below the upper mold base (503). The trimming die (502) has a trimming die floating core (501) in the middle position. The upper mold base (503) has a spring connecting plate (504) installed in the middle position. A nitrogen spring (510) is installed between the connecting block (509) and the spring connecting plate (504). The trimming die floating core (501) is connected to the spring connecting plate (504). The lower end of the spring connecting plate (504) is equipped with The lower template (511) has a trimming punch fixing plate (507) installed in the middle position, and the trimming punch fixing plate (507) is provided with a trimming punch (506). Cylinders (508) are installed on both sides of the lower template (511). A floating positioning plate (505) is installed on the extended end of the cylinder (508). A through hole is provided on the floating positioning plate (505) for the trimming punch (506) to pass through. The flash forging is placed on the floating positioning plate (505) and is directly opposite the trimming punch (506). A guide sleeve (514) is installed on the upper template (512), and a guide post (13) is installed on the lower template (511) to insert into the guide sleeve (514) and cooperate with it.

7. The molding method according to claim 6, characterized in that: The single-sided clearance fit between the trimming die (502) and the trimming punch (506) is d1, and the single-sided clearance fit between the trimming die floating core (501) and the inclined punch (506) is d2, and d1≤0.3mm, 0.3mm≤d2≤0.6mm; The deviation of the peripheral profile of the forging after trimming from its reference surface is Δ≤1.2mm, and the deviation of the peripheral profile of the finished thin-walled part from its reference surface is Δ≤2mm.

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