Swash plate forging process
By optimizing the swash plate head structure and heating method, and combining phosphating and finishing techniques, the problems of low forming accuracy and poor surface quality in traditional swash plate forging have been solved, achieving efficient and high-quality swash plate forging.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-30
- Publication Date
- 2026-04-10
AI Technical Summary
Traditional swash plate forging processes are cumbersome, have low forming accuracy and poor surface quality, and also increase production costs and internal stress concentration.
By optimizing the swashplate head structure into an integral boss, using 45° parting and gradient temperature control heating, combined with phosphating, pulsed air pressure assisted molding, segmented cooling and plasma finishing, the twisting and shaping processes are eliminated, achieving high-precision molding in one step.
It achieves high-precision forming of swashplates, improves production efficiency and surface quality, eliminates additional processes, reduces production costs, and increases the yield rate of finished products.
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Figure CN121820510A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application belongs to the technical field of forging, and particularly relates to a swash plate forging process. BACKGROUND
[0002] As a core transmission component of hydraulic machinery, the complexity of the head structure of the swash plate leads to problems such as complicated process, low forming precision, and poor surface quality in the traditional forging process. Figure 1 , Figure 2 As shown in the swash plate product, such product has great difficulty in mold making and forging forming due to the limitation of the head shape, and the original process is to modify the angle of the swash plate head, first forge forming, and then twist the head after edge cutting. Figure 3 , Figure 4 This process solves the problems of difficult parting of the mold and existence of part of the forging not being filled, and the angle after twisting the head also meets the requirements, but the surface after twisting the head is uneven. Figure 5 To solve this problem, a shaping process is added to solve the problem of uneven plane, and the above process meets the customer's requirements, but increases the processes of twisting the head and shaping, reduces the production efficiency, and increases the production cost. Therefore, the existing technology through the processes of "forging-twisting the head-shaping" can meet the basic size requirements, but the additional processes not only reduce the production efficiency, but also easily lead to stress concentration in the forging and out-of-tolerance of the surface flatness.
[0003] Therefore, the above problems should be considered and solved in the production forging process of the swash plate. SUMMARY
[0004] The purpose of the present application is to overcome the shortcomings of the existing swash plate forging process, provide a swash plate forging process, realize one-time high-precision forming of the swash plate, cancel the processes of twisting the head and shaping, and improve the size precision and surface quality of the forging. The swash plate forging process provided by the present application is characterized by comprising the following steps: (1) forging modeling optimization: the elliptical boss structure of the head of the swash plate is optimized into an integral boss structure, the integral boss is a smooth arc transition structure, the boss width matches the assembly function size requirement of the swash plate, and the arc transition radius is 10-20 mm; (2) swash plate head parting: the horizontal direction parting of the head of the swash plate is changed into 45° direction parting, and the metal flow path during forging of the blank is planned to make the metal preferentially fill the head cavity along the direction of the 45° parting surface; (3) forging forming: firstly, the swash plate blank is subjected to phosphating treatment to form a phosphating film, and then the swash plate blank is subjected to gradient temperature control heating and once forging forming to complete the forming of the swash plate body and the head; (4) edge cutting: the swash plate forge piece after the forging forming is subjected to flexible edge cutting treatment, and then the surface oxide layer and fine burrs are removed through plasma finishing; (5) quality detection: the size precision of the forge piece is detected by laser three-dimensional scanning to ensure that the head angle tolerance of the forge piece is ≤±0.5° and the surface flatness is ≤0.03 mm, and the internal defects of the forge piece are detected by magnetic powder detection.
[0005] Further improvement of the present application is that in the step (2), a pre-forming groove is opened in the area corresponding to the head forming of the blank before the blank is heated, the depth of the pre-forming groove is 1 / 5-1 / 4 of the diameter of the blank, the slotting direction is consistent with the direction of the 45° parting surface, and the metal flow path during forging of the blank is planned in this way, the cross section of the pre-forming groove is semicircular, and a round corner of 0.5-1 mm is arranged at the slot opening.
[0006] Further improvement of the present application is that in the step (3), when the swash plate blank is heated, the blank is subjected to gradient temperature control heating according to the head forming area, the body forming area and the transition area, the heating temperature of the head forming area is 1100-1150℃, the heating temperature of the body forming area is 1050-1100℃, and the heating temperature of the transition area is 1000-1050℃.
[0007] Further improvement of the present application is that in the step (2), the heated blank is put into a forging cavity, the mold is closed along the 45° parting surface, and then forging pressure is applied, the pressure is maintained for 10-20 s, and pulse air pressure is introduced for auxiliary forming in the later pressure maintaining stage, and the forging forming of the swash plate body and the head is completed at one time.
[0008] Further improvement of the present application is that in the step (2), after the forging forming, the swash plate forge piece is subjected to segmented cooling, first air cooling at a rate of 50-70℃ / min to 400℃, and then furnace cooling at a rate of 20-30℃ / min to below 200℃.
[0009] Further improvement of the present application is that in the step (3), the phosphating treatment adopts zinc-based phosphating liquid, the phosphating temperature is 50-60℃, and the thickness of the phosphating film formed after phosphating for 10-15 min is 1-3μm.
[0010] Further improvement of the present application is that in the step (4), the swash plate forge piece after the forging forming is subjected to flexible edge cutting by using a numerical control hydraulic edge cutting machine, and the cutting edge of the cutting tool is an elastic damping structure.
[0011] The further improvement of the present application is that in the step (4), when the plasma finishing is used, the working gas of the jet is the mixed gas of argon and hydrogen, the mixing ratio is 9:1, the height of the jet from the surface of the forging is 5-10mm, and the surface roughness of the forging after the finishing is ensured to be Ra≤1.6μm.
[0012] The further improvement of the present application is that in the step (5), the scanning precision of the laser three-dimensional scanning is ±0.01mm, the scanning rate is 5000 points / s, then the magnetic detection is carried out through the flaw detector, and the detection is repeated twice, finally the finished product is obtained after demagnetization and is detected.
[0013] Compared with the prior art, the present application can obtain the following technical effects: 1. The present application optimizes the shaping of the swash plate forging, optimizes the original oval boss of the swash plate head into an integral boss, effectively solves the problem of difficult parting of the mold and the problem of incomplete filling of the traditional oval boss cavity; 2. The original uniform heating mode is changed, the blank is differentially heated in different regions to match the metal flow demand, and the cavity filling rate is further improved; 3. The swash plate head parting is changed to 45° direction parting to solve the problem of large edge cutting residue, and this way can realize direct forging, cancels the original head twisting process and shaping process, greatly improves the production quality and work efficiency. BRIEF DESCRIPTION OF DRAWINGS
[0014] The drawings described herein are used to provide further understanding of the present application, constitute a part of the present application, and the illustrative embodiments of the present application and the description thereof are used to explain the present application, and do not constitute an improper limitation on the present application. In the drawings: Figure 1 、 Figure 2 is a schematic diagram of the original swash plate product in the present application; Figure 3 is a schematic diagram of the original swash plate forging in the present application; Figure 4 is a schematic diagram of the original swash plate forging after head twisting in the present application; Figure 5 is a schematic diagram of the original swash plate product after head twisting in the present application; Figure 6 is a schematic diagram of the swash plate forging head before optimization in the present application; Figure 7 is a schematic diagram of the swash plate forging head after optimization in the present application; Figure 8 、 Figure 9 is a schematic diagram of the swash plate forging parting in the present application; Figure 10 、 Figure 11 is a schematic diagram of the swash plate forging after process improvement in the present application. DETAILED DESCRIPTION
[0015] The following will describe in detail the implementation of the present invention with reference to the accompanying drawings and embodiments, so as to fully understand how the present invention uses technical means to solve technical problems and achieve technical effects and to implement it accordingly.
[0016] This embodiment provides a swashplate forging process, including the following steps. (1) Forging shape optimization: The elliptical boss structure of the swash plate head is optimized into an integral boss structure. The integral boss is a smooth arc transition structure. The boss width matches the assembly function size requirements of the swash plate, and the arc transition radius is 15mm.
[0017] (2) Swashplate head parting: Change the horizontal parting of the swashplate head to a 45° parting. Before heating the billet, open a pre-forming groove in the area corresponding to the head forming of the billet. The depth of the pre-forming groove is 1 / 5 of the billet diameter. The groove opening direction is consistent with the direction of the 45° parting surface. In this way, the metal flow path during billet forging is planned so that the metal fills the head cavity first along the direction of the 45° parting surface. The cross section of the pre-forming groove is semi-circular, and the groove opening is set with a 1mm rounded corner to prevent the cavity from not being filled.
[0018] (3) Forging and forming: First, the swash plate billet is phosphated using a zinc-based phosphate solution at a temperature of 55°C. After 15 minutes of phosphate treatment, a 3μm thick phosphate film is formed, reducing the coefficient of friction. Then, the swash plate billet is forged in one pass after gradient temperature control heating to complete the forming of the swash plate body and head. When heating the swash plate billet, the billet is heated in a gradient temperature control manner according to the head forming area, the body forming area, and the transition area. The heating temperature of the head forming area is 1100°C, and the heating temperature of the body forming area is... The heating temperature in the transition zone is 1000℃, and the heated billet is 1050℃. Then, the heated billet is placed into the forging cavity, and the mold is closed along the 45° parting surface. Forging pressure is applied and held for 15 seconds. In the later stage of holding pressure, pulse air pressure is introduced to assist in forming and enhance the metal filling. The forging of the swashplate body and head is completed in one step. After forging, the swashplate forging is cooled in stages. First, it is air-cooled to 400℃ at a rate of 60℃ / min, and then furnace-cooled to below 200℃ at a rate of 25℃ / min to release internal stress.
[0019] (4) Edge trimming: A CNC hydraulic edge trimming machine is used to perform flexible edge trimming on the forged slant forging. The cutting edge of the edge trimming tool has an elastic damping structure, and the edge trimming path is corrected in real time according to the actual contour of the forging to avoid edge chipping. Then, the surface oxide layer and fine burrs are removed by plasma finishing. When using plasma finishing, the working gas of the jet is a mixture of argon and hydrogen in a mixing ratio of 9:1. The height of the jet from the surface of the forging is 8mm. After finishing, the surface roughness Ra of the forging is guaranteed to be ≤1.6μm.
[0020] (5) Quality inspection: Laser three-dimensional scanning is used to inspect the dimensional accuracy of the forgings to ensure that the head angle tolerance of the forging is ≤ ±0.5° and the surface flatness is ≤ 0.03mm. At the same time, magnetic particle testing is used to detect internal defects in the forgings. The scanning accuracy of laser three-dimensional scanning is ±0.01mm and the scanning rate is 5000 points / second. Then, magnetic detection is performed by a flaw detector and repeated twice. Finally, after demagnetization, the finished product is obtained and inspected. Unqualified forgings are returned to the billet stage for re-forging to improve the finished product qualification rate.
[0021] This embodiment provides a swashplate forging process, such as Figure 6 , Figure 7 As shown, the elliptical boss topology of the swashplate head is optimized into a monolithic boss structure, and the horizontal parting line of the swashplate head is changed to a 45° parting line, as follows. Figure 8 , Figure 9 As shown, this method solves the problem of incomplete filling of the cavity in traditional elliptical boss forgings. Differentiated heating of different areas of the swashplate billet matches the metal flow requirements. Pulse pneumatic assisted forming further improves the cavity filling rate, increasing the internal microstructure uniformity of the forging by more than 40%. Flexible edge trimming of the swashplate forging avoids edge deformation, and plasma finishing reduces the surface roughness to Ra≤1.6μm, eliminating the need for additional shaping processes. This embodiment eliminates the twisting and shaping processes in the original process, increasing production efficiency by more than 50%. Segmented cooling and quality inspection reduce the forging crack rate to below 0.5%, achieving a finished product qualification rate of 99%, resulting in the desired product. Figure 10 , Figure 11 The slant plate forging has a smooth and flat surface without cracks or defects.
[0022] The foregoing description illustrates and describes several preferred embodiments of the present invention. However, as previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.
Claims
1. A swashplate forging process, characterized in that: Includes the following steps, (1) Forging shape optimization: The elliptical boss structure of the swash plate head is optimized into an integral boss structure. The integral boss is a smooth arc transition structure. The boss width matches the assembly function size requirements of the swash plate, and the arc transition radius is 10-20mm. (2) Swashplate head parting: Change the horizontal parting of the swashplate head to a 45° parting, and plan the metal flow path during billet forging so that the metal fills the head cavity first along the 45° parting surface. (3) Forging and forming: First, the swash plate billet is phosphated to form a phosphate film. Then, the swash plate billet is heated by gradient temperature control and forged in one go to complete the forming of the swash plate body and head. (4) Edge trimming: The forged slant forging is subjected to flexible edge trimming, and then the surface oxide layer and fine burrs are removed by plasma finishing; (5) Quality inspection: Laser three-dimensional scanning is used to inspect the dimensional accuracy of the forgings to ensure that the head angle tolerance of the forging is ≤ ±0.5° and the surface flatness is ≤ 0.03mm. At the same time, magnetic particle testing is used to detect internal defects in the forgings.
2. The swashplate forging process according to claim 1, characterized in that: In step (2), a pre-forming groove is opened in the area corresponding to the head of the billet before heating. The depth of the pre-forming groove is 1 / 5-1 / 4 of the diameter of the billet. The groove direction is consistent with the direction of the 45° parting surface. This is used to plan the metal flow path during billet forging. The cross-section of the pre-forming groove is semi-circular, and the groove opening is set with a radius of 0.5-1mm.
3. The swashplate forging process according to claim 1, characterized in that: In step (3), when heating the slant blank, the blank is heated in a gradient temperature control manner according to the head forming area, the main forming area and the transition area. The heating temperature of the head forming area is 1100-1150℃, the heating temperature of the main forming area is 1050-1100℃, and the heating temperature of the transition area is 1000-1050℃.
4. The swashplate forging process according to claim 1, characterized in that: In step (2), the heated billet is placed into the forging cavity, and forging pressure is applied after the mold is closed along the 45° parting surface. The pressure is held for 10-20 seconds, and pulse air pressure is introduced to assist in the forming process in the later stage of the pressure holding, so as to complete the forging of the swashplate body and head in one go.
5. The swashplate forging process according to claim 1, characterized in that: In step (2), after forging, the swash plate forging is cooled in stages. First, it is air-cooled to 400°C at a rate of 50-70°C / min, and then furnace-cooled to below 200°C at a rate of 20-30°C / min.
6. The swashplate forging process according to claim 1, characterized in that: In step (3), the phosphating treatment uses a zinc-based phosphating solution, wherein the phosphating temperature is 50-60℃, and the thickness of the phosphating film formed after phosphating for 10-15 minutes is 1-3μm.
7. The swashplate forging process according to claim 1, characterized in that: In step (4), a CNC hydraulic trimming machine is used to perform flexible trimming on the forged slant forging, and the cutting edge of the trimming tool is an elastic damping structure.
8. The swashplate forging process according to claim 1, characterized in that: In step (4), when plasma finishing is used, the working gas of the jet is a mixture of argon and hydrogen in a ratio of 9:
1. The height of the jet from the surface of the forging is 5-10 mm. After finishing, the surface roughness Ra of the forging is guaranteed to be ≤1.6 μm.
9. The swashplate forging process according to claim 1, characterized in that: In step (5), the scanning accuracy of the laser three-dimensional scanning is ±0.01mm, the scanning rate is 5000 points / second, then the magnetic detection is performed by a flaw detector and repeated twice. Finally, the finished product is demagnetized and inspected.