A pre-forging device for gear forging production and a pre-forging method thereof

Abstract

This invention provides a pre-forging equipment and method for gear forging production, relating to the field of gear forging technology. It includes a waste collection module, a powder preparation module, and an extrusion bar module, as well as a circulation control module electrically connected to each of these modules. The waste collection module is used to classify and collect waste generated before and after gear forging, and then transport the waste to the powder preparation module. The powder preparation module is used to sequentially crush, grind, remove impurities, clean, dry, and classify the received forging waste to prepare a metal mixed powder, which is then transported to the extrusion bar module. The extrusion bar module is used to press the metal mixed powder filled in the die cavity into pre-forged billets of a preset specification, achieving high-value recycling of gear forging waste, replacing the traditional remelting method, significantly reducing energy consumption and metal loss, improving material utilization, and significantly reducing production costs.

Description

Technical Field

[0001] This invention relates to the field of gear forging technology, and more specifically, to a pre-forging equipment and method for producing gear forgings. Background Technology

[0002] Gears are widely used in many fields such as automobiles, construction machinery, wind power, and ships, and their forming process is mainly hot forging. In the production process of hot forging gears, the pre-forging process is a key link to ensure the forming accuracy of gears, reduce die wear, and improve the yield of finished products. At the same time, in the pre-forging and subsequent forging processes, a large amount of forging waste such as flash, cut ends, and scrap will inevitably be generated.

[0003] Currently, the conventional method for handling gear forging scrap in the industry is to simply collect the scrap and remelt it as scrap steel, then remelt it into steel for billet preparation. This method has many drawbacks: First, the remelting process consumes a large amount of energy, resulting in serious waste of resources and energy; second, impurities are easily introduced during the remelting process, making it impossible to guarantee the purity and uniformity of the recycled steel composition, which in turn affects the mechanical properties and batch stability of subsequent gear forgings; third, the remelted steel needs to undergo multiple processes such as rolling, blanking, and heating to produce pre-forged billets, resulting in a long process flow, low production efficiency, and high raw material costs.

[0004] Meanwhile, existing gear pre-forging processes mostly use solid bar stock for direct heating and pre-forging. The bar stock has poor structural uniformity and forming consistency. During the pre-forging process, defects such as incomplete filling, folding, and cracks are prone to occur, which not only increases the forming difficulty of the subsequent final forging process, but also reduces the service life of the finished gear. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a pre-forging equipment and method for gear forging production, thereby enabling high-value recycling of waste materials, significantly reducing raw material costs, and improving material utilization.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] This invention provides a pre-forging equipment for gear forging production, including a waste collection module, a powder preparation module, and an extrusion bar module, as well as a circulation control module electrically connected to each of the above modules. The waste collection module is used to classify and collect waste generated before and after gear forging and to transport the waste to the powder preparation module. The powder preparation module is used to sequentially crush, grind, remove impurities, clean, dry, and classify the received forging waste to prepare a metal mixed powder that meets the forming requirements, and then transport it to the extrusion bar module. The extrusion bar module includes a lower die seat and an upper die seat. The lower die seat has a die cavity, and the upper die seat has an extrusion punch that cooperates with the die cavity. The upper die seat is driven relative to the lower die seat by a drive mechanism to press the metal mixed powder filled in the die cavity into a pre-forged billet bar.

[0008] According to one embodiment of the present invention, the extrusion rod module further includes a frame base, a top base, and a powder feeding assembly; the top base is fixed to the upper end face of the frame base by guide posts, and both the lower die base and the upper die base are slidably mounted on the guide posts; the top base is provided with a main extrusion cylinder fixedly connected to the upper die base to form a drive mechanism; the frame base is provided with an upper push hydraulic cylinder, the output end of which is fixedly connected to an upper push die sleeve that extends into the die cavity and slides and seals with its inner wall, the two together forming a closed cavity for powder forming; the frame base is also provided with a pull-down hydraulic cylinder fixedly connected to the lower die base for demolding; the powder feeding assembly is located on the side of the lower die base for quantitatively feeding metal powder into the die cavity.

[0009] According to one embodiment of the present invention, the extrusion punch is coaxially provided with an axially expandable punch insert; when the punch insert retracts upward, it cooperates with the extrusion punch to form an annular extrusion end face with a central slot; when it descends to be flush with the lower end face of the extrusion punch, it fills the slot to form a flat end face extrusion structure.

[0010] According to one embodiment of the present invention, the powder feeding assembly includes a feeding slide, a storage hopper, a feeding drive cylinder, and a discharge base plate; the feeding slide is fixedly connected to the lower mold base, the storage hopper is slidably mounted on the feeding slide, and the lower mold base has a groove that communicates with the mold cavity and guides the storage hopper; the feeding drive cylinder is fixedly mounted on the feeding slide, and its output end is fixedly connected to the storage hopper to drive it to discharge; the discharge base plate is fixed to the bottom of the storage hopper and has a discharge through hole that matches the inner diameter of the mold cavity.

[0011] According to one embodiment of the present invention, two sets of powder feeding components are symmetrically arranged and located on both sides of the lower mold base. The two sets of powder feeding components can be driven independently to alternately feed metal powder from different sources into the mold cavity.

[0012] According to one embodiment of the present invention, the waste collection module is provided in two sets, corresponding to the bar cutting and precision turning station and the forging edge trimming station, respectively, for classifying and collecting forging waste generated in different processes; the waste collection module includes a waste bin and a hoist for collecting and transporting waste.

[0013] According to one embodiment of the present invention, the powder preparation module includes a coarse crusher, a grinder, a magnetic separator, an ultrasonic cleaning tank, a vacuum dryer, and a powder sieve connected sequentially along the material conveying direction. The devices are connected by sealed pipes to complete the powder preparation and graded mixing of waste materials.

[0014] According to one embodiment of the present invention, a sintering pretreatment module and a forging module are sequentially connected to the discharge end of the extrusion bar module, both of which are electrically connected to the circulation control module; the sintering pretreatment module is used to perform debinding and pre-sintering treatment on the pre-forged billet bar to obtain a preformed billet; the forging module is used to complete the forging of the preformed billet, and the generated waste is returned to the waste collection module to form a closed-loop regeneration cycle.

[0015] This invention also provides a pre-forging method for gear forging production, comprising the following steps: S1, classifying and collecting waste materials generated during the gear forging process and conveying them to the powder preparation stage; S2, sequentially crushing, grinding, removing impurities, cleaning, drying, grading, sieving, and mixing the collected waste materials to obtain a metal mixed powder; S3, pressing the metal mixed powder into a pre-forged billet bar of a preset specification through an extrusion bar module; S4, sequentially performing glue removal and atmosphere-protected pre-sintering treatment on the pre-forged billet bar to obtain a pre-formed billet and conveying it under heat; S5, reheating the pre-formed billet to the forging temperature, sequentially completing pre-forging, final forging, and edge trimming treatment, conveying and collecting the finished product, and returning the generated waste materials to step S1 for recycling.

[0016] According to one embodiment of the present invention, in step S3, the extrusion into a bar module can optionally execute S3.1 or S3.2; S3.1, core-shell composite pressing molding: metal mixed powder from different sources is fed into the mold cavity through two sets of powder feeding components, and the ring shell blank and solid core blank are pressed into shape in steps, and the two are combined into an integrated pre-forged billet bar; S3.2, material head replenishment and regeneration pressing molding: the pre-treated gear forging material head is positioned in the mold cavity, and the metal mixed powder is pressed to form a combination with the material head, and then metal mixed powder is replenished and final pressing molding is performed to obtain a complete pre-forged billet bar.

[0017] In summary, this application includes at least one of the following beneficial technical effects:

[0018] 1. In this application, a waste collection module, a powder preparation module, and an extrusion rod module are used to realize the high-value recycling of gear forging waste, replacing the traditional remelting mode, which greatly reduces energy consumption and metal loss, improves material utilization, and significantly reduces production costs.

[0019] 2. In this application, the waste material is ground using a powder preparation module and pressed into a pre-forged billet bar using an extrusion bar module, thereby effectively improving the filling performance and forming quality in the subsequent forging process, and improving the mechanical properties and service life of the finished gear.

[0020] 3. In this application, core-shell composite pressing molding and scrap head replenishment recycling pressing molding can be selected. It can be flexibly selected according to the type of waste and product requirements to realize pre-forged billets with differentiated performance design for different parts, further optimize material utilization and product performance, and realize the direct recycling of high-value waste such as scrap heads in the waste, thereby reducing production costs. Attached Figure Description

[0021] Figure 1 This is an overall structural block diagram of a pre-forging equipment for gear forging production according to the present invention;

[0022] Figure 2 This is a structural block diagram of the powder preparation module in this invention;

[0023] Figure 3 This is a connection block diagram of the sintering pretreatment module and the forging forming module in this invention;

[0024] Figure 4 This is an overall structural diagram of the extrusion rod module in this invention;

[0025] Figure 5 This is a cross-sectional view of the extruded rod module;

[0026] Figure 6 This is a partial structural diagram of the upper part of the extrusion rod module;

[0027] Figure 7 This is a partial structural diagram of the lower part of the extrusion rod module;

[0028] Figure 8 This is a structural diagram showing the connection between the storage hopper and the discharge bottom plate in this invention;

[0029] Figure 9 This is a diagram showing the forming state of the semi-finished billet bar after regeneration and pressing by feeding material head in this invention;

[0030] Figure 10 This is a diagram showing the forming state of the pre-forged billet bar produced by the material head replenishment and regeneration pressing process in this invention.

[0031] Figure label:

[0032] 100. Waste collection module;

[0033] 200. Powder preparation module; 201. Coarse crusher; 202. Grinding mill; 203. Magnetic separator; 204. Ultrasonic cleaning tank; 205. Vacuum dryer; 206. Powder sieving machine;

[0034] 300. Extrusion rod module; 301. Machine frame base; 3011. Upper ejector die sleeve; 3012. Upper ejector hydraulic cylinder; 3013. Guide post; 3014. Pull-down hydraulic cylinder; 302. Lower die base; 3021. Die cavity; 3022. Slide groove; 303. Upper die base; 3031. Extrusion punch; 3032. Punch insert; 304. Machine top base; 3041. Main extrusion cylinder; 305. Powder feeding assembly; 3051. Material storage hopper; 3052. Feeding slide base; 3053. Feeding drive cylinder; 3054. Discharge base plate; 30541. Discharge through hole;

[0035] 400. Sintering pretreatment module; 401. Glue removal furnace; 402. Pre-sintering furnace; 403. Insulation conveying channel;

[0036] 500. Forging and forming module; 501. Medium frequency induction heating furnace; 502. Robotic arm; 503. Forging workbench; 504. Finished product conveyor;

[0037] 600. Loop control module. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] Example 1: This invention provides a pre-forging equipment for gear forging production, such as... Figure 1 As shown, it includes a waste collection module 100, a powder preparation module 200, an extrusion rod module 300, a sintering pretreatment module 400, a forging molding module 500 connected in sequence, and a circulation control module 600 electrically connected to each module.

[0040] In the conventional production process of gear forgings, the bar stock is first cut into blocks of a preset size by a cutting device. During the cutting process, to ensure that the blocks still have sufficient forging allowance after the oxide layer is removed by precision machining and to ensure the quality of gear forging, the cutting length of the blocks to be cut is slightly increased compared to the standard forging blocks without an oxide layer. Each block after cutting is inspected for surface condition by a vision inspection device. If an oxide layer is detected on the surface of the block, it is removed by a CNC precision machining device. The qualified blocks after the oxide layer is removed are fed into a medium-frequency heating furnace by a loading robot, heated to the target forging temperature, and then removed by a transfer robot and transferred to a forging platform to complete the subsequent forging process.

[0041] In the above processing flow, after each bar is cut, two ends that cannot be directly used for forging will be generated. The precision turning process of the bar will generate oxide scale and cutting residue. The forging and trimming process will generate a large amount of flash waste. This type of waste accounts for 15%-30% of the total raw material input. The pre-forging equipment in this embodiment can perform closed-loop recycling and high-value regeneration of the forging waste generated in the above process, and directly participate in or prepare the pre-forging billet for gears.

[0042] The waste collection module 100 is configured with two sets. One set is located at the bar cutting station and the surface finishing station of the material block to collect cutting residue and oxide layer waste removed by finishing. The other set is located at the edge trimming station of the forging and forming module 500 to collect forging waste such as flash and slag generated during forging edge trimming. Specifically, the waste collection module 100 includes a waste bin and an elevator. The inlet of the waste bin corresponds to the outlet of each waste generation station and is used to collect 20CrMnTi gear steel forging waste such as flash, cut ends, slag, and oxide scale generated throughout the gear forging process. The elevator is a closed bucket elevator, with its inlet corresponding to the outlet of the waste bin. The outlet of the elevator is connected to the inlet of the powder preparation module 200 to transport the collected waste to the powder preparation module 200, preventing dust from overflowing.

[0043] like Figure 2As shown, the powder preparation module 200 includes a coarse crusher 201, a grinder 202, a magnetic separator 203, an ultrasonic cleaning tank 204, a vacuum dryer 205, and a powder sieve 206 connected in sequence along the material conveying direction. The equipment is connected to each other through sealed conveying pipelines to achieve fully enclosed material conveying. The primary crusher 201 is a jaw crusher, with its feed inlet connected to the discharge end of the elevator, used to crush large forging scrap into granular materials with a particle size of less than 5mm; the grinding mill 202 is a horizontal planetary ball mill, with its feed inlet connected to the discharge end of the primary crusher 201 via a screw conveyor, used to grind the crushed granular materials into metal powder with a mesh size of less than 100 mesh; the magnetic separator 203 is a drum-type high-intensity magnetic separator, with its feed end connected to the discharge end of the grinding mill 202, using a strong magnetic field of over 12000Gs to remove iron filings and other magnetic impurities from the metal powder, ensuring powder purity; the ultrasonic cleaning tank 204 is connected to the discharge end of the magnetic separator 203, using a mixture of neutral environmentally friendly cleaning agent and deionized water at a volume ratio of 1:9 as the cleaning medium, at a temperature of 40°C. The metal powder after impurity removal is deeply cleaned at an ultrasonic frequency of kHz to thoroughly remove oil and residual oxide layer from the powder surface. The feed end of the vacuum dryer 205 is connected to the discharge port of the ultrasonic cleaning tank 204, and is used to continuously dry the cleaned metal powder in a vacuum environment above -0.09MPa and a temperature of 120℃ to remove free and bound moisture from the powder. The powder sieve 206 adopts a multi-stage vibrating screen, and its feed port is connected to the discharge port of the vacuum dryer 205. It is used to sieve the dried metal powder into coarse powder of 100-200 mesh, medium powder of 200-300 mesh, and fine powder of more than 300 mesh, and mix them according to a preset ratio to obtain metal mixed powder. The particle size distribution is optimized to ensure the molding and sintering performance of the powder.

[0044] like Figure 3As shown, the sintering pretreatment module 400 includes a debinding furnace 401, a pre-sintering furnace 402, and a heat-insulating conveying channel 403 connected sequentially along the material conveying direction. The debinding furnace 401 is a box-type debinding furnace, equipped with a waste gas collection and treatment device. It is used to heat the pre-forged billet at 450-550℃ for 2-4 hours, allowing the paraffin-based binder in the billet to fully volatilize and be discharged. Simultaneously, the waste gas collection and treatment device performs catalytic combustion to render the volatilized binder waste gas harmless, preventing environmental pollution. The pre-sintering furnace 402 is a pusher-type atmosphere-protected sintering furnace. Its feed end connects to the discharge port of the debinding furnace 401. Hydrogen or high-purity nitrogen can be introduced into the furnace as a protective atmosphere, used to sinter the debinded billet at 1100-1200℃ for 1-2 hours. This process allows for the formation of a preliminary metallurgical bond between powder particles, resulting in a preformed billet with certain strength and toughness, ensuring that the billet will not crack during subsequent forging. The heat-insulating conveying channel 403 adopts a roller conveyor structure with an aluminum silicate refractory insulation layer. The inner wall of the channel is equipped with resistance wire heating units. Its feed end is connected to the discharge port of the pre-sintering furnace 402, and its discharge end is connected to the feed end of the forging forming module 500. This is used to continuously convey the preformed billet to the forging forming module 500 while maintaining the temperature of the preformed billet at no less than 800°C through the heating unit and the insulation layer, thereby reducing the energy consumption and oxidation loss of the secondary heating before subsequent forging.

[0045] The forging module 500 includes a medium-frequency induction heating furnace 501, a robotic arm 502, a forging worktable 503 with multiple stations, and a finished product conveyor 504. The inlet end of the medium-frequency induction heating furnace 501 connects to the outlet end of the heat-insulating conveyor channel 403, used to quickly reheat the preformed billet to the forging temperature of 1150-1200℃ corresponding to 20CrMnTi gear steel, resulting in fast heating and minimal oxidation loss on the billet surface. The robotic arm 502 is a six-axis industrial robotic arm equipped with high-temperature resistant carbide grippers at its end, used to grasp the heated preformed billet and sequentially transfer it to the corresponding station on the forging worktable 503. The forging worktable 503 is sequentially set with a pre-forging station, a final forging station, and a trimming station. The robotic arm 502 is used to... The preformed billet flows between various workstations. The forging worktable 503 is equipped with a 1000T four-column hydraulic press, which can sequentially complete the pre-forging, final forging, and flash trimming of gear forgings, realizing continuous forming of gear forgings. The finished product conveying channel 504 adopts a high-temperature resistant mesh belt conveyor. Its feeding end corresponds to the finished product discharge end of the forging worktable 503 at multiple workstations, which is used to transport the formed gear forgings to the finished product collection unit. At the same time, the flash waste generated at the trimming station can be directly sent to the waste bin through the waste conveying channel to enter the next round of recycling.

[0046] like Figure 4-6As shown, the extrusion rod module 300 includes a frame base 301, a lower die base 302, an upper die base 303, and a top base 304. The top base 304 is fixedly installed on the upper surface of the frame base 301 by four guide pillars 3013. The four guide pillars 3013 are arranged in a rectangular array to form a four-pillar die frame structure. The lower die base 302 and the upper die base 303 are both slidably installed on the guide pillars 3013 by linear bearings, with the lower die base 302 located below the upper die base 303. A main extrusion cylinder 3041 is fixedly installed at the center of the machine top base 304. The piston rod output end of the main extrusion cylinder 3041 is fixedly connected to the center of the top surface of the upper die base 303, which is used to drive the upper die base 303 to move up and down and reciprocate along the guide post 3013. An extrusion punch 3031 is fixedly installed at the center of the bottom of the upper die base 303. A die cavity 3021 is opened at the center of the lower die base 302. The die cavity 3021 and the extrusion punch 3031 are coaxially arranged, and the inner diameter of the die cavity 3021 is clearance-fitted with the outer diameter of the extrusion punch 3031. When the die is closed, the extrusion punch 3031 can extend into the die cavity 3021 to complete the powder extrusion molding. A top hydraulic cylinder 3012 is fixedly installed at the center of the frame base 301. An upper mold sleeve 3011 is fixedly connected to the upper end of the piston rod of the top hydraulic cylinder 3012. The upper end of the upper mold sleeve 3011 extends into the mold cavity 3021, and the outer wall of the upper mold sleeve 3011 slides and seals with the inner wall of the mold cavity 3021. The upper mold sleeve 3011 and the mold cavity 3021 together form a closed cavity for powder molding. Two sets of bottom hydraulic cylinders 3014 are also symmetrically arranged on the frame base 301. The output ends of the piston rods of both sets of bottom hydraulic cylinders 3014 are fixedly connected to the bottom surface of the lower mold base 302, used to drive the lower mold base 302 to slide up and down along the guide post 3013, cooperating with the top hydraulic cylinder 3012 to achieve demolding of the molded bar stock.

[0047] An inner insert 3032 is coaxially arranged inside the extrusion punch 3031. In this embodiment, the inner insert 3032 is a built-in ejector rod that assists the extrusion punch 3031 in its operation. On one hand, the inner insert 3032 cooperates with the extrusion punch 3031 and forms a slot in the center of the extrusion punch 3031 for forming bar stock with an inner hole. On the other hand, the inner insert 3032 cooperates with the extrusion punch 3031 to fill the central slot of the extrusion punch 3031 for forming bar stock without an inner hole. Powder feeding assemblies 305 are provided on both the left and right sides of the lower die base 302. The powder feeding assembly 305 includes a feeding slide 3052, a storage hopper 3051, a feeding drive cylinder 3053, and a blanking base plate 3054. One end of the feeding slide 3052 is fixedly connected to the end side wall of the lower mold base 302 by bolts. The storage hopper 3051 is slidably installed on the top surface of the feeding slide 3052 via a linear guide pair. The lower mold base 302 has a groove 3022 that is flush with the top surface of the feeding slide 3052. One end of the groove 3022 is connected to the mold cavity 3021. The inner wall of the groove 3022 is slidably engaged with the outer wall of the storage hopper 3051 to provide guidance and limit for the sliding of the storage hopper 3051. A feeding drive cylinder 3053 is fixedly installed at the end of the feeding slide 3052 away from the lower mold base 302. The piston rod output end of the feeding drive cylinder 3053 is fixedly connected to the side wall of the storage hopper 3051, and is used to drive the storage hopper 3051 to slide along the feeding slide 3052 and the slide groove 3022, so that the storage hopper 3051 moves to the top of the mold cavity 3021 to complete the material discharge. The discharge base plate 3054 is fixed to the bottom of the storage hopper 3051 by bolts. The discharge base plate 3054 has a discharge through hole 30541 that communicates with the inner cavity of the storage hopper 3051. The diameter of the discharge through hole 30541 matches the inner diameter of the mold cavity 3021 to ensure that the powder falls into the mold cavity 3021.

[0048] The left powder feeding assembly 305 has a storage hopper 3051 for receiving cutting waste and powder generated from grinding the oxide layer, while the right powder feeding assembly 305 has a storage hopper 3051 for receiving powder generated from grinding forging waste. The two powder feeding assemblies 305 can operate independently and alternately feed metal powder from different sources into the mold cavity 3021 to achieve layered pressing and molding of powders with different strengths, thereby meeting the performance requirements of different parts of the pre-forged billet.

[0049] Using the extrusion rod module 300 described above, waste materials can be directly made into billet rods. The specific working process is as follows: In the initial state, the upper die holder 303 is at the upper stop point, the upper end face of the upper die sleeve 3011 is flush with the bottom surface of the die cavity 3021, and the material storage hopper 3051 is in a waiting position away from the die cavity 3021; ​​during feeding, the feeding drive cylinder 3053 drives the corresponding material storage hopper 3051 to slide directly above the die cavity 3021, and the metal powder falls into the die cavity 3021 through the discharge through hole 30541. After the discharge is completed, the material storage hopper 3051 returns to the waiting position; extrusion... During pressing, the main extrusion cylinder 3041 drives the upper die holder 303 downward, and the extrusion punch 3031 extends into the die cavity 3021 to apply a preset pressure to the metal powder in the die cavity 3021. After holding the pressure for a preset time, the powder is pressed and formed to obtain a pre-forged billet. During demolding, the main extrusion cylinder 3041 drives the upper die holder 303 upward to reset, and the pull-down hydraulic cylinder 3014 drives the lower die holder 302 downward. At the same time, the upper ejector sleeve 3011 and the upper ejector hydraulic cylinder 3012 remain stationary, so that the formed pre-forged billet is removed from the die cavity 3021, completing one extrusion forming cycle.

[0050] To ensure the strength of the pre-forged billet, this embodiment employs a composite pressing process to achieve composite pressing of primary and secondary materials. The primary material consists of metal-mixed powder obtained by processing the flash and forging waste from the trimming station of the forging module 500 through the powder preparation module 200. The secondary material consists of metal-mixed powder obtained by processing the cutting residue and oxide layer waste from the bar cutting station and the block finishing station through the powder preparation module 200. The composite pressing process uses a step-by-step forming method: first forming a ring-shaped shell billet, then filling and pressing a solid core billet. The specific implementation process is as follows:

[0051] In the initial state, the upper die holder 303 is at the upper dead point. The upper hydraulic cylinder 3012 drives the upper die sleeve 3011 to move upward to the preset position, so that the upper end face of the upper die sleeve 3011 and the inner wall of the die cavity 3021 enclose the annular forming cavity for accommodating the annular shell blank. The punch insert 3032 moves upward so that the center of the extrusion punch 3031 leaves a slot for the hydraulic rod of the upper hydraulic cylinder 3012 to be adapted, so that the extrusion punch 3031 forms an annular extrusion end face that matches the cross section of the annular forming cavity. The storage hopper 3051 of the left powder feeding assembly 305 is pre-stored with secondary material, and the storage hopper 3051 of the right powder feeding assembly 305 is pre-stored with primary material. Both sets of powder feeding assemblies 305 are in the waiting position away from the die cavity 3021.

[0052] The feeding drive cylinder 3053 drives the storage hopper 3051 of the left powder feeding assembly 305 to slide along the slide groove 3022 to directly above the mold cavity 3021. The secondary material falls quantitatively into the annular forming cavity of the mold cavity 3021 through the discharge hole 30541. After the discharge is completed, the storage hopper 3051 returns to the waiting position. The main extrusion cylinder 3041 drives the upper mold base 303 to move down along the guide post 3013. The extrusion punch 3031 extends into the mold cavity 3021 to form the annular shape. The secondary material inside the cavity is subjected to a pressure of 400-600MPa and held for 10-30s to complete the pressing and molding of the secondary material, resulting in an annular shell blank coaxially arranged with the mold cavity 3021. After the pressure is held, the main extrusion cylinder 3041 drives the upper mold base 303 to move upward and reset, and the hydraulic rod of the upper push hydraulic cylinder 3012 moves downward until its lower end face is completely flush with the upper end face of the upper push mold sleeve 3011, thereby forming an inner hole forming cavity in the central area of ​​the annular shell blank that matches the size of the solid core blank.

[0053] The feeding drive cylinder 3053 drives the storage hopper 3051 of the right powder feeding assembly 305 to slide along the slide groove 3022 to directly above the mold cavity 3021. The primary material falls quantitatively into the inner forming cavity of the annular shell blank through the dropping hole 30541. After the dropping is completed, the storage hopper 3051 returns to the waiting position. The main extrusion cylinder 3041 drives the upper mold base 303 to move downward along the guide post 3013. The punch insert 3032 first extends into the inner forming cavity, applying a pressure of 400-600MPa to the primary material and holding the pressure for 10-30s, so that the primary material is pressed into a solid core blank. At the same time, the outer circumferential surface of the solid core blank and the inner wall of the annular shell blank form a metallurgical bonding interface under the pressure, finally obtaining a pre-forged billet bar with a core-shell composite structure. After the pressure is held, the main extrusion cylinder 3041 drives the upper mold base 303 to move upward and reset, and the punch insert 3032 resets to the initial state simultaneously. In addition, the height of the first-stage material in the inner forming cavity is slightly lower than that of the annular shell blank to ensure the utilization rate of powder and the pressing strength of the solid core blank. Then, the inner insert 3032 of the punch moves until its lower end face is completely flush with the lower end face of the extrusion punch 3031. The main extrusion cylinder 3041 drives the upper die base 303 to descend along the guide post 3013, applying a pressure of 500-700MPa to the blank in the die cavity 3021 and holding the pressure for 15-35s, so that the blank is pressed into a pre-forged blank bar.

[0054] Furthermore, the pull-down hydraulic cylinder 3014 drives the lower mold base 302 to move down along the guide post 3013, while the upper push hydraulic cylinder 3012 and the upper push mold sleeve 3011 remain in a fixed position, so that the pre-forged billet bar formed by composite pressing is completely removed from the mold cavity 3021.

[0055] It should be noted that setting the drop height of the primary material inside the inner forming cavity to be slightly lower than the height of the annular shell blank is to adapt to the plastic flow law and axial compression characteristics of metal powder during the pressing process, avoid problems such as overflow, poor interface bonding, loss of dimensional accuracy, and mold wear due to uneven load, and at the same time ensure the forming performance of the core blank and the overall quality of the composite blank.

[0056] Furthermore, in this embodiment, the primary material adopts a mass ratio of 20% coarse powder, 50% medium powder, and 30% fine powder, and the secondary material adopts a mass ratio of 30% coarse powder, 40% medium powder, and 30% fine powder, so that the solid core blank has higher density and mechanical strength, and the annular shell blank has better forming and filling performance, taking into account the overall strength and forming adaptability of the pre-forged billet.

[0057] The extrusion rod module 300 described above can be used to replenish the slit material ends, as detailed below:

[0058] The sprue is precision machined and ground to reduce its diameter to a clearance fit with the central slot diameter of the extrusion punch 3031. A scrap bin is used to collect the finished scrap. The upper die holder 303 is at its upper stop position. The upper hydraulic cylinder 3012 drives its piston rod downwards, causing the upper die sleeve 3011 to descend to a preset position. A positioning groove matching the lower end size of the sprue is formed at the center of the upper end face of the upper die sleeve 3011. This positioning groove is coaxially arranged with the die cavity 3021 and is used to axially and radially limit and fix the sprue. The lower hydraulic cylinder 3014 remains locked, fixing the lower die holder 302 at the preset forming position. The inner wall of the die cavity 3021 and the outer wall of the upper die sleeve 3011 form an annular forming cavity. The punch insert 3032 retracts into the central slot of the extrusion punch 3031, ensuring the central slot is in a through-hole state and coaxially aligned with the positioning groove.

[0059] The metal mixed powder obtained by the powder preparation module 200 is quantitatively fed into the annular forming cavity of the mold cavity 3021 by the powder feeding assembly 305. The powder filling height is lower than the preset installation height of the sprue in the positioning groove. The pre-treated sprue is vertically inserted into the positioning groove to complete coaxial fixation. The feeding drive cylinder 3053 drives the powder feeding assembly 305 to reset to the waiting position. The main extrusion cylinder 3041 drives the upper mold base 303 to descend vertically along the guide post 3013. The extrusion punch 3031 extends into the mold cavity 3021. The upper end of the sprue simultaneously extends into the central slot of the extrusion punch 3031. The extrusion punch 3031 applies a preset forming pressure to the metal powder in the annular forming cavity. After holding the pressure for a preset time, the powder densification is completed, so that the powder and the outer peripheral surface of the sprue form a tight mechanical bond and interface interlock, resulting in a semi-finished billet bar with a sprue insert. Figure 9As shown; after the pressure holding is completed, the main extrusion cylinder 3041 drives the upper die holder 303 to move upward and reset to the initial position.

[0060] The driving punch insert 3032 descends vertically until its lower end face is completely flush with the lower end face of the extrusion punch 3031, completely filling the central slot of the extrusion punch 3031 and forming a complete flat-end extrusion molding structure. Metal mixed powder is quantitatively added to the die cavity 3021 via the powder feeding assembly 305, ensuring the total powder filling height reaches the preset molding height of the pre-forged billet. After feeding, the powder feeding assembly 305 returns to the waiting position. The main extrusion cylinder 3041 drives the upper die base 303 to descend vertically along the guide post 3013. The extrusion punch 3031, along with the punch insert 3032, simultaneously extends into the die cavity 3021, applying a preset final pressure to the powder and semi-finished billet within the die cavity 3021. After holding the pressure for a preset time, the overall molding is completed, forming a continuous metallurgical interface between the replenished powder and the upper end face of the semi-finished billet, resulting in the finished pre-forged billet. Figure 10 As shown; after the pressure holding is completed, the main extrusion cylinder 3041 drives the upper die holder 303 to move upward and reset to the initial position.

[0061] In this embodiment, the cycle control module 600 includes a PLC central controller, and temperature sensors, pressure sensors, position sensors, and flow sensors distributed in each module; each sensor is electrically connected to the PLC central controller.

[0062] In this embodiment, a position sensor is installed at the discharge port of the waste bin to collect the amount of waste stored in the waste bin, providing data support for the feeding cycle of the subsequent powder preparation process. Pressure sensors are installed in the hydraulic circuits of the main extrusion cylinder 3041, the upper lifting hydraulic cylinder 3012, and the lowering hydraulic cylinder 3014 to collect the real-time working oil pressure of each hydraulic cylinder. Position sensors are installed at both ends of the lifting stroke of the upper die holder 303 and the lower die holder 302, as well as at both ends of the sliding stroke of the material storage hopper 3051, to collect the status of the mold closing, mold opening, and material feeding / discharging actions.

[0063] In the sintering pretreatment module 400, temperature sensors are installed in the temperature control zones of the debinding furnace 401 and the presintering furnace 402 to collect the real-time heating temperature of the furnace body, ensuring the full volatilization and discharge of the binder in the blank rod and the effect of preliminary metallurgical bonding between powder particles; a pressure sensor is installed inside the furnace body of the presintering furnace 402 to collect the pressure value of the protective atmosphere in the furnace, ensuring a stable positive pressure protection state in the furnace and avoiding oxidation problems during the high-temperature sintering process of the preform; temperature sensors and position sensors are installed at intervals along the conveying rollers of the heat preservation conveying channel 403. The temperature sensors are used to collect the real-time heat preservation temperature in the channel, avoiding excessive temperature drop during the conveying process of the preform and reducing the energy consumption of subsequent secondary heating, and the position sensors are used to collect the conveying position and in-place state of the preform.

[0064] In the forging and forming module 500, a temperature sensor is installed inside the intermediate frequency induction heating furnace 501 to collect the real-time heating temperature of the preform, ensuring the forging and forming performance of the gear forging; a pressure sensor is installed inside the hydraulic system of the forging hydraulic press supporting the forging workbench 503 to collect the real-time forming pressure during the pre-forging and final forging processes, ensuring the forming accuracy of the gear forging and the consistency of the internal metallographic structure; a position sensor is installed at the driving end of the finished product conveying channel 504 to collect the operating state of the finished product conveying, ensuring the continuity of the finished product discharge of the gear forging.

[0065] Example 2. This example provides a pre-forging method for the production of gear forgings, which is realized based on the pre-forging equipment for the production of gear forgings described in Example 1. The pre-forging equipment includes a waste collection module 100, a powder preparation module 200, an extrusion into rod module 300, a sintering pretreatment module 400, a forging and forming module 500 connected in sequence, and a circulation control module 600 electrically connected to each module. The pre-forging method specifically includes the following steps:

[0066] S1. Closed-loop waste collection: The classification collection of waste generated during the entire gear forging process is completed through two groups of waste collection modules 100. The first group of waste collection modules 100 is installed at the bar cutting station and the surface precision turning station of the blank, and is used to collect the cut-off heads generated by bar cutting, the oxide layer removed by precision turning of the blank, and the cutting residues; the second group of waste collection modules 100 is installed at the trimming station of the forging and forming module 500, and is used to collect forging waste such as flash and cut-off heads generated by forging trimming; various types of forging waste of 20CrMnTi gear steel are uniformly stored in the waste box, and then the collected waste is transported to the feeding end of the powder preparation module 200 by a hoist to avoid dust spillage.

[0067] S2. Fine powder preparation: The powder preparation module 200 performs a full-process continuous treatment on the collected forging waste to prepare a metal mixed powder that meets the forming requirements. The specific process is as follows:

[0068] S2.1 Coarse crushing: The coarse crusher 201 crushes the large forging waste into granular materials with a particle size of less than 5mm. The crushed granular materials are then sent to the grinding mill 202 through a sealed conveying pipe.

[0069] S2.2 Grinding process: The granular material is ground into metal powder with a mesh size of less than 100 by a grinding mill 202. The ground powder is then fed into a magnetic separator 203 by a screw conveyor.

[0070] S2.3 Magnetic separation for impurity removal: The metal powder is removed by a drum-type high-intensity magnetic separator 203 with a strong magnetic field of over 12000Gs to ensure the purity of the powder. The powder after impurity removal is sent to an ultrasonic cleaning tank 204.

[0071] S2.4 Ultrasonic Cleaning: A mixture of neutral environmentally friendly cleaning agent and deionized water at a volume ratio of 1:9 is used as the cleaning medium. The metal powder is deeply cleaned at an ultrasonic frequency of 40kHz to remove oil and residual oxide layer from the powder surface. The cleaned powder is then sent to a vacuum dryer 205.

[0072] S2.5 Vacuum drying: Under vacuum conditions above -0.09MPa and temperature conditions of 120℃, the cleaned metal powder is continuously dried by vacuum dryer 205 to remove free and bound moisture from the powder. The dried powder is then sent to powder sieve 206.

[0073] S2.6 Grading and Sieving: The dried metal powder is sieved into coarse powder (100-200 mesh), medium powder (200-300 mesh), and fine powder (300 mesh and above) using a multi-stage vibrating screen. Among them, the metal mixed powder used for basic molding is mixed in a mass ratio of 25% coarse powder, 45% medium powder, and 30% fine powder. The primary material (powder prepared from forging flash and scrap) used for core-shell composite molding is fed into a mixer in a mass ratio of 20% coarse powder, 50% medium powder, and 30% fine powder. The secondary material (powder prepared from cutting residue and oxide layer waste) is mixed in a mass ratio of 30% coarse powder, 40% medium powder, and 30% fine powder. The graded and sized metal powder is fed into the corresponding storage hopper 3051 of the extrusion rod module 300.

[0074] S3. Extrusion into Rod Forming: The metal mixed powder is pressed into a pre-forged billet rod of preset specifications through the extrusion into rod forming module 300. Any one of the following processes can be selected according to production needs: direct pressing of base powder, composite pressing of graded powder core and shell, or regenerated pressing with material replenishment. That is, S3.1 or S3.2 can be selected based on the actual situation. The specific implementation method is as follows:

[0075] S3.1 Composite compression molding

[0076] S3.1.1 Initial mold state adjustment: The upper mold base 303 is at the upper stop point, and the upper hydraulic cylinder 3012 drives the upper mold sleeve 3011 to move upward to the preset position, so that the upper end face of the upper mold sleeve 3011 and the inner wall of the mold cavity 3021 enclose the annular forming cavity for accommodating the annular shell blank; the punch insert 3032 moves downward to its lower end face being completely flush with the lower end face of the extrusion punch 3031, so that the extrusion punch 3031 forms an annular extrusion end face that matches the cross-section of the annular forming cavity; the storage hopper 3051 of the left powder feeding assembly 305 is pre-stored with secondary material, and the storage hopper 3051 of the right powder feeding assembly 305 is pre-stored with primary material, and both sets of powder feeding assemblies 305 are in the waiting position.

[0077] S3.1.2, Ring-shaped shell blank pressing: The feeding drive cylinder 3053 drives the storage hopper 3051 of the left powder feeding component 305 to slide directly above the mold cavity 3021. The secondary material and paraffin-based binder are mixed at a mass ratio of 90:10 and quantitatively fall into the ring-shaped forming cavity. After the material is dropped, the storage hopper 3051 is reset. The main extrusion cylinder 3041 drives the upper mold base 303 to move downward. The extrusion punch 3031 applies a pressure of 400-600MPa to the secondary material and holds the pressure for 10-30s to complete the ring-shaped shell blank forming. After the pressure is held, the upper mold base 303 moves upward to reset, and the punch insert 3032 moves upward to the preset position to form an inner hole forming cavity in the center of the ring-shaped shell blank.

[0078] S3.1.3 Solid core blank pressing composite molding: The feeding drive cylinder 3053 drives the storage hopper 3051 of the right powder feeding assembly 305 to slide directly above the mold cavity 3021. The primary material and paraffin-based binder mixed at a mass ratio of 90:10 are quantitatively fed into the inner forming cavity. After the material is fed, the storage hopper 3051 is reset. The main extrusion cylinder 3041 drives the upper mold base 303 to move downward. The punch insert 3032 applies a 400-6° angle to the primary material. The pressure is 00MPa and held for 10-30s to form a solid core blank and a metallurgical interface with the annular shell blank. Then, the inner insert 3032 of the punch moves until its lower end face is completely flush with the lower end face of the extrusion punch 3031. The main extrusion cylinder 3041 drives the upper die base 303 to descend along the guide post 3013, applying a pressure of 500-700MPa to the blank in the die cavity 3021 and holding it for 15-35s to press the blank into a pre-forged blank bar.

[0079] S3.1.4 Demolding and unloading: After the pressure holding is completed, the upper mold base 303 moves upward to reset, and the lower mold base 302 is driven downward by the hydraulic cylinder 3014. The upper top mold sleeve 3011 remains fixed, so that the pre-forged billet of the core-shell composite structure is completely removed.

[0080] S3.2, Material head replenishment and recycling pressing molding

[0081] S3.2.1, Pre-treatment of the sprue: The 20CrMnTi gear steel sprue generated from the bar stock cutting is precision machined and ground to remove the surface oxide layer and deformation defects. The outer diameter of the sprue is machined to have an H8 / f7 clearance fit with the inner diameter of the central slot of the extrusion punch 3031. The cutting waste generated from precision machining and grinding is synchronously recycled through the waste collection module 100.

[0082] S3.2.2 Mold Initialization: The upper mold base 303 is at the upper stop point. The upper hydraulic cylinder 3012 drives the piston rod to retract downwards, causing the upper mold sleeve 3011 to move down to the preset position. A positioning groove matching the lower end of the material head is formed at the center of the upper end face of the upper mold sleeve 3011. The positioning groove is coaxially set with the mold cavity 3021. The lower hydraulic cylinder 3014 is locked, and the lower mold base 302 is fixed at the preset position. The inner wall of the mold cavity 3021 and the outer wall of the upper mold sleeve 3011 form an annular forming cavity. The inner insert of the punch 3032 retracts into the central slot of the extrusion punch 3031, so that the central slot is coaxially aligned with the positioning groove.

[0083] S3.2.3 Semi-finished billet forming: The metal mixed powder and paraffin-based binder are mixed at a mass ratio of 90:10 and fed into the annular forming cavity by the powder feeding assembly 305. The powder filling height is lower than the preset installation height of the sprue. The pre-treated sprue is vertically inserted into the positioning groove for fixing, and the powder feeding assembly 305 is reset. The main extrusion cylinder 3041 drives the upper die base 303 to move downward. The extrusion punch 3031 extends into the die cavity 3021. The upper end of the sprue extends into the central slot of the extrusion punch 3031. The extrusion punch 3031 applies a preset forming pressure to the powder in the annular forming cavity and holds the pressure, so that the powder and the outer peripheral surface of the sprue form a tight mechanical bond and interface engagement, resulting in a semi-finished billet bar with a sprue insert. After the pressure holding is completed, the upper die base 303 moves upward and resets.

[0084] S3.2.4 Finished billet forming: Drive the inner insert of the driving punch 3032 down until its lower end face is completely flush with the lower end face of the extrusion punch 3031, filling the central slot; feed the pre-forged billet into the mold cavity 3021 through the powder feeding assembly 305 to the preset forming height of the pre-forged billet, and reset the powder feeding assembly 305 after feeding is completed; drive the upper die base 303 down through the main extrusion cylinder 3041, and the extrusion punch 3031 and the inner insert of the punch 3032 extend into the mold cavity 3021 simultaneously, apply the preset final forming pressure and hold the pressure, so that the feed powder and the upper end face of the semi-finished billet form a continuous metallurgical bonding interface, and obtain the finished pre-forged billet; after holding the pressure is completed, the upper die base 303 moves up and resets.

[0085] S3.2.5 Demolding and Unloading: The pull-down hydraulic cylinder 3014 drives the lower mold base 302 to move down along the guide post 3013. The upper mold sleeve 3011 and the upper hydraulic cylinder 3012 keep their positions fixed, so that the finished pre-forged billet is completely ejected from the mold cavity 3021, completing one material head replenishment regeneration pressing molding.

[0086] S4. Sintering Pretreatment: The pre-forged billet is fed into the sintering pretreatment module 400 and first held at 450-550℃ for 2-4 hours in a box-type debinding furnace 401 to remove the paraffin-based binder from the billet. The volatile waste gas is treated by catalytic combustion of the furnace body's supporting device to render it harmless. After debinding, the billet is fed into a pusher-type atmosphere-protected pre-sintering furnace 402, where hydrogen or high-purity nitrogen is introduced as a protective atmosphere. It is sintered at 1100-1200℃ for 1-2 hours to form a preliminary metallurgical bond between the powder particles, thus obtaining a pre-formed billet. The pre-formed billet is transported to the forging forming module 500 through the heat-insulating conveying channel 403. The temperature is maintained at no less than 800℃ throughout the conveying process to reduce the energy consumption and oxidation loss of subsequent secondary heating.

[0087] S5. Continuous Forging: The pre-formed billet is fed into the medium-frequency induction heating furnace 501 and rapidly heated to the forging temperature of 20CrMnTi gear steel (1150-1200℃). It is then held at this temperature until the internal and external temperatures of the billet are uniform. The billet is then transferred sequentially to the pre-forging, final forging, and trimming stations of the forging worktable 503 via a six-axis industrial robotic arm 502 equipped with high-temperature resistant cemented carbide grippers. The billet is then processed by a 1000T four-column hydraulic press, with a forging ratio of 1.3 at the pre-forging station and 1.8 at the final forging station. The finished product is then transported and collected by the high-temperature resistant finished product conveyor 504. The flash generated during trimming is returned to the waste collection module 100 for the next recycling cycle.

[0088] The pre-forging method provided in this embodiment replaces the traditional waste remelting process by implementing closed-loop recycling and high-value reuse of forging waste throughout the entire process. This increases the material utilization rate from 70%-85% in the traditional process to over 95%, with an optimal utilization rate of 96.2%. Through powder refinement and graded forming processes, the compositional uniformity and microstructure consistency of the pre-forged billet are ensured. The gear forgings prepared by this method have optimized internal metallographic structure, refined and uniform grains, and guaranteed mechanical properties such as tensile strength and impact toughness.

[0089] It should be noted that all directional indications in the embodiments of the present invention, such as up, down, left, right, front, and back, are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0090] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0091] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

Claims

1. A pre-forging equipment for gear forging production, characterized in that, It includes a waste collection module (100), a powder preparation module (200) and an extrusion rod module (300), and a circulation control module (600) that is electrically connected to the waste collection module (100), the powder preparation module (200) and the extrusion rod module (300). The waste collection module (100) is used to classify and collect the waste generated before and after gear forging and to transport the waste to the powder preparation module (200). The powder preparation module (200) is used to crush, grind, remove impurities, clean, dry and classify the received forging waste in sequence to prepare metal mixed powder that meets the molding requirements, and then convey it to the extrusion rod module (300). The extrusion bar module (300) includes a lower die base (302) and an upper die base (303). The lower die base (302) is provided with a die cavity (3021), and the upper die base (303) is provided with an extrusion punch (3031) that cooperates with the die cavity (3021). The upper die base (303) is driven to move relative to the lower die base (302) by a drive mechanism to press the metal mixed powder filled in the die cavity (3021) into a pre-forged billet bar. The extrusion rod module (300) also includes a frame base (301), a top base (304), and a powder feeding assembly (305); the top base (304) is fixed to the upper surface of the frame base (301) by a guide post (3013), and the lower die base (302) and the upper die base (303) are both slidably mounted on the guide post (3013); The top base (304) is provided with a main extrusion cylinder (3041) fixedly connected to the upper mold base (303) to form a drive mechanism; the frame base (301) is provided with an upper hydraulic cylinder (3012), the output end of which is fixedly connected to an upper mold sleeve (3011) that extends into the mold cavity (3021) and slides and seals with its inner wall, the two together forming a closed cavity for powder forming; the frame base (301) is also provided with a pull-down hydraulic cylinder (3014) fixedly connected to the lower mold base (302) for demolding; the powder feeding assembly (305) is located on the side of the lower mold base (302) for quantitatively feeding metal powder into the mold cavity (3021); The extrusion punch (3031) is coaxially provided with an axially retractable punch insert (3032); when the punch insert (3032) moves upward and retracts, it cooperates with the extrusion punch (3031) to form an annular extrusion end face with a central slot; when it moves downward and is flush with the lower end face of the extrusion punch (3031), it fills the slot to form a flat end face extrusion structure.

2. The pre-forging equipment for gear forging production according to claim 1, characterized in that, The powder feeding assembly (305) includes a feeding slide (3052), a storage hopper (3051), a feeding drive cylinder (3053), and a discharge base plate (3054). The feeding slide (3052) is fixedly connected to the lower mold base (302), and the storage hopper (3051) is slidably installed on the feeding slide (3052). The lower mold base (302) has a groove (3022) that communicates with the mold cavity (3021) and guides the storage hopper (3051). The feeding drive cylinder (3053) is fixed to the feeding slide (3052), and its output end is fixedly connected to the storage hopper (3051) to drive it to discharge. The discharge base plate (3054) is fixed to the bottom of the storage hopper (3051) and has a discharge through hole (30541) that matches the inner diameter of the mold cavity (3021).

3. The pre-forging equipment for gear forging production according to claim 2, characterized in that, Two sets of powder feeding components (305) are symmetrically arranged on both sides of the lower mold base (302). The two sets of powder feeding components (305) can be driven independently and alternately feed metal powder from different sources into the mold cavity (3021).

4. The pre-forging equipment for gear forging production according to claim 1, characterized in that, The waste collection module (100) is set up in two groups, which are respectively set up for bar cutting and precision turning stations and forging edge trimming stations, and are used to classify and collect forging waste generated in different processes; the waste collection module (100) includes a waste bin and a hoist, which are used for the collection and transportation of waste.

5. A pre-forging equipment for gear forging production according to claim 1, characterized in that, The powder preparation module (200) includes a coarse crusher (201), a grinder (202), a magnetic separator (203), an ultrasonic cleaning tank (204), a vacuum dryer (205), and a powder sieve (206) connected in sequence along the material conveying direction. The equipment is connected by sealed pipes to complete the powder preparation and graded mixing of waste materials.

6. The pre-forging equipment for gear forging production according to claim 1, characterized in that, It also includes a sintering pretreatment module (400) and a forging module (500) connected sequentially to the discharge end of the extrusion rod module (300), both of which are electrically connected to the circulation control module (600); the sintering pretreatment module (400) is used to perform debinding and pre-sintering treatment on the pre-forged billet rod to obtain a preformed billet; the forging module (500) is used to complete the forging of the preformed billet, and the generated waste is returned to the waste collection module (100) to form a closed-loop regeneration cycle.

7. A pre-forging method for producing gear forgings, characterized in that, The pre-forging equipment for producing gear forgings according to any one of claims 1-6 comprises the following steps: S1. Collect waste materials generated during the gear forging process and transport them to the powder preparation stage; S2. The collected waste materials are crushed, ground, impurities removed, washed, dried, graded, sieved and mixed in sequence to obtain metal mixed powder; S3. The metal mixture powder is pressed into a pre-forged billet bar of a preset specification by the extrusion bar module (300); S4. The pre-forged billet is subjected to debinding and atmosphere protection pre-sintering treatment in sequence to obtain a pre-formed billet, which is then kept warm and transported. S5. Reheat the preformed billet to the forging temperature, and complete the pre-forging, final forging, and edge trimming processes in sequence. The finished product is then transported and collected, and the generated waste is returned to step S1 for recycling.

8. A pre-forging method for producing gear forgings according to claim 7, characterized in that, In step S3, the extrusion into rod module (300) can optionally execute S3.1 or S3.2; S3.1 Core-shell composite pressing molding: Two sets of powder feeding components (305) respectively feed metal mixed powder from different sources into the mold cavity (3021), press and form an annular shell blank and a solid core blank in steps, and combine the two into an integrated pre-forged billet bar; S3.2, Material head replenishment and regeneration pressing: The pre-treated gear forging material head is positioned in the mold cavity (3021), and a combination is formed with the material head by pressing with metal mixed powder. Then, metal mixed powder is added and final pressing is performed to obtain a complete pre-forged billet bar.

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