Shell split flow power saving extrusion forming method

Abstract

The application provides a shell split-flow labor-saving extrusion forming method, which comprises the following steps: placing the cushion block at the cavity bottom of the concave die cavity, then placing a blank in the concave die cavity, controlling the upper die assembly assembled with the pressure forming reverse extrusion punch to descend so that the blank is reversely extruded to form an intermediate blank body with a central blind hole; taking out the intermediate blank body and the cushion block from the concave die cavity, dismounting the pressure forming reverse extrusion punch from the upper die plate, and then assembling the extrusion cone drawing punch; controlling the upper die assembly to descend again to form a drawing extrusion on the intermediate blank body to form a blind hole shell. The application realizes the distribution of the deformation of the blank between the reverse extrusion deformation and the drawing extrusion deformation, has the characteristics of more labor-saving and more efficient forming, saves energy consumption, greatly improves the production efficiency, and has the advantages of split-flow labor-saving in the extrusion forming of the blank by the extrusion cone drawing punch.

Description

Technical Field

[0001] This invention belongs to the field of metal forming technology, specifically relating to a shell splitting and labor-saving extrusion forming method. Background Technology

[0002] Thick-walled, long conical shell-type components with high aspect ratios possess excellent resistance to complex loads, lightweight properties, and transport efficiency due to their unique structure. They are widely used in aerospace equipment, weaponry, underwater equipment, and critical load-bearing components of pressure equipment—fields with stringent requirements for component performance under extreme conditions. To ensure high strength, these components typically utilize high-strength alloy steel, ultra-high-strength aluminum alloys, and other metallic materials. The structural characteristics, performance requirements, and material selection of these components present a challenge in balancing manufacturing efficiency, component performance, and manufacturing cost.

[0003] The main methods for manufacturing thick-walled, long conical shell components with high aspect ratios include machining, spin forming, and extrusion forming. Machining eliminates the need for mold development and offers advantages such as fast response and simple operation. However, it suffers from extremely low material utilization and cannot improve the internal structure and mechanical properties of the component. Spin forming is another method for manufacturing such parts. Its advantages include higher material utilization, but it requires extrusion to prepare cylindrical blanks, resulting in a long processing cycle. The rotary feed process leads to poor uniformity in the component's structure and properties, as well as noticeable texture, affecting the anisotropy of the component's mechanical properties and resulting in low manufacturing efficiency. Therefore, spin forming is not suitable for the low-cost manufacturing of small-diameter, high aspect ratio conical shells.

[0004] Extrusion forming is a common mass production method for thick-walled, long conical shell components with large aspect ratios. This method typically employs reverse extrusion forming and reverse extrusion-thinning deep drawing processes, such as... Figure 1 As shown, the advantage of reverse extrusion forming is that it subjects the metal to a triaxial compressive stress state during the extrusion process, allowing for sufficient plastic deformation and achieving significant improvements in microstructure and properties. However, for long conical shells, the long metal flow path during reverse extrusion results in a large contact area between the billet and the die, generating substantial frictional resistance and leading to high forming forces. Furthermore, long conical punches are prone to instability and, due to prolonged operation under heavy loads, have a short die life. For example... Figure 2 As shown, the advantage of reverse extrusion-thinning deep drawing is that the contact area between the blank and the die is small, which can reduce the overall forming load. However, its disadvantage is that the amount of deformation per pass is limited by the thinning stretching coefficient. Multiple thinning stretching passes are required to achieve the required amount of deformation. During the forming process, multiple heating passes and multiple sets of dies are often required to achieve extrusion, thinning and drawing processes. For small-diameter thin-walled shells, instability is easy to occur. The aforementioned problems increase production costs and reduce production efficiency. Summary of the Invention

[0005] Therefore, the present invention provides a shell splitting and labor-saving extrusion forming method, which can overcome the shortcomings of related technologies, such as the long metal flow path of shell forming by single reverse extrusion forming, the large-area contact between the billet and the mold leading to high friction and back stress, or the need for multiple stretching passes and multiple mold replacements for shell forming by reverse extrusion-thinning deep drawing, resulting in high production costs and low production efficiency.

[0006] To address the aforementioned problems, this invention provides a shell splitting and labor-saving extrusion forming method, employing a shell forming mold. The shell forming mold includes an upper mold assembly and a lower mold assembly. The lower mold assembly includes a lower template and a lower die disposed thereon. The lower die has a cavity, and a pad block can be optionally disposed at the bottom of the cavity. The upper mold assembly includes an upper template and a forming reverse extrusion punch and a tapered drawing punch, which can be optionally assembled on the side of the upper template facing the lower die. The forming method includes the following steps:

[0007] The pad is placed at the bottom of the cavity of the die cavity, and then the blank is placed in the cavity of the die cavity. The upper die assembly with the forming reverse extrusion punch is controlled to descend so that the blank is reverse extruded into an intermediate blank with a central blind hole.

[0008] Remove the intermediate blank and the pad from the cavity of the die, and after removing the forming reverse extrusion punch from the upper template, replace and assemble the tapered drawing punch.

[0009] The upper die assembly is lowered again to draw and extrude the intermediate blank to form a blind hole shell.

[0010] In some embodiments, the lower die includes an inner die body and an outer die body fitted onto the radially outer side wall of the inner die body, the die cavity being formed on the inner die body; and / or, the bottom of the die cavity is a cone shape that is larger at the top and smaller at the bottom, and the longitudinal cross-sectional shape of the pad is a cone shape that matches the bottom of the cavity.

[0011] In some embodiments, a cooling channel is formed in the outer mold body. The cooling channel is constructed on the mating ring surface of the inner mold body and the outer mold body, and the cooling channel has an inflow channel and an outflow channel. During the process of the upper mold assembly being controlled to descend and extrude the blank, cooling fluid is introduced into the cooling channel and forms a circulation.

[0012] In some embodiments, a lower pad is provided between the outer mold body and the lower template. The lower pad has a push rod through hole communicating with the bottom of the cavity. The push rod passes through the lower template and the push rod through hole in sequence. The push rod has a limiting ring protruding outward along its radial direction. The push rod has a pushing position and a blocking position and can be driven to move up and down between the pushing position and the blocking position. When the push rod is in the pushing position, the limiting ring abuts against the bottom side of the inner mold body. When the push rod is in the blocking position, the limiting ring abuts against the top side of the lower template and the top end of the push rod is inserted into the bottom of the cavity. When the intermediate blank and the blind hole shell are unloaded from the cavity, the push rod is controlled to be in the pushing position. When force is applied to the blank and the intermediate blank, the push rod is controlled to be in the blocking position.

[0013] In some embodiments, an upper concave template is detachably assembled on the top side end face of the outer mold body. The upper concave template has a first central through hole corresponding to the top side cavity opening of the die cavity. The working ends of the forming reverse extrusion punch and the tapered drawing punch can be inserted into the die cavity through the first central through hole. The lower mold assembly also includes a die guide sleeve and a stripper plate. When the forming reverse extrusion punch is assembled on the upper template, the die guide sleeve is assembled on the upper concave template and coaxially arranged with the first central through hole. A second central through hole is formed in the die guide sleeve. The upper opening diameter of the second central through hole is equal to the outer diameter of the main body of the forming reverse extrusion punch. When the tapered drawing punch is assembled on the upper template, the stripper plate is assembled on the upper concave template so that the blank can be removed from the tapered drawing punch during the lifting process of the tapered drawing punch.

[0014] In some embodiments, the upper concave template has an annular groove surrounding the first central through hole on one end face facing the upper template, and the bottom end seat of the die guide sleeve is installed in the annular groove; and / or, the diameter of the through hole of the second central through hole near the upper concave template is larger than its upper opening diameter and equal to the diameter of the blank; and / or, the first end of the stripper plate is hinged to the upper concave template, the second end of the stripper plate can be fixedly connected to the upper concave template, and the stripper plate has a semi-circular notch matching the outer diameter of the main body of the extrusion tapered drawing punch.

[0015] In some embodiments, the upper die assembly further includes a punch seat and a punch retaining ring, which are stacked sequentially along the direction away from the upper die plate and located on the side of the upper die plate closer to the lower die plate. The punch retaining ring is detachably assembled to the bottom end face of the punch seat, and a punch collar with a tapered positioning hole is formed in the central region of the punch retaining ring. The top of the main body of the forming reverse extrusion punch and the tapered drawing punch are formed with an inverted tapered ring that mates with the tapered positioning hole. The diameter of the tapered positioning hole decreases from top to bottom. The punch seat has a first insertion hole, and the punch retaining ring has a second insertion hole. The diameter of the first insertion hole is larger than the diameter of the second insertion hole.

[0016] In some embodiments, the punch collar and the punch retaining ring are separate components.

[0017] In some embodiments, an upper pad is provided between the upper template and the punch seat, and the top end face of the main body of the forming reverse extrusion punch and the tapered drawing punch can abut against the bottom side end face of the upper pad.

[0018] In some embodiments, a plurality of vertical guide components are provided at intervals between the upper template and the lower template to guide the linear movement of the upper and lower template components toward and away from each other.

[0019] The shell splitting and labor-saving extrusion forming method provided by the present invention has the following beneficial effects:

[0020] A pad is selectively placed at the bottom of the die cavity of the lower die. This allows the pad, whose position remains unchanged, to occupy the bottom area of ​​the die cavity during the reverse extrusion deformation process of the blank placed within the die cavity. This results in a shorter downward extrusion stroke of the forming reverse extrusion punch in this invention, eliminating the need for the forming reverse extrusion punch to descend almost the entire length of the formed shell, as is required in existing reverse extrusion shell forming processes. This effectively shortens the metal flow path, reduces the contact area between the blank and the die, and thus reduces frictional resistance and back stress. Simultaneously, the length of the corresponding forming reverse extrusion punch can be reduced to a certain extent (approximately the height of the aforementioned pad), improving die life (existing technologies often suffer from short die life due to excessively long punches when forming shells with large aspect ratios). After the reverse extrusion forming of the blank is completed, the aforementioned pad is removed from the die cavity, creating a suspended area below the bottom of the reverse-extruded blank. This allows for easier application of the aforementioned tapered drawing punch... When the die is further inserted into the anti-extrusion blind hole formed in the center of the aforementioned blank, the outer wall portion of the blank above the action ring of the extrusion drawing punch is subjected to a vertically upward tensile force, while the blank below the action ring continues to be stretched and deformed downward under the extrusion action of the extrusion drawing punch, ultimately forming a shell with an open top. This achieves the distribution of blank deformation between the two processes of anti-extrusion deformation and tensile extrusion deformation, resulting in more labor-saving and efficient forming, saving energy and significantly improving production efficiency. In addition, it is worth emphasizing that the shell diversion labor-saving extrusion forming method in this invention can achieve the final forming of the blank by simply placing and removing the pad in the die cavity and replacing the forming anti-extrusion punch and the extrusion drawing punch. The types of molds used and the parts that need to be replaced are greatly reduced, which has the advantage of quick disassembly and quick replacement. This solves the problem of difficult mold replacement during the extrusion forming of thick-walled constricted shell components with large height-to-diameter ratio, shortens mold replacement time, further shortens the production cycle, and reduces production costs. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or related technologies, the accompanying drawings used in the description of the embodiments or related technologies will be briefly introduced below. The drawings described below are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the forming process of the shell using a single reverse extrusion method in the prior art;

[0023] Figure 2 This is a schematic diagram of a forming process in the prior art where a shell is formed by reverse extrusion and then further thinned and drawn by a deep drawing ring.

[0024] Figure 3This is a schematic diagram of the steps of the shell diversion and labor-saving extrusion forming method according to an embodiment of the present invention;

[0025] Figure 4 This is a schematic diagram of the working state of the mold before the material is discharged before the reverse extrusion deformation in an embodiment of the present invention. A forming reverse extrusion punch is used in the figure, and the forming reverse extrusion punch in the figure does not apply force to the blank.

[0026] Figure 5 This is a schematic diagram of the working state of the mold after the reverse extrusion deformation ends in an embodiment of the present invention;

[0027] Figure 6 This is a schematic diagram of the working state of the mold after unloading following the reverse extrusion deformation in an embodiment of the present invention;

[0028] Figure 7 This is a schematic diagram of the working state of the die before deep drawing and extrusion deformation in an embodiment of the present invention. The figure shows a tapered deep drawing punch.

[0029] Figure 8 This is a schematic diagram of the working state of the die after the deep drawing and extrusion deformation is completed in an embodiment of the present invention;

[0030] Figure 9 This is a schematic diagram of the working state of the mold after unloading following the deep drawing and extrusion deformation in an embodiment of the present invention;

[0031] Figure 10 This is a top view of the upper die when the stripper plate is assembled (the stripper plate is in the blocking state) in an embodiment of the present invention.

[0032] Figure 11 This is a top view of the upper die when the stripper plate is assembled (the stripper plate is in a non-blocking state) in an embodiment of the present invention.

[0033] Figure 12 This is a vector diagram of metal flow during a traditional reverse extrusion process, with arrows indicating the direction of metal flow.

[0034] Figure 13 Is adopted Figure 12 The extrusion pressure curve (load prediction diagram) of a high-carbon steel billet during the traditional reverse extrusion process is shown in the figure. It can be clearly seen from the figure that the maximum forming extrusion pressure required is as high as 846t.

[0035] Figure 14 This is a vector diagram of metal flow during the deep drawing process after reverse extrusion in this invention. The arrows in the diagram indicate the direction of metal flow.

[0036] Figure 15 The extrusion molding method of the present invention is used for... Figure 13The extrusion pressure curve (load prediction diagram) of the same material blanks when performing tapered deep drawing shows that the maximum forming extrusion pressure required is about 422t.

[0037] The attached figures are labeled as follows:

[0038] 11. Lower die plate; 12. Lower die cavity; 1201. Inner mold body; 1202. Outer mold body; 1203. Cooling channel; 1204. Inflow channel; 1205. Outflow channel; 121. Die cavity; 122. Spacer block; 13. Lower backing plate; 131. Ejector pin through hole; 14. Ejector pin; 141. Limiting ring; 15. Upper die plate; 151. Annular groove; 16. Die opening guide sleeve; 17. Stripper plate; 21. Upper die plate; 22. Forming and reverse extrusion punch; 23. Tapered drawing punch; 26. Upper backing plate; 27. Punch seat; 28. Punch fixing ring; 29. ​​Punch collar; 31. Guide post; 32. Guide sleeve; 33. Guide post pressure plate; 34. Guide sleeve pressure plate; 100. Blank. Detailed Implementation

[0039] 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. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. 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.

[0040] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0041] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90° or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0042] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0043] See also Figures 3 to 15 As shown in the figure, according to an embodiment of the present invention, a shell splitting and labor-saving extrusion forming method is provided, which uses a shell forming mold. The shell forming mold includes an upper mold assembly (not labeled in the figure) and a lower mold assembly (not labeled in the figure). The lower mold assembly includes a lower template 11 and a lower die 12 disposed thereon. Taking the orientation in a specific use state as a reference, the lower die 12 is disposed on the top surface of the lower template 11. The lower die 12 has a die cavity 121. The bottom of the die cavity 121 may optionally be provided with a pad 122. The pad 122 occupies the bottom space of the die cavity 121, thereby providing space for the die cavity 121. The blank 100 within 1 undergoes further downward deformation, providing downward deformation space. The upper die assembly includes an upper die plate 21 and a forming reverse extrusion punch 22 and a tapered drawing punch 23, which are optionally assembled on the side of the upper die plate 21 facing the lower die 12. That is, the aforementioned forming reverse extrusion punch 22 and tapered drawing punch 23 are selectively assembled according to different forming processes. The bottom shape of the aforementioned tapered drawing punch 23 should be consistent with the bottom shape (blind hole end) of the final formed target shell, and the outer wall surface of the aforementioned tapered drawing punch 23 should also have a corresponding working ring (not indicated in the figure, also called the working zone). The forming method includes the following steps:

[0044] After placing the pad 122 at the bottom of the cavity 121, the blank 100 is placed inside the cavity 121. The upper die assembly with the forming reverse extrusion punch 22 is controlled to descend so that the blank 100 is reverse extruded into an intermediate blank with a central blind hole (that is, the forming extrusion of the blank 100 is realized). During this process, the pad 122 is positioned at the bottom of the cavity 121 to occupy the bottom space of the cavity 121. During the reverse extrusion deformation of the blank 100 (that is, forming reverse extrusion), the position of the pad 122 remains unchanged so as to form a clamping and extrusion of the blank 100 together with the forming reverse extrusion punch 22.

[0045] Remove the intermediate blank and the pad 122 from the cavity 121, and after removing the forming reverse extrusion punch 22 from the upper template 21, replace and assemble the tapered drawing punch 23.

[0046] The upper die assembly is lowered again to draw and extrude the intermediate blank to form a blind hole shell. During this process, since the bottom area of ​​the blank 100, that is, the bottom side area of ​​the aforementioned die cavity 121, is no longer provided with the aforementioned pad 122, a space is formed for the aforementioned intermediate blank to be further drawn and extruded downwards. The metal of the blank 100 generates a composite flow of forward extrusion cone and reverse drawing. When the bottom end of the extrusion cone drawing punch 23 is conical (frustum) shaped, the blank 100 is extruded into a shell (thin-walled or thick-walled) with a long conical head and a large height-to-diameter ratio.

[0047] In this technical solution, a pad 122 is selectively placed at the bottom of the cavity 121 of the lower die 12. This allows the pad 122, whose position remains unchanged, to occupy the bottom area of ​​the cavity 121 during the reverse extrusion deformation process of the blank 100 placed within the cavity 121. Consequently, the downward extrusion stroke of the forming reverse extrusion punch 22 in this invention can be shortened, eliminating the need for the forming reverse extrusion punch to descend nearly the entire length of the formed shell, as is required in existing reverse extrusion forming shell processes. This effectively shortens the length of the metal flow path. Reducing the contact area between the blank and the die lowers frictional resistance and back stress. Simultaneously, the length of the corresponding forming punch 22 can be reduced to a certain extent (approximately the height of the aforementioned pad 122), improving die life (in the prior art, excessively long punches lead to low die life when forming shells with large aspect ratios). After the blank 100 is formed by reverse extrusion, the aforementioned pad 122 is removed from the die cavity 121, creating a suspended area below the bottom of the reverse-extruded blank 100. This allows for better control of the forming process when using the aforementioned extrusion cone drawing punch 22. 3. When further inserted into the anti-extrusion blind hole formed in the center of the aforementioned blank 100, the outer wall portion of the blank 100 above the action ring of the extrusion drawing punch 23 is subjected to a vertically upward tensile force, while the blank 100 below the action ring continues to be stretched and deformed downward under the extrusion action of the extrusion drawing punch 23, ultimately forming a shell with a top opening. This achieves the distribution of the deformation of the blank 100 between the two processes of anti-extrusion deformation and stretching extrusion deformation, resulting in more labor-saving and efficient forming, saving energy and significantly improving production efficiency; in addition, It is worth emphasizing that the shell splitting and labor-saving extrusion forming method in this invention can achieve the final forming of the blank 100 by taking the pad 122 out of the die cavity 121 and changing the forming reverse extrusion punch 22 and the extrusion tapered drawing punch 23. The types of molds used and the parts that need to be replaced are greatly reduced, which has the advantage of quick disassembly and quick replacement. It solves the problem of difficult mold replacement in the extrusion forming process of thick-walled shell components with large height-to-diameter ratio, shortens the mold replacement time, further shortens the production cycle, and reduces the production cost. It is especially suitable for the forming of thick-walled shell components with large height-to-diameter ratio.

[0048] See details Figure 14 and Figure 15 As shown in the figure, the wall of the component (i.e., the shell) is the main deformation zone. During the entire extrusion process, the metal flow vector in this zone is divided by the working zone of the punch (the area indicated in the figure). Above the working zone is the flow vector opposite to the extrusion direction, and below the working zone is the flow vector in the same direction as the extrusion direction. That is, the shell material is split vertically by the working zone. At this time, part of the frictional resistance is used to provide tensile stress in the deformation zone of the component wall in the same direction as the metal flow. For comparison, see [reference needed]. Figure 12As shown in the figure, the conventional reverse extrusion forming shell method is adopted. During the entire reverse extrusion process, the metal flow vector in this area always maintains a single vector characteristic opposite to the extrusion direction. At this time, the metal in the wall deformation zone is subjected to the extrusion force in the same direction as the metal flow and the friction force in the opposite direction of the metal flow. All the friction force is the deformation resistance that needs to be overcome. This force provides compressive stress in the wall deformation zone of the component in the opposite direction of the metal flow.

[0049] Further comparison Figure 13 and Figure 15 As shown, the maximum extrusion pressure used in traditional reverse extrusion molding is 846t, while the molding method of the present invention requires about 422t, meaning that the molding method of the present invention is more labor-saving.

[0050] Based on the size requirements of the shell forming and taking into account the forming efficiency, the specific height of the aforementioned pad 122, that is, the proportion of the cavity bottom space occupied by the aforementioned die cavity 121, can be reasonably selected. For example, in a specific embodiment, the height of the aforementioned pad 122 is consistent with (i.e. equal to) the height of the bottom cone portion of the finally formed shell.

[0051] In some embodiments, the lower die 12 includes an inner die body 1201 and an outer die body 1202 fitted onto the radially outer side wall of the inner die body 1201. The die cavity 121 is formed on the inner die body 1201. Specifically, the aforementioned outer die body 1202 is fitted onto the inner die body 1201 with an interference fit. The interference fit applies prestress to the die to improve its load-bearing capacity and increase the die life.

[0052] In this technical solution, the lower die 12 is formed by combining an inner mold body 1201 and an outer mold body 1202 that fit together, and the die cavity 121 is formed on the inner mold body 1201. The lower die 12 with the combined structure can match the inner mold body 1201 with the material corresponding to the forming temperature of the blank 100. At the same time, the material selection of the outer mold body 1202 does not need to consider the high temperature resistance, thus making the material cost of the lower die 12 lower. In addition, the lower die 12 with the combined structure can be replaced separately if one of them, especially the inner mold body 1201, is damaged, without having to replace the outer mold body 1202, which can further reduce the mold manufacturing cost.

[0053] In some embodiments, the bottom of the cavity 121 is a cone shape that is larger at the top and smaller at the bottom. The longitudinal cross-sectional shape of the pad 122 (that is, the cross-section formed by cutting the pad 122 along its center line by a vertical plane) is a cone shape that matches the bottom of the cavity. In this way, the conical fit between the pad 122 and the bottom of the cavity 121 can be used to lock the position of the pad 122, ensuring reliable and stable support of the bottom end of the blank 100 when the blank 100 is reverse extruded, thereby ensuring reliable and stable reverse extrusion forming. Of course, it is understood that the conical shape of the bottom of the cavity 121 should match the bottom conical shape of the shell to be formed.

[0054] In some embodiments, a cooling channel 1203 is formed within the outer mold body 1202. The cooling channel 1203 is constructed on the mating ring surface of the inner mold body 1201 and the outer mold body 1202, and the cooling channel 1203 has an inflow channel 1204 and an outflow channel 1205. During the process of the upper mold assembly being controlled to descend and extrude the blank 100, cooling fluid is introduced into the cooling channel 1203 and forms a circulation. It is understood that the aforementioned inflow channel 1204 and outflow channel 1205 are respectively connected to an external cooling source (such as a cooling air source or a cooling water source) to form a circulation. In this way, the temperature of the outer mold body 1202 and the inner mold body 1201 is controlled, the molding temperature is kept constant, the lower die 12 is prevented from undergoing high-temperature creep deformation, the mold is prevented from softening and being worn at excessively high temperatures, and the service life of the lower die 12 is improved.

[0055] In some embodiments, a lower backing plate 13 is provided between the outer mold body 1202 and the lower mold plate 11. The lower backing plate 13 has a push rod through hole 131 communicating with the bottom of the cavity 121. The push rod 14 passes sequentially through the lower mold plate 11 and the push rod through hole 131. The push rod 14 has a limiting ring 141 protruding radially outward. The push rod 14 has an ejector position and a blocking position and can be driven to move up and down between the ejector position and the blocking position. When the push rod 14 is in the ejector position... When the ejector is in the ejector position, the limiting ring 141 abuts against the bottom side of the inner mold body 1201. When the ejector rod 14 is in the blocking position, the limiting ring 141 abuts against the top side of the lower mold plate 11 and the top end of the ejector rod 14 is inserted into the bottom of the cavity of the die cavity 121. When the intermediate blank and the blind hole shell are unloaded from the die cavity 121, the ejector rod 14 is controlled to be in the ejector position. When force is applied to the blank 100 and the intermediate blank, the ejector rod 14 is controlled to be in the blocking position.

[0056] In this technical solution, a lower pad 13 is further provided between the lower template 11 and the outer mold body 1202. On the one hand, the push rod through hole 131 on the lower pad 13 forms a lifting and lowering movement space for the limiting ring 141 on the push rod 14. The push rod 14 can be driven to lift and lower between the material ejection position and the material blocking position, thereby realizing the limiting and material ejection functions of the bottom end of the blank. On the other hand, it can simplify the structural design of the outer mold body 1202.

[0057] In some embodiments, an upper concave template 15 is detachably assembled on the top side end face of the outer mold body 1202. The upper concave template 15 has a first central through hole (not indicated in the figure) corresponding to the top side cavity opening of the concave mold cavity 121. The working ends of the forming reverse extrusion punch 22 and the tapered drawing punch 23 (i.e., Figure 4 The bottom end (as shown) can be inserted into the cavity 121 through the first central through hole. It is understood that a forming cavity for the shell is formed between the punch and the cavity wall of the cavity. The lower die assembly also includes a die guide sleeve 16 and a stripper plate 17. When the forming and extruding punch 22 is assembled on the upper die plate 21, the die guide sleeve 16 is assembled on the upper die plate 15 and coaxially arranged with the first central through hole. A second central through hole (not shown in the figure) is formed inside the die guide sleeve 16. The diameter of the upper opening of the second central through hole is equal to the outer diameter of the main body of the forming reverse extrusion punch 22. This not only guides the forming reverse extrusion punch 22, but also supports the main structure of the forming reverse extrusion punch 22 away from the lower die 12 during the reverse extrusion process, ensuring reliable and stable axial force application of the forming reverse extrusion punch 22 and preventing large-span bending deformation due to excessive length of the forming reverse extrusion punch 22. When the blank 100 is placed in the aforementioned die cavity 121, the top of the blank 100 (such as...) Figure 4 (As shown) The bottom end of the second central through hole of the aforementioned die guide sleeve 16 is in contact with the die to form an alignment. When the extrusion drawing punch 23 is assembled on the upper template 21, the stripper plate 17 is assembled on the upper concave template 15 so that the blank 100 can be removed from the extrusion drawing punch 23 during the lifting process of the extrusion drawing punch 23, that is, the blank is stripped. For details, please refer to [link to relevant documentation]. Figure 10 and Figure 11 As shown.

[0058] The aforementioned lower template 11, lower pad 13, outer mold body 1202, and upper concave template 15 can be connected by bolts from bottom to top.

[0059] In some embodiments, the upper concave template 15 has an annular groove 151 surrounding the first central through hole on one end face of the upper template 21. The bottom end of the die guide sleeve 16 is installed in the annular groove 151. That is, the bottom end of the die guide sleeve 16 is placed in the annular groove 151 from top to bottom. No other structural design is required. The shape matching and positioning of the annular groove 151 and the die guide sleeve 16 are sufficient. The die guide sleeve 16 can be easily removed from the upper concave template 15 when switching deformation processes.

[0060] In some embodiments, the diameter of the second central through hole on the side near the upper concave template 15 is larger than its upper opening diameter and equal to the diameter of the blank 100, so as to match the end size of the blank 100 with a larger diameter, and at the same time, it can form a limiting radial support for the protruding structure at the top of the blank 100 during the reverse extrusion forming process.

[0061] In some implementations, see reference Figure 10 and Figure 11 As shown, the first end of the unloading plate 17 is hinged to the upper concave template 15, and the second end of the unloading plate 17 can be fixedly connected to the upper concave template 15 (e.g., by a detachable positioning component such as bolts). The unloading plate 17 has a semi-circular notch that matches the outer diameter of the main body of the extrusion drawing punch 23. Thus, during the process of the extrusion drawing punch 23 completing the downward drawing and extrusion forming of the blank 100, the semi-circular notch and the main body of the extrusion drawing punch 23 can be contacted and matched through the semi-circular notch to separate the blank that is held tightly on the extrusion drawing punch 23 from top to bottom.

[0062] In some implementation methods, see details. Figure 4 As shown, the upper die assembly also includes a punch seat 27 and a punch retaining ring 28 stacked sequentially along the direction away from the upper die plate 21 and located on the side of the upper die plate 21 closer to the lower die plate 11. The punch retaining ring 28 is detachably assembled to the bottom end face of the punch seat 27, and a punch collar 29 with a tapered positioning hole (not labeled in the figure) is formed in the central region of the punch retaining ring 28. The top of the main body of the forming reverse extrusion punch 22 and the extrusion tapered drawing punch 23 is formed with an inverted tapered ring (not labeled in the figure, also called a sizing band) that mates with the tapered positioning hole. The diameter of the tapered positioning hole decreases from top to bottom. The punch seat 27 has a first insertion hole (not labeled in the figure), and the punch retaining ring 28 has a second insertion hole (not labeled in the figure). The diameter of the first insertion hole is larger than the diameter of the second insertion hole.

[0063] In this technical solution, the tapered positioning hole and the inverted tapered ring on the punch form an axial positioning, which can have a larger contact area, realize the wedge-type installation between the punch and the mounting component, increase the shear resistance of the corresponding punch, and eliminate the phenomenon of poor connection stability that occurs when using threaded connections.

[0064] In some embodiments, the punch collar 29 and the punch retaining ring 28 are separately configured. The materials of the separately configured punch retaining ring 28 and punch collar 29 can be reasonably selected according to actual conditions. For example, the aforementioned punch collar 29 can be made of a material with a lower hardness than the punch retaining ring 28, which can utilize its softer characteristics to provide dimensional compensation for the punch and other related components. At the same time, if one of them is damaged, it can be replaced separately without replacing the whole, reducing mold maintenance costs. It should be noted that the punch retaining ring 28 and punch collar 29 are in a non-high-temperature state during disassembly and assembly, which can avoid contact with the high-temperature punch and avoid safety hazards during manual disassembly and assembly.

[0065] In some embodiments, an upper pad 26 is provided between the upper template 21 and the punch seat 27. The top end face of the main body of the forming and extruding punch 22 and the drawing punch 23 can abut against the bottom side end face of the upper pad 26. In this way, the upper pad 26 can be used to physically protect the upper template 21, preventing the top end of each punch from directly contacting the upper template 21 and causing damage to the upper template 21, thereby further reducing maintenance costs.

[0066] See details Figure 4 As shown, the upper template 21, upper backing plate 26, and punch seat 27 are assembled and connected from top to bottom using multiple long bolts (not marked in the figure, but in a specific embodiment, six bolts are arranged in a ring at intervals). When replacing the punch during use, only the aforementioned punch fixing ring 28, punch collar 29, and the corresponding punch need to be disassembled and assembled. There is no need to disassemble and assemble the upper template 21, upper backing plate 26, and punch seat 27, which greatly reduces the weight of disassembly and assembly, facilitates quick disassembly and assembly of the mold, meets the requirements of rapid switching of process flow, and further shortens the production cycle.

[0067] In some embodiments, a plurality of vertical guide components (not labeled in the figure) are provided at intervals between the upper template 21 and the lower template 11 to guide the linear movement of the upper and lower template components toward and away from each other. In a specific embodiment, four vertical guide components are provided in total, evenly spaced at the four corner areas of the upper template 21 and the lower template 11. Each vertical guide component specifically includes a guide post 31 and a guide sleeve 32 that are fitted inside and out and can slide along their axial direction. The guide post 31 is fixedly connected to the lower template 11 through a guide post pressure plate 33, and the guide sleeve 32 is fixedly connected to the upper template 21 through a guide sleeve pressure plate 34.

[0068] The following describes the assembly method and assembly sequence of the mold:

[0069] 1. The upper template 21 is assembled with the upper worktable of the press (not shown in the figure) by fastening bolts. The upper template 21, the upper pad 26 and the punch seat 27 are assembled by internal hex bolts to form a whole.

[0070] 2. The guide sleeve 32, guide sleeve pressure plate 34, and upper template 21 are assembled by internal hex bolts;

[0071] 3. The forming reverse extrusion punch 22 and the tapered drawing punch 23 are respectively wedged into and assembled with the punch collar 29;

[0072] 4. The punch retaining ring 28 and the punch seat 27 are assembled by internal hex bolts;

[0073] 5. The inner mold body 1201 and the outer mold body 1202 are assembled by heating the outer mold body 1202 or freezing the inner mold body 1201;

[0074] 6. The upper concave template 15 and the outer mold body 1202 are assembled by internal hex bolts;

[0075] 7. The lower template 11 is assembled with the lower worktable of the press using fastening bolts;

[0076] 8. The guide post 31, guide post pressure plate 33, and lower template 11 are assembled by internal hex bolts;

[0077] 9. The top rod 14 is inserted into the center hole of the lower template 11;

[0078] 10. The outer mold body 1202 is assembled with the lower pad plate 13 and the lower template 11 by internal hex bolts;

[0079] 11. The pad 122 is placed into the cavity of the lower die 12 and contacts the upper end face of the ejector pin 14;

[0080] 12. The mold guide sleeve 16 is inserted into the annular groove 151 of the upper concave template 15;

[0081] 13. The unloading plate 17 and the upper concave template 15 are assembled by hexagon socket bolts (one end is hinged and the other end can be fixed).

[0082] The aforementioned shell splitting and labor-saving extrusion forming method specifically adopts the following steps to form a shell component with a top constriction and a bottom conical opening:

[0083] S1. Pre-forming preparation: Heat the cylindrical blank (i.e., the aforementioned blank 100) to the forming temperature; install the mold on the press according to the above-mentioned combination working method, assembly relationship and assembly steps, and preheat and keep it warm for forming reverse extrusion punch 22, lower die 12, and pad 122; evenly spray oil-based graphite lubricant on the contact parts of the forming reverse extrusion punch 22, upper die plate 15, lower die 12 and pad 122 with the blank 100; turn on the circulating cooling water; place the pad 122 into the die cavity (i.e., the aforementioned die cavity 121); then place the heated blank 100 into the cavity formed by the lower die 12 (specifically the inner mold body 1201) and the upper die plate 15, and install the mold guide sleeve 16 in place, as follows. Figure 4 As shown;

[0084] S2. Reverse extrusion deformation process: such as Figure 4 and Figure 5 As shown, the pad 122 fills the cavity formed by the lower die 12 and the upper die 15 from a "V" shape to a "U" shape. After the extrusion process begins, as the forming reverse extrusion punch 22 moves downward, the blank 100 is gradually filled with the cavity and flows upward to generate reverse extrusion flow. When the forming reverse extrusion punch 22 moves downward to the designated position and stops, the blank 100 is a "U" shape with a designated wall thickness and bottom thickness, and the reverse extrusion deformation process is completed.

[0085] S3. Unloading the "U"-shaped billet: (e.g.) Figure 6 As shown, after the reverse extrusion deformation process is completed, the forming reverse extrusion punch 22 is raised, the die guide sleeve 16 is removed, and then the "U" shaped blank is ejected and taken out by the ejector rod 14.

[0086] S4. Change the mold and place the heated "U"-shaped blank inside: (e.g.) Figure 7 As shown, replace the forming reverse extrusion punch 22 with the tapered drawing punch 23, remove the pad 122 and the die guide sleeve 16, install the stripper plate 17 and rotate it to the non-blocking state (as shown). Figure 11 As shown), the mold replacement is completed. Oil-based graphite lubricant is evenly sprayed onto the contact parts of the extrusion cone drawing punch 23, upper concave template 15 and lower concave template 12 with the "U" shaped blank. The circulating cooling water is turned on, and the heated "U" shaped blank is placed into the cavity formed by the lower concave template 12 and the upper concave template 15.

[0087] S5. Deep drawing and extrusion deformation process: such as... Figure 7 and Figure 8 As shown, the removal of the pad 122 causes the cavity formed by the lower die 12 and the upper die plate 15 to change from a "U" shape to a "V" shape, and the stripper plate 17 is rotated to the stop position (as shown). Figure 10As shown in the figure, after the extrusion process begins, as the extrusion cone drawing punch 23 descends, the "U"-shaped blank gradually fills the cavity and generates a drawing deformation flow. When the extrusion cone drawing punch 23 descends to the designated position and stops, the blank is a "V" shape with a specified wall thickness, bottom thickness and taper, and the drawing extrusion deformation process is completed.

[0088] S6. Unloading of “V” shaped billets: (e.g., ...) Figure 9 As shown, after the deep drawing and extrusion deformation process is completed, the extrusion cone drawing punch 23 is raised and the "V" shaped blank is separated from the extrusion cone drawing punch 23 under the action of the stripper plate 17. Then the stripper plate 17 is rotated to a non-stopping state, and then the "V" shaped blank is ejected and removed by the ejector rod 14 to obtain the blind hole shell (i.e. the target shell).

[0089] It will be readily understood by those skilled in the art that, without conflict, the advantageous technical features of the above-mentioned methods can be freely combined and superimposed.

[0090] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention. The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the protection scope of the present invention.

Claims

1. A method for extruding and forming a shell with a flow-diverting mechanism, characterized in that, The forming process employs a shell forming mold, which includes an upper mold assembly and a lower mold assembly. The lower mold assembly includes a lower template (11) and a lower die (12) disposed thereon. The lower die (12) has a die cavity (121), and a pad (122) may be optionally provided at the bottom of the die cavity (121). The upper mold assembly includes an upper template (21) and a forming punch (22) and a tapered drawing punch (23) optionally assembled on the side of the upper template (21) facing the lower die (12). The forming method includes the following steps: After placing the pad (122) at the bottom of the cavity (121), the blank (100) is placed in the cavity (121), and the upper die assembly with the forming reverse extrusion punch (22) is controlled to descend so that the blank (100) is reverse extruded into an intermediate blank with a central blind hole. The intermediate blank and the pad (122) are removed from the cavity (121), and the forming reverse extrusion punch (22) is removed from the upper template (21) and then the extrusion tapered drawing punch (23) is replaced and assembled. The upper die assembly is lowered again to draw and extrude the intermediate blank to form a blind hole shell.

2. The shell splitting and labor-saving extrusion forming method according to claim 1, characterized in that, The lower die (12) includes an inner die body (1201) and an outer die body (1202) fitted onto the radial outer wall of the inner die body (1201). The die cavity (121) is formed on the inner die body (1201). And / or, the bottom of the die cavity (121) is a cone shape with a larger top and a smaller bottom, and the longitudinal section shape of the pad (122) is a cone shape that matches the bottom of the cavity.

3. The shell splitting and labor-saving extrusion forming method according to claim 2, characterized in that, A cooling channel (1203) is formed inside the outer mold body (1202). The cooling channel (1203) is constructed on the mating ring surface of the inner mold body (1201) and the outer mold body (1202). The cooling channel (1203) has an inflow channel (1204) and an outflow channel (1205). During the process of the upper mold assembly being controlled to descend and extrude the blank (100), cooling fluid is introduced into the cooling channel (1203) and forms a circulation.

4. The shell splitting and labor-saving extrusion forming method according to claim 2, characterized in that, A lower pad (13) is provided between the outer mold body (1202) and the lower template (11). The lower pad (13) has a push rod through hole (131) that communicates with the bottom of the cavity (121). The push rod (14) passes through the lower template (11) and the push rod through hole (131) in sequence. The push rod (14) has a limiting ring (141) that protrudes outward along its radial direction. The push rod (14) has a push position and a block position and can be driven to move up and down between the push position and the block position. When the push rod (14) is in the push position, the push rod (14) can be moved up and down between the push position and the block position. When the material is in the material position, the limiting ring (141) abuts against the bottom side of the inner mold body (1201). When the ejector rod (14) is in the material blocking position, the limiting ring (141) abuts against the top side of the lower mold plate (11) and the top end of the ejector rod (14) is inserted into the bottom of the cavity of the cavity (121). When the intermediate blank and the blind hole shell are unloaded from the cavity of the cavity (121), the ejector rod (14) is controlled to be in the material ejection position. When force is applied to the blank (100) and the intermediate blank, the ejector rod (14) is controlled to be in the material blocking position.

5. The shell splitting and labor-saving extrusion forming method according to claim 2, characterized in that, An upper concave template (15) is detachably assembled on the top side end face of the outer mold body (1202). The upper concave template (15) has a first central through hole corresponding to the top side cavity opening of the die cavity (121). The working ends of the forming reverse extrusion punch (22) and the tapered drawing punch (23) can be inserted into the die cavity (121) through the first central through hole. The lower mold assembly also includes a die guide sleeve (16) and a stripper plate (17). When the forming reverse extrusion punch (22) is assembled on the upper template (21), it guides the die opening. The sleeve (16) is assembled on the upper concave template (15) and is coaxially arranged with the first central through hole. A second central through hole is formed in the die guide sleeve (16). The upper hole diameter of the second central through hole is equal to the outer diameter of the main body of the forming reverse extrusion punch (22). When the extrusion tapered drawing punch (23) is assembled on the upper template (21), the unloading plate (17) is assembled on the upper concave template (15) so that the blank (100) can be removed from the extrusion tapered drawing punch (23) during the process of the extrusion tapered drawing punch (23) being raised.

6. The shell splitting and labor-saving extrusion forming method according to claim 5, characterized in that, The upper concave template (15) has an annular groove (151) surrounding the first central through hole on one end face facing the upper template (21), and the bottom end of the die guide sleeve (16) is installed in the annular groove (151); and / or, the diameter of the through hole of the second central through hole near the upper concave template (15) is greater than its upper hole diameter and equal to the diameter of the blank (100); and / or, the first end of the stripper plate (17) is hinged to the upper concave template (15), the second end of the stripper plate (17) can be fixedly connected to the upper concave template (15), and the stripper plate (17) has a semi-circular notch that matches the outer diameter of the main body of the extrusion tapered drawing punch (23).

7. The shell splitting and labor-saving extrusion forming method according to claim 6, characterized in that, The upper die assembly also includes a punch seat (27) and a punch retaining ring (28) stacked sequentially along the direction away from the upper template (21) and located on the side of the upper template (21) closer to the lower template (11). The punch retaining ring (28) is detachably assembled on the bottom end face of the punch seat (27), and a punch collar (29) with a tapered positioning hole is formed in the central area of ​​the punch retaining ring (20). The top of the main body of the forming reverse extrusion punch (22) and the extrusion tapered drawing punch (23) is formed with an inverted tapered ring that cooperates with the tapered positioning hole. The diameter of the tapered positioning hole decreases from top to bottom. The punch seat (27) has a first insertion hole, and the punch retaining ring (28) has a second insertion hole. The diameter of the first insertion hole is larger than the diameter of the second insertion hole.

8. The shell splitting and labor-saving extrusion forming method according to claim 7, characterized in that, The punch collar (29) and the punch fixing ring (28) are separately configured.

9. The shell splitting and labor-saving extrusion forming method according to claim 7, characterized in that, An upper pad (26) is provided between the upper template (21) and the punch seat (27), and the top end face of the main body of the forming reverse extrusion punch (22) and the tapered drawing punch (23) can abut against the bottom side end face of the upper pad (26).

10. The shell splitting and labor-saving extrusion forming method according to claim 1, characterized in that, Multiple vertical guide components are provided at intervals between the upper template (21) and the lower template (11) to guide the linear movement of the upper and lower template components as they move closer and further apart.

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