Bearing ring forging die

Abstract

The application relates to the technical field of forging dies and discloses a bearing ring forging die, which comprises a forging die body, the forging die body is designed in a layered and modularized mode, and is specifically divided into upper, middle and lower three-layer structures, each layer is composed of two left and right symmetrical parts, the upper, middle and lower three layers are longitudinally slidably matched through sliding guide rails, and the left and right two parts of each layer are connected in a separable mode through longitudinal parting surfaces; the forging die body is formed into six independent module units capable of moving independently, and each module unit is capable of moving independently; a die stripping assembly is arranged on the forging die body, the die stripping assembly comprises a die stripping plate and a die stripping hydraulic rod, each part of the forging die body is connected with one die stripping plate, and the outer side of each die stripping plate is provided with one die stripping hydraulic rod; the forging die body designed in the layered and modularized mode is sequentially pulled by the die stripping hydraulic rods and assisted by the vibration assembly, a pre-separation gap is formed in the initial die stripping stage, the frictional resistance between the die and the forged piece is effectively overcome through vibration energy, and rapid die stripping is realized.

Description

Technical Field

[0001] This invention relates to the field of forging dies, and more specifically, to a forging die for bearing rings. Background Technology

[0002] Bearing rings are an important component of bearings, and their manufacturing precision and surface quality directly affect the performance and life of the bearing. Currently, bearing rings are usually manufactured using forging processes. After forging, traditional bearing ring forging dies often have a large frictional force between the die and the forging, making demolding difficult and requiring a long time and a lot of force to remove the forging from the die.

[0003] In existing technologies, methods such as increasing the draft angle, applying a release agent, or using a mechanical ejection device are commonly employed. However, while mechanical ejection devices can assist in demolding, there is still a risk of incomplete demolding or damage to the forgings, especially for complex shapes or large sizes. Therefore, we propose a bearing ring forging die. Summary of the Invention

[0004] This invention provides a bearing ring forging die, which solves the technical problem in related technologies that although mechanical ejection devices can assist in demolding, there is still a risk of incomplete demolding or damage to forgings with complex shapes or large sizes.

[0005] This invention provides a bearing ring forging die, comprising: a forging die body, which adopts a layered modular design, specifically divided into upper, middle and lower three-layer structures, each layer consisting of two symmetrical parts on the left and right; The upper, middle and lower layers are connected by sliding guide rails to achieve longitudinal sliding fit between the layers, and the left and right parts of each layer are connected by longitudinal parting surfaces to achieve separable connection. The forging die body is composed of six independently moving modular units, each of which has independent movement capabilities; The die removal assembly includes a die removal plate and a die removal hydraulic rod. Each part of the forging die body is connected to a die removal plate. A die removal hydraulic rod is provided on the outer side of each die removal plate. A vibration assembly is provided between the forging die body and the die removal plate. After the bearing ring is forged, the six parts of the forging die are pulled back in sequence according to the programmable control by the die removal hydraulic rod. First, a pre-separation gap of 0.1-10mm is formed between the die removal plate and the corresponding module unit. Then, the vibration assembly is started to transmit the vibration to the module unit. The laser scanner is positioned directly in front of the scanning space formed after the forging die has been completely removed. The laser scanner is equipped with a 3D scanning module and a defect detection algorithm module. After the forging die is completely retracted, the laser scanner performs a non-contact 3D scan on the exposed bearing sleeve, and the defect detection algorithm module analyzes the dimensional accuracy and surface defects of the bearing sleeve in real time.

[0006] Furthermore, the upper, middle and lower layers of the forging die body are the upper die, the middle die and the lower die, respectively. The left and right sides of the upper die, the middle die and the lower die are all connected to a pull-out plate, and there are a total of six pull-out plates, which correspond one-to-one with the six parts of the forging die body.

[0007] Furthermore, the vibration assembly includes a mold release column, one end of which is connected to a micro vibrator, and a pull-out ball head is fixedly installed at the end of the mold release column away from the micro vibrator. The vibration generated by the micro vibrator is transmitted to the pull-out ball head through the mold release column.

[0008] Furthermore, each mold release plate has two flat cover chambers inside, and a total of twelve flat cover chambers are set inside the six mold release plates. Each flat cover chamber is fixedly equipped with a miniature vibrator.

[0009] Furthermore, the upper mold, middle mold, and bottom mold each have a limiting groove at the position of the mold release pillar. The pull-out ball head passes through the inside of the limiting groove and is slidably connected to it. The diameter of the limiting groove gradually increases from the inside to the outside, and the diameter of the innermost end of the limiting groove is the same as the diameter of the pull-out ball head.

[0010] Furthermore, after the pulling die plate retracts, the pulling ball head slides to the outer end of the limiting groove. At this time, there is a gap between the pulling ball head and the limiting groove. Through the vibration of the pulling ball head, the forging die body retains a certain swaying space under vibration. As the pulling die plate continues to retract, the corresponding upper die, middle die and bottom die are pulled away from the forming bearing sleeve.

[0011] Furthermore, a forging die outer frame is provided on the outside of the forging die body, the die removal hydraulic rod is fixed on the forging die outer frame, and the telescopic arm of the die removal hydraulic rod passes through the forging die outer frame. The laser scanner is also fixed on the forging die outer frame, and the scanning port of the laser scanner is directly facing the center of the forging die body.

[0012] Furthermore, a pressing plate is provided below the forging die body, and a lowering plate groove is opened at the center of the pressing plate. A lifting plate is provided in the lowering plate groove. A hydraulic lifting machine is provided below the pressing plate. The telescopic arm of the hydraulic lifting machine is fixedly connected to the lifting plate. The diameter of the lifting plate is smaller than the size of the forging die body after separation. The lifting plate is pushed up to cooperate with the part removal equipment to remove the formed bearing sleeve.

[0013] Furthermore, a drive motor assembly is installed at the bottom of the hydraulic lifting machine, and the hydraulic lifting machine is connected to the rotating end of the drive motor assembly. The drive motor assembly drives the hydraulic lifting machine and the forming bearing sleeve to rotate 360°, and the laser scanner scans the forming bearing sleeve 360°.

[0014] Furthermore, a receiving box groove is provided on the inner bottom wall of the lowering plate groove, and a pressure box is fixedly installed inside the receiving box groove. The upper wall of the pressure plate is arranged with air jet holes around the periphery of the lowering plate groove. Several air jet holes are interconnected with the pressure box through air transmission channels. After the forming bearing sleeve is removed, the lifting plate descends and squeezes the pressure box, causing air to be ejected from the air jet holes.

[0015] The beneficial effects of this invention are as follows: This invention employs a layered, modular forging die body. Combined with the sequential pulling of the demolding hydraulic rod and the assistance of a vibration assembly, a pre-separation gap is formed in the initial stage of demolding. Subsequently, vibration energy effectively overcomes the frictional resistance between the die and the forging, achieving rapid and stable demolding. This demolding method avoids forging damage that may be caused by traditional mechanical ejection, significantly improving demolding efficiency and product qualification rate. The introduction of laser scanners enables non-contact 3D scanning and defect detection of forgings immediately after the forging die is completely removed. This allows for real-time online monitoring of forging quality, timely detection and feedback of problems in the production process, avoidance of mass production of defective products, and significant improvement in production efficiency and product quality control. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the position and structure of the forging die body of the present invention in the forging machine; Figure 2 This is a schematic diagram of the forging die structure of the present invention; Figure 3 This is a schematic diagram of the pull-out plate structure of the present invention; Figure 4 This is a schematic diagram of the pressure plate structure of the present invention; Figure 5 This is a schematic diagram of the air pressure box structure of the present invention; Figure 6 This is a top view of the forging die body of the present invention; Figure 7 This is a schematic diagram of the demolding column structure of the present invention.

[0017] In the diagram: 11. Forging die body; 12. Forging die outer frame; 13. Demolding hydraulic rod; 141. Upper die; 142. Middle die; 143. Bottom die; 15. Pulling die removal plate; 16. Flat cover chamber; 17. Miniature vibrator; 18. Demolding column; 19. Limiting groove; 101. Pulling ball head; 21. Hydraulic lifting machine; 22. Pressing plate; 23. Drive motor assembly; 24. Lowering plate groove; 25. Lifting plate; 26. Receiving box groove; 27. Air pressure box; 28. Air transmission channel; 29. ​​Air jet hole; 31. Laser scanner; 32. Scanning port. Detailed Implementation

[0018] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0019] like Figure 1 and Figure 7 As shown, a bearing ring forging die includes: a forging die body 11, which adopts a layered modular design, specifically divided into upper, middle and lower three-layer structures, each layer consisting of two symmetrical parts on the left and right. The upper, middle and lower layers are connected by sliding guide rails to achieve longitudinal sliding fit between the layers, and the left and right parts of each layer are connected by longitudinal parting surfaces to achieve separable connection. The forging die 11 is composed of six independently moving modular units, each of which has independent movement capabilities; The mold removal assembly includes a mold removal plate 15 and a mold removal hydraulic rod 13. Each part of the forging die body 11 is connected to a mold removal plate 15. A mold removal hydraulic rod 13 is provided on the outer side of each mold removal plate 15. A vibration assembly is provided between the forging die body 11 and the mold removal plate 15. After the bearing ring is forged, the six parts of the forging die body 11 are pulled backward in sequence according to the programmable control by the die removal hydraulic rod 13. First, a pre-separation gap of 0.1-10mm is formed between the die removal plate 15 and the corresponding module unit. Then, the vibration assembly is started to transmit the vibration to the module unit. The laser scanner 31 is positioned directly in front of the scanning space formed after the forging die 11 is completely removed from the mold. The laser scanner 31 is equipped with a three-dimensional scanning module and a defect detection algorithm module. After the forging die 11 is completely retracted, the laser scanner 31 performs a non-contact three-dimensional scan on the exposed bearing sleeve, and the defect detection algorithm module analyzes the dimensional accuracy and surface defects of the bearing sleeve in real time.

[0020] The forging die body 11 has three layers: upper die 141, middle die 142, and lower die 143. The upper die 141, middle die 142, and lower die 143 are connected to a pull-die plate 15 on both the left and right sides. There are six pull-die plates 15 in total, which correspond to the six parts of the forging die body 11.

[0021] The vibration assembly includes a mold release column 18, one end of which is connected to a micro vibrator 17, and a pull-out ball head 101 is fixedly installed at the end of the mold release column 18 away from the micro vibrator 17. The vibration generated by the micro vibrator 17 is transmitted to the pull-out ball head 101 through the mold release column 18.

[0022] Each mold release plate 15 has two flat cover chambers 16 inside, and a total of twelve flat cover chambers 16 are set inside the six mold release plates 15. Each flat cover chamber 16 is fixedly equipped with a miniature vibrator 17.

[0023] The upper mold 141, the middle mold 142 and the bottom mold 143 each have a limiting groove 19 at the position corresponding to the mold release pillar 18. The pull-out ball head 101 passes through the inside of the limiting groove 19 and is slidably connected to it. The diameter of the limiting groove 19 gradually increases from the inside to the outside. The diameter of the innermost end of the limiting groove 19 is the same as the diameter of the pull-out ball head 101.

[0024] As the pulling plate 15 retracts, the pulling ball head 101 slides to the outer end of the limiting groove 19. At this time, there is a gap between the pulling ball head 101 and the limiting groove 19. Through the vibration of the pulling ball head 101, the forging die body 11 retains a certain swaying space under vibration. As the pulling plate 15 continues to retract, the corresponding upper die 141, middle die 142 and bottom die 143 are pulled away from the forming bearing sleeve.

[0025] The forging die body 11 is provided with a forging die outer frame 12. The die removal hydraulic rod 13 is fixed on the forging die outer frame 12, and the telescopic arm of the die removal hydraulic rod 13 passes through the forging die outer frame 12. The laser scanner 31 is also fixed on the forging die outer frame 12, and the scanning port 32 of the laser scanner 31 is directly facing the center of the forging die body 11.

[0026] A pressing plate 22 is provided below the forging die body 11. A lowering plate groove 24 is opened at the center of the pressing plate 22. A lifting plate 25 is provided in the lowering plate groove 24. A hydraulic lifting machine 21 is provided below the pressing plate 22. The telescopic arm of the hydraulic lifting machine 21 is fixedly connected to the lifting plate 25. The diameter of the lifting plate 25 is smaller than the size of the forging die body 11 after it is separated. The lifting plate 25 is pushed up to cooperate with the part removal equipment to remove the formed bearing sleeve.

[0027] The bottom of the hydraulic lifting machine 21 is provided with a drive motor assembly 23, and the hydraulic lifting machine 21 is connected to the rotating end of the drive motor assembly 23. The drive motor assembly 23 drives the hydraulic lifting machine 21 and the forming bearing sleeve to rotate 360°, and the laser scanner 31 scans the forming bearing sleeve 360°.

[0028] The inner bottom wall of the descending plate groove 24 is provided with a receiving box groove 26. A pressure box 27 is fixedly installed inside the receiving box groove 26. The upper wall of the pressure plate 22 is arranged with air jet holes 29 around the periphery of the descending plate groove 24. Several air jet holes 29 are interconnected with the pressure box 27 through the air transmission channel 28. After the molded bearing sleeve is removed, the lifting plate 25 descends and squeezes the pressure box 27, causing air to be ejected from the air jet holes 29.

[0029] Forging Stage: Before forging, the left and right portions of the six independent modular units—the upper mold 141, the middle mold 142, and the bottom mold 143—are precisely closed along the sliding guide rails under the push of the mold release hydraulic rod 13, forming a complete forging die body 11 with the final forming cavity of the bearing ring. At this time, the modules are tightly fitted together through the longitudinal parting surface, and the pull-out ball head 101 is located at the innermost end of the corresponding limiting groove 19, ensuring that the overall rigidity of the die meets the requirements of high-temperature and high-pressure forging. Under the action of external forging equipment, the billet undergoes plastic deformation in the cavity, forming the bearing ring forging.

[0030] Step-by-step vibration-assisted demolding stage: After forging, the core demolding process begins. This process is not a simple overall mold opening, but rather, according to the programmable logic controller (PLC), the demolding hydraulic rod 13 sequentially pulls the six mold-pulling plates 15 and their connected module units backward.

[0031] Pre-separation and vibration start-up: First, the hydraulic rod pulls a certain pulling die release plate 15 backward by 0.1-10mm. Since the release ball head 101 is connected to the module through the limiting groove 19, and the diameter of the limiting groove 19 gradually expands from the inside to the outside, this action causes the release ball head 101 to slide to the outer end of the limiting groove 19, forming a small gap between the ball head and the groove wall, realizing the initial "loosening" of the module and the forging. At the same time, the micro vibrator 17 installed in the flat cover chamber 16 is started, and the vibration generated by it is transmitted to the release ball head 101 through the die release column 18.

[0032] Vibration-assisted demolding mechanism: Vibration energy is transmitted to the module unit through the pull-out ball head 101. Vibration (usually high frequency and low amplitude, such as frequency 50-200Hz, amplitude 0.05-0.5mm) can effectively reduce the coefficient of friction and adhesion between the module and the high-temperature forging. The scientific principle is that vibration causes micro-amplitude relative motion at the contact interface, destroying static friction and converting it into dynamic friction. At the same time, it may produce a "vibration liquefaction" effect, reducing the actual contact area.

[0033] Orderly demolding: The six modules repeat the above "pre-tension-vibration-demolding" process in sequence according to the set program. This asymmetrical, time-sequential demolding method avoids stress concentration, deformation or jamming of the forgings that may be caused by simultaneous demolding, and is especially suitable for bearing rings with complex structures and deep mold enclosure.

[0034] Online 3D scanning and defect detection stage: When all modules of the forging die 11 are completely retracted, the forging is fully exposed to the formed scanning space.

[0035] Data Acquisition: The laser scanner 31, fixed on the outer frame 12 of the forging die, activates its 3D scanning module to perform a non-contact full-surface scan of the stationary or rotating bearing ring. By driving the hydraulic lifting machine 21 and its top lifting plate 25 to rotate the forging 360° through the drive motor assembly 23, complete point cloud data of the forging can be obtained.

[0036] Data Analysis: The point cloud data obtained from scanning is transmitted to the defect detection algorithm module in real time. This algorithm performs a high-precision comparison between the point cloud and the CAD design model (comparison accuracy up to ±0.05mm), calculating deviations in key dimensions (such as outer diameter, channel curvature, wall thickness, etc.). Simultaneously, by analyzing the normal vector changes and curvature continuity of the point cloud, or applying a defect model trained using machine learning, it identifies surface defects in real time, such as folds, cracks, pits, and incomplete filling. All detection results (dimensional deviations, defect location and type) can be output instantly for process adjustments or product sorting.

[0037] Forging ejection and die self-cleaning stage: Forging Transfer: After scanning, the telescopic arm of the hydraulic lifting machine 21 rises, pushing the lifting plate 25 up from the lowering plate slot 24. Since the diameter of the lifting plate 25 is smaller than the inner diameter of the separated mold, it can smoothly lift the formed bearing ring to a height that is convenient for the part-retrieving equipment (such as a robot arm) to grasp.

[0038] Cavity cleaning: After the forging is removed, the lifting plate 25 descends and resets. During the descent, its bottom compresses the air pressure box 27 in the receiving box groove 26. The compressed air in the air pressure box 27 is delivered to the air jet holes 29 arrayed on the upper wall of the pressure plate 22 through the air transmission channel 28, forming an upward cleaning airflow that blows away residual oxide scale, lubricant residue, or small particles, preparing a clean cavity for the next forging and reducing the defect rate.

[0039] Significantly reduces demolding difficulty and mold wear: Layered and segmented design and step-by-step demolding: The overall demolding is decomposed into six modules that are separated in sequence and in small strokes, which greatly reduces the clamping force and the required demolding force for a single demolding.

[0040] Vibration-assisted demolding: Scientifically utilizing vibration to reduce friction and adhesion, further significantly reducing demolding force, effectively preventing forging scratches, deformation, and mold (especially precision cavities) wear, extending mold life by 20%-40%.

[0041] Achieving high-efficiency and automated production: The mold removal sequence is programmable and seamlessly linked with vibration, scanning detection, and ejection actions to form a complete automated production cycle, reducing manual intervention and workpiece turnaround time.

[0042] Online non-contact inspection replaces offline sampling inspection or cumbersome manual inspection, reducing inspection time from minutes to seconds and enabling 100% full inspection, greatly improving production efficiency and quality control.

[0043] Improve product quality and process controllability: Vibration assistance and orderly mold removal ensure the integrity of the forging during the sensitive demolding process, reducing the generation of internal stress and surface defects.

[0044] High-precision 3D scanning and intelligent algorithms provide objective, accurate and comprehensive quality data, which can be used not only for post-process judgment, but also for real-time adjustment of process parameters (such as temperature, pressure and lubrication), realizing closed-loop quality control and process optimization in the forging process.

[0045] The embodiments of the present invention have been described above, but the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms based on the guidance of the present embodiments, all of which are within the protection scope of the present embodiments.

Claims

1. A forging die for bearing rings, characterized in that, include: The forging die body (11) adopts a layered modular design, specifically divided into three layers: upper, middle and lower, each layer consisting of two symmetrical parts on the left and right. The upper, middle and lower layers are connected by sliding guide rails to achieve longitudinal sliding fit between the layers, and the left and right parts of each layer are connected by longitudinal parting surfaces to achieve separable connection. The forging die (11) is composed of six independently moving modular units, each of which has independent movement. The mold removal assembly includes a mold removal plate (15) and a mold removal hydraulic rod (13). Each part of the forging die body (11) is connected to a mold removal plate (15). A mold removal hydraulic rod (13) is provided on the outer side of each mold removal plate (15). A vibration assembly is provided between the forging die body (11) and the mold removal plate (15). After the bearing ring is forged, the six parts of the forging die body (11) are pulled back in sequence by the mold removal hydraulic rod (13) in a programmable controlled order. First, a pre-separation gap of 0.1-10mm is formed between the mold removal plate (15) and the corresponding module unit. Then, the vibration assembly is started to transmit the vibration to the module unit. A laser scanner (31) is positioned directly in front of the scanning space formed after the forging die (11) has been completely removed; The laser scanner (31) is equipped with a three-dimensional scanning module and a defect detection algorithm module. After the forging die (11) is completely withdrawn, the laser scanner (31) performs a non-contact three-dimensional scan on the exposed bearing sleeve, and the defect detection algorithm module analyzes the dimensional accuracy and surface defects of the bearing sleeve in real time.

2. The bearing ring forging die according to claim 1, characterized in that, The forging die body (11) has three layers: upper die (141), middle die (142), and lower die (143). The upper die (141), middle die (142), and lower die (143) are connected to a die-pulling plate (15) on both the left and right sides. There are six die-pulling plates (15) in total, which correspond one-to-one with the six parts of the forging die body (11).

3. The bearing ring forging die according to claim 2, characterized in that, The vibration assembly includes a mold release column (18), one end of which is connected to a micro vibrator (17), and a pull-out ball head (101) is fixedly provided at the end of the mold release column (18) away from the micro vibrator (17). The vibration generated by the micro vibrator (17) is transmitted to the pull-out ball head (101) through the mold release column (18).

4. The bearing ring forging die according to claim 3, characterized in that, Each of the pull mold removal plates (15) has two flat cover chambers (16) inside, and a total of twelve flat cover chambers (16) are provided inside the six pull mold removal plates (15). Each flat cover chamber (16) is fixedly equipped with a micro vibrator (17).

5. A bearing ring forging die according to claim 4, characterized in that, The upper mold (141), middle mold (142) and lower mold (143) are each provided with a limiting groove (19) at the position of the mold release column (18). The pull-out ball head (101) passes through the inside of the limiting groove (19) and is slidably connected to it. The diameter of the limiting groove (19) gradually increases from the inside to the outside. The innermost diameter of the limiting groove (19) is the same as the diameter of the pull-out ball head (101).

6. A bearing ring forging die according to claim 5, characterized in that, The pulling plate (15) retracts and pulls the ball head (101) to slide to the outer end of the limiting groove (19). At this time, there is a gap between the ball head (101) and the limiting groove (19). By vibrating the ball head (101), the forging die body (11) retains a swaying space under vibration. As the pulling plate (15) continues to retract, the corresponding upper die (141), middle die (142) and bottom die (143) are pulled away from the forming bearing sleeve.

7. A bearing ring forging die according to claim 1, characterized in that, The forging die body (11) is provided with a forging die outer frame (12), the die removal hydraulic rod (13) is fixed on the forging die outer frame (12), and the telescopic arm of the die removal hydraulic rod (13) passes through the forging die outer frame (12). The laser scanner (31) is also fixed on the forging die outer frame (12), and the scanning port (32) of the laser scanner (31) is directly facing the center of the forging die body (11).

8. A bearing ring forging die according to claim 1, characterized in that, A pressing plate (22) is provided below the forging die body (11). A lowering plate groove (24) is provided at the center of the pressing plate (22). A lifting plate (25) is provided in the lowering plate groove (24). A hydraulic lifting machine (21) is provided below the pressing plate (22). The telescopic arm of the hydraulic lifting machine (21) is fixedly connected to the lifting plate (25). The diameter of the lifting plate (25) is smaller than the size of the forging die body (11) after separation. The lifting plate (25) is pushed up to cooperate with the part removal equipment to remove the formed bearing sleeve.

9. A bearing ring forging die according to claim 8, characterized in that, The bottom of the hydraulic lifting machine (21) is provided with a drive motor assembly (23), and the hydraulic lifting machine (21) is connected to the rotating end of the drive motor assembly (23). The drive motor assembly (23) drives the hydraulic lifting machine (21) and the forming bearing sleeve to rotate 360°, and the laser scanner (31) scans the forming bearing sleeve 360°.

10. A bearing ring forging die according to claim 8, characterized in that, The bottom wall of the lowering plate groove (24) is provided with a receiving box groove (26), and a pressure box (27) is fixedly installed inside the receiving box groove (26). The upper wall of the pressure plate (22) is arranged with air jet holes (29) around the periphery of the lowering plate groove (24). Several air jet holes (29) are interconnected with the pressure box (27) through the air transmission channel (28). After the forming bearing sleeve is removed, the lifting plate (25) descends and squeezes the pressure box (27), causing air to be ejected from the air jet holes (29).

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