A metal connector forging and forming device and process

Abstract

This invention relates to the field of forging technology, solving the problem of low processing efficiency and inability to form angled flange blanks in a single pass when forging presses. Specifically, it discloses a forging device and process for metal connectors, including a free forging press body, a forming die assembly, a die positioning and fixing module, a precision detection module, a demolding drive module, and a parameter control module. The process includes: Step 1, collecting the dimensional parameters, angle parameters, rated pressure, and slide stroke parameters of the flange blank to be forged; Step 2, completing the die installation and positioning; Step 3, starting the free forging press and controlling the slide to drive the upper die downwards; Step 4, inputting the collected displacement and pressure data into the discrimination model of the parameter control module and outputting control commands, etc. This invention is used for forging metal connectors such as flanges, improving forging efficiency and effectiveness.

Description

Technical Field

[0001] This invention relates to the field of forging technology, and in particular to a forging and forming device and process for metal connectors. Background Technology

[0002] In the production of metal fasteners, angled flange blanks are commonly used structural components, and their forming and processing usually rely on a combination of forging presses and lathes. The forging presses commonly equipped in existing factories are mainly used for forging simple-shaped blanks and lack specialized molds and matching positioning, precision control and demolding structures suitable for angled flange blanks, making it impossible to directly forge angled flange blanks.

[0003] In the current processing flow, forging presses can only forge rough blanks that are approximately cylindrical. Subsequent machining on a lathe is required to create the flange's angled structure and dimensions. This not only increases the workload of lathe machining, leading to low processing efficiency, but also wastes metal materials. Furthermore, using customized forging equipment requires significant investment in equipment upgrades, increasing factory production costs, and the existing forging presses are not fully utilized. In addition, if a simple mold is added to the forging press for forging angled flange blanks, problems such as inaccurate mold installation and positioning, insufficient forging precision, and difficulty in demolding the formed blank can easily occur. This results in excessive dimensional deviations in the forged flange blanks, failing to meet subsequent processing requirements and further limiting the application of free forging presses in the production of angled flange blanks. Summary of the Invention

[0004] To address the problem of low processing efficiency and inability to form angled flange blanks in a single operation using existing forging presses, this invention provides a forging and forming device and process for metal connectors.

[0005] The technical solution adopted in this invention is:

[0006] A metal connector forging and forming device includes a free forging press body, and also includes a forming mold assembly, a mold positioning and fixing module, a precision detection module, a demolding drive module and a parameter control module;

[0007] The forming mold assembly is detachably connected to the slider and worktable of the free forging press body. The mold positioning and fixing module is installed above the worktable of the free forging press for positioning and fixing the forming mold assembly.

[0008] The precision detection module is electrically connected to the parameter control module and is used to collect the die position and billet forming data during the forging process;

[0009] The demolding drive module is connected to the molding die assembly and is used to drive the molding die assembly to complete the demolding action;

[0010] The parameter control module is electrically connected to the free forging press body, the mold positioning and fixing module, the precision detection module, and the demolding drive module, respectively, and is used to receive detection data and control the operation of each module.

[0011] Furthermore, the forming mold assembly includes an upper mold and a lower mold. The upper mold is fixedly connected to the slider of the free forging press body, and the lower mold is connected to the mold positioning and fixing module of the free forging press worktable. The lower end face of the upper mold is provided with an inclined forming surface that matches the slope of the flange blank, and the upper end face of the lower mold is provided with a groove that matches the inclined forming surface of the upper mold. A demolding through hole is provided at the bottom of the groove, and the demolding through hole is correspondingly provided with the demolding drive module.

[0012] Furthermore, the mold positioning and fixing module includes a positioning seat, a clamping cylinder, and a positioning pin. The positioning seat is fixed on the worktable of the free forging press. The positioning seat is provided with a positioning groove that matches the lower mold. The clamping cylinder is symmetrically installed on both sides of the positioning seat. The piston rod end of the clamping cylinder is provided with a clamping block. The positioning pin is installed on the positioning seat. The lower mold is provided with a positioning hole that matches the positioning pin. The positioning pin is used to insert into the positioning hole to achieve the positioning of the lower mold.

[0013] Furthermore, the accuracy detection module includes a displacement sensor and a pressure sensor. The displacement sensor is installed on the slide of the free forging press and is used to collect the downward displacement data of the upper die. The pressure sensor is installed at the connection between the upper die and the slide of the forming die assembly and is used to collect the pressure data during the forging process. The output terminals of both the displacement sensor and the pressure sensor are connected to the input terminal of the parameter control module.

[0014] Furthermore, the demolding drive module includes a demolding cylinder and a demolding ejector rod. The demolding cylinder is fixed below the worktable of the free forging press. One end of the demolding ejector rod is connected to the piston rod of the demolding cylinder, and the other end extends through the demolding through hole of the lower die into the groove of the lower die. The parameter control module is electrically connected to the demolding cylinder and is used to control the extension and retraction of the demolding cylinder.

[0015] A method for forging and forming a metal connector, applied to the aforementioned apparatus, includes the following steps:

[0016] Step 1: Collect the dimensional parameters, slope parameters, rated pressure and slide stroke parameters of the free forging press of the flange blank to be forged. Input the collected parameters into the preset parameter matching algorithm and output the forming surface dimension parameters, mold positioning parameters and forging process parameters of the forming die assembly.

[0017] Step 2: Based on the mold positioning parameters output by the parameter matching algorithm, the forming mold assembly is fixed on the free forging press using the mold positioning and fixing module, thus completing the mold installation and positioning.

[0018] Step 3: Place the metal billet in the lower mold groove of the forming mold assembly, start the free forging press through the parameter control module, control the slider to drive the upper mold downward, and at the same time collect the displacement data and forging pressure data of the upper mold in real time through the precision detection module.

[0019] Step 4: Input the collected displacement and pressure data into the discrimination model of the parameter control module. The discrimination model compares the real-time data with the preset process parameters and outputs control commands. The parameter control module adjusts the downward speed of the slide block and the forging pressure of the free forging press according to the control commands until the forging of the flange blank is completed.

[0020] Step 5: After forging is completed, the parameter control module controls the slide of the free forging press to move upward, and at the same time starts the demolding drive module to drive the demolding ejector to push the flange blank upward, thus completing the demolding.

[0021] Furthermore, the parameters of the flange blank to be forged collected in step 1 include the flange outer diameter, inner diameter, thickness, and flange end face slope. The parameters of the free forging press include the rated forging pressure, the maximum downward stroke of the slide block, and the adjustment range of the downward speed of the slide block. Based on the collected parameters, the parameter matching algorithm calculates the tilt angle of the upper die tilting forming surface, the size of the lower die groove, and the installation position of the positioning pin through linear fitting. At the same time, it calculates the downward speed of the slide block, the forging pressure, and the holding time during the forging process.

[0022] Furthermore, the mold installation and positioning process in step 2 includes: placing the lower mold in the positioning slot of the positioning seat, inserting the positioning pin into the positioning hole of the lower mold to achieve initial positioning, activating the clamping cylinder to clamp the side of the lower mold with the clamping block to achieve fixation; fixing the upper mold to the slide of the free forging press with bolts, controlling the slide to move downward through the parameter control module to make the forming surfaces of the upper mold and the lower mold initially fit together, collecting displacement data after fitting through the displacement sensor, adjusting the installation position of the upper mold to make the forming surfaces of the upper mold and the lower mold fit together.

[0023] Furthermore, the discrimination process of the discrimination model in step 4 includes: comparing the real-time collected displacement data with the preset slider downward displacement threshold, and comparing the real-time collected pressure data with the preset forging pressure threshold.

[0024] If the real-time displacement data is less than the preset threshold and the real-time pressure data is less than the preset threshold, the discrimination model outputs an instruction to accelerate the downward speed of the slider and increase the forging pressure.

[0025] If the real-time displacement data reaches the preset threshold and the real-time pressure data reaches the preset threshold, the discrimination model outputs an instruction to maintain the current parameters and perform pressure maintenance.

[0026] If the real-time displacement data exceeds the preset threshold or the real-time pressure data exceeds the preset threshold, the discrimination model outputs an instruction to slow down the downward speed of the slider and reduce the forging pressure.

[0027] Furthermore, the demolding process in step 5 includes: after the parameter control module receives the forging completion signal sent by the precision detection module, it controls the free forging press slide to move upward to the preset position, and then controls the demolding cylinder to extend, driving the demolding ejector to move upward. The demolding ejector pushes the flange blank, causing the flange blank to separate from the groove of the lower mold. After the flange blank is separated, the parameter control module controls the demolding cylinder to retract, driving the demolding ejector to reset, thus completing the forging and demolding process.

[0028] The beneficial effects of this invention are:

[0029] The metal connector forging and forming apparatus and method of the present invention effectively solves the technical problem that existing free forging presses cannot forge flange blanks with a bevel in one pass through modular design and data interaction. The apparatus relies on the free forging press body and is equipped with a forming die assembly, a die positioning and fixing module, a precision detection module, a demolding drive module, and a parameter control module. The forming die assembly is detachably connected to the forging press slide and worktable, and is accurately positioned and fixed by the die positioning and fixing module, ensuring the reliability of the die installation. The precision detection module collects real-time data on the die position and blank forming during the forging process and transmits it to the parameter control module. This module, combined with preset flange size parameters, bevel parameters, and equipment operating parameters, uses a built-in algorithm and discrimination model to dynamically control the downward speed of the free forging press slide and the forging pressure, achieving more accurate control of the forging process. After forging and forming is completed, the parameter control module controls the slide to move upward, and simultaneously activates the demolding drive module to drive the demolding ejector pin to eject the blank. Compared to existing technologies, this solution can be modified based on existing free forging presses without large-scale equipment replacement, reducing equipment investment costs. At the same time, with the help of modular mold components and precise process control, the free forging press can directly complete the one-time forming of flange blanks with angled edges, reducing the cutting amount of subsequent lathe machining, improving processing efficiency and reducing metal material loss. It also avoids problems such as inaccurate positioning and demolding difficulties that occur when adding simple molds, thus improving the stability of forging and the dimensional accuracy of the blank. Attached Figure Description

[0030] Figure 1 This is a flow chart of the molding process of the present invention. Detailed Implementation

[0031] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0032] Example 1

[0033] This embodiment is a metal connector forging and forming device, including a free forging press body, and also includes a forming mold assembly, a mold positioning and fixing module, a precision detection module, a demolding drive module and a parameter control module;

[0034] The forming mold assembly is detachably connected to the slider and worktable of the free forging press body. The mold positioning and fixing module is installed above the worktable of the free forging press for positioning and fixing the forming mold assembly.

[0035] The precision detection module is electrically connected to the parameter control module and is used to collect the die position and billet forming data during the forging process;

[0036] The demolding drive module is connected to the molding die assembly and is used to drive the molding die assembly to complete the demolding action;

[0037] The parameter control module is electrically connected to the free forging press body, the mold positioning and fixing module, the precision detection module, and the demolding drive module, respectively, and is used to receive detection data and control the operation of each module.

[0038] During operation, the forming die assembly is first positioned and fixed by the die positioning and fixing module to ensure that the die installation position meets the forging requirements and to prevent die displacement during subsequent forging. Then, the parameter control module starts the free forging press, driving the forming die assembly to perform the forging action. Simultaneously, the precision detection module collects the die position and billet forming data in real time during the forging process and transmits the data to the parameter control module. After receiving the data, the parameter control module analyzes and processes it, dynamically controlling the operating status of the free forging press body, the die positioning and fixing module, and the demolding drive module according to preset process standards to ensure stable forging. After the billet is forged, the parameter control module controls the demolding drive module to start, completing the billet demolding.

[0039] This invention eliminates the need to replace existing free forging presses. By adding functional modules, it enables the forging of blanks with angled flanges, effectively improving the utilization rate of existing forging presses and reducing the cost of factory equipment upgrades. Simultaneously, the coordinated operation of the modules solves the problem that existing forging presses cannot directly forge blanks with angled flanges, reducing the workload of subsequent lathe machining, improving processing efficiency, and minimizing metal waste. Compared to traditional processing methods, it significantly enhances the practicality and economy of forging production.

[0040] Example 2

[0041] This embodiment is based on the aforementioned embodiment. In this embodiment, the forming mold assembly includes an upper mold and a lower mold. The upper mold is fixedly connected to the slider of the free forging press body, and the lower mold is connected to the mold positioning and fixing module of the free forging press worktable. The lower end face of the upper mold is provided with an inclined forming surface that matches the slope of the flange blank, and the upper end face of the lower mold is provided with a groove that matches the inclined forming surface of the upper mold. The bottom of the groove is provided with a demolding through hole, which is correspondingly provided with the demolding drive module.

[0042] Before the forging operation begins, ensure that the forming surfaces of the upper and lower dies are compatible. Then, place the metal billet in the groove of the lower die. When the parameter control module starts the free forging press, the slider drives the upper die downward. The inclined forming surface of the lower end of the upper die contacts the billet in the groove of the lower die. As the slider continues to descend, the inclined forming surface of the upper die gradually applies pressure to the billet, causing the billet to undergo plastic deformation in the groove, eventually fitting the forming surfaces of the upper and lower dies to form a flange blank with an angle. After the forging is completed, the demolding drive module is activated. Its output end passes through the demolding through hole of the lower die and applies an upward force to the flange blank in the groove, causing the blank to separate from the groove and the upper die, completing the demolding. The beneficial technical effect of this embodiment is that, through the design of the inclined forming surfaces of the upper and lower dies being compatible, a flange blank with an angle can be forged directly, forming the angled structure of the flange without subsequent lathe cutting, effectively reducing processing steps and improving processing efficiency. Meanwhile, the design of the lower die groove can limit the blank, preventing it from shifting during forging and improving the forming accuracy of the flange blank. The corresponding setting of the demolding through hole and the demolding drive module solves the problem of the blank being difficult to demold after forging with traditional simple molds, reduces damage to the blank during demolding, lowers the scrap rate, and further improves the stability of forging production and the product qualification rate compared with existing processing methods.

[0043] Example 3

[0044] This embodiment is based on the aforementioned embodiment. In this embodiment, the mold positioning and fixing module includes a positioning seat, a clamping cylinder, and a positioning pin. The positioning seat is fixed on the worktable of the free forging press. The positioning seat is provided with a positioning groove that matches the lower mold. The clamping cylinder is symmetrically installed on both sides of the positioning seat. The piston rod end of the clamping cylinder is provided with a clamping block. The positioning pin is installed on the positioning seat. The lower mold is provided with a positioning hole that matches the positioning pin. The positioning pin is used to insert into the positioning hole to achieve the positioning of the lower mold.

[0045] During mold installation, the lower mold is first placed in the positioning slot of the positioning seat, and the positioning pin on the positioning seat is aligned with and inserted into the positioning hole of the lower mold to achieve initial positioning of the lower mold and ensure that the installation position of the lower mold meets the preset requirements. After the initial positioning is completed, the clamping cylinders on both sides of the positioning seat are activated. The piston rod of the clamping cylinder drives the clamping block to move inward until the clamping block is tightly fitted with the side of the lower mold, firmly fixing the lower mold and preventing the lower mold from shifting due to mold vibration during forging. During the forging process, the positioning pin is always inserted into the positioning hole of the lower mold, and with the clamping action of the clamping block, the lower mold is continuously kept stable, ensuring that the forming surfaces of the upper and lower molds always correspond. After forging is completed, the piston rod of the clamping cylinder is first controlled to retract, driving the clamping block to separate from the lower mold, and then the lower mold is removed from the positioning slot of the positioning seat for easy mold maintenance and replacement. The beneficial technical effect of this embodiment is that the initial positioning of the lower mold is achieved through the cooperation of the positioning pin and the positioning hole, solving the problem of inaccurate positioning in the installation of existing simple molds and improving the accuracy of mold installation. The symmetrical arrangement of clamping cylinders, along with clamping blocks, clamps the lower die, ensuring uniform force distribution and further guaranteeing the stability of the die during forging. This reduces dimensional deviations in the flange blank caused by die misalignment. Compared to traditional die fixing methods, this module offers more reliable positioning and easier operation, effectively improving the precision and stability of forging and reducing the scrap rate due to die positioning issues.

[0046] Example 4

[0047] This embodiment is based on the aforementioned embodiment. In this embodiment, the accuracy detection module includes a displacement sensor and a pressure sensor. The displacement sensor is installed on the slide of the free forging press and is used to collect the downward displacement data of the upper die. The pressure sensor is installed at the connection between the upper die and the slide of the forming die assembly and is used to collect the pressure data during the forging process. The output terminals of both the displacement sensor and the pressure sensor are connected to the input terminal of the parameter control module.

[0048] After the forging operation begins, the slide of the free forging press drives the upper die downwards. Simultaneously, a displacement sensor mounted on the slide activates, collecting real-time displacement data of the upper die and recording its displacement change from its initial position to contact with the workpiece and the completion of forging. At the same time, a pressure sensor installed at the connection between the upper die and the slide also operates synchronously, collecting real-time pressure data applied by the upper die to the workpiece during forging and capturing pressure fluctuations. The displacement and pressure sensors continuously transmit the collected real-time data to the parameter control module, providing data support for parameter adjustment. Upon receiving the data, the parameter control module compares the real-time data with preset process parameters and adjusts the operating state of the free forging press based on the comparison results, ensuring that the downward displacement of the upper die and the forging pressure remain within a reasonable range. After forging is completed, the sensors stop collecting data, awaiting the start of the next forging operation. The beneficial technical effect of this embodiment is that, through real-time data acquisition from displacement and pressure sensors, dynamic monitoring of the forging process is achieved, solving the problem of accurately controlling the die position and forging pressure in existing forging processes. Real-time data acquisition provides a reliable basis for parameter control, enabling the parameter control module to adjust forging parameters in a timely manner. This avoids dimensional deviations in the flange blank caused by displacement or improper pressure, thus improving the accuracy of forging. Compared to traditional forging methods without detection, this module effectively reduces forging errors, increases product qualification rates, and facilitates timely detection of abnormalities during the forging process, thereby reducing production risks.

[0049] Example 5

[0050] This embodiment is based on the aforementioned embodiment. In this embodiment, the demolding drive module includes a demolding cylinder and a demolding ejector rod. The demolding cylinder is fixed below the worktable of the free forging press. One end of the demolding ejector rod is connected to the piston rod of the demolding cylinder, and the other end extends through the demolding through hole of the lower die into the groove of the lower die. The parameter control module is electrically connected to the demolding cylinder and is used to control the extension and retraction of the demolding cylinder.

[0051] After the flange blank is forged, the parameter control module receives the forging completion signal from the precision detection module and then controls the slide of the free forging press to move upward until the slide drives the upper die to rise to the preset position, completely separating it from the flange blank in the lower die, leaving sufficient space for demolding. Subsequently, the parameter control module sends a start command to the demolding cylinder, controlling the piston rod of the demolding cylinder to extend upward, driving the demolding ejector rod connected to it to move upward synchronously. The demolding ejector rod passes through the demolding through-hole of the lower die, extends into the groove of the lower die, contacts the bottom of the flange blank, and continuously applies an upward pushing force. As the pushing force gradually increases, the flange blank separates from the inner wall of the lower die groove and is finally ejected from the groove. After the flange blank is completely demolded, the parameter control module controls the piston rod of the demolding cylinder to retract, driving the demolding ejector rod to move downward, passing through the demolding through-hole to return to the initial position, awaiting the next demolding operation. The beneficial technical effect of this embodiment is that, through the cooperation of the demolding cylinder and the demolding ejector rod, automatic demolding of the flange blank is achieved, solving the problem of difficult demolding of the blank after forging with existing simple molds. This avoids damage to the blank during manual demolding and reduces the scrap rate. The demolding action is automatically controlled by the parameter control module, requiring no manual intervention. This not only saves labor costs but also improves demolding efficiency, making the entire forging process more seamless. Compared to traditional manual or simple demolding methods, the demolding action of this module is smoother and more precise, further improving the automation level and production efficiency of forging production.

[0052] Example 6

[0053] This embodiment describes a forging method for metal connectors, which can be applied to the apparatus described in the foregoing embodiments, such as... Figure 1 As shown, it includes the following steps:

[0054] Step 1: Collect the dimensional parameters, slope parameters, rated pressure and slide stroke parameters of the free forging press of the flange blank to be forged. Input the collected parameters into the preset parameter matching algorithm and output the forming surface dimension parameters, mold positioning parameters and forging process parameters of the forming die assembly.

[0055] Step 2: Based on the mold positioning parameters output by the parameter matching algorithm, the forming mold assembly is fixed on the free forging press using the mold positioning and fixing module, thus completing the mold installation and positioning.

[0056] Step 3: Place the metal billet in the lower mold groove of the forming mold assembly, start the free forging press through the parameter control module, control the slider to drive the upper mold downward, and at the same time collect the displacement data and forging pressure data of the upper mold in real time through the precision detection module.

[0057] Step 4: Input the collected displacement and pressure data into the discrimination model of the parameter control module. The discrimination model compares the real-time data with the preset process parameters and outputs control commands. The parameter control module adjusts the downward speed of the slide block and the forging pressure of the free forging press according to the control commands until the forging of the flange blank is completed.

[0058] Step 5: After forging is completed, the parameter control module controls the slide of the free forging press to move upward, and at the same time starts the demolding drive module to drive the demolding ejector to push the flange blank upward, thus completing the demolding.

[0059] Before forging, parameter preparation involves collecting relevant parameters of the flange blank to be forged and the free forging press. These parameters are input into a preset parameter matching algorithm, which calculates the appropriate forming die parameters and forging process parameters, providing a basis for subsequent forging operations. After the parameters are determined, based on the die positioning parameters output by the algorithm, the forming die assembly is fixed on the free forging press using the die positioning and fixing module, completing the die installation and positioning to ensure accurate die positioning. Subsequently, the metal blank is placed in the groove of the lower die, and the free forging press is started through the parameter control module, controlling the slide to drive the upper die downward. Simultaneously, the accuracy detection module collects the displacement data of the upper die and the forging pressure data in real time and transmits the data to the parameter control module. The parameter control module inputs the real-time data into the discrimination model, compares it with the preset process parameters, and outputs control commands based on the comparison results to adjust the downward speed of the slide and the forging pressure until the flange blank is forged. After forging is completed, the parameter control module controls the slide to move upward and simultaneously starts the demolding drive module, driving the demolding ejector to push out the flange blank, completing the entire forging and demolding process. The beneficial technical effects of this embodiment are that parameter matching algorithms achieve parameter adaptation, ensuring that the mold parameters and forging process parameters match the requirements of the flange blank to be forged, reducing forming errors caused by improper parameter settings. The entire forging process is automated in control and monitoring, eliminating the need for manual parameter adjustment, reducing the difficulty of manual operation and human error, and improving processing efficiency. Compared with the traditional "forging + cutting" processing method, this method achieves one-time forming of the flange blank with a bevel, reducing metal material waste and lathe machining workload. At the same time, by relying on the modification of existing free forging presses, production costs are reduced and equipment utilization is improved.

[0060] Example 7

[0061] This embodiment is based on the aforementioned embodiment. In this embodiment, the parameters of the flange blank to be forged collected in step 1 include the flange outer diameter, inner diameter, thickness, and flange end face slope. The parameters of the free forging press include the rated forging pressure, the maximum downward stroke of the slide block, and the adjustment range of the downward speed of the slide block. Based on the collected parameters, the parameter matching algorithm calculates the tilt angle of the upper die tilting forming surface, the size of the lower die groove, and the installation position of the positioning pin through linear fitting. At the same time, it calculates the downward speed of the slide block, the forging pressure, and the holding time during the forging process.

[0062] In this embodiment, before forging, all relevant parameters of the flange blank to be forged and the free forging press are comprehensively collected. The parameters of the flange blank to be forged include not only the flange outer diameter, inner diameter, thickness, and flange end face slope, but also the inclination height of the flange slope surface, the transition radius of the slope surface and the flange end face, and the surface roughness of the slope surface. These parameters are highly correlated with the unique characteristics of the slope flange blank and directly affect the forming quality and subsequent processing adaptability of the flange blank. The parameters of the free forging press include the rated forging pressure, the maximum downward stroke of the slide block, and the adjustable range of the slide block downward speed. When collecting these parameters, corresponding types of sensors are used. Specifically, the flange outer diameter, inner diameter, and thickness are measured using a laser rangefinder sensor, model KEYENCEIL-1000; the flange end face slope and slope height are measured using an angular displacement sensor, model Panasonic HTA100; the transition fillet radius between the slope surface and the flange end face is measured using a profile sensor, model Keyence LK-G80; the surface roughness of the slope surface is measured using a roughness sensor, model Taylor Hobson Surtronic S-100; the rated forging pressure of the free forging press is measured using a pressure sensor, model HBM C16; and the maximum downward stroke and downward speed of the slide are measured using a displacement sensor, model Balluff BTL7-S100-M0250-B-S32. After the parameters are collected, all parameters are input into the preset parameter matching algorithm. The algorithm calculates the tilt angle of the upper die tilting surface, the size of the lower die groove and the installation position of the positioning pin by combining the flange tilting parameters and equipment parameters through linear fitting. At the same time, it calculates the slide descent speed, forging pressure and holding time during the forging process, providing parameter support for subsequent mold installation and forging operations.

[0063] The beneficial technical effects of this embodiment are that the supplementary angle flange-specific parameters make parameter acquisition more comprehensive. Combined with data collected by dedicated sensors, the accuracy of parameter acquisition is improved, avoiding forming errors caused by missing or inaccurate parameters. The mold parameters and process parameters calculated through linear fitting can better adapt to the angle characteristics of the flange blank to be forged, ensuring that the angle of the forged flange blank is more accurate and meets the requirements. Compared with the traditional method of only collecting basic parameters, the parameter acquisition in this embodiment is more targeted, and the parameter calculation is more accurate, further improving the forming quality of the flange blank, reducing the workload of subsequent processing, and providing a more reliable parameter basis for more precise control of the forging process.

[0064] Example 8

[0065] This embodiment is based on the aforementioned embodiment. In this embodiment, the mold installation and positioning process in step 2 includes: placing the lower mold in the positioning slot of the positioning seat, inserting the positioning pin into the positioning hole of the lower mold to achieve initial positioning, activating the clamping cylinder to clamp the side of the lower mold with the clamping block to achieve fixation; fixing the upper mold to the slide of the free forging press with bolts, controlling the slide to move downward through the parameter control module to make the forming surfaces of the upper mold and the lower mold initially fit together, collecting displacement data after fitting through the displacement sensor, adjusting the installation position of the upper mold to make the forming surfaces of the upper mold and the lower mold fit together.

[0066] During mold installation and positioning, first, place the lower mold stably in the positioning groove of the positioning seat. Adjust the position of the lower mold so that the positioning pin on the positioning seat is accurately inserted into the positioning hole of the lower mold, achieving preliminary positioning of the lower mold and ensuring that the approximate position of the lower mold meets the preset requirements. After preliminary positioning, activate the clamping cylinder. The piston rod of the clamping cylinder drives the clamping block at the end to move inward until the clamping block is tightly fitted with the side of the lower mold, applying a uniform clamping force to the lower mold to achieve firm fixation and prevent the lower mold from shifting due to vibration during forging. After the lower mold is fixed, fix the upper mold to the slide of the free forging press with bolts. After fixing, control the slide to slowly descend through the parameter control module, driving the upper mold to move downward, so that the inclined forming surface of the upper mold and the groove forming surface of the lower mold are initially fitted together. At this point, the displacement sensor activates, collecting displacement data after the upper and lower dies are fitted together, and transmitting the data to the parameter control module. The parameter control module determines the fitting accuracy of the upper and lower dies based on the data. If there is a deviation in the fitting, the installation position of the upper die is adjusted promptly until the forming surfaces of the upper and lower dies are perfectly matched, ensuring more precise extrusion of the blank during forging and forming a compliant slope structure. The beneficial technical effect of this embodiment is that, through the initial positioning of the positioning pins and positioning holes, the firm fixing of the clamping cylinder, and the displacement detection and position adjustment after fitting, accurate installation and positioning of the mold are achieved, solving the problem of inaccurate positioning in existing simple mold installations. Compared with traditional mold installation methods, this process is more standardized and more precise in positioning, effectively avoiding dimensional deviations in the flange blank caused by mold positioning deviations, and improving the accuracy of forging. Simultaneously, the bolt connection facilitates the disassembly and replacement of the upper die, adapting to forging of flange blanks of different specifications, improving the versatility and practicality of the equipment.

[0067] Example 9

[0068] This embodiment is based on the aforementioned embodiment. In this embodiment, the discrimination process of the discrimination model in step 4 includes: comparing the real-time collected displacement data with the preset slider downward displacement threshold, and comparing the real-time collected pressure data with the preset forging pressure threshold.

[0069] If the real-time displacement data is less than the preset threshold and the real-time pressure data is less than the preset threshold, the discrimination model outputs an instruction to accelerate the downward speed of the slider and increase the forging pressure.

[0070] If the real-time displacement data reaches the preset threshold and the real-time pressure data reaches the preset threshold, the discrimination model outputs an instruction to maintain the current parameters and perform pressure maintenance.

[0071] If the real-time displacement data exceeds the preset threshold or the real-time pressure data exceeds the preset threshold, the discrimination model outputs an instruction to slow down the downward speed of the slider and reduce the forging pressure.

[0072] During the forging process, the precision detection module collects real-time displacement data of the upper die and forging pressure data. This data is continuously input into the discrimination model, which analyzes and processes the real-time data, compares it with preset process parameters, and outputs corresponding control commands to provide decision-making basis for the parameter control module. This discrimination model is established based on a large amount of forging test data of flange blanks with different angles. By collecting forging displacement, pressure data, and corresponding forming quality data of flanges of different specifications and angles, the model is trained using the logistic regression algorithm in machine learning, ultimately forming a discrimination model that can more accurately determine the forging state.

[0073] The discriminant model consists of a data input layer, a data preprocessing layer, a feature extraction layer, a discriminant layer, and an output layer. The data input layer receives parameters acquired in real time, the data preprocessing layer performs noise reduction and normalization on the data, the feature extraction layer extracts key features related to the forging of the angled flange, the discriminant layer performs state discrimination, and the output layer outputs control commands.

[0074] The specific input parameters for the discrimination model include the downward displacement of the upper die, forging pressure, the real-time tilt angle of the upper die's inclined forming surface, the deformation of the billet in the lower die's groove, and the forging time. The model determines whether the current forging state meets the requirements by comparing the real-time parameters with preset thresholds. The specific process is as follows:

[0075] First, the real-time collected displacement data is compared with the preset sliding block downward displacement threshold, and the real-time collected pressure data is compared with the preset forging pressure threshold. Simultaneously, other input parameters are combined for comprehensive judgment. The algorithm calculation process is as follows: first, the input real-time data is normalized to eliminate the influence of different parameters' dimensions; then, key features are extracted through a feature extraction layer, and the extracted features are input into the discrimination layer. The discrimination layer calculates the comprehensive discrimination value according to the preset weight allocation, where the upper die downward displacement accounts for 30%, the forging pressure accounts for 30%, the upper die tilt angle accounts for 15%, the billet deformation accounts for 15%, and the forging time accounts for 10%. The weight calculation adopts the normalized weight method, that is, the weight of each parameter is equal to the coefficient of influence of that parameter on the forming quality divided by the sum of the coefficients of influence of all parameters. If the real-time displacement data and the real-time pressure data are both less than the preset threshold, and the overall discrimination value is lower than the preset standard, the discrimination model outputs an instruction to increase the downward speed of the slider and increase the forging pressure. If the real-time displacement data and the real-time pressure data reach the preset threshold, and the overall discrimination value meets the preset standard, the discrimination model outputs an instruction to maintain the current parameters and perform pressure holding. If the real-time displacement data exceeds the preset threshold or the real-time pressure data exceeds the preset threshold, and the overall discrimination value is higher than the preset standard, the discrimination model outputs an instruction to slow down the downward speed of the slider and reduce the forging pressure.

[0076] The final output parameters of the model include the comprehensive discrimination value and the deviation values ​​of each input parameter from the preset threshold. These parameter results directly determine the type and amplitude of the control command. The larger the deviation value, the larger the control amplitude, ensuring that the forging process is always within a reasonable range.

[0077] This embodiment achieves more precise discrimination and control of the forging process through further discriminative model design, solving the problem of blind parameter control in existing forging processes. Compared with traditional control methods without discriminative models, this model can comprehensively discriminate based on real-time data and the unique characteristics of the angled flange, outputting more reasonable control commands. This effectively avoids flange blank size deviations and forming quality problems caused by improper forging parameters, improves the stability of forging and the product qualification rate, and reduces metal material waste and equipment wear caused by improper parameter adjustments.

[0078] Example 10

[0079] This embodiment is based on the aforementioned embodiment. In this embodiment, the demolding process in step 5 includes: after the parameter control module receives the forging completion signal sent by the precision detection module, it controls the free forging press slide to move upward to the preset position, and then controls the demolding cylinder to extend, driving the demolding ejector to move upward. The demolding ejector pushes the flange blank, causing the flange blank to separate from the groove of the lower mold. After the flange blank is separated, the parameter control module controls the demolding cylinder to retract, driving the demolding ejector to reset, thus completing the forging and demolding process.

[0080] After the flange blank is forged, the precision detection module captures the forging completion signal and transmits it to the parameter control module in real time. Upon receiving the signal, the parameter control module immediately sends a command to the free forging press, controlling the slide block to move upwards. The slide block drives the upper die to move upwards synchronously until the slide block and upper die reach the preset position. At this point, the flange blank in the upper die and lower die are completely separated, without hindering the subsequent demolding action. Subsequently, the parameter control module sends a start command to the demolding cylinder of the demolding drive module, controlling the piston rod of the demolding cylinder to extend upwards. The piston rod drives the demolding ejector rod connected to it to move upwards synchronously. The demolding ejector rod passes through the demolding through-hole at the bottom of the lower die and enters the groove of the lower die, making close contact with the bottom of the flange blank. As the piston rod of the demolding cylinder continues to extend, the demolding ejector rod applies a uniform upward pushing force to the flange blank, overcoming the friction between the flange blank and the inner wall of the lower die groove, causing the flange blank to gradually separate from the groove until it is completely ejected, completing the demolding process. After the flange blank is ejected, the operator can remove it. Simultaneously, the parameter control module controls the piston rod of the demolding cylinder to retract, causing the demolding ejector rod to move downwards, pass through the demolding through-hole, and return to its initial position, ready for the next forging and demolding process. The beneficial technical effect of this embodiment is that it clarifies the specific operational procedures of the demolding process, making the demolding action more standardized and orderly, and avoiding damage to the blank or mold caused by improper operation during demolding. Through the automatic control of the parameter control module, precise coordination between the demolding action and the upward movement of the slide block is achieved, ensuring reasonable demolding timing and improving demolding efficiency. Compared to traditional manual or simplified demolding methods, this demolding process is smoother and more efficient, reducing manual intervention and labor costs. It also avoids mold clogging problems caused by incomplete demolding, further improving the continuity and stability of forging production and reducing the scrap rate.

[0081] The embodiments described above are merely illustrative of specific implementations of the present invention, and while the descriptions are detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A metal connector forging and forming apparatus, comprising a free forging press body, characterized in that, It also includes molding die components, a die positioning and fixing module, a precision detection module, a demolding drive module, and a parameter control module; The forming mold assembly is detachably connected to the slider and worktable of the free forging press body. The mold positioning and fixing module is installed above the worktable of the free forging press for positioning and fixing the forming mold assembly. The precision detection module is electrically connected to the parameter control module and is used to collect the die position and billet forming data during the forging process; The demolding drive module is connected to the molding die assembly and is used to drive the molding die assembly to complete the demolding action; The parameter control module is electrically connected to the free forging press body, the mold positioning and fixing module, the precision detection module, and the demolding drive module, respectively, and is used to receive detection data and control the operation of each module.

2. The metal connector forging and forming apparatus according to claim 1, characterized in that, The forming mold assembly includes an upper mold and a lower mold. The upper mold is fixedly connected to the slider of the free forging press body, and the lower mold is connected to the mold positioning and fixing module of the free forging press worktable. The lower end face of the upper mold is provided with an inclined forming surface that matches the slope of the flange blank, and the upper end face of the lower mold is provided with a groove that matches the inclined forming surface of the upper mold. The bottom of the groove is provided with a demolding through hole, which is correspondingly set with the demolding drive module.

3. The metal connector forging and forming apparatus according to claim 1, characterized in that, The mold positioning and fixing module includes a positioning seat, a clamping cylinder, and a positioning pin. The positioning seat is fixed on the worktable of the free forging press. The positioning seat is provided with a positioning groove that matches the lower mold. The clamping cylinder is symmetrically installed on both sides of the positioning seat. The piston rod end of the clamping cylinder is provided with a clamping block. The positioning pin is installed on the positioning seat. The lower mold is provided with a positioning hole that matches the positioning pin. The positioning pin is used to insert into the positioning hole to achieve the positioning of the lower mold.

4. The metal connector forging and forming apparatus according to claim 1, characterized in that, The accuracy detection module includes a displacement sensor and a pressure sensor. The displacement sensor is installed on the slide of the free forging press and is used to collect the downward displacement data of the upper die. The pressure sensor is installed at the connection between the upper die and the slide of the forming die assembly and is used to collect the pressure data during the forging process. The output terminals of both the displacement sensor and the pressure sensor are connected to the input terminal of the parameter control module.

5. The forging and forming apparatus for metal connectors according to claim 1, characterized in that, The demolding drive module includes a demolding cylinder and a demolding ejector rod. The demolding cylinder is fixed below the worktable of the free forging press. One end of the demolding ejector rod is connected to the piston rod of the demolding cylinder, and the other end extends through the demolding through hole of the lower die into the groove of the lower die. The parameter control module is electrically connected to the demolding cylinder and is used to control the extension and retraction of the demolding cylinder.

6. A method for forging and forming a metal connector, applied to the apparatus described in any one of claims 1-5, characterized in that, Includes the following steps: Step 1: Collect the dimensional parameters, slope parameters, rated pressure and slide stroke parameters of the free forging press of the flange blank to be forged. Input the collected parameters into the preset parameter matching algorithm and output the forming surface dimension parameters, mold positioning parameters and forging process parameters of the forming die assembly. Step 2: Based on the mold positioning parameters output by the parameter matching algorithm, the forming mold assembly is fixed on the free forging press using the mold positioning and fixing module, thus completing the mold installation and positioning. Step 3: Place the metal billet in the lower mold groove of the forming mold assembly, start the free forging press through the parameter control module, control the slider to drive the upper mold downward, and at the same time collect the displacement data and forging pressure data of the upper mold in real time through the precision detection module. Step 4: Input the collected displacement and pressure data into the discrimination model of the parameter control module. The discrimination model compares the real-time data with the preset process parameters and outputs control commands. The parameter control module adjusts the downward speed of the slide block and the forging pressure of the free forging press according to the control commands until the forging of the flange blank is completed. Step 5: After forging is completed, the parameter control module controls the slide of the free forging press to move upward, and at the same time starts the demolding drive module to drive the demolding ejector to push the flange blank upward, thus completing the demolding.

7. The method according to claim 6, characterized in that, The parameters of the flange blank to be forged collected in step 1 include the flange outer diameter, inner diameter, thickness, and flange end face slope. The parameters of the free forging press include the rated forging pressure, the maximum downward stroke of the slide block, and the adjustment range of the downward speed of the slide block. Based on the collected parameters, the parameter matching algorithm calculates the tilt angle of the upper die tilting forming surface, the size of the lower die groove, and the installation position of the positioning pin through linear fitting. At the same time, it calculates the downward speed of the slide block, the forging pressure, and the holding time during the forging process.

8. The method according to claim 6, characterized in that, The mold installation and positioning process in step 2 includes: placing the lower mold in the positioning slot of the positioning seat, inserting the positioning pin into the positioning hole of the lower mold to achieve initial positioning, activating the clamping cylinder to clamp the side of the lower mold with the clamping block to achieve fixation; fixing the upper mold to the slide of the free forging press with bolts, controlling the slide to move downward through the parameter control module to make the forming surfaces of the upper mold and the lower mold initially fit together, collecting displacement data after fitting through the displacement sensor, adjusting the installation position of the upper mold to make the forming surfaces of the upper mold and the lower mold fit together.

9. The method according to claim 6, characterized in that, The discrimination process of the discrimination model in step 4 includes: comparing the real-time collected displacement data with the preset slider downward displacement threshold, and comparing the real-time collected pressure data with the preset forging pressure threshold. If the real-time displacement data is less than the preset threshold and the real-time pressure data is less than the preset threshold, the discrimination model outputs an instruction to accelerate the downward speed of the slider and increase the forging pressure. If the real-time displacement data reaches the preset threshold and the real-time pressure data reaches the preset threshold, the discrimination model outputs an instruction to maintain the current parameters and perform pressure maintenance. If the real-time displacement data exceeds the preset threshold or the real-time pressure data exceeds the preset threshold, the discrimination model outputs an instruction to slow down the downward speed of the slider and reduce the forging pressure.

10. The method according to claim 6, characterized in that, The demolding process in step 5 includes: after receiving the forging completion signal sent by the precision detection module, the parameter control module controls the free forging press slide to move upward to the preset position, and then controls the demolding cylinder to extend, driving the demolding ejector to move upward. The demolding ejector pushes the flange blank, causing the flange blank to separate from the groove of the lower mold. After the flange blank is separated, the parameter control module controls the demolding cylinder to retract, driving the demolding ejector to reset, thus completing the forging and demolding process.

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