Forming system of aluminum alloy synchronous belt pulley

Abstract

The utility model provides a forming system of an aluminum alloy synchronous belt pulley, which comprises an extrusion forming system used for heating an aluminum alloy blank at high temperature to soften the aluminum alloy blank and extruding the aluminum alloy blank into an aluminum alloy section with an inner hole in the middle and teeth on the peripheral surface; wherein the tooth surface structure of the aluminum alloy profile with the teeth on the peripheral surface is smaller than a standard tooth forming structure; the modeling and slitting system is used for measuring and calculating the mass or volume required by the product and slitting the aluminum alloy section to form a plurality of tooth forming blanks; the upsetting forming system is used for extruding the tooth forming blank through a press machine, and finally, the bottom face end of the tooth forming blank forms a belt pulley die with the face wall thickness and the periphery forms a standard tooth shape; and the machining system is used for carrying out auxiliary machining such as cleaning, trimming and chamfering on the belt pulley die to form the aluminum alloy synchronous belt pulley.

Description

TECHNICAL FIELD

[0001] The utility model relates to a kind of forming system of aluminum alloy synchronous pulley. BACKGROUND

[0002] Synchronous pulley is a kind of mechanical component for transmitting power and motion, widely used in industrial automation, automobile, textile, agricultural machinery and other fields. The key technologies of synchronous pulley include tooth profile design, material selection, manufacturing process, etc. Tooth profile design usually follows certain international or industry standards, such as DIN, ISO, etc., to ensure that synchronous belts and pulleys produced by different manufacturers are compatible and achieve parameter standardization.

[0003] Currently, synchronous pulley manufacturing process includes precision casting, numerical control machining, laser cutting, stamping and other technologies; high-precision numerical control machine tools are widely used in tooth profile machining of synchronous pulley to ensure the accuracy and consistency of tooth profile; material surface treatment technologies such as heat treatment, electroplating, spraying, etc. are used to improve the wear resistance and corrosion resistance of synchronous pulley; among them, the forming of wheel body and teeth of aluminum alloy pulley is two important aspects of synchronous pulley manufacturing, which directly determines the quality and feasibility of manufacturing. The forming of aluminum alloy structure can be selected according to the size, shape, performance requirements and production batch of the part; common methods include casting, pressure casting, forging, extrusion, machining, etc. The forming process of aluminum alloy parts needs to be selected according to specific application requirements and production conditions to achieve the best cost-effectiveness and product quality; in addition, tooth profile machining is a complex process that requires precise equipment and process control to meet higher precision and efficiency requirements.

[0004] Currently, enterprises use traditional mechanical machining methods, the main process route is to use aluminum alloy bar material, then process the blank outer diameter, end face and inner hole on numerical control lathe, change to machining center to mill tooth profile (here, gear hobbing machine can also be used), finally process guide angle, deburring and other surface treatment (as shown in the product Figure 7 There are limitations such as low processing efficiency, high processing cost and long process flow, and the following shortcomings:

[0005] 1. The production efficiency is not high enough, especially when machining tooth profile, multiple layer repeated milling operation is required, which is time-consuming and limited by the number of machining centers. In addition, different machine tools are needed for different processes, and clamping, moving and adjusting are required on different machine tools.

[0006] 2. The processing equipment cost is high, and the material removal rate is high, which easily leads to material waste.

[0007] 3. Heat is easily generated during the processing process, which affects the material properties.

[0008] 4. It has certain requirements for cutting tools and coolant, and the processing generates a lot of waste, increasing the site treatment cost. Utility Model Content

[0009] The purpose of this invention is to overcome the above-mentioned defects. During repeated experiments, the inventors discovered that directly using the high-temperature aluminum drawing process to form standard teeth in one step results in poor precision of the stretched profile due to factors such as thermal expansion and contraction deformation and extrusion pressure, and also requires a base-building process. On the other hand, the inventors directly use cold heading to form standard teeth from the blank in one step, which has problems such as high cold heading pressure, poor material flow, high probability of cracking, and easy jamming during unloading. This invention provides a forming process and forming system for aluminum alloy synchronous belt pulleys.

[0010] The present invention adopts the following technical solution:

[0011] A forming process for an aluminum alloy synchronous belt pulley includes the following steps:

[0012] S1, High-temperature aluminum drawing: The aluminum alloy billet is heated at high temperature to soften it, and then extruded into an aluminum alloy profile with an inner hole in the middle and teeth on the outer peripheral surface; wherein, the tooth structure of the aluminum alloy profile with teeth on the outer peripheral surface is smaller than that of the standard tooth structure.

[0013] S2, Bar Material Measurement and Slitting: Calculate the required mass or volume of the product and slit the aluminum alloy profile into multiple toothed blanks.

[0014] S3, Upsetting: The toothed blank is extruded by a press, and finally the bottom end of the toothed blank forms a pulley mold with a thick wall and a standard tooth shape around the perimeter.

[0015] S4, Machining: Auxiliary machining processes such as surface finishing, edge trimming, and chamfering are performed on the pulley mold to form an aluminum alloy synchronous pulley.

[0016] Preferably, step S1 further includes an aluminum drawing die; the high-temperature heated aluminum alloy billet is softened and then formed into an aluminum alloy profile with a hole in the middle and teeth on the outer peripheral surface by the extruder and the aluminum drawing die.

[0017] Preferably, in step S2, the required mass or volume of the product is calculated by modeling and simulation software, and the aluminum alloy profile is cut into multiple toothed blanks.

[0018] Preferably, in step S3, the press is a hydraulic press, and the punch of the hydraulic press is slightly larger than the inner hole of the gear blank. During upsetting, the excess material of the hole wall of the gear blank is gradually squeezed downward, accumulating at the bottom of the gear to form the end face wall thickness of the gear. Step S3 also includes a gear forming mold. The gear blank is placed in the gear forming mold and upsetting is performed by the hydraulic press to form a standard tooth shape around the periphery of the gear blank.

[0019] Preferably, in step S1, the aluminum die is also included; the high-temperature heated aluminum alloy blank is softened, and an aluminum alloy profile with an intermediate hole and a toothed outer periphery is formed by the extruder and the aluminum die; in step S2, the modeling simulation software is used to calculate the required mass or volume of the product, and the aluminum alloy profile is cut to form a plurality of toothed blanks; in step S3, the press is an oil press, the punch of the oil press is slightly larger than the inner hole of the toothed blank, and the hole wall excess of the toothed blank is gradually extruded downward during upsetting, and the gear end face wall thickness is accumulated at the toothed bottom; in step S3, the toothed die is also included, the toothed blank is placed in the toothed die, and the toothed blank periphery forms a standard tooth shape by upsetting with the oil press; step S5 is also included, feedback adjustment: adjusting the mold and tooth blank related parameters according to the deviation of the toothed structure of the aluminum alloy synchronous belt pulley in S4.

[0020] A forming system of an aluminum alloy synchronous belt pulley, comprising: an extrusion forming system: for high-temperature heating of an aluminum alloy blank to soften it, and extruding an aluminum alloy profile with an inner hole in the middle and a toothed outer periphery; wherein the tooth surface structure of the toothed outer periphery of the aluminum alloy profile is smaller than the standard toothed structure.

[0021] A modeling and cutting system: for calculating the required mass or volume of the product, and cutting the aluminum alloy profile to form a plurality of toothed blanks.

[0022] An upsetting forming system: for extruding the toothed blank by a press, and finally forming a pulley die with a face wall thickness at the toothed blank bottom surface end and a standard tooth shape at the periphery.

[0023] A machining system: for finishing, edge removal, angle guiding and other auxiliary machining of the pulley die to form an aluminum alloy synchronous belt pulley.

[0024] Preferably, the extrusion forming system includes a high-temperature aluminum material extruder and an aluminum die, the high-temperature aluminum material extruder is connected to the aluminum die, and is used for high-temperature heating of an aluminum alloy blank to soften it, and extruding an aluminum alloy profile with an inner hole in the middle and a toothed outer periphery.

[0025] Preferably, the modeling and cutting system includes a modeling simulation system and a cutting system; the modeling simulation system is used to calculate the required mass or volume of the product; and the cutting system is used to cut the aluminum alloy profile to form a plurality of toothed blanks.

[0026] Preferably, the upsetting forming system includes an oil press and a toothed die; the punch size of the oil press is equal to the inner hole diameter of the aluminum alloy synchronous belt pulley, and is larger than the inner hole of the toothed blank; and the tooth surface structure size of the toothed die is equal to the standard toothed structure size.

[0027] Preferably, the bottom of the toothed mold is provided with an ejection system; the ejection system comprises a movable bottom plate of the toothed mold bottom, a hydraulic cylinder; the hydraulic cylinder is connected below the bottom plate, providing support force for the bottom plate while driving the bottom plate to move upward.

[0028] Compared with the prior art, the utility model has the advantages and positive effects that:

[0029] I. The application of the light aluminum pulley cold heading process greatly improves the raw material utilization rate. The raw material utilization rate is increased by 45%, the processing cost is reduced by 28%, and more than 5 million yuan of profit is realized according to the annual output of 800,000 pieces, which has good social benefits.

[0030] II. The original complex and tedious machining process is broken, and the machining efficiency is low, the processing cost is high, and the process flow is long. In the case of bar profile outsourcing, only oil pressure machine is needed to complete the product by once heading and simple part surface treatment; the piling forming reaches the standard size of the outer shape and tooth shape, and is suitable for size stable control of batch production of products and adaptation to automatic production line batch production; the product quality is guaranteed, and the manufacturing cost is low.

[0031] III. The tooth surface structure is formed by extrusion, and the surface quality is smoother, avoiding the influence of tool marks on the surface quality during layered milling. At the same time, the material will be work hardened during the extrusion process, thereby improving the strength and hardness of the material.

[0032] IV. Cold heading forming belongs to a kind of precision pressure processing technology, and after metal extrusion forming, the fiber is continuous and complete, the grain is refined, and the mechanical properties are improved. The product metal surface has the effect of calendering during the extrusion forming process. The surface roughness of the workpiece is low (smooth), and generally reaches Ra0.8. The improvement of the precision and smoothness of the tooth surface of the synchronous pulley can greatly prolong the service life of the belt, reduce the cost and improve the overall performance of the equipment.

[0033] V. The manufacturing cost is low, a set of cold heading die can complete batch production, and different models and specifications only need to invest in die cost to realize the production and manufacturing of synchronous pulleys of different varieties and specifications. Cold precision pressure processing is a kind of little or no cutting processing technology, and the formed workpiece is very close to the product, the machining allowance is small, the material utilization rate is high, the raw materials are saved, and the production cost is reduced. For batch processing products, not only the working hours are saved, but also the product cost is low. Compared with the conventional machining process, the technical and economic effect is increased by 30%.

[0034] VI. And first by extrusion preforming, is for the subsequent pulley tooth shape size stability; This is because the synchronous pulley tooth shape is a special-shaped part, and the extrusion forming pre can first do the material pre-distribution, which can reduce the secondary cold heading pressure, the material flows smoothly during cold heading, and can also reduce the material fission, ensure the fullness of the secondary forming tooth shape, size stability, three is easy to remove, not to affect the deformation of the material.BRIEF DESCRIPTION OF DRAWINGS BRIEF DESCRIPTION OF DRAWINGS

[0035] Figure 1 is the overall schematic diagram of the extrusion forming system of the utility model.

[0036] Figure 2 is the schematic diagram of the extrusion forming system of the utility model.

[0037] Figure 3 is the schematic diagram of the aluminum alloy profile and the toothed blank of the utility model.

[0038] Figure 4 is the three-dimensional schematic diagram of the upsetting forming system of the utility model.

[0039] Figure 5 is the schematic diagram of the upsetting forming system of the utility model.

[0040] Figure 6 is the punch working schematic diagram of the oil press of the utility model.

[0041] Figure 7 is the schematic diagram of the aluminum alloy synchronous pulley of the utility model. DETAILED DESCRIPTION

[0042] In order to make the purpose, technical scheme of the utility model more clearly, the utility model is further explained as follows by combining with the drawings and examples:

[0043] A forming process of an aluminum alloy synchronous pulley, comprising the following steps:

[0044] S1, high-temperature aluminum drawing: high-temperature heating of aluminum alloy blank to soften it, and forming an aluminum alloy profile with a hole in the middle and a toothed outer peripheral surface through an extruder; wherein the tooth surface structure of the toothed outer peripheral surface of the aluminum alloy profile is smaller than the standard toothed structure.

[0045] In step S1, high-temperature aluminum extrusion and aluminum drawing die can be used to realize: high-temperature heating of aluminum alloy blank to soften it, and forming an aluminum alloy profile 3 with a hole in the middle and a toothed outer peripheral surface through an extruder (high-temperature aluminum extrusion machine 1), aluminum drawing die 2, wherein high-temperature heating, i.e. extrusion, can directly use a high-temperature aluminum extrusion machine (such as shown in Figure 1 、 Figure 2 ).

[0046] S2, rod measurement and cutting: measuring the required mass or volume of the product, and cutting the aluminum alloy profile 3 to form a plurality of toothed blanks 4.

[0047] In step S2, the required mass or volume of the product can be measured by modeling simulation software, and a cutting machine (not shown in the figure) is used to cut the aluminum alloy profile to form a plurality of toothed blanks 4 (such as shown in Figure 3(as shown);

[0048] S3, Upsetting: The toothed blank is extruded by a press, and finally the bottom end of the toothed blank forms a pulley mold with a thick wall and a standard tooth shape around the perimeter.

[0049] In step S3, the press is a hydraulic press, and the punch 5 of the hydraulic press is slightly larger than the inner hole of the gear blank. During upsetting, the excess material of the gear blank is gradually squeezed downwards, accumulating at the bottom of the gear to form the end face wall thickness of the gear. Step S3 also includes a gear forming mold 6, in which the gear blank is placed and upset by the hydraulic press, forming a standard tooth shape around the periphery of the gear blank. Figures 4 to 6 (As shown).

[0050] S4, Machining: The pulley mold is machined by a machine tool (not shown in the figure) to perform auxiliary machining such as smoothing, edge removal, and chamfering to form an aluminum alloy synchronous pulley. The machine tool machining is a traditional process, which will not be described in detail in this utility model.

[0051] It also includes step S5, feedback adjustment: adjusting the relevant parameters of the mold and gear blank based on the deviation of the tooth structure of the aluminum alloy synchronous belt pulley in S4.

[0052] The inventor's experimental research allows for adjustments based on experimental tests and adjustments made to key areas during the adjustment process.

[0053] 1. Synchronous belt pulleys generally undergo periodic cyclic motion. At a certain fixed moment, multiple teeth will often contact the synchronous belt and be subjected to force simultaneously. However, the force on each tooth is generally consistent. The stress of multiple teeth can be regarded as the superposition of the stress effect of a single tooth. Therefore, stress analysis can be performed on only a single tooth, and the actual effect can achieve the expected purpose of strain trend analysis.

[0054] Second, according to the stress analysis simulation, the stress-strain trend is most obvious in the center hole of the pulley and on the surface of the gear teeth, with the maximum value appearing on the inner cylindrical surface of the small hole. Therefore, this is the location that needs the most monitoring.

[0055] Third, regarding the gear teeth, since synchronous belts have a unified standard, if it is necessary to increase the strength of the gear teeth, a larger series of synchronous belts can be selected. At the same time, the size of the gear teeth will also be increased accordingly. This requires adjustment from the initial mold size.

[0056] Fourth, at the shaft hole, add a hub and lengthen and thicken the shaft hole, but generally leave a certain strength margin, because lightweighting improves transmission efficiency.

[0057] like Figures 1 to 7 As shown, this utility model also provides a forming system for aluminum alloy synchronous belt pulleys, comprising:

[0058] Extrusion forming system: for high temperature heating of aluminum alloy blank to soften, extrusion of intermediate with inner hole, and the outer peripheral surface with teeth aluminum alloy profile; wherein, the outer peripheral surface with teeth of the aluminum alloy profile tooth surface structure is less than the standard tooth structure; the extrusion forming system includes high temperature aluminum material extrusion machine 1, pull aluminum mold 2, the high temperature aluminum material extrusion machine 1 connects pull aluminum mold 2, for high temperature heating of aluminum alloy blank to soften, extrusion of intermediate with inner hole, and the outer peripheral surface with teeth aluminum alloy profile 3.

[0059] Modeling cutting system: for measuring the quality or volume required by the product, cutting the aluminum alloy profile to form a plurality of toothed blank 4; the modeling cutting system includes modeling simulation system (not shown in the figure), cutting system; the modeling simulation system is used to measure the quality or volume required by the product; the cutting system is used to cut the aluminum alloy profile to form a plurality of toothed blank, the cutting system of the embodiment adopts cutting machine (not shown in the figure).

[0060] Upset forming system: for extruding the toothed blank through the press, finally forming the pulley mold with the face wall thickness and the standard tooth shape on the periphery of the toothed blank bottom end; the press is an oil press, the punch 5 of the oil press is slightly larger than the inner hole of the toothed blank 4, the tooth surface structure size of the toothed mold is equal to the standard tooth structure size, and the hole wall excess of the toothed blank is gradually extruded downward during upsetting, and the gear end face wall thickness is accumulated at the toothed bottom; in step S3, the toothed mold 6 is also included, the toothed blank 4 is put into the toothed mold, and the toothed blank periphery forms the standard tooth shape (as shown) through the upsetting of the oil press. Figures 4 to 6

[0061] Machining system: for finishing, edge removal, angle guide and other auxiliary machining of the pulley mold to form the aluminum alloy synchronous pulley 7; the machining of the pulley mold is finished, edge removed, angle guided and other auxiliary machining to form the aluminum alloy synchronous pulley by using the machine tool (not shown in the figure) in the embodiment.

[0062] Preferably, the bottom of the toothed mold is provided with an ejection system; the ejection system includes a movable bottom plate 61 at the bottom of the toothed mold and a hydraulic cylinder (not shown in the figure); the hydraulic cylinder is connected below the bottom plate, provides support force for the movable bottom plate, and can drive the bottom plate to move upward to eject the upset toothed blank.

[0063] ​In the description of the utility model, it needs to be explained that the terms "upper", "lower", "inner", "outer", "front end", "rear end", "two ends", "one end", "the other end" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the utility model. In addition, the terms "first", "second" are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0064] In the description of the utility model, it needs to be explained that unless otherwise explicitly specified and limited, the terms "mounting", "provided with", "connection" and the like should be broadly understood, for example, "connection" can be fixed connection, can also be detachable connection, or integral connection; can be mechanical connection, can also be electrical connection; can be directly connected, can also be indirectly connected through an intermediate medium, can be the communication inside two elements. For ordinary skilled persons in the art, the specific meaning of the above terms in the utility model can be understood according to the specific circumstances.

[0065] The components used in the utility model are all general standard components or components known to those skilled in the art, for example, its high-temperature aluminum material extrusion machine, aluminum drawing die, oil press and the like, the structure and principle of which are known to the skilled person through technical manuals or through conventional experimental methods.

[0066] The above is only the preferred embodiment of the utility model, and does not limit the technical scope of the utility model in any way, so any slight modification, equivalent change and modification made according to the technical essence of the utility model to the above embodiment still belongs to the protection scope of the utility model.

Claims

1. A forming system for an aluminum alloy synchronous pulley, characterized by, Comprise: Extrusion forming system: for high temperature heating of aluminum alloy blank to soften, extrusion of intermediate hole, and the outer peripheral surface with teeth aluminum alloy profile; wherein, the outer peripheral surface with teeth aluminum alloy profile tooth surface structure is less than the standard tooth structure; Modeling cutting system: for measuring the required quality or volume of products, cutting aluminum alloy profile to form a plurality of toothed blank; Upset forming system: for the toothed blank by the press extrusion, the final toothed blank bottom end forming face wall thickness, the periphery of the standard tooth shape of the pulley mold; Machining system: for the pulley mold to smooth, edge, guide angle auxiliary machining, forming aluminum alloy synchronous pulley.

2. The aluminum alloy synchronous pulley forming system according to claim 1, wherein: The extrusion forming system comprises a high temperature aluminum material extruder and a drawing aluminum mold, the high temperature aluminum material extruder is connected with the drawing aluminum mold, and is used for high temperature heating of aluminum alloy blank to soften.

3. The aluminum alloy synchronous pulley forming system according to claim 1, wherein: The modeling cutting system comprises a modeling simulation system and a cutting system; The modeling simulation system is used for measuring the required quality or volume of products; The cutting system is used for cutting aluminum alloy profile to form a plurality of toothed blank.

4. The aluminum alloy synchronous pulley forming system according to claim 1, wherein: The upset forming system comprises an oil press and a toothed mold; The punch size of the oil press is equal to the inner hole diameter of the aluminum alloy synchronous pulley, and is greater than the inner hole of the toothed blank; The tooth surface structure size of the toothed mold is equal to the standard tooth structure size.

5. The aluminum alloy synchronous pulley forming system according to claim 4, wherein: The bottom of the toothed mold is provided with an ejection system; The ejection system comprises a movable bottom plate at the bottom of the toothed mold and a hydraulic cylinder, the hydraulic cylinder is connected below the movable bottom plate, provides support force for the bottom plate, and can drive the bottom plate to move upward.

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