Rudder ball cover plate machining device of rudder ball structure

Abstract

According to the rudder ball cover plate machining device of the rudder ball structure, a rudder ball cover plate is machined and pressed through a rudder ball cover plate upper die and a rudder ball cover plate lower die, the rudder ball cover plate upper die comprises a fixed panel, an extending round pipe and a rudder ball equal-curvature die, and the fixed panel is used for being connected with a pressure applying mechanism of an oil press. The center of the fixed panel is vertically connected with an extending circular pipe, the top end of the extending circular pipe is arranged on the fixed panel, the tail end of the extending circular pipe is connected with a rudder ball equal-curvature mold, and the rudder ball equal-curvature mold is manufactured according to the curve radian of the rudder ball cover plate; the rudder ball cover plate lower die comprises a rudder ball equal-curvature lower die which is in a disc shape, an equal-curvature groove is formed in the center of the top face of the rudder ball equal-curvature lower die, and the equal-curvature groove corresponds to the rudder ball equal-curvature lower die in a matched mode. The rudder ball cover plate is formed by combining a block pressing process with a high-strength mold, so that the crack resistance and the fatigue resistance of the rudder ball cover plate are effectively enhanced.

Description

Technical Field

[0001] This utility model relates to the field of shipbuilding technology, and in particular to a rudder ball cover plate processing device for a rudder ball structure. Background Technology

[0002] With the development of the shipbuilding and marine engineering fields, various ship types have emerged to meet the transportation needs of bulk commodities. The hull plating of these ships is typically composed of complex, non-developable spatial curved surfaces, requiring a smooth overall profile. This is not only for aesthetic purposes but also affects the ship's construction quality and overall performance. The rudder bulb is a key component of the ship's rudder system, and its structure must meet the requirements of high strength, high precision, and complex curved surface forming. Due to the large profile and high machining difficulty of the rudder bulb, traditional machining methods mainly rely on cast steel rudder bulbs, but this has the following significant drawbacks:

[0003] (1) Insufficient material properties: Cast steel parts have poor toughness and are prone to cracks or even fractures under complex sea conditions, threatening the safety of ships.

[0004] (2) Process defects are hard to avoid: defects such as porosity, sand holes and shrinkage are easily generated during the casting process, which leads to a decrease in the density of the finished product and a shortened fatigue life.

[0005] (3) Long production cycle: The production of ship cast steel parts involves many processes such as mold making, casting, heat treatment and machining. Each process requires a certain amount of time, resulting in a long overall production cycle, which seriously affects the progress of ship construction.

[0006] Therefore, there is an urgent need for a high-efficiency and low-cost processing device for rudder ball cover plates in rudder ball structures to overcome the shortcomings of existing technologies. Utility Model Content

[0007] The purpose of this utility model is to overcome the above-mentioned shortcomings and provide a rudder ball cover plate processing device for a rudder ball structure. Through special mold design, it solves the problems of long production cycle and many defects of traditional cast steel parts.

[0008] The purpose of this utility model is achieved as follows:

[0009] A rudder ball structure rudder ball cover plate processing device, wherein the rudder ball structure is divided into a rudder body and a rudder ball cover plate as a whole, the rudder ball cover plate as a whole is the end plate of the rudder ball structure, a dividing line is divided between the rudder body and the rudder ball cover plate as a whole, multiple evenly distributed dividing lines are set on the rudder body parallel to the dividing line, and multiple dividing lines are evenly divided laterally on the rudder ball structure, dividing the rudder ball cover plate as a whole into multiple rudder ball cover plates.

[0010] The rudder ball cover is processed and pressed using an upper rudder ball cover mold and a lower rudder ball cover mold. Both the upper and lower rudder ball cover molds are mounted on a hydraulic press. The hydraulic press includes a stamping table and a pressure applying mechanism. The pressure applying mechanism of the hydraulic press is connected to the upper rudder ball cover mold, and the lower rudder ball cover mold is mounted on the stamping table. The upper and lower rudder ball cover molds are matched vertically.

[0011] The mold on the rudder ball cover plate includes a fixed panel, an extension tube, and a rudder ball and other curved molds. The fixed panel is used to connect to the pressure application mechanism of the hydraulic press. The fixed panel is a rectangular plate with an extension tube vertically connected to its center. The top end of the extension tube is set on the fixed panel, and the end end of the extension tube is connected to the rudder ball and other curved molds. The rudder ball and other curved molds are made according to the curve curvature of the rudder ball cover plate.

[0012] The rudder ball cover plate lower mold includes a rudder ball equal curve lower mold, which is disc-shaped. The top surface of the rudder ball equal curve lower mold is provided with an equal curve groove, which matches and corresponds to the rudder ball equal curve mold, so as to facilitate the pressing of the curve of the rudder ball cover plate.

[0013] Furthermore, the top outer wall of the extended circular tube is provided with a ring of evenly distributed reinforcing elbow plates, one right-angled side of the reinforcing elbow plate is welded to the fixed panel, and the other right-angled side is welded to the outer wall of the extended circular tube.

[0014] Furthermore, the interior of the extended circular tube is provided with multiple longitudinal reinforcing ribs and transverse reinforcing ribs to increase the strength of the extended circular tube.

[0015] Compared with the prior art, the beneficial effects of this utility model are:

[0016] This utility model provides a rudder ball cover plate processing device for a rudder ball structure. Through an innovative mold structure, it systematically solves the pain points of traditional technologies, providing a high-efficiency, low-cost, and highly reliable rudder ball structure rudder body processing solution for the shipbuilding industry. It has the following specific advantages:

[0017] (1) Improve material performance and structural reliability: The use of block pressing process combined with high-strength mold forming avoids the defect of insufficient toughness of cast steel parts, effectively enhances the crack resistance and fatigue resistance of the rudder ball cover, and ensures the safety of ships in complex sea conditions.

[0018] (2) Eliminate casting process defects: Through precise pressing by hydraulic press and the design of waist drum groove of mold, casting defects such as air holes and sand holes are significantly reduced, the density and surface smoothness of the rudder ball cover plate are improved, and the service life is extended.

[0019] (3) Significantly shorten the production cycle: The modular processing mode supports the parallel pressing of multiple parts, while eliminating the lengthy steps such as mold manufacturing and heat treatment in traditional casting, greatly improving production efficiency and meeting the rapid delivery requirements of shipbuilding.

[0020] (4) Improve processing accuracy and consistency: Standardized molds ensure the precise forming of the complex curved surface of the rudder ball cover, and the dimensional tolerances of each component are strictly controllable, reducing assembly errors and improving the smoothness of the ship's lines and sailing performance. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the mold on the rudder ball cover plate of this utility model.

[0022] Figure 2 This is a front view of the mold on the rudder ball cover plate of this utility model.

[0023] Figure 3 This is a bottom view of the mold on the rudder ball cover plate of this utility model.

[0024] Figure 4 This is a schematic diagram of the structure of the lower mold of the rudder ball cover plate of this utility model.

[0025] Figure 5 This is a front view of the lower mold of the rudder ball cover plate of this utility model.

[0026] Figure 6 This is a side view of the lower mold of the rudder ball cover plate of this utility model.

[0027] Figure 7 This is a schematic diagram showing the division of the rudder ball structure of this utility model.

[0028] Figure 8 This is a diagram showing the material preparation for the rudder ball cover of this utility model.

[0029] in:

[0030] The components include: upper mold 1 for the rudder ball cover plate, fixed panel 1.1, extended round tube 1.2, rudder ball equal curve mold 1.3, reinforcing elbow plate 1.4, round tube longitudinal reinforcing rib 1.5, round tube transverse reinforcing rib 1.6, lower mold 2 for the rudder ball cover plate, lower mold 2.1 for the rudder ball equal curve, and equal curve groove 2.2. Detailed Implementation

[0031] To better understand the technical solution of this utility model, a detailed description will be provided below in conjunction with relevant illustrations. It should be understood that the specific embodiments described below are not intended to limit the specific implementation of the technical solution of this utility model, but are merely possible implementations of the technical solution of this utility model. It should be noted that the descriptions of the positional relationships of the components herein, such as component A being located above component B, are based on the relative positions of the components in the illustrations and are not intended to limit the actual positional relationships of the components. Example 1

[0032] See Figures 1-8 , Figure 7 A schematic diagram of the rudder ball structure of this utility model is shown. As shown in the figure, the rudder ball cover plate processing device of this utility model is used to manufacture the rudder ball structure. First, the rudder ball structure is divided into the rudder body and the rudder ball cover plate. Since the rudder ball structure is shaped like a baseball bat, it is a smooth round rod with lines converging at one end and a hemispherical cover at the other end. Therefore, the rudder ball structure is divided into the rudder body and the rudder ball cover plate. The rudder ball structure is vertically divided into four equal dividing lines, of which the fourth dividing line is the dividing line between the rudder body and the rudder ball cover plate. The rudder ball structure is horizontally divided into four equal dividing lines, thereby dividing the rudder body into multiple rudder body outer plates and dividing the rudder ball cover plate into multiple rudder ball cover plates.

[0033] The rudder ball cover is processed and pressed using an upper mold 1 and a lower mold 2. Both the upper mold 1 and the lower mold 2 are mounted on a hydraulic press. The hydraulic press includes a stamping table and a pressing mechanism. The pressing mechanism of the hydraulic press is connected to the upper mold 1 of the rudder ball cover, and the lower mold 2 is mounted on the stamping table. The upper mold 1 and the lower mold 2 of the rudder ball cover are matched vertically.

[0034] The mold 1 on the rudder ball cover plate includes a fixed panel 1.1, an extension tube 1.2, and a rudder ball curved mold 1.3. The fixed panel 1.1 is used to connect to the pressure application mechanism of the hydraulic press. The fixed panel 1.1 is a rectangular plate with an extension tube 1.2 vertically connected to its center. The top end of the extension tube 1.2 is set on the fixed panel 1.1, and the end of the extension tube 1.2 is connected to the rudder ball curved mold 1.3. The rudder ball curved mold 1.3 is made according to the curve of the rudder ball cover plate. The top outer wall of the extension tube 1.2 is provided with a ring of evenly distributed reinforcing elbow plates 1.4. One right-angled side of the reinforcing elbow plate 1.4 is welded to the fixed panel 1.1, and the other right-angled side is welded to the outer wall of the extension tube 1.2.

[0035] The extended circular tube 1.2 is provided with multiple longitudinal reinforcing ribs 1.5 and transverse reinforcing ribs 1.6 inside to increase the strength of the extended circular tube 1.2.

[0036] The rudder ball cover plate lower mold 2 includes a rudder ball equal curve lower mold 2.1, which is disc-shaped. The top surface of the rudder ball equal curve lower mold 2.1 is provided with an equal curve groove 2.2, which matches and corresponds to the rudder ball equal curve mold 1.3 to facilitate the pressing of the curve of the rudder ball cover plate.

[0037] See Figures 1-8This embodiment relates to a machining process for a rudder ball structure, and a rudder ball cover plate machining device based on the above-mentioned rudder ball structure, including the following:

[0038] S1. Raw material inspection and pretreatment:

[0039] S1.1 Conduct mechanical property testing (tensile strength ≥ 450 MPa, elongation ≥ 20%) and visual inspection on the rudder body and cover plate, and remove defective materials with cracks and pits;

[0040] S1.2 Draw the machining baseline with an error of ≤0.5mm to ensure accurate positioning in subsequent processes.

[0041] S2. Divide the rudder body and rudder ball cover:

[0042] See Figure 7 The rudder ball cover plate is the end plate of the rudder ball structure. The rudder ball structure is divided vertically into four equal dividing lines. The fourth dividing line is the dividing line between the rudder body and the rudder ball cover plate. The rudder ball structure is also divided horizontally into four equal dividing lines, thereby dividing the rudder body into multiple rudder body outer plates and the rudder ball cover plate into multiple rudder ball cover plates.

[0043] S2.1 The rudder body is composed of the outer rudder body plate. The division of the outer rudder body plate is as follows:

[0044] The outer plate of the rudder is cone-shaped, and is laid out and nested according to the mold parameters;

[0045] The width of the outer plate of the rudder is a quarter circle;

[0046] The length of the outer plate of the rudder is within 2.5 meters;

[0047] The thickness and material of the outer plate of the rudder are not limited;

[0048] The curvature of the outer plate of the rudder is unlimited;

[0049] S2.2, Rudder ball cover plate, i.e., the end plate of the rudder ball spherical structure, see [link / reference]. Figure 8 The overall shape is hemispherical. The rudder ball cover is divided as follows:

[0050] The overall shape of the rudder ball cover is either a concentric semicircle or a non-concentric semicircle, and the layout and nesting are carried out according to the mold parameters.

[0051] The width of the rudder ball cover sleeve is a quarter circle;

[0052] The length of the rudder ball cover sleeve is within 2.5 meters;

[0053] The thickness and material of the rudder ball cover plate are not limited;

[0054] The curvature of the rudder ball cover is unlimited.

[0055] S3, Cold forming:

[0056] S1.1, Cold working of the rudder body;

[0057] S1.11, Pre-operation inspection;

[0058] (1) Check the hydraulic press: Connect the main power supply of the hydraulic press control panel and check the lifting, lowering and pressing operations before using the manual control of the equipment.

[0059] (2) Inspect the lifting equipment;

[0060] (3) Check the matching of the sheet part number with the sample box, and whether the part number matches;

[0061] S1.12. Draw the center line on the board and divide it into two equal parts in the first and last directions;

[0062] S1.13. Find the corresponding wooden template based on the sample box's lines;

[0063] S1.14, Edge pressing;

[0064] First, the outer plate of the rudder structure is pressed, with the machining width of each cut maintained at 5mm, and the machining width in the upper and lower directions maintained at 200mm.

[0065] During the edge pressing process, a general-purpose wooden template is used to replicate the edge, and the forming degree of the edge is strictly controlled to ensure that it is smooth and free of rough edges.

[0066] Draw the processing line at the originally marked location;

[0067] S1.15. Hoist the outer plate of the rudder body onto the lower mold of the rudder body, and start processing from the edge of the plate. Use the "less pressure, more stops" strategy to cold press and form the plate in stages.

[0068] S1.16 After each stage of processing, use a wooden template to replicate the sample, mark the areas that do not meet the standards and correct them, repeating until the lines are smooth (surface error ≤ 1.5mm).

[0069] After processing to 300mm, the sheet material's lines are replicated and corrected.

[0070] After processing on both sides simultaneously, a template is used for verification.

[0071] S1.17 After the first batch of processing line work is completed, the mold is lifted out and a sample box is used for replication. During the replication process, pay attention to the placement position, mark the areas that are not processed properly, and then carry out the processing work according to the original processing method.

[0072] S1.18 After the outer plate of the rudder is processed, draw the allowance line according to the sample box size and mark the quality mark;

[0073] S1.19. After splicing on site, observe whether the lines are smooth. If they are not smooth, repeat the correction. If they are smooth, the work is finished.

[0074] S1.110. Work completed: The operator shall operate the equipment to lower the upper mold onto the lower mold and turn off the main power switch to end the work.

[0075] S1.2, Cold working of the rudder ball cover;

[0076] S1.21, Pre-operation inspection;

[0077] (1) Check the hydraulic press: Connect the main power supply of the hydraulic press control panel and check the lifting, lowering and pressing operations before using the manual control of the equipment.

[0078] (2) Inspect the lifting equipment;

[0079] (3) Check the matching of the sheet part number with the sample box, and whether the part number matches;

[0080] S1.22, Welding manual assistance;

[0081] Since the plates cannot be hoisted after processing and need to be moved manually, hand-pulled supports are welded to the three sharp corners of each rudder ball cover before processing.

[0082] S1.23 After the rudder ball mold is installed, place the rudder ball cover plate on the rudder ball and other curved molds, and observe and draw the processing lines according to the matching wooden sample box;

[0083] S1.24. Cold press in sections along the processing line, adopt the "less pressing and more closing" strategy, control the indentation depth to ≤2mm, and process repeatedly from the center to both sides (when processing, first press down 10mm and wait for the surrounding area to be smooth before processing step by step according to the above steps).

[0084] S1.25. During the process, the processing position is constantly changed along the processing line to make the forging more uniform. During the processing, the forming quality is detected in real time by "visual inspection and manual inspection", and deviations are corrected by sample box replication to ensure smooth transition of curved surfaces.

[0085] S1.26 After the rudder ball cover plate is processed, draw the allowance line according to the sample box size and mark the quality mark;

[0086] S1.27. After splicing the segments, observe whether the overall line shape is smooth. If it is not smooth, repeat the correction. If it is smooth, the work is finished.

[0087] S1.28. End of Operation: The operator shall operate the equipment to lower the upper mold onto the lower mold and turn off the main power switch to end the operation.

[0088] S4. Hot working straightening:

[0089] S2.1 Fix the cold-formed rudder ball cover plate to the multi-hole work platform, use a sample box to replicate the plate, observe the areas where the line shape is not in place, and draw the processing line.

[0090] S2.2 After securing the rudder ball cover, proceed with the flame work, using flame heating (temperature controlled at 800~1000℃, heating wire width ≤10mm, water-fire distance controlled at approximately 100mm).

[0091] S2.3 After the first batch of processing line work is completed, a replica is made. Based on the thermal deformation law, it is heated and corrected 2 to 3 times to eliminate residual stress and optimize the surface accuracy (local error ≤ 0.8mm). After 2 to 3 replicas and processing, the rudder ball cover plate is completed.

[0092] S2.4 Then, surface polishing, repair, and rust prevention treatment are carried out;

[0093] S2.5 Finally, draw the machining allowance lines and mark various machining information.

[0094] S5. Overall Assembly and Inspection:

[0095] S5.1. Weld the rudder body and cover plate together and use ultrasonic testing to inspect the weld quality (defect rate ≤0.5%).

[0096] S5.2 Use a 3D scanner to compare the design model and ensure that the overall line shape error is ≤2mm.

[0097] Working principle:

[0098] This utility model provides a rudder ball cover plate processing device for a rudder ball structure. The rudder ball cover plate processing mold adopts a modular multi-curved surface design: based on the spherical characteristics of the rudder ball cover plate, a segmented adjustable mold is designed to support cold pressing and uniform forming.

[0099] The above are merely specific application examples of this utility model and do not constitute any limitation on the scope of protection of this utility model. All technical solutions formed by equivalent transformations or equivalent substitutions fall within the scope of protection of this utility model.

Claims

1. A rudder ball cover plate processing device for a rudder ball structure, characterized in that: The rudder ball structure is divided into the rudder body and the rudder ball cover plate as a whole. The rudder ball cover plate as a whole is the end plate of the rudder ball structure. A dividing line is drawn between the rudder body and the rudder ball cover plate as a whole. Multiple evenly distributed dividing lines are set on the rudder body parallel to the dividing line. Multiple dividing lines are evenly divided laterally on the rudder ball structure, dividing the rudder ball cover plate as a whole into multiple rudder ball cover plates. The rudder ball cover is processed and pressed using an upper mold (1) and a lower mold (2). Both the upper mold (1) and the lower mold (2) are mounted on a hydraulic press. The hydraulic press includes a stamping table and a pressing mechanism. The pressing mechanism of the hydraulic press is connected to the upper mold (1) of the rudder ball cover. The lower mold (2) of the rudder ball cover is mounted on the stamping table. The upper mold (1) and the lower mold (2) of the rudder ball cover are matched vertically. The mold (1) on the rudder ball cover plate includes a fixed panel (1.1), an extension tube (1.2), and a rudder ball curved mold (1.3). The fixed panel (1.1) is used to connect with the pressure application mechanism of the hydraulic press. The fixed panel (1.1) is a rectangular plate with an extension tube (1.2) vertically connected to its center. The top end of the extension tube (1.2) is set on the fixed panel (1.1), and the end of the extension tube (1.2) is connected to the rudder ball curved mold (1.3). The rudder ball curved mold (1.3) is made according to the curve arc of the rudder ball cover plate. The rudder ball cover plate lower mold (2) includes a rudder ball equal curve lower mold (2.1). The rudder ball equal curve lower mold (2.1) is disc-shaped. An equal curve groove (2.2) is provided at the center of the top surface of the rudder ball equal curve lower mold (2.1). The equal curve groove (2.2) matches and corresponds to the rudder ball equal curve mold (1.3), which facilitates the pressing of the curve of the rudder ball cover plate.

2. The rudder ball cover plate processing device according to claim 1, characterized in that: The top outer wall of the extended circular tube (1.2) is provided with a ring of evenly distributed reinforcing elbow plates (1.4). One right-angled side of the reinforcing elbow plate (1.4) is welded to the fixed panel (1.1), and the other right-angled side is welded to the outer wall of the extended circular tube (1.2).

3. The rudder ball cover plate processing device according to claim 1, characterized in that: The interior of the extended circular tube (1.2) is provided with multiple longitudinal reinforcing ribs (1.5) and transverse reinforcing ribs (1.6) to increase the strength of the extended circular tube (1.2).

Images