Rudder body outer plate machining device of rudder ball structure

Abstract

According to the rudder body outer plate machining device of the rudder ball structure, a rudder body outer plate is machined and pressed through an upper rudder body mold and a lower rudder body mold, the upper rudder body mold comprises an upper fixing plate and a linear web plate, the upper fixing plate is used for being connected with a pressure applying mechanism of an oil press, and the upper fixing plate is a rectangular plate; the side, connected with the fixed upper plate, of the linear web plate is a plane, and the side face, facing the rudder body lower mold, of the other side of the linear web plate is a curved surface with a radian; the rudder body lower die comprises a box body with an opening in the top face and composed of a bottom plate, two sealing plates and two longitudinal side plates, the left end and the right end of the bottom plate are perpendicularly connected with the sealing plates respectively, the front side and the rear side of the bottom plate are perpendicularly connected with the longitudinal side plates respectively, and the sealing plates and the longitudinal side plates are the same in height. And a waist-drum-shaped groove is formed in the top surface of the opening of the box body of the rudder body lower mold through a bidirectional panel. According to the utility model, a block pressing process is combined with a high-strength mold for forming, so that the crack resistance and the fatigue resistance of the rudder body are effectively enhanced.

Description

Technical Field

[0001] This utility model relates to the field of shipbuilding technology, and in particular to a rudder body 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 machining device for the outer plate of the rudder ball structure to overcome the shortcomings of the existing technology. Utility Model Content

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

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

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

[0010] The outer plate of the rudder body is processed and pressed using an upper rudder body mold and a lower rudder body mold. Both the upper rudder body mold and the lower rudder body mold 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 rudder body mold, and the lower rudder body mold is mounted on the stamping table. The upper rudder body mold and the lower rudder body mold are matched vertically.

[0011] The upper mold of the rudder includes a fixed upper plate and a linear web plate. The fixed upper plate is used to connect with the pressure application mechanism of the hydraulic press. The fixed upper plate is a rectangular plate with a linear web plate vertically arranged on its transverse central axis. The side of the linear web plate connected to the fixed upper plate is a plane, and the other side facing the lower mold of the rudder is a curved surface with an arc.

[0012] The rudder lower mold includes a box with an open top surface, consisting of a base plate, two sealing plates, and two longitudinal side plates. The left and right ends of the base plate are vertically connected to the sealing plates, and the front and rear sides of the base plate are vertically connected to the longitudinal side plates. The sealing plates and the longitudinal side plates are at the same height. The top surface of the box opening of the rudder lower mold is provided with a waist-drum shaped groove through a two-way panel.

[0013] Furthermore, a two-way panel is provided above each longitudinal side panel, and the front and rear two-way panels are symmetrically arranged on the opening surface of the box. The two ends of the two-way panels are respectively set on the left and right sealing plates; the opposite side of the two two-way panels is set as a concave arc surface to form a waist drum-shaped groove.

[0014] Furthermore, the width of the bidirectional panel is no more than 1 / 3 of the width of the sealing plate, thereby forming a drum-shaped through hole between the two bidirectional panels, which facilitates the pressing of the curve of the outer plate of the rudder body.

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

[0016] This utility model provides a machining device for the outer plate of a rudder ball structure. Through an innovative mold structure, it systematically solves the pain points of traditional technologies, providing a highly efficient, low-cost, and highly reliable rudder ball structure machining 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 anti-crack and anti-fatigue performance of the rudder structure, and ensures the safety of the ship 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 outer plate of the rudder 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 (such as R6000mm arc upper mold and hyperboloid arch lower mold) ensure the accurate forming of complex curved surfaces of the rudder body, 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 structure of the upper mold of the rudder body of this utility model.

[0022] Figure 2 This is a front view of the upper mold of the rudder body of this utility model.

[0023] Figure 3 This is a top view of the upper mold of the rudder body of this utility model.

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

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

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

[0029] in:

[0030] upper mold of the rudder body 1, fixed upper plate 1.1, linear web plate 1.2, lower mold of the rudder body 2, bottom plate 2.1, sealing plate 2.2, longitudinal side plate 2.3, two-way panel 2.4. 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 structure of this utility model is a rudder body outer plate processing device used to manufacture the rudder ball structure. First, the rudder ball structure is divided into a rudder body and a 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 a rudder body and a 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 outer plate of the rudder is processed and pressed using an upper rudder mold 1 and a lower rudder mold 2. Both the upper rudder mold 1 and the lower rudder 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 rudder mold 1, and the lower rudder mold 2 is mounted on the stamping table. The upper rudder mold 1 and the lower rudder mold 2 are matched vertically.

[0034] The upper mold 1 of the rudder body includes a fixed upper plate 1.1 and a linear web plate 1.2. The fixed upper plate 1.1 is used to connect with the pressure application mechanism of the hydraulic press. The fixed upper plate 1.1 is a rectangular plate, and a linear web plate 1.2 is vertically arranged on its transverse central axis. The side of the linear web plate 1.2 that connects to the fixed upper plate 1.1 is a plane, and the other side facing the lower mold 2 of the rudder body is a curved surface with an arc.

[0035] The rudder lower mold 2 includes a box with an open top surface, consisting of a base plate 2.1, two sealing plates 2.2, and two longitudinal side plates 2.3. The left and right ends of the base plate 2.1 are vertically connected to the sealing plates 2.2, and the front and rear sides of the base plate 2.1 are vertically connected to the longitudinal side plates 2.3. The sealing plates 2.2 and the longitudinal side plates 2.3 are at the same height. A two-way panel 2.4 is provided above each longitudinal side plate 2.3. The front and rear two-way panels 2.4 are symmetrically arranged on the opening surface of the box. The two ends of the two-way panels 2.4 are respectively provided on the left and right sealing plates 2.2.

[0036] One side of each of the two bidirectional panels 2.4 is set as a concave arc surface. The width of the bidirectional panel 2.4 is no more than 1 / 3 of the width of the sealing plate 2.2. Thus, a waist-drum shaped through hole is formed between the two bidirectional panels 2.4, which facilitates the pressing of the curve of the outer plate of the rudder body.

[0037] See Figures 1-8 This embodiment relates to a machining process for a rudder ball structure, and a rudder outer 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 plate of the rudder body, see [reference]. Figure 8 Explanation of the outer plate division of the rudder body:

[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, also known as the end plate of the rudder ball spherical structure, is generally hemispherical. Rudder ball cover plate division description:

[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] S3.1, Cold working of the rudder body;

[0057] S3.11, 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] S3.12. Draw the center line on the board and divide it into two equal parts in the first and last directions;

[0062] S3.13. Find the corresponding wooden template based on the sample box's lines;

[0063] S3.14, 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] S3.15. 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] S3.16 After each stage of processing, use a wooden template to replicate the sample, mark any 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] S3.17 After the first batch of processing line work is completed, lift out the mold and use the sample box to make a replica. During the replica 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] S3.18 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] S3.19. 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] S3.110. 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] S3.2 Cold working of the rudder ball cover;

[0076] S3.21. 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] S3.22, 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] S3.23 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] S3.24. 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] S3.25. 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 tactile inspection", and deviations are corrected by sample box replication to ensure smooth transition of curved surfaces.

[0085] S3.26 After the rudder ball cover plate is processed, draw the allowance line according to the sample box size and mark the quality mark;

[0086] S3.27. 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] S3.28. 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] S4.1 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] S4.2 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] S4.3 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] S4.4 Then, surface polishing, repair, and rust prevention treatment are carried out;

[0093] S4.5 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 processing device for the outer plate of a rudder ball structure, which has the following technical content:

[0099] The upper mold of the outer plate of the rudder body adopts an R6000mm arc structure to precisely match the hyperbolic curve of the upper part of the rudder body;

[0100] The lower mold of the outer plate of the rudder body is designed as a composite structure with a double-curved surface and an arch height of 20mm on both the upper and lower sides, which is suitable for the complex curved surface of the lower part of the rudder body.

[0101] 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 processing device for the outer plate of a rudder ball structure, characterized in that: The rudder ball structure is divided into the rudder body and the rudder ball cover plate. The rudder ball cover plate is the end plate of the rudder ball structure. A dividing line is drawn between the rudder body and the rudder ball cover plate. Multiple evenly distributed dividing lines parallel to this dividing line are set on the rudder body. Multiple dividing lines are evenly divided laterally on the rudder ball structure, dividing the rudder body into multiple outer plates of the rudder body. The outer plate of the rudder body is processed and pressed using an upper rudder body mold (1) and a lower rudder body mold (2). Both the upper rudder body mold (1) and the lower rudder body 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 rudder body mold (1). The lower rudder body mold (2) is mounted on the stamping table. The upper rudder body mold (1) and the lower rudder body mold (2) are matched vertically. The upper mold (1) of the rudder body includes a fixed upper plate (1.1) and a linear web plate (1.2). The fixed upper plate (1.1) is used to connect with the pressure application mechanism of the hydraulic press. The fixed upper plate (1.1) is a rectangular plate with a linear web plate (1.2) vertically arranged on its transverse central axis. The side of the linear web plate (1.2) connected to the fixed upper plate (1.1) is a plane, and the other side facing the lower mold (2) of the rudder body is a curved surface with an arc. The rudder lower mold (2) includes a box with an open top surface, consisting of a base plate (2.1), two sealing plates (2.2) and two longitudinal side plates (2.3). The left and right ends of the base plate (2.1) are vertically connected to the sealing plates (2.2), and the front and rear sides of the base plate (2.1) are vertically connected to the longitudinal side plates (2.3). The sealing plates (2.2) and the longitudinal side plates (2.3) have the same height. The top surface of the box opening of the rudder lower mold (2) is provided with a waist-drum shaped groove through a two-way panel (2.4).

2. The rudder body outer plate processing device according to claim 1, characterized in that: A two-way panel (2.4) is provided above each longitudinal side plate (2.3). The two two-way panels (2.4) are symmetrically arranged on the opening surface of the box body. The two ends of the two-way panels (2.4) are respectively set on the left and right sealing plates (2.2). The opposite side of the two two-way panels (2.4) is set as a concave arc surface to form a waist drum-shaped groove.

3. The rudder body outer plate processing device according to claim 2, characterized in that: The width of the bidirectional panel (2.4) is no more than 1 / 3 of the width of the sealing plate (2.2), thereby forming a waist-drum shaped through hole between the two bidirectional panels (2.4), which facilitates the pressing of the curve of the outer plate of the rudder body.

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