Method for manufacturing aluminum alloy stop valve, and aluminum alloy stop valve

Abstract

A method for manufacturing an aluminum alloy stop valve, the method comprising the following steps: (1) aluminum alloy material selection and smelting; (2) casting, involving: casting an aluminum alloy melt into an aluminum alloy rod; (3) a homogenization treatment of the aluminum alloy rod, involving: placing the aluminum alloy rod obtained by cooling in step (2) into a homogenizing furnace for the homogenization treatment; (4) special-shaped extrusion molding, involving: cutting the aluminum alloy rod, which underwent the homogenization treatment in step (3), into a short rod, and subjecting the short rod to special-shaped extrusion to form a section product having a cross-shaped longitudinal section; (5) strengthening by means of a heat treatment; (6) cutting into blanks, involving: cutting a long-section valve seat aluminum alloy profile blank, which has been strengthened by means of the heat treatment, into a plurality of aluminum alloy stop valve blanks; and (7) lathing same into aluminum alloy stop valves.

Description

Manufacturing method of aluminum alloy stop valve and aluminum alloy stop valve

[0001] Related applications

[0002] The present application claims priority to Chinese Patent Applications No. 202411389529.7, entitled "Manufacturing method of aluminum alloy stop valve and aluminum alloy stop valve" and filed on September 30, 2024, and No. 202421545152.5, entitled "Aluminum alloy stop valve" and filed on July 2, 2024, the contents of which are incorporated herein by reference in their entirety. TECHNICAL FIELD

[0003] The present application belongs to the technical field of stop valves, and specifically relates to a manufacturing method of an aluminum alloy stop valve and an aluminum alloy stop valve. BACKGROUND

[0004] Currently, the stop valves in the related art are all made of brass, and a few are made of aluminum alloy. Moreover, the production process of the existing aluminum stop valve seat is all referred to the production process of the copper stop valve: aluminum alloy smelting-casting aluminum bar-casting bar homogenization-extruding round bar-blanking-rolling graphite-heating-forging- trimming- shot blasting-heat treatment strengthening-machining forming. The manufacturing of the copper material stop valve in the related art mainly depends on the forging process. This process applies pressure to the copper material by a forging press to cause plastic deformation, so as to obtain the required shape and size. This complex process usually includes separate cutting of the blank, stamping pretreatment, and subsequent machining. When this process is applied to the production of the aluminum alloy stop valve, due to the characteristics of the aluminum material, such as narrow forging temperature range, easy sticking to the mold, and poor flowability, there are problems such as large deformation rate of the aluminum alloy valve body, difficulty in forming the flange end, many defects such as peeling, and high rejection rate in the forging process. Moreover, it is difficult to forge the aluminum stop valve by using the crank press with the half die. SUMMARY

[0005] According to various embodiments of the present application, a manufacturing method of an aluminum alloy stop valve and an aluminum alloy stop valve are provided.

[0006] A manufacturing method of an aluminum alloy stop valve, specifically comprising the following steps:

[0007] (1) Selecting and smelting aluminum alloy;

[0008] (2) Casting: casting the aluminum alloy melt into an aluminum alloy bar;

[0009] (3) Homogenizing treatment of the aluminum alloy bar: placing the aluminum alloy bar cooled in step (2) into a homogenizing furnace for homogenizing treatment;

[0010] (4) Special-shaped extrusion forming: the aluminum alloy rod after homogenization treatment in (3) is cut into short rods, the short rods are heated to 450-550℃, and the extrusion profile is formed by using a 2000T and above positive extrusion machine, and the extrusion die temperature is controlled at 400-500℃;

[0011] (5) Heat treatment strengthening: after the extruded profile is water-cooled to room temperature within a certain time, after a certain time, the profile is heated to a temperature within a certain time and kept for several hours, then heated to a temperature within a certain time and kept for several hours, and finally air-cooled after leaving the furnace, a long-section valve seat aluminum alloy profile blank with a cross-shaped longitudinal section is obtained, the height of the long-section valve seat aluminum alloy profile blank in the vertical direction is not less than the maximum height of the stop valve in the vertical direction, and the width of the long-section valve seat aluminum alloy profile blank is not less than the width of the stop valve, the height is the height of the longitudinal section of the long-section valve seat aluminum alloy profile blank, and the width is the width of the longitudinal section of the long-section valve seat aluminum alloy profile blank;

[0012] (6) Cutting and blanking: the long-section valve seat aluminum alloy profile blank after heat treatment strengthening is cut into a plurality of aluminum alloy stop valve blanks according to the width value of the stop valve;

[0013] (7) Turning into an aluminum alloy stop valve.

[0014] The details of one or more embodiments of the application are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the application will be apparent from the description, drawings, and claims. BRIEF DESCRIPTION OF DRAWINGS

[0015] To better describe and illustrate the embodiments and / or examples of the inventions disclosed herein, reference can be made to one or more drawings. Additional details or examples used to describe the drawings should not be considered limiting to the scope of any of the disclosed inventions, the presently described embodiments and / or examples, and the best mode presently contemplated of these inventions.

[0016] FIG. 1 is a structure schematic diagram of an aluminum alloy stop valve profile blank of an aluminum alloy stop valve according to an embodiment of the application.

[0017] FIG. 2 is a structure size marked diagram of an aluminum alloy stop valve profile blank of an aluminum alloy stop valve according to an embodiment of the application.

[0018] FIG. 3 is a structure schematic diagram of an aluminum alloy stop valve according to an embodiment of the application.

[0019] FIG. 4 is a top view of an aluminum alloy stop valve according to an embodiment of the application.

[0020] FIG. 5 is a structure schematic diagram of an aluminum alloy stop valve profile blank of an aluminum alloy stop valve according to an embodiment of the application.

[0021] Figure 6 is a structural dimension marking diagram of an aluminum alloy stop valve profile blank of an aluminum alloy stop valve according to an embodiment of the present application.

[0022] Figure 7 is a structural schematic diagram of an aluminum alloy stop valve according to an embodiment of the present application.

[0023] Figure 8 is a side schematic diagram of an aluminum alloy stop valve according to an embodiment of the present application.

[0024] Figure 9 is a sectional view of Figure 8 along line A-A.

[0025] Figure 10 is a sectional view of Figure 8 along line B-B.

[0026] Figure 11 is a top view of an aluminum alloy stop valve according to an embodiment of the present application.

[0027] Figure 12 is a top view of a valve body of an aluminum alloy stop valve according to an embodiment of the present application.

[0028] Figure 13 is a structural schematic diagram of a flange of an aluminum alloy stop valve according to an embodiment of the present application.

[0029] Figure 14 is a top view of a flange of an aluminum alloy stop valve according to an embodiment of the present application.

[0030] Figure 15 is a longitudinal sectional view of a flange of an aluminum alloy stop valve according to an embodiment of the present application.

[0031] Figure 16 is a structural schematic diagram of another embodiment of an aluminum alloy stop valve according to the present application.

[0032] Figure 17 is a structural schematic diagram of a flange of Figure 16.

[0033] In the figures, 51 is a flange forming portion, 52 is a first forming portion, 53 is a second forming portion of a valve body, 531 is a vertical main body portion, 532 is a circular arc-shaped outer protruding portion, 533 is a rectangular outer protruding portion, 40 is a valve body forming portion, 41 is a reinforcing portion forming portion, 42 is a valve body forming portion, 43 is a first connecting pipe forming portion, 44 is a second connecting pipe forming portion, 45 is a third connecting pipe forming portion, 46 is a third body forming portion, 10 is a valve body, 11 is a valve body, 111 is a valve cavity, 112 is a valve port, 11a is a cap mounting position, 12 is a reinforcing portion, 121 is a first body portion, 122 is a second body portion, 123 is a third body portion, 124 is an extension portion, 13 is a valve pipe, 131 is a first connecting pipe, 132 is a second connecting pipe, 132a is a joint mounting position, 133 is a third connecting pipe, 14 is a mounting portion, 20 is a flange, 23 is a flange mounting hole, 20a is an inner corner, 14a is an upper end, 21 is a first body, 22 is a second body, 231 is a first half hole, and 232 is a second half hole. DETAILED DESCRIPTION

[0034] In order to make the above objectives, features and advantages of the present application more clear and comprehensible, the detailed description of the specific embodiments of the present application is made below in conjunction with the accompanying drawings. In the following description, a lot of specific details are set forth in order to provide a thorough understanding of the present application. However, the present application can be implemented in many different ways other than the one described herein, and one of ordinary skill in the art can make similar improvements without departing from the scope of the present application, and therefore the present application is not limited to the specific embodiments disclosed below.

[0035] It is noted that when a component is referred to as being "on" or "disposed on" another component, it can be directly on the other component or there can be intervening components present. When a component is referred to as being "connected" to another component, it can be directly connected to the other component or there can be intervening components present. The terms "vertical", "horizontal", "upper", "lower", "left", "right", and similar terms as used in the description of the specification are for the purpose of illustration only and do not indicate an exclusive embodiment.

[0036] In addition, the terms "first", "second", and the like, are used merely to describe the features and do not imply or suggest relative importance or a number of the features indicated. Thus, the features defined with "first", "second" can include at least one of the features explicitly or implicitly. In the description of the present application, the meaning of "a plurality of" is at least two, such as two, three, etc., unless otherwise explicitly specified and limited.

[0037] In the present application, unless otherwise explicitly specified and limited, the "on", "under", "above" and "over" of the first feature to the second feature can be that the first feature is in direct contact with the second feature, or the first feature is indirectly in contact with the second feature through an intermediate medium. Moreover, the "on", "above" and "over" of the first feature to the second feature can be that the first feature is directly above or obliquely above the second feature, or only indicates that the horizontal height of the first feature is higher than that of the second feature. The "under", "below" and "under" of the first feature to the second feature can be that the first feature is directly below or obliquely below the second feature, or only indicates that the horizontal height of the first feature is less than that of the second feature.

[0038] Unless otherwise defined, all technical and scientific terms used in the specification of the present application have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs. The terms used in the specification of the present application are only for the purpose of describing the specific embodiments and are not intended to limit the present application. The term "and / or" used in the specification of the present application includes any and all combinations of one or more of the related listed items.

[0039] The present application provides a manufacturing method of an aluminum alloy stop valve, and an aluminum alloy stop valve manufactured by the method.

[0040] A method for manufacturing an aluminum alloy stop valve, specifically comprising the following steps:

[0041] (1) Selecting and melting an aluminum alloy;

[0042] (2) Casting: casting the aluminum alloy melt into an aluminum alloy rod;

[0043] (3) Homogenizing the aluminum alloy rod: placing the cooled aluminum alloy rod obtained in step (2) into a homogenizing furnace for homogenization treatment; the 6061 aluminum alloy is heated from room temperature to 520-540℃ within 3h, kept for 12h, then cooled to 300℃ in the furnace, and then air-cooled to room temperature;

[0044] (4) Profile extrusion: cutting the aluminum alloy rod after homogenization in (3) into short rods, heating the short rods to 450-550℃, and using a 2000T or above direct extruder to extrude the profile, with the extrusion die temperature controlled at 400-500℃; the extrusion parameters used in this step are the same for different aluminum alloy materials;

[0045] (5) Heat treatment strengthening: after the extruded profile is water-cooled to room temperature within 20s, it is heated to 180℃ within 30min and kept for 2h within 12h, then heated to 220℃ within 10min and kept for 2h, air-cooled after being taken out of the furnace, to obtain a long-section valve seat aluminum alloy profile blank with a cross-shaped longitudinal section, the height h of the long-section valve seat aluminum alloy profile blank in the height direction Z is not less than the maximum height of the stop valve in the height direction Z, and the width g of the long-section valve seat aluminum alloy profile blank is not less than the width of the stop valve, the height h is the height of the longitudinal section of the long-section valve seat aluminum alloy profile blank, and the width g is the width of the longitudinal section of the long-section valve seat aluminum alloy profile blank;

[0046] (6) Cutting and blanking: cutting the long-section valve seat aluminum alloy profile blank after heat treatment strengthening into multiple aluminum alloy stop valve blanks according to the width value of the stop valve, when the stop valve is a valve body and flange integrated stop valve, the width is the width m in the direction of the center axis of the valve nozzle, and when the stop valve is a valve body and flange split structure, the width is the width n perpendicular to the center axis of the valve nozzle and the center axis of the valve core, i.e. the width L4 of the mounting part;

[0047] (7) Turning into an aluminum alloy stop valve.

[0048] In step (1), the selected aluminum alloy is a heat-treatable aluminum alloy, which can be a 2-series, 6-series or 7-series aluminum alloy, and the temperature and time parameters during melting are determined according to the selected aluminum alloy model.

[0049] In step (2), the temperature of the melt required for casting the aluminum alloy melt into an aluminum rod is determined according to the selected aluminum alloy model.

[0050] In order to ensure the structure and performance of the profile, the cast bar needs to be subjected to homogenization annealing. In step (3), different homogenization process conditions are also adopted according to the selected aluminum alloy type, for example, when 6061 aluminum alloy is selected, the aluminum alloy bar is first raised from room temperature to 520-540 DEG C within 3h, and then cooled to 300 DEG C in the furnace, and then air-cooled to room temperature.

[0051] It can be understood that, by adopting the press forming process, the forging step in the related method is directly omitted, thereby avoiding the technical problems of large deformation rate of the forged aluminum stop valve, difficulty in forming the end of the flange, many defects such as peeling, and high rejection rate, greatly reducing the rejection rate, and realizing a simplified production process.

[0052] By adopting the manufacturing method, the aluminum alloy raw material manufacturer can uniformly extrude the stop valve profile blank into the required shape in advance, and then uniformly heat treat the extruded profile blank. For the stop valve manufacturer, only the blanking and machining processes need to be completed. On the one hand, compared with the previous heat treatment of the blank, heat treatment space can be saved, and transportation is more convenient. On the other hand, compared with the related process flow, 5 processes can be saved, equipment, site, and labor input can be reduced, production cost can be reduced, and production efficiency can be improved.

[0053] In an embodiment, with reference to FIGS. 1-6, the stop valve manufactured according to the above method is an integrated aluminum alloy stop valve with the valve body and the flange integrally arranged. Specifically, the aluminum alloy stop valve includes a valve body 10, the valve body 10 including a valve pipe 11, a reinforcing portion 12, a valve pipe 13, and a flange 20. The valve pipe 11 is provided with a valve cavity 111 and a valve port 112, the valve pipe 13 is connected to the valve pipe 11, the reinforcing portion 12 is arranged on the valve pipe 11 and corresponds to the position of the valve port 112. The reinforcing portion 12 extends to the valve pipe 13 and protrudes from the outer wall of the valve pipe 11, and the reinforcing portion 12 is connected to the valve pipe 13. The reinforcing portion 12 and the valve pipe 11 covered by the reinforcing portion 12 have a cuboid shape.

[0054] With reference to FIG. 3, the valve pipe 13 includes a first connecting pipe 131, a second connecting pipe 132, and a third connecting pipe 133. The first connecting pipe 131 is coaxially arranged with the valve pipe 11. The second connecting pipe 132 and the third connecting pipe 133 are both perpendicular to the valve pipe, and the third connecting pipe 133 is coaxially arranged with the second connecting pipe 132. The second connecting pipe 132 is provided with a joint mounting position 132a. When mounted, the joint nut is connected to the joint mounting position 132a. The axis of the valve port is coaxially arranged with the valve pipe 11. The axis of the second connecting pipe 132 is intersectingly arranged with the axis of the valve port 112.

[0055] The reinforcing part 12 comprises a first part body 121 and a second part body 122. The first part body 121 extends from the valve body 11 to the first connecting pipe 131 and is connected with the first connecting pipe 131. The second part body 122 extends from the valve body 11 to the second connecting pipe 132 and is connected with the second connecting pipe 132. In some embodiments, the first connecting pipe 131 is coaxially arranged with the valve body 11, and the second connecting pipe 132 is arranged perpendicularly to the valve body.

[0056] Further, the cross section of the first part body 121 is rectangular. Of course, in other embodiments, the cross section of the first part body 121 can also be arranged in other shapes, which can be selected according to actual needs.

[0057] Further, the cross section of the second part body 122 is rectangular. Of course, in other embodiments, the cross section of the first part body 121 can also be arranged in other shapes, which can be selected according to actual needs.

[0058] Specifically, the second connecting pipe 132 is provided with a joint mounting position 132a, and the joint nut is connected with the joint mounting position 132a during installation. The axis of the valve port 112 is coaxially arranged with the valve body 11, and the axis of the second connecting pipe 132 is arranged intersecting with the axis of the valve port 112.

[0059] The top of the valve pipe 11 is provided with a cap mounting position 11a, and the cap is connected with the cap mounting position 11a during installation. The top of the reinforcing part 12 is provided with an extension part 124, which extends from the reinforcing part 12 to the direction of the cap mounting position 11a. The cross section of the extension part 124 is rectangular. Of course, in other embodiments, the cross section of the first part body 121 can also be arranged in other shapes, which can be selected according to actual needs.

[0060] The flange 20 is arranged below the lower end surface of the reinforcing part 12, and the flange 20 is an integral structure with the valve body 10, and the length direction of the flange 20 extends along the X-axis direction.

[0061] In this embodiment, referring to FIG. 1 and FIG. 5, when the aluminum alloy stop valve is manufactured by the method of this embodiment, the longitudinal section of the aluminum alloy stop valve blank obtained in step (6) is in a cross shape, comprising a flange forming part 51 and a valve body forming part 40, the flange forming part 51 is the horizontal part in the cross shape, the valve body forming part 40 is the vertical part in the cross shape, and the relative position of the flange forming part 51 and the valve body forming part 40 height direction center point is determined according to the structure of the aluminum alloy stop valve manufactured, and in this embodiment, the flange forming part 51 is located in the middle and lower part of the valve body forming part 40.

[0062] Specifically, the valve body forming part 40 includes a valve body first forming part 52 located below the flange forming part 51 and a valve body second forming part 53 located above the flange forming part 51, the valve body first forming part 52 is used for forming the first connecting pipe 131 opposite to the valve pipe, and the valve body second forming part 53 is used for forming the valve pipe 13, the second connecting pipe 132 and the third connecting pipe 133 located on both sides of the valve pipe 13, and the reinforcing part 12.

[0063] In the embodiment, the valve body first forming part 52 is in the shape of a cuboid, and of course, in other embodiments, the valve body first forming part 52 can also be in other shapes as long as it meets the forming size requirements of the first connecting pipe 131.

[0064] It can be understood that the outer periphery of the aluminum alloy stop valve blank with such a shape structure is a regular plane or a circular arc surface, has good machining positioning capability, is convenient for machining clamp design, can achieve very high machining precision, and ensures good sealing performance.

[0065] In the embodiment, the valve body second forming part 53 includes a vertical main body part 531, two circular-arc-shaped outer protrusions 532 and two rectangular outer protrusions 533 are mirror-symmetrically arranged along the height direction Z on both sides of the vertical main body part 531 in the width direction of the vertical main body part 531, the two circular-arc-shaped outer protrusions 532 are arranged in a spaced manner with the flange plate, the center of the circle of the upper circular arc of the two circular-arc-shaped outer protrusions 532 is the center point of the valve body forming part in the height direction, and is located on the center axis of the second connecting pipe 132 and the third connecting pipe 133, the diameter of the circular-arc-shaped outer protrusion 532 is not less than the diameter of the outer thread on the second connecting pipe 132, and the circular-arc-shaped outer protrusion 532 forms a second extending part 122 after machining; the two rectangular outer protrusions 533 are located on the upper part of the vertical main body part 531, the upper end surface of the rectangular outer protrusion 533 is located in the same plane with the upper end surface of the vertical main body part 531, and the rectangular outer protrusion 533 is used for cap thread forming machining.

[0066] It can be understood that the shape of the aluminum alloy stop valve is set to a special-shaped structure, the position of the circular-arc-shaped outer protrusion 532 is set to facilitate determination of the machining position of the second connecting pipe 132 and the third connecting pipe 133 during machining, the rectangular outer protrusion 533 is set to facilitate determination of the machining height of the cap mounting position 11a during machining, and the machining precision of the stop valve is improved.

[0067] Specifically, referring to FIG. 2, the perpendicular distance between the center point of the valve body forming portion 40 in the height direction Z and the bottom end surface of the flange forming portion 51 is defined as the center height A, the perpendicular distance between the center point of the valve body forming portion 40 in the height direction and the upper end surface thereof is defined as the total height B, the width of the vertical main body portion 531 is defined as the neck length D, the sum of the widths of the vertical main body portion 531 and the two rectangular outer protrusions 533 is defined as the threaded fitting portion width C, the radius of the circular-arc-shaped outer protrusion 532 is defined as the joint nut outer diameter E, the perpendicular distance between the lower end surface of the flange forming portion 51 and the lower end surface of the valve body forming portion 40 is defined as the boss height F, and the thickness of the flange forming portion 51 is G.

[0068] The size of the center height A must ensure that the joint nut can be assembled, the size of the total height B must ensure the requirements of the valve core installation, the size of the threaded fitting portion width C must meet the size requirements required for the cap threading, the size of the neck length D must meet the size requirements required for the cap torque strength, the size of the joint nut outer diameter E must meet the size requirements required for the joint threading, the size of the boss height F must meet the size requirements required for ensuring the valve body strength after welding, and the size of the flange thickness G must meet the size requirements required for ensuring the flange strength. The sizes of the above-mentioned dimensions are determined according to the size of the nominal diameter, and according to the different size ranges of the nominal diameter, the sizes of the above-mentioned dimensions must meet the size ranges shown in Table 1.

[0069] Table 1

[0070] It can be understood that the setting of the above-mentioned structural dimensions requires that, under the premise of ensuring the structural machining precision and structural strength of the stop valve, the subsequent machining amount is maximally reduced.

[0071] In another embodiment, referring to FIGS. 7-17, a stop valve manufactured according to the above-mentioned method is a combined aluminum alloy stop valve with the valve body and the flange being separately arranged, specifically, the aluminum alloy stop valve comprises a valve body 10, the valve body 10 comprising a valve body 11, a reinforcing portion 12 and a valve pipe 13. The valve body 11 is internally provided with a valve cavity 111 and a valve port 112. The valve pipe 13 is connected to the valve body 11. The reinforcing portion 12 is arranged on the valve body 11 and corresponds to the position of the valve port 112. The reinforcing portion 12 extends to the valve pipe 13 and protrudes outside the valve body 11, and the reinforcing portion 12 is connected to the valve pipe 13.

[0072] It can be understood that, in the installation process of the aluminum alloy stop valve, the valve pipe 13 needs to be inserted into the joint nut and the joint nut is tightened by applying torque to it with a wrench, so that the valve pipe 13 and the joint nut are in hard sealing fit. The top of the valve body needs to be connected with a cap, and the cap is tightened by applying torque to it with a wrench. During the tightening of the joint nut, the joint nut applies a force to the valve pipe 13, so that the valve pipe 13 will apply a force in the X-axis direction to the reinforcing part 12 and the valve body 11. During the tightening of the cap, the cap will apply a force in the Y-axis direction to the valve body. Due to the increase in the cross-sectional area of the valve body 11 caused by the arrangement of the reinforcing part 12, the valve body 11 can withstand the forces in both directions, thereby preventing plastic deformation, valve core and valve port 112 sealing failure or valve body 11 cracking, effectively improving the sealing effect and service life of the aluminum alloy stop valve.

[0073] The reinforcing part 12 covers the outside of the valve body 11, and the reinforcing part 12 and the valve body 11 covered thereby are in the shape of a cuboid.

[0074] It can be understood that the above-mentioned cuboid shape refers to the reinforcing part 12 and the part of the valve body covered thereby being in the shape of a cuboid, and the corners and edges of the cuboid can also be chamfered without affecting the expression of the rectangular shape. Since the valve body 10 of the aluminum alloy stop valve is obtained by extruding a profile and then machining, the shape of a cuboid is easier to process, effectively reducing the processing procedures, facilitating intensive production and saving costs.

[0075] In this embodiment, referring to FIG. 9, the diameter of the valve body 11 is set as Φ1, and the diameter of the valve pipe 13 is set as Φ2; the width of the reinforcing part 12 is set as D1, and D1, Φ1 and Φ2 satisfy the relationship: D1>Φ1, D1>Φ2. That is, the reinforcing part 12 can completely cover the width of the valve body 11 and the width of the connection of the valve pipe 13, ensuring the strength of the connection of the valve pipe 13 and the valve body 11 and reducing the possibility of deformation at this position.

[0076] Further, the height of the reinforcing part 12 is set as H, and H and Φ2 satisfy the relationship: H>Φ2. That is, the height and width of the reinforcing part 12 will completely cover the valve pipe 13, ensuring the strength of the connection of the valve pipe 13 and the valve body 11 and reducing the possibility of deformation at this position.

[0077] The valve body 11, the reinforcing part 12 and the valve pipe 13 are in an integrated structure, which means that they are obtained by machining such as turning and cutting at one time. The valve cavity 111 penetrates the valve body 11 in the height direction Z of the valve body 11, the valve pipe 13 is a hollow structure and communicates with the valve cavity 111, and the valve port 112 is arranged at a position close to the connection of the valve pipe 13 and the valve cavity 111, which is the above-mentioned one-line sealing position.

[0078] Specifically, the valve pipe 13 comprises a first connecting pipe 131 and a second connecting pipe 132. The reinforcing part 12 comprises a first part body 121 and a second part body 122. The first part body 121 extends from the valve body 11 to the first connecting pipe 131 and is connected with the first connecting pipe 131. The second part body 122 extends from the valve body 11 to the second connecting pipe 132 and is connected with the second connecting pipe 132. In some embodiments, the first connecting pipe 131 is coaxially arranged with the valve body 11, and the second connecting pipe 132 is arranged perpendicularly to the valve pipe.

[0079] Further, the cross section of the first part body 121 is in a rectangular shape. Of course, in other embodiments, the cross section of the first part body 121 can also be in other shapes, which can be selected according to actual needs.

[0080] Further, the cross section of the second part body 122 is in a rectangular shape. Of course, in other embodiments, the cross section of the first part body 121 can also be in other shapes, which can be selected according to actual needs.

[0081] Specifically, the second connecting pipe 132 is provided with a joint mounting position 132a, and the joint nut is connected with the joint mounting position 132a during installation. The axis of the valve port 112 is coaxially arranged with the valve body 11, and the axis of the second connecting pipe 132 is arranged intersecting with the axis of the valve port 112.

[0082] In an embodiment, the valve pipe 13 further comprises a third connecting pipe 133, which is coaxially arranged with the second connecting pipe 132, and the first connecting pipe 131 is coaxially arranged with the valve pipe 13. The reinforcing part 12 further comprises a third part body 123, which extends from the valve body 11 to the third connecting pipe 133 and is connected with the third connecting pipe 133. Further, the cross section of the third part body 123 is in a rectangular shape. Of course, in other embodiments, the cross section of the first part body 121 can also be in other shapes, which can be selected according to actual needs.

[0083] Further, the top of the valve body 11 is provided with a cap mounting position 11a, and the cap is connected with the cap mounting position 11a during installation. The reinforcing part 12 is provided with an extension part 124, which extends from the reinforcing part 12 to the direction of the cap mounting position 11a, and the cross section of the extension part 124 is in a rectangular shape. Of course, in other embodiments, the cross section of the first part body 121 can also be in other shapes, which can be selected according to actual needs.

[0084] In the embodiment, referring to FIG. 13, the flange 20 is provided with a flange mounting hole 23 matched with the mounting part 14.

[0085] It can be understood that when the cap is installed on the top of the valve body 11, the torque exerted by the wrench on the cap will cause the flange 20 of the valve body 10 to be subjected to a shearing force. The presence of the flange mounting hole 23 enables the flange 20 to withstand a larger torsional force and is not prone to cracking. The mounting portion 14 can be provided on the valve body 11 or on the reinforcing portion 12, and the specific installation position can be selected according to actual use needs. In the embodiment, the mounting portion 14 is provided on the reinforcing portion 12, so that the force during installation of the flange 20 will not cause torsional deformation of the valve body 11, further improving the sealing effect and service life of the valve body 10. Specifically, referring to FIG. 7, the flange 20 is sleeved on the mounting portion 14. Specifically, the mounting portion 14 and the reinforcing portion 12 are an integral structure and are obtained by turning the reinforcing portion 12. The flange 20 and the mounting portion 14 can be fixedly connected by arc welding, gas welding, laser welding, etc., and in the embodiment, laser welding is adopted, which is firm. The welding position and the welding length are selected according to actual conditions, and are not limited herein.

[0086] Alternatively, referring to FIG. 16, the flange 20 is inserted into the mounting portion 14. Specifically, the mounting portion 14 is a ring groove provided on the reinforcing portion 12.

[0087] Referring to FIG. 17, the flange 20 includes a first body 21 and a second body 22, and the flange mounting hole 23 includes a first half hole 231 and a second half hole 232. The first half hole 231 is arranged on the first body 21, and the second half hole 232 is arranged on the second body 22. After the first body 21 and the second body 22 are inserted into the mounting portion 14, they are spliced to form a complete flange 20. The first body 21 and the second body 22 can be fixedly connected by arc welding, gas welding, laser welding, etc. Under this structure, the flange 20 also plays a role in increasing the thickness of the valve body 11, further improving the strength of the valve body 11, and ensuring that the valve body 11 can withstand a larger joint torque. In the embodiment, in order to ensure that the flange can be installed in the valve seat and meet the fitting gap requirement, a transition arc is arranged at four corners of the flange mounting hole, and the angle of the arc is greater than 90°. In some embodiments, the flange is a symmetrical double-hole structure. Of course, in other embodiments, the flange can also adopt various forms of mounting holes such as single-hole single-edge, double-hole single-edge, etc., and the specific form can be selected according to actual needs.

[0088] In some embodiments, the length of the flange mounting hole 23 is set as L1, and the length of the mounting portion 14 is set as L2, and L1 and L2 satisfy the relationship: 0.05mm≤L1-L2≤0.4mm. The value of L1-L2 can be 0.05mm, 0.1mm, 0.15mm, 0.2mm, 0.35mm, 0.4mm, etc.

[0089] Further, the length of the flange mounting hole 23 is set as L1, the length of the mounting portion 14 is set as L2, and B and b satisfy the relationship: 0.1≤L1-L2≤0.3mm. Furthermore, the flange mounting hole 23 and the mounting portion 14 have a certain gap in the width direction, which ensures that the flange 20 can be easily mounted on the mounting portion 14, and the gap is not too large, which ensures that the flange 20 has sufficient strength after welding. The value of L1-L2 can be 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, etc. Of course, the value of L1-L2 can also be selected according to the actual situation, which is not described here.

[0090] In some embodiments, the width of the flange mounting hole 23 is set as L3, the width of the mounting portion 14 is set as L4, and L3 and L4 satisfy the relationship: 0.05mm≤L3-L4≤0.4mm. The value of L3-L4 can be 0.05mm, 0.1mm, 0.15mm, 0.2mm, 0.35mm, 0.4mm, etc.

[0091] Further, the width of the flange mounting hole 23 is set as L3, the width of the mounting portion 14 is set as L4, and L3 and L4 satisfy the relationship: 0.1≤L3-L4≤0.3mm. Furthermore, the flange mounting hole 23 and the mounting portion 14 have a certain gap in the length direction, which ensures that the flange 20 can be easily mounted on the mounting portion 14, and the gap is not too large, which ensures that the flange 20 has sufficient strength after welding. The value of L3-L4 can be 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, etc. Of course, the value of L3-L4 can also be selected according to the actual situation, which is not described here.

[0092] In some embodiments, the thickness of the flange 20 is set as D3, and D3≥5mm. The value of D3 can be 5mm, 10mm, 15mm, 20mm, etc. Of course, the value of D3 can also be selected according to the actual situation, which is not described here.

[0093] Specifically, the shape of the flange mounting hole 23 can be set and is not limited to an ellipse, a rectangle, a square, in this embodiment, the flange mounting hole 23 is set as a rectangular shape, and in some embodiments, as a rectangle.

[0094] In some embodiments, the inner corner 20a of the flange mounting hole 23 is set as a chamfer structure. The chamfer structure means that the inner corner 20a is processed as a chamfer, and the angle of the chamfer can be selected according to actual needs, which is not limited here. Since the straight angle cannot be formed by profile extrusion, there will be a certain arc on the valve body 11, the reinforcing portion 12, and the mounting portion 14, so the inner corner 20a of the flange mounting hole 23 is set as a chamfer, which ensures that the flange 20 can be smoothly assembled with the valve body 10.

[0095] In some embodiments, the upper end 14a of the mounting portion 14 is also chamfered to facilitate the installation of the flange 20, and the angle of the chamfer can be selected according to actual needs, which is not limited herein.

[0096] In the present embodiment, referring to FIG. 5, when the combined aluminum alloy stop valve is manufactured by the method of the present embodiment, the longitudinal section of the aluminum alloy stop valve blank obtained in step (6) is in a cross shape, including a valve body forming portion 40, the valve body forming portion 40 including a reinforcing portion forming portion 41, a valve body forming portion 42 and a first connecting pipe forming portion 43 located at the upper and lower ends of the reinforcing portion forming portion 41, and a second connecting pipe forming portion 44 and a third connecting pipe forming portion 45 located at the left and right sides of the reinforcing portion forming portion 41.

[0097] It can be understood that when the valve body and the flange of the aluminum alloy stop valve are in a split structure, the aluminum alloy stop valve blank only needs to be extruded into a long cross structure, then the blank is cut according to the width of the valve body, and then the valve seat structure is machined and formed, and the flange plate is additionally arranged on the valve seat structure, so as to realize the effect of the related stop valve. Compared with the double cross structure (both the front view and the top view are in a cross shape) stop valve blank structure in the related art, the present application only maintains the cross structure in the front view, and the width of the blank is reduced to the actual width of the valve body when cutting, thereby significantly saving the use of materials.

[0098] Further, a first portion 121 is arranged on the lower part of the reinforcing portion forming portion 41, and a mounting portion 14 is arranged on the lower end surface of the first portion 121.

[0099] It can be understood that the first portion 121 and the mounting portion 14 are directly extruded on the aluminum alloy stop valve blank, which reduces the processing amount in the machining stage and improves the production efficiency.

[0100] Like the finished aluminum alloy stop valve, the upper end of the mounting portion 14 is chamfered at the connection with the first portion 121. Such a design further reduces the processing amount in the machining stage and improves the production efficiency.

[0101] Further, a third portion forming portion 46 is arranged on the upper part of the valve body forming portion 42 on the side close to the third connecting pipe 133 of the reinforcing portion forming portion 41, and the upper end surface of the third portion forming portion 46 is higher than the upper end surface of the third connecting pipe forming portion 45. It can be understood that when the special-shaped press forming is performed, the upper end of the third portion forming portion 46 and the upper end surface of the third connecting pipe forming portion 45 form a height difference, which facilitates accurate determination of the processing position of the third connecting pipe 133 in the machining stage, and improves the processing precision and processing efficiency of the stop valve.

[0102] In the embodiment, in order to facilitate the machining of the third part 123 and the accurate positioning machining of the extension part 124, the reinforcing part forming part 41 is connected to the upper end face of the valve body forming part 42 on the side close to the third connector 133 and the third connector forming part 45 through a downward inclined slope. Of course, in other embodiments, the reinforcing part forming part 41 and the third connector forming part 45 can be connected through other transition forms, which can be selected according to actual needs.

[0103] Further, the reinforcing part forming part 41 is in the same plane with the second connector forming part 44 on the upper end face of the valve body forming part 42 on the side close to the second connector 132. It can be understood that, since the second part 122 and the third part 123 and the extension part 124 are arranged in mirror image on both sides of the center axis of the valve body forming part 42, one side can be omitted in the case of setting the accurate positioning division line. Of course, in other embodiments, the upper end faces of the reinforcing part forming part 41 and the second connector forming part 44 can also be connected through an inclined surface or other forms, which can be selected according to actual needs.

[0104] In the embodiment, the first connector forming part 43 is below the mounting part 14, the length of the first connector forming part 43 is greater than the length of the mounting part 14, and the upper part of the width direction side of the first connector forming part 43 is connected to the lower end of the mounting part 14 through an inclined surface inclined from outside to inside. It can be understood that the length difference between the mounting part 14 and the first connector forming part 43 makes the division line between the mounting part 14 and the first connector forming part 43 prominent, facilitating the cutting and positioning machining of the first connector forming part 43, and on the other hand, ensuring that the welding position has sufficient wall thickness after machining.

[0105] In the embodiment, the extension part forming part 47 is arranged on the upper part of the reinforcing part forming part 41, the extension part forming part 47 is coaxially arranged below the valve body forming part 42, the length of the extension part forming part 47 is less than the width of the valve body forming part 42, and the lower part of the valve body forming part 42 is connected to the upper end of the extension part forming part 47 through an inclined surface inclined inward. The valve body forming part 42 is used for forming the valve pipe 13 and the cap mounting position 11a. It can be understood that, on the one hand, the length difference between the extension part forming part 47 and the valve body forming part 42 makes the division line between them prominent, facilitating quick and accurate positioning during machining and improving production efficiency, and on the other hand, meeting the size requirements of cap thread machining and cap torque strength.

[0106] Referring to Fig. 6, the vertical distance between the center point of the valve body forming portion 40 in the height direction and the bottom end surface of the third connecting pipe forming portion 45 is defined as the center height a, the vertical distance between the center point of the valve body forming portion 40 in the height direction and the upper end surface thereof is defined as the total height b, the length of the extension forming portion 47 is defined as the neck length d, the length of the valve body forming portion 40 is defined as the threaded fitting portion width c, the width of the third connecting pipe forming portion 45 is defined as e, and the height of the first connecting pipe forming portion 43 is defined as the boss height f. The center height a must be large enough to allow the joint nut to be assembled, the total height b must be large enough to meet the requirements of the valve core installation, the threaded fitting portion width c must meet the size requirements of the cap threading, the neck length d must meet the size requirements of the cap torque strength, the width e of the third connecting pipe forming portion 45 must meet the size requirements of the joint threading, and the boss height f must meet the size requirements of the post-welding valve body strength.

[0107] The size of each of the above dimensions is determined according to the size of the nominal diameter, and according to the different size ranges of the nominal diameter, the size of each of the above dimensions must meet the size range shown in Table 2.

[0108] Table 2

[0109] It can be understood that the setting of the above structural dimensions requires that, under the premise of ensuring the machining precision and structural strength of the stop valve, the subsequent machining amount is minimized.

[0110] Obviously, the above-described embodiments are only some of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work should fall within the scope of protection of the present application.

[0111] The technical features of the above-described embodiments can be combined in any manner. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described, and as long as the combinations of the technical features do not exist, they should be considered as falling within the scope of the present application.

[0112] The above-described embodiments only express several implementation manners of the present application, and the description is relatively specific and detailed, but it should not be understood as a limitation on the patent application scope. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which should fall within the scope of protection of the present application. Therefore, the patent protection scope of the present application should be subject to the appended claims.

Claims

1. A method of manufacturing an aluminum alloy stop valve, characterized by, Specifically comprising the following steps: (1) aluminum alloy selection smelting; (2) casting: casting the aluminum alloy melt into an aluminum alloy rod; (3) aluminum alloy rod homogenization treatment: placing the aluminum alloy rod obtained by cooling in step (2) into a homogenization furnace for homogenization treatment; (4) profile extrusion forming: cutting the aluminum alloy rod after homogenization treatment in (3) into a short rod, heating the short rod to 450-550℃, and using a 2000T and above positive extruder to extrude a profile, with the extrusion die temperature controlled at 400-500℃; (5) heat treatment strengthening: after the extruded profile is water-cooled to room temperature within a certain time, after a certain time, it is heated to a temperature within a certain time and kept for several hours, then heated to a temperature within a certain time and kept for several hours, and finally air-cooled after being taken out of the furnace, a long section valve seat aluminum alloy profile blank in the shape of a cross section is obtained, the height h of the long section valve seat aluminum alloy profile blank in the vertical direction is not less than the maximum height of the stop valve in the vertical direction, and the width g of the long section valve seat aluminum alloy profile blank is not less than the width of the stop valve, the height h is the height of the longitudinal section of the long section valve seat aluminum alloy profile blank, and the width g is the width of the longitudinal section of the long section valve seat aluminum alloy profile blank; (6) cutting and blanking: cutting the long section valve seat aluminum alloy profile blank after heat treatment strengthening into a plurality of aluminum alloy stop valve blanks according to the width value of the stop valve; (7) machining into an aluminum alloy stop valve.

2. The method of claim 1, wherein the aluminum alloy stop valve is manufactured by the steps of: In step (6), when the aluminum alloy stop valve is an aluminum alloy stop valve with a valve body and a flange integrated, the width g is the width m in the direction along the center axis of the stop valve nozzle mouth, and when the valve body and the flange of the aluminum alloy stop valve are in a split structure, the width g is the width n perpendicular to both the center axis of the nozzle mouth and the center axis of the valve core.

3. A method of manufacturing an aluminum alloy stop valve according to claim 2, wherein, The aluminum alloy stop valve blank includes a valve body and a flange, the valve body includes a valve body, a valve pipe, a reinforcing part, a first connecting pipe, a second connecting pipe and a third connecting pipe, the valve body and the flange are arranged in a split structure, a horizontal part in the aluminum alloy stop valve blank is a flange forming part, a vertical part in the aluminum alloy stop valve blank is a valve body forming part, and the width of the horizontal part is greater than the width of the vertical part; the valve body forming part includes a valve body first forming part below the flange forming part and a valve body second forming part above the flange forming part, the valve body first forming part is used for machining and forming the first connecting pipe below the flange, and the valve body second forming part is used for machining and forming the valve pipe, the second connecting pipe and the third connecting pipe on both sides of the valve pipe, and the reinforcing part above the flange; the shape of the valve body first forming part is a cuboid.

4. A method of manufacturing an aluminum alloy stop valve according to claim 3, wherein The second forming part of the valve body comprises a vertical main body part for forming the reinforcing part and the valve pipe, two circular-arc-shaped outer convex parts and two rectangular outer convex parts are symmetrically arranged along the vertical direction on both sides of the vertical main body part along the width direction of the vertical main body part, the two circular-arc-shaped outer convex parts are arranged at intervals from the flange, and the centers of the circles on which the circular arcs of the two circular-arc-shaped outer convex parts are located are the center points of the valve body forming part in the height direction and are located on the central axis of the valve pipe, and the diameter of the circular-arc-shaped outer convex part is not less than the diameter of the external thread on the left and right sides of the valve pipe; the two rectangular outer convex parts are located on the upper part of the vertical main body part, the upper end surface of the rectangular outer convex part is located in the same plane as the upper end surface of the vertical main body part, and the rectangular outer convex part is used for thread forming processing of the cap of the valve pipe.

5. A method of manufacturing an aluminum alloy stop valve according to claim 2, wherein, The aluminum alloy stop valve blank is a valve body forming part, the valve body forming part comprises a reinforcing part forming part, the valve body forming part and the first connecting pipe forming part located on both sides of the reinforcing part forming part, and the second connecting pipe forming part and the second connecting pipe forming part located on both sides of the reinforcing part forming part; a first part body and a mounting part matched with the structure size of the corresponding part of the aluminum alloy stop valve are sequentially arranged between the reinforcing part forming part and the first connecting pipe forming part.

6. A method of manufacturing an aluminum alloy stop valve according to claim 5, wherein The third part body forming part is arranged on the upper part of the valve body forming part on the side close to the third connecting pipe of the reinforcing part forming part, and the upper end surface of the third part body forming part is higher than the upper end surface of the third connecting pipe forming part.

7. A method of manufacturing an aluminum alloy stop valve according to claim 6, wherein An inclined surface is arranged between the upper end surface of the valve body forming part on the side close to the third connecting pipe of the reinforcing part forming part and the third connecting pipe forming part and is connected through the inclined surface.

8. A method of manufacturing an aluminum alloy stop valve according to claim 7, wherein The upper end surface of the valve body forming part on the side close to the second connecting pipe of the reinforcing part forming part is in the same plane as the second connecting pipe forming part; the length of the first connecting pipe forming part on the flange forming part is greater than the length of the mounting part, and the upper part of the side surface of the first connecting pipe forming part in the width direction is connected with the lower end of the mounting part through an inclined surface inclined from outside to inside.

9. A method of manufacturing an aluminum alloy stop valve according to claim 8, wherein, An extension part forming part is arranged between the reinforcing part forming part and the valve body forming part, the extension part forming part is coaxially arranged with the valve body forming part, the length of the extension part forming part on the flange forming part is less than the width of the valve body forming part, and the lower part of the valve body forming part in the width direction is connected with the upper end of the extension part forming part through an inclined surface inclined inward.

10. An aluminum alloy stop valve characterized by, The aluminum alloy stop valve is manufactured according to the method of any one of claims 1-4.

11. An aluminum alloy stop valve characterized by, The aluminum alloy stop valve is manufactured according to the method of any one of claims 1-2, 5-9.

12. The aluminum alloy stop valve of claim 11, wherein, The flange is provided with a flange mounting hole, the mounting part is inserted into the flange mounting hole; a transition arc is arranged at four corners of the flange mounting hole, and the angle of the arc is greater than 90°; the flange is a symmetric double-hole structure; the length of the flange mounting hole is set as L1, the length of the mounting part is set as L2, and L1 and L2 satisfy the relationship: 0.1≤L1-L2≤0.3 mm; the width of the flange mounting hole is set as L3, the width of the mounting part is set as L4, and L3 and L4 satisfy the relationship: 0.1≤L3-L4≤0.3 mm.

13. The aluminum alloy stop valve of claim 11, wherein, The flange comprises a first body and a second body connected by splicing; the flange mounting hole comprises a first half hole and a second half hole, the first half hole is arranged on the first body, and the second half hole is arranged on the second body.

14. The aluminum alloy stop valve of any of claims 10-13, wherein, The valve body is provided with a valve cavity and a valve port; The valve pipe is connected to the valve body; The reinforcing part is arranged on the valve body and is arranged at a position corresponding to the valve port; the reinforcing part extends to the valve pipe and protrudes from the outer side wall of the valve body, and the reinforcing part is connected to the valve pipe; the reinforcing part covers the outer side of the valve body, and the reinforcing part and the valve body covered by the reinforcing part have a cuboid shape; the valve body, the valve pipe and the reinforcing part are in an integrated structure.

15. The aluminum alloy stop valve of claim 14, wherein, The valve pipe comprises a first connecting pipe and a second connecting pipe; the reinforcing part comprises a first part and a second part, the first part extends from the valve body to the first connecting pipe and is connected to the first connecting pipe, and the second part extends from the valve body to the second connecting pipe and is connected to the second connecting pipe; a joint mounting position is arranged on the second connecting pipe, and the axis of the valve port intersects the axis of the second connecting pipe; the valve pipe further comprises a third connecting pipe, the third connecting pipe is coaxially arranged with the second connecting pipe, and the first connecting pipe is coaxially arranged with the valve body; the reinforcing part further comprises a third part, the third part extends from the valve body to the third connecting pipe and is connected to the third connecting pipe.

16. The aluminum alloy stop valve of claim 14, wherein, The diameter of the valve body is set as Φ1, the diameter of the valve pipe is set as Φ2; the width of the reinforcing part is set as D1, D1, Φ1 and Φ2 satisfy the relationship: D1>Φ1, D1>Φ2; the height of the reinforcing part is set as H, and H and Φ2 satisfy the relationship: H>Φ2.

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