Apparatus and method for stamping metal parts

Abstract

The invention relates to the field of mechanical engineering, and more particularly to shaping metals using compressive forces, and even more particularly relates to stamping and forging devices for shaping parts by impact. An apparatus and a corresponding method for stamping metal parts are characterized by the use of a counterblow hammer having two striking masses which are oppositely movable toward a point of impact by means of pneumatic drives and away from the point of impact by means of hydraulic drives. The apparatus is equipped with at least one source of gas pressure and at least one source of liquid pressure, as well as a control unit for automatically controlling the stamping process. The method for stamping metal parts includes controlling the pressure in the drives, separating the striking masses, positioning a workpiece, carrying out an impact, and removing the finished article. The technical result of the invention consists in increasing the operating reliability of the apparatus and improving operator safety.

Description

[0001] METAL PART STAMPING MACHINE

[0002] AND METHOD OF STAMPING A METAL PART

[0003] DESCRIPTION

[0004] The invention relates to the field of mechanical engineering, including metal pressure processing, namely to devices for stamping and forging, intended for forming parts by applying impact loads [B21J7 / 14; B21J7 / 34],

[0005] The prior art includes a HIGH-SPEED IMPACT MACHINE [GB972821A, publ.

[0006] [14.10.1964], consisting of a pair of opposite and generally identical pneumatic pistons, the piston end of each of which is adapted for use as a tool holder or anvil, the cylinder of each piston being surrounded by an annular gas reservoir into which gas is supplied under high pressure, and in which the supply of gas to the cylinders of the pistons from the reservoir is carried out through openings usually closed by quick-acting valves controlled by an electric drive.

[0007] A disadvantage of this machine is the gas discharge outside the unit, which heats up due to compression, posing a risk to maintenance personnel due to high pressure and temperature. Furthermore, using a single gas reservoir for piston expansion and contraction operations places additional stress on the piston cylinder, increasing the likelihood of accelerated wear and reducing equipment reliability.

[0008] Also known from the prior art is a JACKHAMMER [US4142397A, published 06.03.1979], comprising two sections of a jackhammer; guide means for supporting said sections of the jackhammer in mutually opposite relationships in such a way that the front working ends of said sections of the jackhammer face each other, and the rear ends face away from each other, wherein the rear ends are located in separate air chambers formed by first housings defined in said guide means, wherein the rear ends of said sections of the jackhammer have portions protruding from said first housings; a second housing means intended to form separate chambers for receiving said protruding parts of the corresponding sections of said sections of the jackhammer, wherein said protruding parts include pistons located in the second housing, the housing means;a pneumatic drive means acting on said rear ends of said hammer rods to pneumatically drive said hammer rods towards each other in the direction of a forward working movement, said pneumatic drive means including a first pipeline means for connecting said separate compressed air chambers and a second pipeline means for connecting said first pipeline means to a source of compressed air; and a hydraulic means acting on said pistons of said protruding parts to hydraulically retract said hammer rods from each other.

[0009] A disadvantage of this hammer is the location of the hydraulic drive behind the pneumatic drive relative to the impact site, which creates a potential safety hazard for personnel. In the event of a sudden failure or disruption of the pneumatic drive, the external hydraulic drive could move uncontrollably, posing a hazard to personnel. Furthermore, this location makes it difficult to evenly distribute the loads, increasing the risk of premature component wear and reducing the reliability of the machine.

[0010] The closest in technical essence is a MACHINE FOR SHAPING WORKPIECES BY IMPACT [US3429174A, published 25.02.1969], comprising a pair of pressure rollers, means for guiding the rollers to move towards each other, gas-powered driving plungers for moving the rollers towards each other, ejector cylinders, ejector pistons movable within said ejector cylinders and attached respectively to the two rollers, connecting piston and cylinder devices connected to the rollers, wherein the connecting cylinders are configured to receive fluid under pressure from the ejector cylinders when the rollers move together, means for hydraulically actuating the ejector pistons to move the rollers apart, and check valve means for connecting the ejector cylinder of each roller to the connecting cylinder of the other roller during the movement of the rollers towards each other,wherein a channel for liquid under pressure is provided, and the check valve means is provided with a movable part which is connected on one side to the liquid under pressure of the displacing cylinders, and on the other side - to the said channel, and a means forming a relatively small hole which is located with the possibility of opening shortly before the closing of the valve for connecting the displacing cylinder with the said channel, due to which an unintentional operation occurs in the event of a malfunction that reduces the pressure in the said air duct.,

[0011] The prototype's main technical problem is the connection of the hydraulic drive of one impact mass through a channel to the connecting cylinders and connecting pistons located on the opposite side of the impact mass. Fluid flow between the cavities creates sharp pressure surges, which reduces the equipment's operational reliability and can lead to emergency situations. These pressure surges also pose a potential safety hazard to maintenance personnel.

[0012] The objective of the invention is to eliminate the shortcomings of the prototype.

[0013] The technical result of the invention consists in increasing the operational reliability of the installation and the safety of the maintenance personnel.

[0014] The specified technical result is achieved due to the fact that the installation for stamping a metal part contains a countersunk hammer, at least one gas pressure source, at least one liquid pressure source and a control unit configured to remotely control the process of stamping a metal part;a countersink hammer comprising two impact masses spaced apart from each other on opposite sides relative to the impact site, configured to move both impact masses in the direction towards the impact site using pneumatic drives located on the side of each impact mass, and to move both impact masses in the direction away from the impact site using hydraulic drives coupled to a corresponding pneumatic drive on the side of the impact site, wherein the pneumatic drives are connected to at least one gas pressure source, and the hydraulic drives are connected to at least one liquid pressure source.

[0015] In a particular case, the pneumatic drives are connected to at least one gas pressure source with the possibility of simultaneously providing the same or different gas pressure in both pneumatic drives.

[0016] In a particular case, the hydraulic drives are connected to at least one source of fluid pressure with the possibility of simultaneously providing the same or different fluid pressure in both hydraulic drives.

[0017] In a particular case, the installation is equipped with two manipulators, designed with the ability to automatically load and unload blanks and finished products through the corresponding windows in the side surface of the anvil-less hammer.

[0018] Also, the said technical result is achieved due to the fact that the method of stamping a metal part, carried out with the help of the said installation, is characterized in that each pneumatic drive is first filled with gas under pressure from at least one gas pressure source through a control unit, after which each striking mass of the anvil-less hammer is moved apart by a calculated distance, ensuring the loading of the blank of the metal part; for this, the fluid pressure in each hydraulic drive is increased through the control unit from at least one fluid pressure source, then the blank of the metal part is placed in the impact zone through the control unit, after which each striking mass of the anvil-less hammer is moved apart by a calculated distance for the impact, for which, through the control unit, the fluid pressure in each hydraulic drive is increased from at least one fluid pressure source;then, through the control unit, the fluid pressure in each hydraulic drive is released; after the impact, through the control unit, fluid under pressure is supplied to each hydraulic drive from at least one source of fluid pressure to supply the finished product to the service location, then, through the control unit, the finished product of the metal part is removed from the installation.

[0019] In a particular case, the gas pressure in one pneumatic drive is the same as or different from the gas pressure in another pneumatic drive. In a particular case, each pneumatic drive is filled with gas pressure simultaneously.

[0020] In a particular case, the fluid pressure in one hydraulic drive is the same as or different from the fluid pressure in another hydraulic drive.

[0021] In a particular case, the fluid pressure in each hydraulic drive is increased or the fluid pressure in each hydraulic drive is released simultaneously.

[0022] In a particular case, the placement of the workpiece in the impact zone and the removal of the finished metal part from the installation are carried out using two manipulators designed to operate through corresponding windows in the side surface of the anvil-less hammer.

[0023] Brief description of the drawings.

[0024] Fig. 1 shows a variant of an installation for stamping a metal part with one gas pressure source and one liquid pressure source.

[0025] Fig. 2 shows a variant of an installation for stamping a metal part with two gas pressure sources and two liquid pressure sources.

[0026] The figures show: 1 - anvil-less hammer; 2 - gas pressure source; 3 - liquid pressure source; 4 - control unit; 5 - impact masses; 6 - vertical impact axis; 7 - pneumatic drives; 8 - hydraulic drives; 9 - pipelines; 10 - windows; 11 - manipulators.

[0027] Implementation of the invention.

[0028] The installation for stamping a metal part (see Fig. 1, Fig. 2) includes the following main elements: a countersink hammer 1, at least one gas pressure source 2, at least one liquid pressure source 3 and a control unit 4.

[0029] The anvil-less hammer 1 comprises two striking masses 5 located at a distance from each other relative to the impact point (not shown in the figure). The anvil-less hammer 1 is configured to move both striking masses 5 along a vertical impact axis 6 in the direction toward the impact point using pneumatic drives 7, and to move both striking masses along a vertical impact axis in the direction away from the impact point using hydraulic drives 8, each of which is coupled with a corresponding pneumatic drive 7 on the side of the impact point. The hydraulic drives 8, the pneumatic drives 7, and the striking masses 5 are located along a single vertical impact axis 6. This design solution eliminates bending stresses and stress concentrators, increasing the reliability of the installation and reducing the risk of failures. The absence of mechanical friction in the moving parts, with the exception of the hydraulic cylinder sealing zones, prevents wear, reduces mechanical losses, and contributes to increased efficiency.This ensures stable operation and durability of the unit. Its simple design reduces the risk of mechanical failure and uneven load distribution. The main load-bearing elements are housed within the frame of the anvil-less hammer 1, eliminating operator contact with moving parts in the hot zone and preventing uncontrolled leaks of hydraulic fluid during pressure surges. The unit's compact size and its weight-to-impact energy ratio exceed those of existing anvil-less hammers, enabling greater efficiency. The gas-filled cavities of each pneumatic drive 7 are structurally isolated from those of the hydraulic drive 8, preventing gas and liquid mixing and ensuring stable operating parameters.

[0030] Pneumatic drives 7 are connected to at least one gas pressure source 2 via pipelines 9. If one gas pressure source 2 is used (see Fig. 1), then the gas pressure in both pneumatic drives 7 is the same. In the case of connection to several gas pressure sources 2 (see Fig. 2), it is possible to ensure the same or different gas pressure in the pneumatic drives 7, which allows for more precise control of the stamping process and eliminates unwanted overloads of the installation components.

[0031] The hydraulic drives 8 are connected to at least one fluid pressure source 3 through pipelines 9 containing quick-acting valves (not shown in the Fig.). When using a single fluid pressure source 3 (see Fig. 1), the pressure in both hydraulic drives 8 is the same. If several fluid pressure sources 3 are connected (see Fig. 2), the fluid pressure in the hydraulic drives 8 may be the same or different. The quick-acting valves integrated into the pipelines 9 are connected to the control unit 4 and ensure the synchronous supply or discharge of fluid to the corresponding hydraulic drives 8. This allows for precise coordination of the movements of the impact masses 5 during the stamping process, which eliminates uncoordinated impacts and associated emergency situations, increasing operational safety.

[0032] In the frame of the anvil-free hammer 1, a window 10 is provided, which ensures the loading of a tool with a workpiece (not shown in the figure) and the unloading of a tool with a finished metal part (not shown in the figure) using a manipulator 11. It is also possible to design the anvil-free hammer 1, on the opposite sides of the side surface of which two through windows 10 are located, configured to allow the loading of a tool with a workpiece and the unloading of a tool with a finished metal part through these windows 10 using manipulators 11. Manipulators 11 are installed on the side of each window 10, configured to move a workpiece or a finished product in a shuttle mode. Manipulators 11 can move on a rigid connection with each other. Manipulators 11 can ensure free forging of long products on the anvil-free hammer, extending beyond the working space of the hammer.The presence of manipulators 11 minimizes operator involvement in the work process, reducing the likelihood of injury and increasing personnel safety, facilitating the work of plant operators.

[0033] Control unit 4 is capable of automatic or manual control of the metal part stamping process. In automatic mode, control unit 4 regulates gas and liquid pressures and coordinates the operation of manipulators 11 according to a preset program. This minimizes the influence of the human factor, eliminating errors associated with improper operation of the system and increasing its operational reliability. In manual mode, the operator can independently control the gas and liquid pressures in pneumatic drives 7 and hydraulic drives 8, as well as the actions of manipulators 11, via the interface (not shown in the figure) of control unit 4. This allows for prompt adjustments to the stamping process and adaptation of the system to changing production conditions.Synchronizing manipulators 11 with the anvil-free hammer 1 in automatic mode minimizes downtime and increases productivity, while manual control provides flexibility for non-standard tasks. This ensures increased safety for personnel, as precise control prevents accidents. The method for stamping a metal part is carried out using the described setup and includes the following steps:

[0034] Each pneumatic actuator 7 is first filled with pressurized gas from at least one gas pressure source via control unit 4 (see Fig. 1, Fig. 2). The gas pressure in the pneumatic actuators 7 may be the same or different, depending on the number of gas pressure sources 2 and their settings in control unit 4. This allows for multiple impact cycles to be performed without changing the gas mass, since each pneumatic actuator 7 operates by compressing and expanding the gas in a closed volume. There is no pressurized liquid in the hydraulic actuators 8, and the air pressure is 1 atm, resulting in smooth contact of the impact masses 5 along the vertical impact axis 6.

[0035] Each striking mass 5 of the anvil-less hammer 1 is then moved apart by the calculated distance required to load the tool with the metal workpiece. To do this, the fluid pressure in each hydraulic drive 8 is increased via the control unit 4 from at least one fluid pressure source 3. As the pressure increases, each hydraulic drive 8 presses the corresponding pneumatic drive 7 along the vertical impact axis 6 in the direction away from the impact point, causing each striking mass 5 to move a distance away from the impact point. This controlled movement creates safe conditions for loading the tool with the workpiece.

[0036] Next, via control unit 4, the first manipulator 11 places the tool with the metal workpiece onto the impact site through window 10. The tool may be two halves of a closed or open die, a die and punch, or open-die forging dies. After loading the workpiece, each striking mass 5 of the anvil-less hammer 1 is again moved along the vertical impact axis 6 from the impact site to a distance sufficient to deliver the required impact energy. To achieve this, the fluid pressure in each hydraulic drive 8 is regulated via control unit 4. At this point, the accelerating gas pressure in the pneumatic drives 7 increases due to gas compression within the cavities of each pneumatic drive 7.

[0037] Then, via control unit 4, the fluid pressure in hydraulic drives 8 is simultaneously released, resulting in accelerated movement of striking masses 5 toward the impact site and the execution of the stamping strike. After the strike, the pressure in each hydraulic drive 8 equalizes with atmospheric pressure.

[0038] After the impact, through the control unit 4, the pressurized liquid is again supplied to the hydraulic drives 8, which, acting on the corresponding pneumatic drives 7, move the impact masses 5, ensuring the possibility of safe servicing of the tool and the product through the windows 10. Thus, the stamping cycle is completed.

[0039] In a particular case, the tool can remain on the impact masses 5, and only the finished product will be unloaded and a new workpiece will be loaded.

[0040] In one embodiment of the invention, two through windows 5 are located on opposite sides of the side surface of the anvil-free hammer, configured to load a tool with a workpiece and unload a tool with a finished product through these windows 10 using manipulators 11. When working with two manipulators 11, the first manipulator 11, after striking, unloads the tool with the finished product through one window 10, after which the second manipulator 11 loads the second tool with the workpiece through the opposite window 10. At this time, at the servicing location outside the anvil-free hammer 1, the finished part is removed from the first tool and a new workpiece is loaded. Then, the movement of the manipulators 11 in the stamping cycle is repeated in reverse order. Such shuttle loading and unloading of the anvil-free hammer 1 by two manipulators 11 halves the servicing time at a distance remote from the hot working zone of the anvil-free hammer 1.

[0041] The gas pressure in the pneumatic drives 7 can be regulated via the control unit 4 depending on the settings of the gas pressure sources 2. With equal accelerations of the impact masses 5, depending on the pressure in the pneumatic drives 7 and the multidirectional acceleration of gravity, they travel equal distances and have equal impact velocities. In the case of equal impact masses 5, the impact point and the point where their movement stops will be located midway between the initial positions of the impact masses 5. The impact energy, equal to the sum of the kinetic energies of the impact masses 5, is converted into the deformation energy of the workpiece, and the force impulses acting on the impact masses 5 will be equal and opposite in sign, which ensures the instantaneous stop of the impact masses 5 at the impact point. If the impact masses 5 have different force impulses before the impact, their joint motion after the impact will continue for some time until the forces of their interaction are equalized due to the established pressures in the pneumatic drives 7.As a result, the stopping point after the impact may not be at window 10. In this case, the fluid pressure in the hydraulic drives 8 is increased through the control unit 4, which allows the hydraulic drives 8 to act on the corresponding pneumatic drive ?. This ensures that each impact mass 5 moves the required distance and accesses the tool with the finished product through window 10 of the anvil-less hammer 1.

[0042] The adjustment of the anvil-less hammer to a given impact energy occurs through the control unit 4 by setting the pressures in the pneumatic drives 7 and hydraulic drives 8, which ensure the initial position of the separated impact masses 4 and their accumulation of the required amount of movement.

Claims

FORMULA 1. An installation for stamping a metal part, comprising a non-anvil hammer, at least one gas pressure source, at least one liquid pressure source and a control unit configured to remotely control the process of stamping the metal part; the non-anvil hammer, comprising two impact masses at a distance from each other on opposite sides relative to the impact point, configured to move both impact masses in the direction toward the impact point using pneumatic drives located on the side of each impact mass, and to move both impact masses in the direction away from the impact point using hydraulic drives coupled to a corresponding pneumatic drive on the side of the impact point, wherein the pneumatic drives are connected to at least one gas pressure source, and the hydraulic drives are connected to at least one liquid pressure source.

2. The installation according to paragraph 1, characterized in that the pneumatic drives are connected to at least one source of gas pressure with the possibility of simultaneously providing the same or different gas pressure in both pneumatic drives.

3. The installation according to paragraph 1, characterized in that the hydraulic drives are connected to at least one source of liquid pressure with the possibility of simultaneously providing the same or different liquid pressure in both hydraulic drives.

4. The installation according to paragraph 1, characterized in that the installation is equipped with two manipulators designed with the possibility of automatically loading and unloading blanks and finished products through corresponding windows in the side surface of the anvil-less hammer.

5. A method for stamping a metal part, carried out using the installation according to paragraph 1, characterized in that each pneumatic drive is first filled with gas under pressure from at least one gas pressure source via a control unit, after which each striking mass of the anvil-less hammer is moved apart by a calculated distance that ensures loading of the blank of the metal part; for this, the fluid pressure in each hydraulic drive is increased via the control unit from at least one fluid pressure source, then the blank of the metal part is placed in the impact zone via the control unit, after which each striking mass of the anvil-less hammer is moved apart by a calculated distance for the impact, for which, the fluid pressure in each hydraulic drive is increased via the control unit from at least one fluid pressure source; then, the fluid pressure in each hydraulic drive is released via the control unit;after the impact, through the control unit, pressurized liquid is supplied to each hydraulic drive from at least one source of liquid pressure to supply the finished product to the service location, then, through the control unit, the finished product of the metal part is removed from the installation.

6. The method according to paragraph 5, characterized in that the gas pressure in one pneumatic drive corresponds to or differs from the gas pressure in the other pneumatic drive.

7. The method according to paragraph 5, characterized in that each pneumatic drive is filled with gas pressure simultaneously.

8. The method according to paragraph 5, characterized in that the fluid pressure in one hydraulic drive corresponds to or differs from the fluid pressure in the other hydraulic drive.

9. The method according to paragraph 5, characterized in that the fluid pressure in each hydraulic drive is increased or the fluid pressure in each hydraulic drive is released simultaneously.

10. The method according to paragraph 5, characterized in that the placement of the workpiece in the impact zone and the removal of the finished metal part from the installation are carried out using two manipulators designed with the ability to operate through corresponding windows in the side surface of the anvil-less hammer.

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