Closed-Frame Hydraulic Press for Axle Housing Bulging Precision
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Solution Overview
Problem
Current manufacturing methods for automobile axle housings, such as casting, stamping, and welding, face issues like excessive mass, material inefficiency, and potential oil leakage due to long weld seams, while the steel-tube bulging pressing forming method lacks a specialized hydraulic press for precise control, leading to bending and leakage issues.
Innovation Solution
A special hydraulic press with a closed frame structure, including an upper and lower cross beam, stand columns, vertical and horizontal pull rods, and a pressing forming die, utilizing a main hydraulic cylinder and smaller vertical and horizontal cylinders to control the pressing process, ensuring balanced forces and precise movement to prevent bending during the bulging pressing forming of automobile axle housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional hydraulic press is used for bulging pressing forming, then the equipment structure is simpler, but the deformation forces cannot be balanced precisely leading to bending and leakage issues
Solution Approach 1:
The hydraulic press is segmented into multiple independent hydraulic cylinders (first hydraulic cylinder for vertical pressing, second hydraulic cylinder for horizontal pressing, third hydraulic cylinder for diagonal pressing) that can be controlled separately. This segmentation allows precise control of deformation forces in different directions, preventing bending and leakage while maintaining manageable equipment complexity through modular design.
Solution Approach 2:
The patent changes the parameters of the hydraulic system by using multiple hydraulic cylinders with different pressing directions and independently controllable pressures. This allows dynamic adjustment of deformation parameters to balance the 3000 T forces precisely, achieving high forming precision without excessive equipment complexity through intelligent parameter control.
2Shape
If casting method is used for axle housing manufacturing, then the wall thickness is adequately distributed, but the mass of the manufactured part is large
Solution Approach 1:
The bulging pressing forming process changes the physical and geometric parameters of the steel tube blank through controlled deformation. The tube blank undergoes diameter reduction at ends and hydraulic bulging in the middle, transforming it into an axles housing shape with optimized wall thickness distribution that reduces mass while maintaining structural integrity.
Solution Approach 2:
The patent uses a seamless steel tube as the base material, which is then formed into a composite structure through bulging pressing. The resulting axle housing combines the advantages of steel tube material with optimized geometry, achieving both adequate wall thickness distribution and reduced mass compared to traditional casting.
3Weight of moving object
If stamped and welded method is used, then the mass of the manufactured part is reduced, but the utilization of materials is low and weld seams are prone to oil leakage
Solution Approach 1:
The bulging pressing forming process merges multiple forming operations into a single integrated process. The steel tube blank is directly formed into the final axle housing shape with front and rear covers integrated, eliminating the need for separate stamping and welding operations. This merging achieves both mass reduction and elimination of weld seams, improving reliability.
Solution Approach 2:
The patent extracts the welding operation from the manufacturing process entirely. By using bulging pressing forming to create an integrally formed axle housing from a steel tube blank, the weld seam element is removed from the system, eliminating the reliability issues associated with weld seams while maintaining reduced mass.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The special hydraulic press effectively balances deformation forces up to 3000 T, ensures precise control of the pressing process, and reduces production costs by optimizing the structure, preventing bending and leakage, thus producing a high-strength, weld-seam-free axle housing with reduced mass.
Implementation Method 1
a hydraulic system, an electrical system, a pressurization system, front and rear high-pressure jacks
Implementation Method 2
Overall pressing forming is then performed in an upward direction, a downward direction, a forward direction, and a backward direction
Data Source
AI summary
The present invention discloses a special hydraulic press for bulging pressing forming of an automobile axle housing and a pressing forming method. A hydraulic press body is a closed frame consisting of an upper cross beam, a lower cross beam, four stand columns I, II, III, and IV, four vertical pull rods I, II, III, and IV, and four transverse pull rods I, II, III, and IV, and is used for balancing a deformation force up to 3000 T in the vertical direction or the horizontal direction in the pressing forming process. During pressing forming, the downward speeds of a main hydraulic cylinder, small left and right vertical hydraulic cylinders are precisely controlled to prevent the left end, the right end and the middle of the tube blank from bending.