Closed-Frame Hydraulic Press for Seamless Axle Housing Forming
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Solution Overview
Problem
Current methods for manufacturing 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 requires precise control of pressing forces to prevent bending and ensure seamless integration.
Innovation Solution
A special hydraulic press with a closed frame structure, featuring an upper and lower cross beam connected by vertical and transverse pull rods, a main hydraulic cylinder, and horizontal and vertical sliders, along with a pressurization system, is used to precisely control the pressing process, ensuring balanced forces and preventing bending during the bulging pressing forming of automobile axle housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a four-direction hydraulic press with two independent large hydraulic cylinders is used, then the pressing force can be sufficient for bulging forming, but the equipment structure becomes complex and control precision deteriorates
Solution Approach 1:
The patent merges two independent hydraulic systems into a single centralized hydraulic system. One hydraulic station with a single hydraulic cylinder replaces the previously required two independent large hydraulic cylinders, while still achieving the necessary pressing force through optimized mechanical force transmission paths and the closed frame structure.
Solution Approach 2:
The single hydraulic system is designed to perform multiple functions: it provides both the main pressing force for bulging forming and the auxiliary pressing force for preventing tube bending, replacing what previously required two separate hydraulic systems. The system achieves multi-functionality through coordinated action of the hydraulic cylinder with the closed frame structure and auxiliary pressing mechanisms.
2Force
If two independent large hydraulic cylinders are used, then sufficient pressing force can be applied, but control precision of pressing speed deteriorates
Solution Approach 1:
The patent combines the control of both main pressing and auxiliary pressing functions into a single control system. One hydraulic station with centralized control replaces two independent control systems, achieving precise coordination of pressing speeds through unified control while maintaining sufficient pressing force.
Solution Approach 2:
The patent implements feedback control mechanisms to precisely regulate the pressing speed. The control system monitors and adjusts the hydraulic cylinder operation to maintain precise pressing speed control, preventing tube bending while achieving the required deformation.
3Reliability
If pressing force is increased to prevent tube bending, then forming reliability improves, but the risk of tube burst increases
Solution Approach 1:
The patent segments the pressing function into two distinct components: main pressing force for bulging forming and auxiliary pressing force for preventing tube bending. This segmentation allows each component to be optimized independently - the main pressing provides necessary deformation while the auxiliary pressing prevents bending, together achieving high reliability without excessive force that could cause tube burst.
Solution Approach 2:
The patent applies different pressing forces to different locations of the tube. The auxiliary pressing mechanism applies localized force specifically at critical sections prone to bending, while the main pressing applies distributed force for overall bulging forming. This local quality approach prevents tube bending without uniformly increasing force that could cause tube burst.
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
This solution allows for the formation of a seamless, high-strength axle housing with reduced mass, optimized structure, and lower manufacturing costs by balancing deformation forces up to 3000 T and precisely controlling the pressing speeds to prevent bending, thus ensuring effective bulging pressing forming.
Implementation Method 1
a main hydraulic cylinder is mounted upside down on the upper cross beam... a left vertical hydraulic cylinder and a right vertical hydraulic cylinder... piston rods of a left horizontal hydraulic cylinder and a right horizontal hydraulic cylinder are respectively connected to a left horizontal slider and a right horizontal slider
Implementation Method 2
a pressurization system... Front and rear high-pressure jacks... (5) filling the preformed tube blank with a liquid through the left pressing head by using a low-pressure pressurizer of a pressurization system... (7) filling the preformed tube blank with a liquid through the left pressing head by using a high-pressure pressurizer of a pressurization system
Implementation Method 3
the upper cross beam and the lower cross beam are respectively connected in the vertical direction by four vertical pull rods I, II, III, and IV for balancing external forces applied to the upper cross beam and the lower cross beam in the vertical direction when the hydraulic press is operating, and the upper cross beam and the lower cross beam are respectively connected to upper end parts and lower end parts of the four stand columns I, II, III, and IV in the horizontal direction by four transverse pull rods I, II, III, and IV for balancing external forces applied to the four stand columns I, II, III, and IV in the left-right direction when the hydraulic press is operating
Data Source
Figure 1~3
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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.