CN111036831A - Automatic forging system and method for annular gear blank - Google Patents
Automatic forging system and method for annular gear blank Download PDFInfo
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- CN111036831A CN111036831A CN201911411374.1A CN201911411374A CN111036831A CN 111036831 A CN111036831 A CN 111036831A CN 201911411374 A CN201911411374 A CN 201911411374A CN 111036831 A CN111036831 A CN 111036831A
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- 238000005242 forging Methods 0.000 title claims abstract description 107
- 238000000034 method Methods 0.000 title claims abstract description 29
- 238000010438 heat treatment Methods 0.000 claims abstract description 44
- 238000001514 detection method Methods 0.000 claims abstract description 37
- 238000005096 rolling process Methods 0.000 claims abstract description 18
- 230000006698 induction Effects 0.000 claims abstract description 17
- 238000004080 punching Methods 0.000 claims abstract description 11
- 239000000463 material Substances 0.000 claims description 23
- 239000002994 raw material Substances 0.000 claims description 16
- 230000008569 process Effects 0.000 claims description 15
- 238000006073 displacement reaction Methods 0.000 claims description 13
- 238000005507 spraying Methods 0.000 claims description 12
- 238000003825 pressing Methods 0.000 claims description 8
- 238000001125 extrusion Methods 0.000 claims description 5
- 238000000465 moulding Methods 0.000 claims description 5
- 238000011282 treatment Methods 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 4
- 238000010079 rubber tapping Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 15
- 239000003795 chemical substances by application Substances 0.000 description 6
- 238000009434 installation Methods 0.000 description 6
- 238000012545 processing Methods 0.000 description 6
- 239000002184 metal Substances 0.000 description 4
- 239000007921 spray Substances 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000004146 energy storage Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/28—Making machine elements wheels; discs
- B21K1/30—Making machine elements wheels; discs with gear-teeth
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
- B07C5/342—Sorting according to other particular properties according to optical properties, e.g. colour
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/38—Collecting or arranging articles in groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
- B21H5/00—Making gear wheels, racks, spline shafts or worms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/002—Hybrid process, e.g. forging following casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/08—Upsetting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/10—Piercing billets
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
Abstract
The invention discloses an automatic forging system and method for a ring gear blank, wherein the system comprises a sawing machine, a medium-frequency induction heating furnace (2), a robot (3), a multi-station blank-making servo hydraulic machine (4) for a ring part, a numerical control ring rolling machine (6) and a screw press (7) which are connected in sequence; the multi-station blank-making servo hydraulic press (4) for the ring-shaped parts is provided with a first station, a second station and a third station, wherein the first station is used for upsetting the bars, the second station is used for extruding blind holes of the bars subjected to upsetting, and the third station is used for punching blanks subjected to extruding blind holes, and then the blanks are subjected to ring rolling reaming and die forging to form the gear blanks. The system avoids the occurrence of large batches of unqualified products, and simultaneously avoids the damage of high temperature to human bodies in the traditional manual detection; the full-automatic control of blanking, heating, multi-station blank making, hole expanding, pre-forging, finish forging and size detection is realized, and unmanned and intelligent gear forging production is realized.
Description
Technical Field
The invention belongs to the technical field of gear forging, and particularly relates to an automatic forging system and method for an annular gear blank.
Background
Forging is a processing method which utilizes forging machinery to apply pressure on a metal blank to cause the metal blank to generate plastic deformation so as to obtain a forged piece with certain mechanical property, certain shape and certain size. The defects of as-cast porosity and the like generated in the smelting process of metal can be eliminated through forging, the microstructure is optimized, and meanwhile, because the complete metal streamline is preserved, the mechanical property of the forging is generally superior to that of a casting made of the same material. The gear parts always bear a very severe working environment and continuously work in a high-speed rotating working environment, so that the performance requirements on the gear parts are greatly higher than those of common parts. Therefore, the gear parts are machined in a forging mode, and a series of treatments are carried out after machining to optimize the performance of the finished gear.
At present, along with the improvement of product requirements and product quality requirements of the market and the great direction of modern and automatic production, enterprises are urgently required to design an automatic production process of gear products and cooperate with an automatic production line for building the gear products so as to meet the production requirements. And in order to guarantee the quality of product, the outward appearance of the gear product after forging detects indispensably, and to the detection of gear product, mostly judge the letter sorting through artifical selective examination at present, has uncertainty and error, and sorting efficiency is also not high, and has the completion that hinders full automatic production line.
The gear in the prior art is very widely applied, and the requirements on the structural stability and the size accuracy of the gear are very high due to the large-range application. The traditional gear forging mode usually adopts a traditional forging process, the process from blank to finished product manufacturing is complicated, the efficiency is low, the loss is large, the utilization rate of raw materials is low, the tonnage of equipment is large, the input cost is high, the gear manufactured by manual production has poor dimensional accuracy consistency, and stable product performance cannot be obtained.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides an automatic forging system and method for annular gear blanks, which can automatically sort the sizes of forged gear pieces, prevent errors possibly caused by manual operation, have high sorting accuracy and save time and labor; the full-automatic control of blanking, heating, multi-station blank making, hole expanding, pre-forging, finish forging and size detection can be realized, and unmanned and intelligent gear forging production is realized.
In order to achieve the aim, the invention provides an automatic forging system for a ring gear blank, which comprises a sawing machine, a medium-frequency induction heating furnace, a robot, a multi-station blank-making servo hydraulic machine for a ring part, a numerical control ring rolling machine and a screw press which are sequentially connected; wherein,
the sawing machine is used for sawing materials, and the intermediate frequency induction heating furnace is used for heating the materials to form bars;
the multi-station blank-making servo hydraulic press for the ring-shaped parts is provided with a first station, a second station and a third station, wherein the first station is used for upsetting the bars, the second station is used for extruding blind holes of the bars subjected to upsetting, and the third station is used for punching blanks subjected to blind hole extruding treatment to form gear forging blanks;
the robot comprises a first robot and a second robot, the first robot is used for conveying the material heated by the medium-frequency induction heating furnace into a die, and the second robot is used for conveying the gear blank to a numerical control ring rolling machine;
the numerical control ring rolling machine is used for carrying out reaming treatment on the gear blank;
the screw press comprises a first screw press for pre-forging the gear blank after reaming by the numerical control ring rolling machine, and a second screw press for forging the gear blank after pre-forging to form a gear forging.
Further, the device comprises a heating device for heating the mould;
and the spraying device is used for spraying a release agent on the die so as to enable the bar stock to be released from the die.
Further, the gear detecting device comprises a blue light detecting device for detecting the outline dimension of the gear;
and the bin is used for accommodating the unqualified gear detected by the blue light detection device.
Further, the multi-station blank-making servo hydraulic press for the ring-shaped parts comprises a mounting support structure, wherein the mounting support structure comprises a machine body and a platform.
Furthermore, the multi-station blank-making servo hydraulic press for the ring-shaped part comprises a hydraulic structure, the hydraulic structure comprises a lower ejection cylinder arranged on the bottom end face of the machine body, and a hydraulic rod of the lower ejection cylinder is matched with the bottom end face of the forging die;
the main oil cylinder is arranged at the circular through hole of the platform, the bottom of a hydraulic rod of the main oil cylinder is fixedly connected with the bottom of the sliding block, and the bottom of the sliding block is fixedly connected with the forging and pressing die.
Further, the hydraulic structure comprises a servo motor, a hydraulic pump, a pump head valve, a main pipe and an integrated block;
the servo motor is connected with the hydraulic pump and is used for controlling the flow and the flow speed of the hydraulic pump in real time to realize rapid pressure boosting or pressure relief;
the pump head valve is arranged at the outlet of the hydraulic pump and is provided with a pressure threshold value, so that the safety of a hydraulic structure is ensured;
the hydraulic pump is communicated with the integrated block through a main pipe and is used for realizing large-displacement pressing in the tapping process and multi-stage unloading in the return process.
Furthermore, a through hole is formed in the bottom end face of the forging die, and a hydraulic rod of the lower ejection cylinder penetrates through the through hole to be in contact with the workpiece.
Furthermore, the multi-station blank-making servo hydraulic press for the ring-shaped parts comprises a control and safety structure, wherein the control and safety structure comprises a safety cylinder and a main cylinder displacement sensor.
Further, the master cylinder displacement sensor comprises a detection groove fixedly arranged on the machine body and a connecting part for connecting the detection groove and the sliding block.
According to another aspect of the present invention, there is provided an automated forging method of a ring gear blank, comprising the steps of:
step 1: heating the raw material to a temperature required by the process by using a medium-frequency induction heating furnace, heating the mold to the required temperature by using a mold heating device, putting the heated raw material into the heated mold, and spraying a release agent by using a spraying device after molding to obtain a bar material;
step 2: the robot places the bar on a first station of a multi-station blank-making servo hydraulic press of the annular part for upsetting;
and step 3: the robot moves the blank at the upsetting position to a second station of the multi-station blank-making servo hydraulic press of the ring-shaped part to extrude the blind hole;
and 4, step 4: the robot moves the blank on the second station to a third station of the multi-station blank-making servo hydraulic press for the ring-shaped piece to punch holes, meanwhile, the robot places the newly heated bar on the first station of the multi-station blank-making servo hydraulic press for the ring-shaped piece, and the punching and upsetting work are carried out simultaneously;
and 5: placing the punched bar on a numerical control ring rolling machine by a robot for reaming;
step 6: placing the blank subjected to hole expanding on a first screw press by a robot for pre-forging;
and 7: the robot conveys the pre-forged blank from the first screw press to a second screw press for finish forging to obtain a gear piece;
and 8: the robot conveys the gear piece to a blue light detection device for blue light detection;
and step 9: the robot will detect qualified gear spare through blue light detection device and place the air-operated cooling on the transfer chain, put into the workbin with unqualified gear spare.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
1. the automatic forging system can automatically sort the forged gear pieces in size, prevents errors possibly caused by manual operation, is high in sorting accuracy, and is time-saving and labor-saving; the full-automatic control of blanking, heating, multi-station blank making, hole expanding, pre-forging, finish forging and size detection can be realized, and unmanned and intelligent gear forging production is realized.
2. According to the automatic forging system, the plurality of working positions are arranged on the multi-station blank-making servo hydraulic press for the ring-shaped piece, so that the processing of upsetting, blind hole extruding and punching of the workpiece is realized, and the forging efficiency is greatly improved.
3. The automatic forging system is provided with a plurality of robots, workpieces can be conveyed in the processes of blanking, heating, multi-station blank making, hole expanding, pre-forging, finish forging and size detection at the same time, and the forging efficiency is greatly improved. .
4. The automatic forging system disclosed by the invention realizes full-automatic control of blanking, heating, multi-station blank making, hole expanding, pre-forging, finish forging and size detection, and greatly improves the working efficiency of gear forging.
5. According to the automatic forging method, a medium-frequency induction heating furnace heats raw materials to a temperature required by a process, a mold heating device heats a mold to the required temperature, the heated raw materials are placed into the heated mold, a release agent is sprayed by a spraying device after molding, the raw materials are changed into bars, a first station is used for upsetting the bars, a second station is used for performing blind hole extrusion processing on the bars after upsetting, a third station is used for punching blanks after the blind hole extrusion processing to form gear forging blanks, a first screw press is used for performing pre-forging, and a second screw press is used for performing finish forging to obtain gear pieces, so that intelligent gear manufacturing is realized, and manufacturing accuracy and efficiency are high.
Drawings
FIG. 1 is a schematic structural diagram of an automated ring gear blank forging system according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a multi-station blank-making servo hydraulic press for ring-shaped parts in the embodiment of the invention;
FIG. 3 is a schematic flow chart of an automated forging method for a ring gear blank according to an embodiment of the invention.
In all the figures, the same reference numerals denote the same features, in particular: 1-raw material; 2-medium frequency induction heating furnace; 3-a robot; 4-a multi-station blank-making servo hydraulic press for the ring-shaped piece; 6-a numerical control ring rolling machine; 7-screw press; 8-a blue light detection device; 9-a conveyor chain; 10-a gear transmission chain; 11-air cooling gear transmission chain; 12-a material box; 14-unqualified material slide way; 15-unqualified bin; 401-machine body, 402-slide block, 403-main oil cylinder, 404-lower top cylinder, 405-safety cylinder, 406-main cylinder displacement sensor, 407-platform and 408-forging die.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
It should be noted that in the description of the present invention, the terms of direction or positional relationship indicated by the terms "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, which are merely for convenience of description, and do not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
The embodiment of the invention provides an automatic forging system for a ring gear blank, which comprises a sawing machine, a medium-frequency induction heating furnace 2, a robot 3, a multi-station blank-making servo hydraulic machine 4 for a ring part, a numerical control ring rolling machine 6, a screw press 7 and a blue light detection device 8 which are connected in sequence. Wherein, the sawing machine is used for sawing raw materials 1, and after the sawing is finished, the robot 3 conveys the sawed materials to the intermediate frequency induction heating furnace 2. The medium-frequency induction heating furnace 2 is used for heating the material according to a set temperature; the robot 3 carries the qualified material heated by the medium frequency induction heating furnace 2 to the die, if the material is unqualified, the material is conveyed to an unqualified material box 15 through an unqualified material slide way 14, the forging system is further provided with a die heating device which is used for preheating the die, and when the robot carries the material to the die, the material is heated according to the set temperature, so that the material in the die forms a bar.
Preferably, the forging system further comprises a spray device, and when the material in the mold is formed into the bar, the spray device is activated to spray a release agent to release the bar from the mold.
And further, the multi-station blank-making servo hydraulic press 4 for the ring part is used for making blanks for the bars released from the die and making the bars into gear blanks. The multi-station blank-making servo hydraulic machine 4 for the ring-shaped parts comprises a mounting support structure, a hydraulic structure and a control and safety structure. Hydraulic pressure structure and control and safety structure locate installation bearing structure, are provided stable support by installation bearing structure for it, and hydraulic pressure structure is used for forging and pressing gear blank, simultaneously, carries out the in-process of forging and pressing gear blank, and accessible control and safety structure are to hydraulic pressure structure's detection and carry out the feedback of data, are convenient for carry out real time control to ring member multistation blanking servo hydraulic press.
Further, as shown in fig. 1, the multi-station ring blanking servo hydraulic press comprises a mounting support structure, a hydraulic structure and a control and safety structure. Hydraulic pressure structure and control and safety structure locate installation bearing structure, are provided stable support by installation bearing structure for it, and hydraulic pressure structure is used for forging and pressing the work piece, simultaneously, carries out the in-process of forging and pressing to the work piece, and accessible control and safety structure are to hydraulic pressure structure's detection and carry out the feedback of data, are convenient for carry out real time control to ring member multistation blanking servo hydraulic press.
As shown in fig. 1, the mounting support structure includes a fuselage 1 and a platform 7. The machine body 1 is a main body supporting structure of the multi-station blank-making servo hydraulic machine for the ring-shaped parts, is fixed on embedded bolts on the concrete ground in a bolt connection mode, and is provided with a circular through hole in advance in the bottom end face of the cuboid frame-shaped structure so as to facilitate installation and operation of the lower top cylinder 4. The platform 7 is a rectangular plate arranged on the top end face of the machine body 1, and the platform 7 is used for providing direct support for the main oil cylinder 3 and the energy storage driving structure on the top.
As shown in fig. 1, the hydraulic structure includes a slider 2, a master cylinder 3, a lower top cylinder 4, and a die 8. Wherein, the bottom mechanism of the main oil cylinder 3 is positioned below the bottom end surface of the platform 7, the bottom mechanism is provided with a hydraulic rod, and the bottom end of the hydraulic rod is fixedly connected with the top end of the slide block 2, so that the driving power of the main oil cylinder 3 is directly transmitted to the slide block 2. The slider 2 is wholly the cuboid structure, is equipped with the slope on the vertical four sides of this slider 2 and connects the face, connects the face and cooperate with the inclined plane on the fuselage 1 by this slope, when guaranteeing that slider 2 stable installation, for this slider 2 provides reliable direction, the smooth of guarantee forging and pressing work goes on, and is further, improves the security and the reliability of this multistation loop forming element multistation blanking servo hydraulic press. In addition, the forging die 8 is divided into an upper die and a lower die, a through hole is formed in the bottom of the lower die, the top surface of the upper die is fixedly connected with the slider 2 in the forging die 8, and the bottom surface of the lower die is fixedly connected with the top surface of the lower jacking cylinder 4.
As shown in fig. 1, the control and safety structure includes a safety cylinder 5 and a master cylinder displacement sensor 6. The main cylinder displacement sensor 6 is arranged on one side of the machine body 1, the main cylinder displacement sensor 6 comprises a detection groove and a connecting portion, the detection groove is longitudinally and fixedly installed on the machine body 1, meanwhile, the sliding block end of the connecting portion is arranged inside the detection groove, the other end of the connecting portion is fixedly installed and fixedly connected with the sliding block 2, the sliding block 2 moves and meanwhile drives the connecting portion to synchronously move inside the detection groove, then data collected by the main cylinder displacement sensor 6 are transmitted to the control end, the detection of the displacement of the main oil cylinder 3 is completed, the control system is convenient to control the movement of the main oil cylinder 3, and the controllability of the multi-station ring-shaped piece blank-making servo hydraulic machine is improved. The safety cylinder 5 is horizontally arranged on one side of the top of the machine body 1, and the safety cylinder 5 and the main cylinder displacement sensor 6 are arranged on two opposite surfaces.
Furthermore, the multi-station blank-making servo hydraulic press for the ring-shaped parts is provided with a first station, a second station and a third station, wherein the first station is used for upsetting bars, the second station is used for extruding blind holes in the bars subjected to upsetting, and the third station is used for punching the bars subjected to extruding blind holes to form the gear blanks; the robot carries the gear blank to the numerical control ring rolling machine 6, and the numerical control ring rolling machine 6 carries out reaming treatment on the gear blank; after the reaming process, the gear blank is transferred via a transfer chain 9 into a screw press 7.
Further, the screw press 7 is divided into a first screw press and a second screw press, and the first screw press is used for pre-forging the gear blank which is subjected to hole expansion by the numerical control ring rolling machine 6; and the second screw press is used for forging the gear blank subjected to pre-forging to form the gear.
Further, a blue light detecting device 8 for detecting the size of the forged gear according to the set size.
Further, a bin 12 is connected behind the blue light detection device 8, the bin 12 is used for accommodating unqualified gears detected by the blue light detection device, and unqualified gear pieces are conveyed into the bin 12 through the gear conveying chain 10 and the air-cooled gear conveying chain 11.
According to the automatic forging system for the annular gear blank, provided by the embodiment of the invention, the forged gear piece can be automatically size-sorted, so that errors possibly generated by manual operation are prevented, the sorting accuracy is high, and time and labor are saved; the full-automatic control of blanking, heating, multi-station blank making, hole expanding, pre-forging, finish forging and size detection can be realized, and unmanned and intelligent gear forging production is realized.
According to the automatic forging system for the ring gear blank, provided by the embodiment of the invention, the plurality of working positions are arranged on the multi-station blank-making servo hydraulic press for the ring-shaped part, so that the processing of upsetting, blind hole extruding and punching of a workpiece is realized, and the forging efficiency is greatly improved.
The automatic forging system for the ring gear blank, provided by the embodiment of the invention, is provided with a plurality of robots, can be used for simultaneously carrying workpieces in the processes of blanking, heating, multi-station blank making, hole expanding, pre-forging, finish forging and size detection, and greatly improves the forging efficiency.
As shown in fig. 3, an embodiment of the present invention provides an automated forging method for a ring gear blank, including the following steps:
step 1: heating the raw material to a temperature required by the process by using a medium-frequency induction heating furnace, heating the mold to the required temperature by using a mold heating device, putting the heated raw material into the heated mold, and spraying a release agent by using a spraying device after molding to obtain a bar material;
step 2: the robot places the bar on a first station of a multi-station blank-making servo hydraulic press of the annular part for upsetting;
and step 3: the robot moves the blank at the upsetting position to a second station of the multi-station blank-making servo hydraulic press of the ring-shaped part to extrude the blind hole;
and 4, step 4: the robot moves the blank on the second station to a third station of the multi-station blank-making servo hydraulic press for the ring-shaped piece to punch holes, meanwhile, the robot places the newly heated bar on the first station of the multi-station blank-making servo hydraulic press for the ring-shaped piece, and the punching and upsetting work are carried out simultaneously;
and 5: placing the punched bar on a numerical control ring rolling machine by a robot for reaming;
step 6: placing the blank subjected to hole expanding on a first screw press by a robot for pre-forging;
and 7: the robot conveys the pre-forged blank from the first screw press to a second screw press for finish forging to obtain a gear piece;
and 8: the robot conveys the gear piece to a blue light detection device for blue light detection;
and step 9: the robot will detect qualified gear spare through blue light detection device and place on the transfer chain and carry out the forced air cooling, put into unqualified workbin with unqualified gear spare.
The gear forging method provided by the embodiment of the invention realizes full-automatic control of blanking, heating, multi-station blank making, hole expanding, pre-forging, finish forging and size detection, and greatly improves the working efficiency of gear forging.
According to the automatic forging method, a medium-frequency induction heating furnace heats raw materials to a temperature required by a process, a mold heating device heats a mold to the required temperature, the heated raw materials are placed into the heated mold, a release agent is sprayed by a spraying device after molding, the raw materials are changed into bars, a first station is used for upsetting the bars, a second station is used for performing blind hole extrusion processing on the bars after upsetting, a third station is used for punching blanks after the blind hole extrusion processing to form gear forging blanks, a first screw press is used for performing pre-forging, and a second screw press is used for performing finish forging to obtain gear pieces, so that intelligent gear manufacturing is realized, and manufacturing accuracy and efficiency are high.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. An automatic forging system for a ring gear blank is characterized by comprising a sawing machine, a medium-frequency induction heating furnace (2), a robot (3), a multi-station blank-making servo hydraulic machine (4) for a ring part, a numerical control ring rolling machine (6) and a screw press (7) which are sequentially connected; wherein,
the sawing machine is used for sawing materials, and the intermediate frequency induction heating furnace (2) is used for heating the materials to form bars;
the multi-station blank-making servo hydraulic press (4) for the ring-shaped part is provided with a first station, a second station and a third station, wherein the first station is used for upsetting the bar, the second station is used for extruding blind holes in the upset bar, and the third station is used for punching the blank subjected to the blind hole extrusion to form a gear forging blank;
the robot (3) comprises a first robot and a second robot, the first robot is used for conveying the material heated by the medium-frequency induction heating furnace into a die, and the second robot is used for conveying the gear blank to a numerical control ring rolling machine;
the numerical control ring rolling machine (6) is used for carrying out reaming treatment on the gear blank;
the screw press (7) comprises a first screw press and a second screw press, wherein the first screw press is used for pre-forging the gear blank which is reamed by the numerical control rolling machine, and the second screw press is used for forging the gear blank which is pre-forged to form a gear forging.
2. The automated forging system for ring gear blanks as recited in claim 1, including heating means for heating the dies;
and the spraying device is used for spraying a release agent on the die so as to enable the bar stock to be released from the die.
3. The automated forging system for ring gear blanks as recited in claim 2, including blue light detection means for detecting the gear form factor;
and the bin is used for accommodating the unqualified gear detected by the blue light detection device.
4. An automated ring gear blank forging system according to any one of claims 1 to 3, wherein the ring gear multi-station blanking servo hydraulic machine (4) comprises a mounting support structure comprising a body (401) and a platform (407).
5. The automatic forging system for the ring gear blank according to claim 4, wherein the multi-station blank-making servo hydraulic machine (4) for the ring gear comprises a hydraulic structure, the hydraulic structure comprises a lower jacking cylinder (404) arranged on the bottom end face of the machine body (401), and a hydraulic rod of the lower jacking cylinder (404) is matched with the bottom end face of a forging die (408);
the main oil cylinder (403) is arranged at the circular through hole of the platform (407), the bottom of a hydraulic rod of the main oil cylinder (403) is fixedly connected with the bottom of the sliding block (402), and the bottom of the sliding block (402) is fixedly connected with the forging die (408).
6. The automated ring gear blank forging system of claim 5, wherein the hydraulic structure comprises a servo motor, a hydraulic pump, a pump head valve, a main pipe and an integrated block;
the servo motor is connected with the hydraulic pump and is used for controlling the flow and the flow speed of the hydraulic pump in real time to realize rapid pressure boosting or pressure relief;
the pump head valve is arranged at the outlet of the hydraulic pump and is provided with a pressure threshold value, so that the safety of a hydraulic structure is ensured;
the hydraulic pump is communicated with the integrated block through a main pipe and is used for realizing large-displacement pressing in the tapping process and multi-stage unloading in the return process.
7. The automated forging system for ring gear blanks according to claim 6, wherein the bottom end face of the forging die (408) is provided with a through hole through which the hydraulic rod of the lower knock cylinder (404) is passed to contact the workpiece.
8. An automated ring gear blank forging system according to any one of claims 5 to 7, wherein the ring gear multi-station blanking servo hydraulic machine (4) comprises control and safety structures, and the control and safety structures comprise a safety cylinder (405) and a main cylinder displacement sensor (406).
9. The automated forging system for ring gear blanks as recited in claim 8, wherein the master cylinder displacement sensor (406) includes a detection groove fixedly provided on the body (401) and a connecting portion connecting the detection groove and the slide block (402).
10. An automatic forging method of an annular gear blank is characterized by comprising the following steps:
step 1: heating the raw material (1) to a temperature required by the process by the intermediate frequency induction heating furnace (2), heating the mold to the required temperature by the mold heating device, putting the heated raw material (1) into the heated mold, spraying a release agent by the spraying device after molding, and changing the raw material (1) into a bar;
step 2: the robot (3) places the bar on a first station of the multi-station blank-making servo hydraulic machine (4) of the annular piece for upsetting;
and step 3: the robot (3) moves the blank at the upsetting position to a second station of the multi-station blank-making servo hydraulic machine (4) of the annular part to extrude the blind hole;
and 4, step 4: the robot moves the blank on the second station to a third station of the multi-station blank-making servo hydraulic machine (4) for the ring-shaped piece to punch, meanwhile, the robot places the newly heated bar on the first station of the multi-station blank-making servo hydraulic machine (4) for the ring-shaped piece, and the punching and upsetting work are carried out simultaneously;
and 5: the robot (3) places the punched bar on a numerical control ring rolling machine (6) for reaming;
step 6: the robot (3) places the reamed blank on a first screw press for pre-forging;
and 7: the robot (3) conveys the pre-forged blank from the first screw press to a second screw press for finish forging to obtain a gear piece;
and 8: the robot (3) conveys the gear piece to a blue light detection device (8) for blue light detection;
and step 9: the robot (3) places qualified gear parts detected by the blue light detection device (8) on the conveying chain (9) for air-controlled cooling, and places unqualified gear parts into the material box (12).
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| CN111673023A (en) * | 2020-06-17 | 2020-09-18 | 张家港中环海陆高端装备股份有限公司 | Manufacturing method of superfine crystal grain ring forging for wind power gear box |
| CN111673036A (en) * | 2020-06-30 | 2020-09-18 | 郑州机械研究所有限公司 | A planetary carrier automatic forging production system and process |
| CN112719928A (en) * | 2020-12-21 | 2021-04-30 | 武汉理工大学 | Intelligent production method and system of annular forging |
| CN113198961A (en) * | 2021-05-17 | 2021-08-03 | 定襄县宇特法兰有限公司 | Automatic production process of large flange |
| CN113617995A (en) * | 2021-08-27 | 2021-11-09 | 四川凯茨阀门制造有限公司 | Finish forging forming process for rolling and expanding rough blank with thin wall and wide wheel width and main reducing teeth |
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| CN111673023A (en) * | 2020-06-17 | 2020-09-18 | 张家港中环海陆高端装备股份有限公司 | Manufacturing method of superfine crystal grain ring forging for wind power gear box |
| CN111673036A (en) * | 2020-06-30 | 2020-09-18 | 郑州机械研究所有限公司 | A planetary carrier automatic forging production system and process |
| CN112719928A (en) * | 2020-12-21 | 2021-04-30 | 武汉理工大学 | Intelligent production method and system of annular forging |
| CN113198961A (en) * | 2021-05-17 | 2021-08-03 | 定襄县宇特法兰有限公司 | Automatic production process of large flange |
| CN113617995B (en) * | 2021-08-27 | 2023-11-17 | 四川凯茨阀门制造有限公司 | Rolling and final forging forming process for thin-wall wide-spoke main tooth reduction blank |
| CN113617995A (en) * | 2021-08-27 | 2021-11-09 | 四川凯茨阀门制造有限公司 | Finish forging forming process for rolling and expanding rough blank with thin wall and wide wheel width and main reducing teeth |
| CN113618005A (en) * | 2021-08-27 | 2021-11-09 | 四川凯茨阀门制造有限公司 | Three-station quick-change blank making die for main reduction gear blank |
| CN113618005B (en) * | 2021-08-27 | 2023-12-19 | 四川凯茨阀门制造有限公司 | Three-station quick-change blank making die for main reduction gear blank |
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| CN113976786B (en) * | 2021-10-29 | 2024-08-09 | 重庆江东机械有限责任公司 | Ring forging method |
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