Method for making double-flange bushings

FIELD: plastic working of metals, possibly in forging shops of metallurgical and machine engineering plants for manufacturing automobile wheels and similar products.

SUBSTANCE: method comprises steps of preparing initial blank; forming of it intermediate semi-finished product in the form of cup having shaped bottom, wall and in zone of transition of wall to bottom - thickened portion defined at inner side of cup by surface of revolution, by annular protrusion on outer end of bottom and by flange on end of wall; making central protrusion on inner end of bottom; forming flange on wall by applying axial effort to its end for increasing thickness of wall having constant diametrical size at inner side; then finally shaping blank due to expanding annular protrusion on bottom of cup for forming other flange. Blank is finally shaped during two stages. At first stage height of central protrusion of bottom is increased due to radial motion of bottom material from its center and simultaneously thickness of said protrusion and diametrical size of bottom with flange are decreased, part of wall adjoined to bottom is thickened. At second stage sleeve is calibrated from inside for achieving final diametrical size of its cavity. Then bushings are subjected to heat treatment and mechanical working.

EFFECT: enhanced strength characteristics of reduced-cost wheels.

3 cl, 3 dwg, 2 ex

 

The present invention relates to the field of metal forming and can be used in forging shops of metallurgical and machine-building plants in the manufacture of automobile wheels and the like products.

A known method of manufacturing products of the type wheels, including the preparation of the original piece, forming an intermediate semi-finished product in the form of a bowl, education annular ledge and the ridge on the bottom of the bowl, forming on the Cup flange and the disk part with a relief, the formation of the rim and the other flange of an annular ledge, and thermal and mechanical processing (Patent RF №2063838, CL 21 To 1/28, publ. 1996).

The disadvantage of this method is the complexity of die tooling, and low productivity due to the need to implement a large number of process steps of processing by pressure.

A known method of manufacture glasses with the two flanges, such as car wheels, including the preparation of the original piece, the formation of intermediate semi-finished product in the form of a bowl shaped bottom wall thickening in the transition wall in the bottom, limited to the inside of the bowl surface of rotation, an annular protrusion on the outer face of the bottom flange on the end wall, the final shaping of the workpiece, including the distribution of an annular ledge on the not bowl in the other flange, heat treatment and mechanical processing (Patent RF №2135320, CL 21 To 1/28, publ. 1999 - prototype).

The disadvantage of this method is the difficulty of ensuring the desired quality of the finished products due to a lack of rational structure of the fibers during deformation that affects the strength characteristics under conditions of cyclic loading during operation and specialization receive blanks, which significantly increases the cost of manufacture of small batches of wheels. The last is most important for wheels sports cars, the shape and dimensions of which are strictly individualized to fit the requirements of each customer.

The proposed method for the manufacture of glasses with two flanges, such as car wheels, includes preparation of the original piece and the formation of intermediate semi-finished product in the form of a bowl shaped bottom wall thickening in the transition wall in the bottom, limited to the inside of the bowl surface of rotation, an annular protrusion on the outer face of the bottom flange on the end wall. Then finally form the workpiece by hand annular ledge at the bottom of the bowl in the other flange. When forming the intermediate semi-finished product on the inner face of the bottom perform the Central ledge. The flange on the wall of the form, applying axial force to its end, by increasing the women of the wall at the end with her constant diametrical sizes on the inside. The final shaping of the workpiece lead into two stages. At the first stage to increase the height referred to the Central protrusion on the bottom of reducing a thickness of the latter, and also increase the diametrical size of the bottom with its flange, the said thickening and adjacent to the last part of the wall by radial movement of material from the bottom of his heart. In the second stage are calibrated by hand from the inside glass on the end diametrical size of its cavity. The phases of the first and second can be repeated in the same sequence. The height of the Central protrusion and the thickness of the bottom is determined by the ratios:

and

where

h1and h2- the height of the Central protrusion,

H1and H2the thickness of the bottom

accordingly, the intermediate semi-finished product and finally formed on the workpiece. Then conduct the heat treatment and mechanical processing.

The proposed method differs from the prototype in that the formation of intermediate semi-finished product on the inner face of the bottom perform the Central protrusion, the flange on the wall of the form, applying axial force to its end, by increasing the wall thickness at the end with her constant diametrical sizes on the inner side, and the final shaping of the workpiece lead into two stages: at the PE the vom - increase the height referred to the Central protrusion on the bottom of reducing a thickness of the latter, and also increase the diametrical size of the bottom with its flange, the said thickening and adjacent to the last part of the wall by radial movement of material from the bottom of his heart, and the second - calibrated distribution inside the glass on the end diametrical size of its cavity.

While the final stages of forming of the workpiece can be repeated in the same sequence. The height of the Central protrusion and the thickness of the bottom is determined by the ratios:

and

h1and h2- the height of the Central protrusion,

H1and H2the thickness of the bottom

accordingly, the intermediate semi-finished product and finally formed billet.

The technical result of the invention is the ability to group processing close to the geometrical parameters of the wheels when the rational structure of the fibers during deformation, which allows to combine high strength characteristics under conditions of cyclic loading in extreme conditions and low-cost wheels. This is particularly important in the manufacture of small batches of sports wheels with a relatively thin wall thickness bottom.

The present invention is illustrated drawing is m, showing:

figure 1 - the formation of an intermediate material;

figure 2 - the first stage of the final formation of glass;

figure 3 - the second stage of the final formation of glass.

Example.

Produced sports wheel sizes 13’×21’ aluminum alloy type 6061. Source procurement 1 size ⊘500 mm × 125 mm weight 66 kg was heated and placed in the cavity of the stamp 2 with shaped ejector 3 and the plug 4.

Applied deforming force and backward extrusion of the formed cake mix in a bowl height H=400 mm, outside diameter D1=505 mm and wall thickness 5S=10 m at the same time as the axial force acted on the open end of the Cup shaped flange 6 by increasing the thickness of the wall 5 at the end of Sf=25 mm, while maintaining the internal diameter of D2- permanent. The outer surface of the bottom part formed annular protrusion 7. The transition zone from the bottom 8 of the wall 5 has performed thickened. Thickening 9 internally limited to a conical surface with a cone angle α=32°, the shape and size of which is determined by the conical part 10 of the punch 4. The angle of the taper surface of annular ledge β=7°. At the end of the punch 4 is made of the cavity 11, which forms the Central protrusion 12.

The final formation of the billet wheel Khujand who have been in two stages. First calibration punch 13 has started to distribute the flange 6, and then formed the flange 14 of an annular protrusion 7 with partial stiffness of the workpiece material into the cavity 15 of the plug 13, converting the Central protrusion 12 in more massive ledge 16. Then deformed the whole bottom part of the glass, to move the workpiece material in the projection 16 and creating intensive course from the center of the bottom in a radial direction to the periphery, which not only contributed to the formation of the flange 14, but increased diametrical dimensions of the actual walls of the Cup near its bottom to D3=530 mm Wall 5 thus lagged behind the punch 13 with the formation of the annular gap 17.

Later he completed the second stage of the final formation of the billet wheel, changing the calibration plug 13 on the plug 18 large Diametric sizes, carried out the calibration of the shape of the glass from the inside, increasing the flange 6 to the diameter D4=574 mm, equal to the diameter of the flanges of the wheels 21". Simultaneously deformed bottom part, increasing the size of the flange 14 to a diameter of D4=574 mm In this transition zone from the flange 14 to the wall 5 kept diametrical sizes close to the size after the first calibration. The height of the Central projection 12 h1=40 mm increased to the height of the projection 16 h2=70 mm, and the thickness of the bottom 8 reduced from the thickness of the 1=25 mm to the thickness of the N2=16 mm

Thus, using the minimum number of die tooling and minimal effort press, received the workpiece is relatively large. A semi with a maximum diameter of D1+2Sf=535 mm and an area of the projection of F535=2247 cm2was obtained billet wheels with a maximum diameter of D4=574 mm and an area of the projection of F574=2586 cm2that is 15% more than the bulk.

Example 2.

For the manufacture of the data obtained in example 1 billet wheels 13’×21’ new material for the wheel 13’×22’ repeated both final stage of morphogenesis similar to the previously described in example 1, but the punches of larger diameter, namely: in the first stage, the final formation continued to increase the height of the Central projection 16 and to reduce the thickness of the bottom 8.

In addition distributed the flange 6 and increased the diameter of the flange 14 with a simultaneous increase in diametral size of the wall 5 of the Cup.

In this example, completing the final shaping, the next punch of increased diameter D4flange 6 to 600 mm, increased the height h2the Central protrusion to 74 mm and reduced the thickness of the N2the bottom 15 mm, increasing the diameter D4flange 14 is also up to 600 mm

Thus, the received zag the training area projection F=2826 cm 2i.e. cumulatively increased the size of the workpiece by more than 25% of the original.

The proposed method can significantly expand the range and improve the quality of finished products rationalization of the die tooling and, consequently, improve the structure of the fibers during deformation and to prevent cracking during formation of ribs. The latter is particularly important in the production of alloys of the system magnesium-lithium.

1. The method of manufacture of glasses with two flanges, for example, road wheels, including the preparation of the original piece, the formation of intermediate semi-finished product in the form of a bowl shaped bottom wall thickening in the transition wall in the bottom, limited to the inside of the bowl surface of rotation, an annular protrusion on the outer face of the bottom flange on the end wall, the final shaping of the workpiece, including the distribution of an annular protrusion on the bottom of the bowl in the other flange, heat treatment and machining, characterized in that when forming the intermediate semi-finished product on the inner face of the bottom perform the Central protrusion, the flange on the wall of the form, applying axial force to its end, by increasing the wall thickness at the end with her constant diametrical sizes on the inner side, and the final shaping of the workpiece Vedas is t in two stages: first, increase the height referred to the Central protrusion on the bottom when reducing the thickness of the latter, as well as increase the diametrical size of the bottom with its flange, the said thickening and adjacent to the last part of the wall by radial movement of material from the bottom of his heart, and the second calibrated distribution inside the glass on the end diametrical size of its cavity.

2. The method according to claim 1, characterized in that the final stages of forming of the workpiece is repeated in the same sequence.

3. The method according to claim 1, characterized in that the height of the Central protrusion and the thickness of the bottom is determined from the formula:

where h1and h2- the height of the Central projection, respectively, of the intermediate semi-finished product and finally formed workpiece;

H1and H2the thickness of the bottom respectively of the intermediate semi-finished product and finally formed billet.



 

Same patents:

FIELD: instrument engineering.

SUBSTANCE: according to the method the blank of hanger is made taking direction of rolled stock into account. Then blank is subject to thermal processing, both sides of blank are cleared from material and hanger is formed by means of double-sided shaped embossing. According to the first variant of the method, blank is subject to heat-cyclical processing prior to double-sided embossing. According to the second variant, double-sided shaped embossing is made in two steps and heat-cyclical processing is performed between those two steps.

EFFECT: prolonged life of hanger; increased service life of press tool.

2 dwg, 2 ex

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The invention relates to the processing of metals by pressure

FIELD: instrument engineering.

SUBSTANCE: according to the method the blank of hanger is made taking direction of rolled stock into account. Then blank is subject to thermal processing, both sides of blank are cleared from material and hanger is formed by means of double-sided shaped embossing. According to the first variant of the method, blank is subject to heat-cyclical processing prior to double-sided embossing. According to the second variant, double-sided shaped embossing is made in two steps and heat-cyclical processing is performed between those two steps.

EFFECT: prolonged life of hanger; increased service life of press tool.

2 dwg, 2 ex

FIELD: plastic working of metals, possibly in forging shops of metallurgical and machine engineering plants for manufacturing automobile wheels and similar products.

SUBSTANCE: method comprises steps of preparing initial blank; forming of it intermediate semi-finished product in the form of cup having shaped bottom, wall and in zone of transition of wall to bottom - thickened portion defined at inner side of cup by surface of revolution, by annular protrusion on outer end of bottom and by flange on end of wall; making central protrusion on inner end of bottom; forming flange on wall by applying axial effort to its end for increasing thickness of wall having constant diametrical size at inner side; then finally shaping blank due to expanding annular protrusion on bottom of cup for forming other flange. Blank is finally shaped during two stages. At first stage height of central protrusion of bottom is increased due to radial motion of bottom material from its center and simultaneously thickness of said protrusion and diametrical size of bottom with flange are decreased, part of wall adjoined to bottom is thickened. At second stage sleeve is calibrated from inside for achieving final diametrical size of its cavity. Then bushings are subjected to heat treatment and mechanical working.

EFFECT: enhanced strength characteristics of reduced-cost wheels.

3 cl, 3 dwg, 2 ex

FIELD: plastic working of metals, possibly in forging shops of metallurgical and machine engineering plants for making motor vehicle wheels and similar articles.

SUBSTANCE: method comprises steps of preparing initial blank; then forming intermediate semi-finished product in the form of cup having shaped bottom, wall, thickened portion in zone of wall-bottom transition restricted at inner side of cup by surface of revolution, by annular protrusion on outer end of bottom and by flange on end of wall; forming flange of wall due to applying axial effort to its end at increasing wall thickness while keeping stable diametrical dimensions at inner side of wall; then finally shaping bushing due to expanding wall until final diametrical dimensions of its flange and deforming annular protrusion on cup bottom to other flange; restricting the last in peripheral zone of its outer end by cone surface of revolution having apex in axis of bushing; selecting conicity angle of said surface in predetermined range; realizing heat treatment of formed bushings.

EFFECT: enhanced strength characteristics of wheels in condition of cyclic loading during exploitation.

2 dwg, 1 ex

FIELD: plastic working of metals, possibly in forging shops of metallurgical and machine engineering plants for making motor vehicle wheels and similar products.

SUBSTANCE: method comprises steps of preparing initial blank; forming intermediate semi-finished product in the form of cup with flange on end of wall and with annular protrusion on outer end of bottom; forming flange of wall due to increasing thickness of wall near its end at constant diametrical dimensions at inner side of wall; then finally shaping blank with two beads; forming ne bead due to deforming flange of cup wall at expanding wall from inside at least in zone of its end; forming other bead due to expanding annular protrusion to cone at conicity angle of inner surface of protrusion in end zone exceeding conicity angle in zone adjacent to cup bottom; determining geometry sizes of semi-finished product and final blank according to given relations; then performing heat treatment and mechanical working of products.

EFFECT: significantly decreased cost of small lots of products.

2 dwg, 1 ex

FIELD: plastic working of metals, possibly in forging shops of metallurgical and machine engineering plants for making motor vehicle wheels and similar products.

SUBSTANCE: method comprises steps of preparing initial axially symmetrical blank and piercing dead seat along axis of blank; forming intermediate semi-finished product in the form of cup with shaped bottom, wall, thickened portion in zone of wall-bottom transition restricted at inner side of cup by surface of revolution, by annular protrusion of outer end of bottom and by flange of end of wall; forming flange of wall due to applying axial effort to its end while increasing thickness of wall near its end at constant diametrical dimensions at inner side; then finally shaping blank at deforming annular protrusion of cup bottom to other flange and expanding from inside end portion of wall. Expression is given for relating geometry parameters of initial and final blanks. Then formed sleeves are subjected to heat treatment and mechanical working.

EFFECT: enhanced quality of ready products due to providing rational structure of fibers at deforming blank and due to enhanced strength characteristics of fibers in condition of cyclic loading during exploitation.

3 dwg, 1 ex

FIELD: plastic working of metal, possibly in forging shops of metallurgical and machine engineering plants for making wheels of automobiles and similar articles.

SUBSTANCE: tool includes die, punch, knocking out member with shaped portion, unit for stepped regulation of bottom thickness and height of cup. Said unit is in the form of apparatuses for changing length of punch and depth of die. In upper part of punch female type yoke with through stepped opening is mounted. In upper part of die there is seat whose diameter dimension corresponds to outer diameter of yoke. Depth of die is changed by means of apparatus in the form of flat ring arranged over shaped portion of knocking out member. Apparatus for changing length of punch is in the form of flat round gasket arranged inside yoke over punch. Punch has in its upper portion large-diameter step corresponding to diameter of large step of yoke opening.

EFFECT: possibility for producing by means of one tool semi-finished products of wheels with different combinations of width and thickness values.

3 cl, 3 dwg

FIELD: plastic working of metals, possibly in forging shops of metallurgical and machine engineering plants for making wheels of automobiles and similar articles.

SUBSTANCE: method comprises steps of preparing initial blank; forming intermediate semi-product in the form of cup having shaped bottom, wall, thickened part in zone of wall-to-bottom transition. Said thickened part is restricted at one side by surface of revolution, by annular protrusion on outer end of bottom and flange on end of wall. Intermediate semi-product is formed by two stages. At first stage bottom is partially punched for forming on outer end of bottom dead cavity and for forming on inner end of bottom central protrusion. Flange is formed on wall due to increasing thickness of wall near its end at keeping constant diameter dimensions of inner side. At second stage annular protrusion is formed and central zone of bottom is finally shaped due to lowering thickness of central protrusion while keeping its height. Simultaneously flange is formed on end of wall by its final size. Then blank is finally formed due to expanding annular protrusion on bottom of cup to other flange. Such sleeve is subjected to heat treatment and mechanical working.

EFFECT: enhanced strength characteristics of low-cost wheels.

3 dwg, 1 ex

FIELD: metallurgy; metal plastic working.

SUBSTANCE: invention can be used in form forging shops of metallurgical and machine-building plant in manufacture of vehicle wheels and like articles. Proposed tool contains die and punch holder with punch and knock-out with shaped part movable relative to die. Punch is enclosed by replaceable round holder with support flat and support surface. Die is provided with socket in upper part whose diameter corresponds to outer diameter of holder, and with support flat. Holder is installed for longitudinal displacement and engagement by its support flat and support surface with support flat of die and with punch holder, respectively. Shaped part of knock-out is made replaceable to provide possibility of making wheels of different type-sizes using one tool.

EFFECT: enlarged operating capabilities.

2 cl, 2 dwg

FIELD: plastic working of metals, possibly forging shops of metallurgical and machine engineering factories at making automobile wheels and similar products.

SUBSTANCE: method comprises steps of preparing initial blank by hot die forging; forming intermediate semi-finished product in the form of cup with wall passing to its bottom and with front rim in bottom zone and back rim near free end of cup; calibrating received intermediate semi-finished product according to final size between rims due to changing cup depth at applying deforming effort along axis of sleeve to back rim or to near-bottom portion of sleeve and fixing other of said two portions. Then calibrated semi-finished product is subjected to heat treatment and mechanical working.

EFFECT: possibility for producing semi-finished products of wheels with different distances between rims due to using universal fitting that needs only minimized tuning.

5 cl, 2 dwg, 4 ex

FIELD: plastic working of metals, possibly forming forged pieces, for example rings, gear wheels, flanges.

SUBSTANCE: initial blank is heated, preliminarily shaped, finally formed and trimmed. At final forming open die set is used; said die set has gap between its upper and lower halves. Said gap is arranged in zone of forging that is formed last. Dimensions of die set are no more than respective dimensions of forging in order to prevent deforming of displaced excess of metal.

EFFECT: lowered deforming efforts, decreased metal consumption.

11 cl, 2 dwg, 1 ex

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