Since the beginning of the 21st century, the Chinese automobile industry has maintained a momentum of sustained development. Before the 1990s, the leading products of the domestic automobile industry were trucks. After nearly a decade of development, there has been a gratifying pattern of taking cars as the leader. The key shift in the development of cars in the automotive industry has brought unprecedented opportunities for development in the equipment manufacturing industry. Among all walks of life, the largest related to the equipment manufacturing industry is the automotive industry. Relevant information shows that more than 50% of US machine tools and more than 60% of industrial robots are used in the automotive industry. Therefore, as the automobile kingdom, the United States has become a major machine tool producer. The development history of the automobile industry in developed countries proves this. The development of the automobile industry has improved the equipment manufacturing industry, especially the machine tool manufacturing industry. The improvement of the machine tool manufacturing industry supports and guarantees the prosperity of the automobile industry. As an important part of the machine tool manufacturing industry, forging machinery is closely related to the development of the automotive industry. In this paper, the typical metal sheet metal stampings and typical forgings are taken as examples to discuss the application of the automotive industry to forging machinery.
Process equipment for typical sheet metal stampings
In the production of complete cars, stamping, welding, painting and final assembly are collectively referred to as the four major processes of car production. According to statistics, in the 2000 parts of the car, the sheet metal stamping parts accounted for more than 40% of the number of pieces, and the stamping process equipment in the automobile industry can be seen. Today's car production highlights the individualized features of the car, making the change cycle shorter and shorter. The car change is mainly reflected in the change of the shape and structure of the car body, and the corresponding one is the ever-changing metal sheet metal stamping parts. Sheet metal stampings can be roughly divided into three categories, namely body panels, body structural parts and small and medium-sized stampings. The body cover and the body structure member are parts having a function of maintaining the shape of the body, such as a door, a top cover, a side cover, a trunk lid, etc., and are the main body of the metal plate stamping. The distribution of small and medium-sized stamping parts in cars is relatively scattered, such as wheels, clutches, automotive air conditioners, micro-motors and other components, there are a large number of stamping parts. Studying the technical equipment of the typical sheet metal stamping parts of the sedan, there is no doubt that the craft equipment of the body covering parts should be treated as a leader.
Process equipment for metal cover
Since the industrial production of body panels, mechanical presses have always been the main body of their equipment. The typical combination is a stamping production line consisting of a double-acting mechanical press and several single-action mechanical presses. Although the form of the stamping production line has been widely adopted, its connotation has been constantly changing. First of all, with the improvement of the level of single machine automation, the application of automatic rapid adjustment technology and automatic rapid mold change technology, the degree of flexibility of the stamping production line is enhanced. Secondly, the structural form of the stamping production line is continuously improved, and the production line of manual loading and unloading is developed. It is a semi-automatic press line and an automatic press line; thirdly, it is more technologically advanced. The multi-station press enters the press line, and the laser processing is integrated with the press process to form a generalized press line.
The progress of China's forging machinery industry in the process of body coverings is obvious to all. Through the scientific and technological research since the "Eighth Five-Year Plan", the independent development capability of the forging machinery industry has been significantly improved. On this basis, the relevant enterprises have provided dozens of stamping production lines for Chinese car manufacturers by introducing the design and manufacturing technologies of famous companies such as Schuler, American Wilson, and Komatsu in Japan, or by cooperating with foreign manufacturers. And has a place in the international market.
At present, the rapid development of body panel stamping technology is remarkable, mainly in the three aspects of the joining of hydraulic presses, the use of multi-station presses and the maturity of flexible technology.
As mentioned above, the mechanical press is the main body of the stamping production line, and no other equipment can shake its dominance for a long time. However, with the breakthrough of some key technologies of the hydraulic press, the advantages and potentials of the hydraulic press in the stamping are fully exerted, the productivity is obviously improved, and the problems of the synchronization of the stroke and the linkage with the conveyor are satisfactorily solved, and the trend of the hydraulic press as the main body of the press production line is generated. . Of course, this does not mean that the hydraulic press will replace the mechanical press. Although the press line can all use hydraulic presses, it can also be used in combination with hydraulic presses and mechanical presses. However, the press line of mechanical presses as the mainframe is still the mainstream.
The stamping line, which was widely used in the early days, consisted of a double-acting mechanical press and several single-acting mechanical presses with a workpiece turning device between them. The emergence of multi-station sheet automatic presses is highly favored by the automotive industry due to its multi-step processing, compact structure and high production efficiency. The multi-station press is used as the main machine for the stamping production line, which is much more difficult than the single machine. It must solve a series of technical problems such as the drive system, the transmission system and the detection system. In recent years, with the above technical problems solved one by one, multi-station presses have become possible as a host into the press line.
The flexible technology is becoming more mature and is the most important technological advancement in the production of car body panels. First of all, the numerical control of the equipment that forms the press line has laid the foundation for the automation of the press line. The flexible transfer technology, off-board simulation technology, off-line programming technology are improving day by day, especially the mold system including automatic mold storage, automatic mold recognition and extraction, automatic adjustment of mold working parameters, etc., marking the flexibility of the body cover The technology has matured, making "personalized" production of large-scale covers, order-based production and "just-in-time production" possible.
The introduction of the flexible stamping automatic line indicates that the development of flexible technology is gradually complete. The basic structure of the flexible stamping automatic line is still a double acting press and several single-action presses arranged in series. Before the double acting press, there is a demolition device, which is composed of a loading truck, a hydraulic jacking device, a magnetic layerer, a vacuum chuck lifter, a double material detector, a magnetic roller conveyor, a double material discharger, a cleaning oil coating device and a feeding device. Composition; there is a loading and unloading device between the double-acting press and the single-action press, including a hopper, a turning device, a conveying device and a feeder; a loading and unloading device between the single-action presses, by a hopper, conveying The device and the feeder are composed; the last single-action press is followed by a palletizing device consisting of a feeder, a conveyor and a pallet truck. In addition, automatic quick change systems, automatic quick adjustment systems, fault detection systems, and waste removal and transportation systems are essential. Due to the full application of robotics, microelectronics and hydraulics, not only the automation of the stamping process, but also the flexibility of the production organization is achieved.
The large-scale multi-station press automatic stamping production line represents an advanced combination method and should be paid special attention. The continuous improvement of large-scale multi-station presses and the demand for the production of large-size car covers have promoted the development of automatic stamping production lines for large multi-station presses. The more primitive combination consists of a double-action stretching press and a single-action large-scale multi-station press, equipped with a set of turning devices and synchronizing devices, which improves the production cycle to a certain extent. And reduce the floor space. The configuration of the second-generation production line is greatly simplified. A multi-station press with a double-action stretching station is equipped with a demolition device and a palletizing device in front and rear, respectively, to form an automatic stamping production line. Such multi-station presses are mostly four-column and three-slide structures. The first station under the first slide is a double-acting stretching station, and the boring station is a single-action punching station. Since the stretching station adopts the reverse stretching method, the workpiece is prevented from being turned over, so that the turning device is not required, and the productivity is further improved and the floor space is also reduced. The emergence of large-scale multi-station presses with CNC hydraulic air cushions has abandoned the traditional double-action stretching process concept and truly combines stretching and other stamping processes onto a single press. The hardware composition of the automatic stamping production line is still a main unit equipped with a demolition device and a palletizing device. The main machine is a multi-station press with a numerical control hydraulic air cushion, and the numerical control hydraulic air cushion is the core of its technology. The CNC hydraulic air cushion is controlled by four corners to adjust the blanking force of the stretching work, thereby achieving single-action deep drawing. The use of digital hydraulic air cushion to replace the single-action press with a single-action press not only simplifies the structure of the press, eliminates the turning device, but also achieves optimal control of the blanking force, improves the quality of the tensile member, and reduces the workpiece. Rejection rate.
China's auto industry has a long-term diversification of equipment demand, so the production process of large-scale covers is also diverse. With the development of technology, many companies have or will transform the line of manual loading and unloading into semi-automatic press lines and automatic press lines, but there are still few companies using flexible press automatic lines. Due to the high cost and technical problems, the large-scale multi-station press automatic stamping production line will take time to promote it in China. At present, China's forging machinery industry can not only provide the traditional configuration of stamping production line, semi-automatic press line and automatic press line, but also the ability to provide flexible stamping automatic line and large multi-station press automatic press line.
Process equipment for steel plate forming wheels
In terms of structure, the car wheel is mainly divided into a combined wheel and an integral wheel, and the material is divided into a steel plate forming wheel and an aluminum alloy wheel. At present, the combined steel plate forming wheel occupies a very important position, and in the short term, there will be no situation in which the integral aluminum alloy wheel dominates the world. The combined steel plate forming wheel is mainly composed of rims and spokes, and the production process of rims and spokes has been receiving much attention. At present, there are two main methods for producing rims. One is the rolling production process, and the other is the spinning production process. There are two main methods for producing spokes, namely, the stamping forming process and the spin forming process.
The typical configuration of the automatic production line for producing the rim of the car by the rolling process can be divided into three parts according to the nature of the process: the first part includes the automatic unwinding unit, the leveling shearing unit, and the coil material is prepared into a fixed length sheet for processing the rim; Some include reeling units, welding and weld cleaning units, chamfering and flaring units, rolling the blanks required for the pre-processed sheet into rims; the third part consists of a roll forming unit (usually three rolls) The forming machine is composed of a finishing and expanding unit, and the annular blank is rolled into a forming rim. The advantage of the rolling process is high productivity, and the productivity of such automatic production lines abroad is generally 800-1200 pieces/hour.
The advantage of the spinning process for producing a car rim is that by effectively controlling the plastic flow of the metal, a variable cross-section strength rim can be machined to improve the rim quality. However, the spinning process has the disadvantage of low productivity, and the productivity of a typical foreign production line is usually 200-250 pieces/hour, so it is not suitable for enterprises that produce rims in large quantities. A more common practice is to use the flexibility features of the spinning process for new product development and small batch production. The configuration of the automatic production line of the spinning process car rim, the first and second parts are similar to the rolling process, and the third part of the spinning forming machine replaces the roll forming machine.
The process of stamping and forming spokes was relatively simple. In the early stage, multiple single-station presses were used to form the steps. Later, multi-station presses were used to complete on one piece of equipment. The thick-walled and heavy-weight spokes of the press forming can not meet the needs of high-speed driving of the car, and the material utilization rate and wheel life are low. The spinning process can obtain thick-walled and other strength structure spokes, which not only improves material utilization and wheel life, but also increases the safety and reliability of the car at high speed. Typical processes for spin forming lines include blanking, strong spinning, trimming, and punching. The main body of the spinning forming production line is a numerical control spinning forming machine. The first roller pre-spins the material to complete the fabric, and the second roller rotates the wall thickness to a predetermined value.
The production process equipment of Chinese car wheels is relatively backward, and the rolling process and the spinning process have great development space. From the development trend of foreign countries, although the spinning process has the disadvantage of low production efficiency, its high processing precision, the ability to produce variable cross-section and other strength rims and spokes, the large rigidity of the workpiece and the small rebound are still not negligible, especially suitable for new Product development and small and medium batch production. With the continuous improvement of the spinning process productivity and the improvement of control technology, people may re-examine the evaluation of the spin forming process today as the model change cycle becomes shorter and shorter.
Process equipment for typical forgings
The automotive industry is the most important user of forgings, as more than 60% of the forgings are used in the automotive industry. Compared with the mechanical industry, the automotive industry pays more attention to the precision of forgings, the fine structure of forgings and the formation of hollow parts and the maximum weight reduction. Due to the high strength and high reliability of forgings, forgings are always used as important parts of the car. Typical forgings include the crankshaft and connecting rod of the engine, the gears of the gearbox, the shaft parts, the wheel carrier, the tie rod and the steering knuckle in the operating system. Parts, etc. The forging of typical forgings for cars can be divided into two categories, namely ordinary die forging and special die forging. Ordinary die forging is carried out on a forging hammer and hot forging press using a small flash and no flashing process. The special die forging adopts a wedge cross rolling process, a swing rolling process and a radial forging process.
Engine connecting rod forging process equipment
There are two main types of forging engine connecting rods, one is the hot forging press production line, and the other is the electro-hydraulic die forging hammer production line. The former is suitable for mass production, while the latter is suitable for small and medium-sized, multi-variety production methods. The basic components of the hot forging press production line are bar stock, automatic bar sorting and feeding device, induction heating furnace, discharging device, bar cutting mechanism and hot die forging press. The hot forging press production line adopts a one-die two-piece forging process with a productivity of 800-1200 pieces/hour and a material utilization rate of over 95%. Although the hot forging press production line has economic and technical advantages, it is constrained by many manufacturers because of its large investment, high degree of specialization, high mold manufacturing and maintenance costs, and the need to have a driving rate of more than 70%. The electro-hydraulic die forging hammer production line produces the forgings of the car engine connecting rods, and adopts a one-piece forging process to cut the bar material into billets, then heat and then forge. The basic components of the electro-hydraulic die forging hammer production line are bar bar shearing machine, induction heating furnace, feeding device, cross wedge rolling mill or roll forging machine, electro-hydraulic die forging hammer, trimming correction machine and the like. With the development of control technology, the electro-hydraulic die tamper can control and adjust the process parameters such as the striking energy, the number of strikes, the striking interval, etc., to meet the energy requirements of forging forming with the best striking force, which can not only improve the quality of forgings, but also extend The life of the mold. Although the productivity of the electro-hydraulic forging hammer production line is usually only about one-half of that of the hot forging press production line, its investment is only one-third of the latter's investment. The organization is very flexible in production, so it is deeply affected by the production scale of small and medium-sized batches. The favor of manufacturers.
The technical development trend of car engine connecting rod forging is to improve the mechanization and automation level of the forging production line and adopt a new forging process. Obviously, it is the consensus of the industry to improve the mechanization and automation level of the forging line. The use of mechanized loading and unloading devices, mechanized conveyors, robots and automatic control technology to technically transform the production line to reduce manual operations and achieve automated or semi-automated production is a common practice in developed countries. There are two attempts at the new forging process. One is the powder forging process, that is, the billet for sintering the metal powder is heated and then subjected to die forging; the second is to form a high speed forging on a multi-station automatic hot stamping machine. The advantages of the former are small weight deviation of forgings and the ability to produce complex forgings, etc., which are especially suitable for advanced engines with high dynamic balance requirements, which are used by many manufacturers; the latter is difficult due to excessive threshold value of economic batches and too expensive equipment. Accepted by the manufacturer.
Disc tooth forging process equipment
Disc tooth blanks are typical representatives of car disc forgings. Due to their large quantity, high precision, high efficiency and low cost process are required. The early production process uses a forging hammer, a mechanical press, a screw press or a hot die forging press as the main machine. The bar material is cut into billets and heated, and is completed in several steps. The production efficiency is low, the forging precision is bottom, and the processing is performed. Large amount and low material utilization rate. Since the concept of roughening of the blank, the automatic production line of high-speed hot stamping machine has become the most ideal choice for the production of disc blanks. The typical configuration of the high-speed hot stamping machine automatic production line is the material rack, automatic feeding device, induction heating furnace, roller feeding mechanism and multi-station high-speed hot rolling machine. After the heated bar material enters the high-speed hot-pressing machine, all the processes of blank cutting, shaping, pre-forging, final forging and punching are completed in sequence, and the transfer of the forgings between the stations is automatically completed by the robot. The high-speed hot stamping machine automatic production line can realize real roughing. The size and shape of the forgings are close to the machined parts, the material utilization rate is improved and the machining time is saved. The forgings have better metallographic structure and mechanical properties, and the productivity is ordinary forging. The method is several times or even ten times, and its comprehensive economic benefits are very significant.
Gear shaft forging process equipment
The car gear shaft is an important part of the gearbox. It is a typical car shaft type with slender and multi-step features. The traditional process for producing shaft parts is die forging on a die forging hammer or a hot forging press, but the forgings produced by this process have low precision, low material utilization rate, large processing capacity, and effective cross wedge rolling process. This problem. The cross wedge rolling process is a new technology of high efficiency, energy saving and material saving. The heated bar material enters the cross wedge rolling mill, and the cross wedge rolling die continuously distributes the metal in a working cycle to form a stepped shaft forging that meets the shape and size requirements. Moreover, hollow shaft forgings can be produced from pipes as blanks. Since the cross wedge rolling process is suitable for processing symmetrical parts, it is often necessary to symmetrically arrange a pair of parts to design a mold, which benefits both processability and productivity. The wedge cross-rolling process is characterized by one or a pair of parts in one stroke, high production efficiency; continuous deformation of metal, low deformation force, high die life; forging dimensional accuracy, high processing capacity and high material utilization. The cross-rolling automatic production line has a relatively simple composition, and is usually composed of an automatic feeding device, an induction heating furnace and a cross wedge rolling mill. The cross wedge rolling mill has a two-roller and flat plate type structure. The flat wedge cross rolling mill is driven by mechanical or hydraulic pressure, and two flat plate templates are used for linear reciprocating rolling stock; the mold of the two-roll cross wedge rolling mill is a pair of rolling Roller, the blank is formed in a rotating roll. The advantages of the former are simple structure, convenient adjustment, low cost of the mold, and high precision of the forging; the disadvantages are limited stroke, small degree of deformation, free space, low production efficiency; the latter has a compact structure, which can realize continuous production and production efficiency. High, the disadvantage is that the mold is difficult to manufacture and the forging accuracy is low.
Throughout the application of forging machinery in China's auto industry, the level of stamping process equipment is higher than forging, manifested in the advancement of technology and equipment, automation and flexibility of production lines, intensive production level and so on. Although the domestic forging machinery industry can provide almost all of the stamping and forging equipment for the automotive industry, it goes without saying that the level and strength of the Chinese forging machinery industry is not strong in the international market. The position of the forging machinery industry in the automotive industry depends not only on the technological advancement and structural adjustment of the forging machinery industry, but also on the development strategy and market prospects of the automotive industry.
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