Domestic and foreign alternator magnetic pole production process

1 rumors With the furnace in the car production process, the magnetic poles (as shown) are important parts of the alternator, which are used in pairs to form the stator. The shape of the part is very complicated, and the six pointed claws on the periphery are quite difficult to plastically form.

There are several kinds of magnetic pole production processes currently used at home and abroad, but most of them have many processes, long process flow, low production efficiency, high cost, and quality casting and sheet forming cold extrusion forming hot forging cold finishing 2 magnetic pole materials The choice of magnetic pole materials is usually made of low carbon steel, such as 08 steel and 10 steel. The less carbon content, the better the magnetic properties of the material. Currently, more electromagnetic pure iron is used. Electromagnetic pure iron is about 900% from austenite! -Fe changes to ferrite "-Fe when there is a sudden change in volume, when the intergranular connection is weak, plasticity is poor, in the red brittle region; 400% or so is in the blue-brittle region. Magnetic pole forging must avoid these two Temperature zone. Therefore, when the electromagnetic pure iron is hot forged (1050%~1250%) and warm forging (650%~800%), the temperature range is narrower, which is worse than the forging performance of ordinary low carbon steel. After forging, electromagnetic purity Iron products need to be annealed to eliminate work hardening, maintain the electrical conductivity, magnetic permeability, temperature coefficient of resistance of the product, and meet the technical requirements after assembly. The annealing process route is as shown.

3 magnetic pole forming process receiving period: 2001-12-27 time / h annealing process line magnetic pole forming process development can be expressed. The history of foundry production is the longest, but because the foundry structure has shrinkage and porosity, it is easy to demagnetize, and because of its high carbon content and poor magnetic properties, this method has been gradually eliminated at home and abroad. The sheet forming material utilization rate is low. Most of the foreign countries now use hot forging cold finishing. The cold extrusion process is numerous and requires annealing, phosphating, and saponification, and the process is complicated. Hot forging cold finishing and warm cold forging combined process more. After investigation and exploration, our institute has developed a split-reverse extrusion forming process, which requires only one pair of molds, one temperature and cold forging combined process|advanced technology.

3.1 Sheet metal forming process The sheet metal forming process is an earlier process, and its process (): cutting one! Finishing! one! Punching one! Bend one! Claw shape finishing! Overall finishing. The thickness of the plate selected during the blanking process is the thickness of the magnetic pole part required for the design. Since the billet is thick, the tip of the pole claw is too sharp, which is difficult to punch and affect the life of the die. Therefore, when designing the blanking part, the arc of the sharp corner should be appropriately enlarged to finish the claws! Just to make the workpiece straight, so that the subsequent production process can be carried out normally. After punching, take six belts! The claws are bent perpendicular to the bottom surface. The accuracy of the claws is required to be higher in the forming of the magnetic poles, so the claws must be separately pre-finished before the overall finishing. The production process is simple, and the requirements for the (e) punching (f) bending (g) claw finishing (h) integral finishing and machining equipment are not high, but the process can only be used for the magnetless core. The magnetic pole (with no boss in the middle) is not suitable for punching sharp-point parts. The punching process material has low utilization rate, low precision and poor economic efficiency. In addition, the anisotropy of the dairy sheet can also affect the performance of the alternator pole.

3.2 Cold extrusion forming cold extrusion forming process (): cutting! annealing! Phosphating saponification! Being squeezed! Correction! annealing! Phosphating saponification! Shantou! Punching one> trimming one> annealing one> phosphating saponification one> bending one> the first precision one!

The second fine pressure. Since electromagnetic pure iron is sensitive to work hardening, severe work hardening occurs during cold extrusion, and in order to make the blank structure uniform and deformation resistance small, the material needs multiple intermediate annealing. The purpose of phosphating is to form a porous structure having a relatively small coefficient of friction on the surface of the blank, which can better store the lubricant. Saponification also acts as a lubricant. The process has many steps, and the pre-forging piece generated in the previous process is required to be accurately positioned in the mold cavity of the latter process. In actual production, the equipment needs to be large, the number of operators is large, the investment is large, and the production cost is high.

3.3 Hot forging cold finishing forming hot forging cold finishing process (): cutting! Forging heating 1100 (! - secondary preforming! secondary preforming! final hot forging cold finishing process simple figure (d) secondary preforming (e) final forming (f) trimming (g) annealing (h Phosphating, saponification (1) Fine shaping! Trimming! Annealing! Phosphating saponification! Finishing. The effect of annealing and phosphating saponification is the same as that used for cold forming. The forging heating temperature is about 1100 (the temperature is It is the hot forging temperature of electromagnetic pure iron (1050()1250(). If low carbon steel is used, its temperature range can be wider. Due to the complex shape of the magnetic pole, secondary pre-forming must be used. Compared with cold extrusion The steps of the forging cold finishing process are obviously reduced, and the plasticity is improved when the metal is heated, the deformation force is greatly reduced, the work hardening is avoided, and the precision of the forging is improved and the mechanical properties are improved.

3.4 Warm cold forging combined process This process can give full play to the advantages of warm forging and cold forging, and its process flow (): unloading one> heating 780 (―> 镦头一 radial extrusion one!

Shantou! Cut the edges! Phosphating saponification! punching! bending! punching! Precision pressure. Forging temperature 780 (can reduce the oxidation effect and ensure that the ferromagnetism is not destroyed. In warm forging (radial extrusion), the billet is easy to form due to the small deformation force, which reduces the limitation of the blank size. The obtained magnetic pole product has high precision. There are fewer defective products, but the process needs, the number of equipment is large, the investment is large, and the production cost is high.

Warm cold forging combined process extrusion (e) hoe (f) trimming (g) phosphating, saponification (h) punching (1) bending (j) punching (k) coining 3.5 magnetic pole high speed temperature extrusion forming Shanghai Jiaotong University has proposed a high-speed warm extrusion process-2: cutting! Heating (700 (~750()! High-speed extrusion. Its biggest feature is that it only uses one pair of molds, requires less equipment, and has high material utilization rate, which can reduce machining time, reduce cost and improve economic efficiency. 3.6 Diversion Counter-extrusion forming multi-station press electronic feeding technology 250101 Jinan Qingqi Motorcycle Co., Ltd. engine factory Jiang Tianhua 250022 Jinan Second Machine Tool Group Co., Ltd. Liu Yanhui Zhou Ying 1 Introduction The performance and productivity of multi-station press mainly depends on its feeding The processing capacity of the stamping parts of the system. Although the multi-station press has been used in mass production for many years, its basic structure has changed little. With the development of electronic computer control technology, it provides for the feeding of multi-station presses. A very flexible and reliable means, the electronic multi-station feeding system is the product of this modern electronic computer technology. It has the characteristics of fine-tuning the stroke trajectory, fast acceleration and deceleration, etc., so that it can adapt to different mold sets.

Electronic multi-station feeding (ETF) technology has been the designated standard for some automotive plants in the United States since 1985. However, car factories in other developed countries have only just considered adopting such a feeding system.

The development of industrial computer electronics has accelerated the pace of upgrading of electromechanical devices. Due to the speed and complexity of the processor, distributed data processing has become the accepted standard. Electronic feeding systems are faster, more flexible and more reliable than mechanical feeding systems, with higher productivity, easier operation and longer life.

The classification of the multi-station feeding system The multi-station feeding system is a device similar to the moving arm, and its main function is to shift the stamping parts from one work to another. The stamping of each pair of molds in a set of molds is done in the same press. The multi-station feed moving rods are moved along the mold area, they are the main structural members on which the end pickers of the moving stampings are mounted. In the automobile body stamping factory, there are three types of multi-station feeding systems that are often used: mechanical feeding; electronic feeding and combined feeding (1) mechanical feeding is through the direct connection with the press transmission system to complete the stamping parts from a station Move to another station. The power take-off on the beam of the press outputs energy from the top of the press to the ground. A large mechanical cam driven by the follower is mounted on the feed mechanism, which rotates the cam to drive the mechanical feed.

The split-type reverse extrusion forming process () developed by our institute is: one-time extrusion molding of cylindrical blanks. Compared with the above forming process, the processing process is further reduced. It eliminates the pre-formed and annealed split-flow reverse extrusion forming process diagram (a) blank (b) heating (c) upsetting ([d) forming (e) punching trimming (f) residual heat annealing (g) phosphorus The saponification (h) finishing softening process increases productivity, reduces energy consumption, and further reduces costs. After more than two years of production practice verification, significant economic benefits have been achieved. After searching, the magnetic pole forming process has reached the international advanced level.

4 Conclusion When China joins WT0, the competition in the automotive industry will become more intense. The production of auto parts must reach high quality, high efficiency and low cost. Only in this way can China's auto industry dominate the international competition. As a key part of the engine system of a car, the magnetic pole has a large demand, so it has a good development prospect.

Obviously, the use of advanced split reverse extrusion molding can not only improve product quality and material utilization, but also economic benefits.

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