Forging process The original bow-shaped bolt forgings have a special structure of vertical double-buds at both ends, which is extremely difficult to be fully formed at the same time, and belongs to complex type die forgings. According to the shape and size characteristics of the forging, the main process of forming the bow-shaped bolt is die forging (the die forging step should be lengthening, pressing, pre-forging and final forging) or free forging and then forging (pre-forging and Final forging and other methods. No matter the forging process, the forging process is poor. For example, it is difficult to make the vertical double-branched buds at both ends of the forging and the final forging and filling is difficult. The process is complicated and complicated, the raw materials are consumed, the forging tonnage is large, and the forging efficiency is low. The forging die has high manufacturing cost, the forging die has a low service life, and the forging is high. Production practices have shown that by optimizing the forging process and forging die design, there is little success in improving the forging processability and reducing the cost of forgings.

Threading machine plus process bow-shaped bolt parts generally belong to black-skinned parts that do not need to be machined. Only bolt threads are processed during machine-adding, but due to the particularity of shape and size, the manufacturing process is poor. For example, the forging is difficult to locate, the operation is difficult, the machine addition efficiency is low, the dimensional stability is poor, the machine plus the qualified product rate is low, the machining processing is complicated, and the large-scale mechanical adding equipment is required, the manufacturing cost is high, and the machine cost is high.

Production practice shows that by improving the tooling of the bow-shaped bolts and optimizing the machining process, it has little effect on improving the machine performance and reducing the cost of adding parts.

Bow-shaped card bolt structure improved design working conditions analysis Bow-shaped card bolts are mainly connected with scraping coal, chain ring and nut to transmit motion and power, and its service life should reach about 5kh (more than the service life of 3.6kh of its mating parts). Through the analysis of the importance degree, working condition, failure mode, structural size and strength performance of the bow-shaped card bolt, it is known that the bow-shaped bolts mainly work under the conditions of bending, torsion, shear and shock vibration, and the failure type is the bolt-and-rod diameter. Damage to fracture and deformation is much.

Improvement of the structure of the parts The company has many years of experience in the development of mining models of E-bolts, U-bolts and bow-shaped bolt forgings, and achieved phased results. Theoretical and practical research shows that due to differences in structure, shape and size, it is difficult to reduce the total manufacturing cost of bow-shaped bolt parts by optimizing the forging process and forging die design and optimizing the machining process and tooling design. Only the structural design of the parts is improved. It is an effective way to reduce the manufacturing cost of the bow-shaped bolts and achieve the organic integration of the performance, process performance and economy.

The improved design of the bow-shaped bolt part structure is as shown. The improved bow-shaped bolt part structure is composed of two parts of the bolt rod 1 and the bolt body 2 being screwed and then welded. The strength of use of the bolt rod 1 determines the overall strength of use of the bow-shaped bolt parts, and the bolt body 2 is used at a lower strength than the bolt rod 1. The installation practice shows that the improved structure of the bow-shaped bolt parts has the characteristics of simple structure, high reliability, high service life, high production efficiency and low manufacturing cost.

The improved manufacturing process has improved bow-shaped card bolts forging, forming only the bolt body without bolt rods, and the bolt body forging has only two steps of lengthening and final forging, and the forging process of the bolt body is good. The forging die diagram of the bolt body forging is shown.

The bow-shaped bolt body forging has fewer steps, simple operation, less forging deformation energy, 60% reduction of die forging times, high forging efficiency; less raw material consumption, original material weight 11kg, and current material weight 8kg (including bolt rod) The weight of the machine is reduced by 32%; the raw material consumption is reduced by 32%; the forging is easy to form and the forging is good; the forging die is small, the module size is small, the die shape is relatively simple, the forging die manufacturing cost is low, and the forging die manufacturing is reduced. The cost is 30%; due to the small number of die forging, high forging efficiency and relatively simple shape of the die, the service life of the die is high; due to the reduction of raw materials, forging energy, forging time, forging die manufacturing cost, etc. Improved forging processability and reduced forging costs by at least 20%.

The bolt rod machine plus the process bow card bolt only needs to add the bolt thread external thread, the bolt body thread and the partial welding when the machine is added. Therefore, the manufacturing process is good, such as simple operation, high machine-adding efficiency, good dimensional stability, high machine-acceptable rate, and can be completed on ordinary machine-added equipment, the machine cost is low, and the machine cost is reduced. 20%.

End (1) The improved design of the bow-and-bolt part structure is technically feasible, reliable in quality and economically reasonable. Compared with the traditional manufacturing process, the manufacturing cost of the bow-shaped card bolt forging and machine-adding processes is greatly reduced, the total manufacturing cost of the parts can be reduced by at least 40%, and the performance of the bow-shaped bolt manufacturing is achieved. The organic unity of process performance and economy. (2) This paper is based on the localized manufacturing of bow-shaped bolts for mining large-scale coal mining conveyors imported from Germany. It also has certain reference value for the manufacture of other similar bow-shaped bolt parts.

Motor Springs

Motor Springs,Torsion Spring Motor Spring,Adjustable Steel Tension Spring

Compression Springs ,Stampings,Extension Springs Co., Ltd. , http://www.ns-springs.com