WO2016004776A1 - 金属管件的优化连接结构及其实现方法 - Google Patents

金属管件的优化连接结构及其实现方法 Download PDF

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Publication number
WO2016004776A1
WO2016004776A1 PCT/CN2015/075212 CN2015075212W WO2016004776A1 WO 2016004776 A1 WO2016004776 A1 WO 2016004776A1 CN 2015075212 W CN2015075212 W CN 2015075212W WO 2016004776 A1 WO2016004776 A1 WO 2016004776A1
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WIPO (PCT)
Prior art keywords
pipe
plug
joint
front fork
fork
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PCT/CN2015/075212
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English (en)
French (fr)
Inventor
黄启达
Original Assignee
黄启达
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Filing date
Publication date
Application filed by 黄启达 filed Critical 黄启达
Priority to US15/115,432 priority Critical patent/US20170158280A1/en
Priority to EP15819256.7A priority patent/EP3168120A4/en
Publication of WO2016004776A1 publication Critical patent/WO2016004776A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/18—Joints between frame members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/28—Making tube fittings for connecting pipes, e.g. U-pieces
    • 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
    • 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
    • B21K25/00—Uniting components to form integral members, e.g. turbine wheels and shafts, caulks with inserts, with or without shaping of the components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/02—Cycle frames characterised by material or cross-section of frame members
    • B62K19/04—Cycle frames characterised by material or cross-section of frame members the material being wholly or mainly metallic, e.g. of high elasticity
    • B62K19/06—Cycle frames characterised by material or cross-section of frame members the material being wholly or mainly metallic, e.g. of high elasticity tubular
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/18—Joints between frame members
    • B62K19/28—Means for strengthening joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K3/00—Bicycles
    • B62K3/02—Frames
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B7/00—Connections of rods or tubes, e.g. of non-circular section, mutually, including resilient connections
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B17/00—Connecting constructional elements or machine parts by a part of or on one member entering a hole in the other and involving plastic deformation
    • F16B17/004—Connecting constructional elements or machine parts by a part of or on one member entering a hole in the other and involving plastic deformation of rods or tubes mutually

Definitions

  • the invention relates to the technical field of metal pipe joint connection, in particular to a high strength and toughness joint structure for various frame pipe fittings and a realization method thereof.
  • the world is currently in the light maneuvering or non-motor vehicle manufacturing industry.
  • most of the lightweight metal hollow thin-walled pipes are used to connect into a frame or other products through a welding process.
  • the investment is small, the product style is new and fast, and the disadvantage is that the connection strength and toughness are greatly reduced, and there are potential safety hazards.
  • the reason is that the weld is an as-cast coarse-grained structure, which is prone to slag inclusion, shrinkage, cracking, and the volume of the pipe fittings involved in the connection is too small. It destroys the original high-strength, forged fine-grained structure of the seamless pipe.
  • the welding can only be carried out between the same materials, and it is not possible to weld two different material pipes in the same frame to obtain a variety of excellent performance.
  • This is the most comprehensive and comprehensive exposure of the metal bicycle frame and fork manufacturing industry to the welding of aluminum alloy, magnesium alloy, titanium alloy and stainless steel frame or fork pipe fittings; to solve the above problems, the world in recent decades The relevant industry has carried out many experiments and research and development work on alternative welding.
  • Chinese Patent Publication No. CN86106439 published (Announcement) No. 1987.04.08, discloses a frame connection portion of a bicycle and the like including a short tube bushing, a connecting part, an adhesive, and Ring jacket.
  • the short tube bushing includes a stem, a short tube, and an annular shoulder.
  • the short tube protrudes from the tube seat, the annular shoulder is located between the tube seat and the short tube;
  • the connecting part has a tubular end portion with an annular end surface, which is press-fitted on the short tube;
  • the adhesive sticks the tubular end portion with the short tube Knot together;
  • the ring clamp fits over the short tube between the end face and the shoulder.
  • the jacket includes an inner end and an outer end.
  • the inner end includes a first convex portion extending along the circumferential surface and overlapping the tube seat at the shoulder; the outer end includes a second convex portion having a concave concave surface; and the end surface of the connecting part overlaps and cooperates.
  • This technology uses a short tube bushing, an annular jacket, a connecting part and an adhesive to connect a connection point at each connection point of the front triangle of the bicycle frame, although the connection of the front frame of the welded frame is solved.
  • Cipheral Patent Publication No. CN86101907 (Announcement) No. 1986.12.17 discloses a bicycle frame and a bicycle, the technology comprising a seat rod and a front head connected by an upper rod and a lower rod, and integrally made of light metal or alloy, in particular It is made of magnesium.
  • At least the lower rod, preferably the seat rod is cast into an open section, which is then closed by a second casting and secured to the open section by an adhesive, preferably with a mechanical connection.
  • the mechanical connection is obtained with a fitting arranged obliquely in the longitudinal direction of the casting.
  • the upper and lower bars are connected by a structural bridge to the ground between the front and the seatpost.
  • the lower rod is attached to the midpoint of the seatpost.
  • the technology uses magnesium alloy to integrally cast the upper rod, the lower rod, the seat rod and the front of the bicycle frame, and the lower rod and the seat rod are cast with a large C-shaped open section, and are bonded with a small C-shaped cross-section cover. Sealing of the agent; the remaining pair of rear upper and lower forks, connecting bridges and journals of the frame are also integrally cast with magnesium alloy And the use of adhesives and mechanical auxiliary connection to complete the frame connection processing; the metal thickness of each part of the frame is 5mm.
  • the structural advantages of the cast-bonded total assembly frame are: strong torsion and bending resistance, and the metal involved in the connection is bulky and rigid.
  • the shortcomings are: large investment in molds, difficulty in controlling the uniform gap between the castings, and aging of the adhesive; this production method is difficult to adapt to the problem of rapid changes in the size and style of the current frame market.
  • the invention aims at the problems that the existing metal pipe welding process is easy to produce slag inclusion, shrinkage hole, crack, connection strength and toughness, and the connection volume is too small; and the invention provides an optimized connection structure of the metal pipe fitting and the realization method thereof: a radial through hole is arranged around the end of the pipe member, and a multi-function plug is inserted into the hole at the end of the pipe; one or more pipe fittings that have been inserted into the plug head are firstly placed as inserts of the connecting piece, and are placed in advance After the corresponding position of the casting die under the connecting piece is fastened and closed, and then under the PLC control of the casting and forging compound machine, when the laminar filling process of the connecting part cavity is performed, the metal fluid injected into the connecting part cavity can be The radial through hole of the pipe member and the axial through hole of the plug head flow into the groove of the plug head.
  • the connecting piece When the connecting piece is completed by extrusion forging, two metal rings of the inner layer and the outer layer are formed, and the joint portion of the pipe to be connected and the plug head is connected.
  • the structure is wrapped in a three-dimensional direction and integrated into a unit, thereby completing the high-strength connection of the connecting member and the pipe member. Since the connection difficulty, complexity and high strength requirements of the bicycle frame and the front fork are much higher than those of other light vehicles, the present invention focuses on solving the high-strength connection of the bicycle frame and the front fork pipe. problem.
  • the invention relates to an optimized connection structure of a metal pipe fitting, comprising: a pipe member, a multifunctional plug head placed in the inner hole of the pipe end, and a connecting member connecting the pipe members.
  • the pipe member is provided with a radial through hole at a periphery of the connecting portion, and the center connecting line of the through hole is parallel to the end surface of the pipe member;
  • the multi-function plug includes: a blocking body at the end, a groove or a through hole at the middle end, and connected large and small positioning steps at the top end, wherein: the outer end surface of the large step is provided with an axial through hole or a through groove Communicating with the groove and having a intersecting arc surface intersecting the inner hole of the connecting member;
  • the connecting member comprises: an inner metal ring, an outer metal ring and a plurality of radial and axial metal columns connected thereto, the inner and outer metal rings and the metal column will participate in the casting and forging processing
  • the pipe fittings and the multi-purpose plug head forging joints are forged and integrated into a high-strength and tough joint structure in three dimensions.
  • the pipe member includes, but is not limited to, an upper pipe, a lower pipe, a riser pipe, an upper fork, a lower fork, a front fork pipe or a vertical pipe of the bicycle frame and the front fork;
  • the connecting portion at the upper end of the riser is provided with a connecting pipe for connecting the upper pipe and the two upper forks, and the connecting portion of the upper end of the riser is provided with an inner hole obtained by partial expansion processing of the axial length and diameter, and The through hole is machined to realize that the upper tube and the upper fork can enter the inner diameter of the expanded diameter riser to provide a space position for the forming of the riser joint.
  • the tubular multifunctional plug includes but is not limited to: upper tube two-end plug, lower tube two-end plug, riser plug, upper fork plug, lower fork plug, hook double plug, shoulder cover Double plug or front fork hook plug;
  • the multi-function plug may be round, flat or profiled, wherein: the multi-head plug tip and the end plug have the same radial cross-sectional shape and size and are associated with the tube The inner hole of the piece is used for sliding fit;
  • the flat end of the flat-shaped multifunctional plug has a radial cross-sectional thickness that is less than a radial cross-sectional thickness of the end plug.
  • the hook double plug is an integrated structure, and the plug has a circular or flat structure.
  • the double plug of the shoulder cover is an integrated structure, and the plug head is circular, flat or shaped, and: a positioning circular groove of the front fork vertical pipe is arranged above the plug joint; on the plug joint A through hole is provided, which is respectively communicated with the front fork riser plug groove and the shoulder cover joint.
  • the optimized connection structure of the present invention may include: a front tube, a riser joint, a five-way joint, a claw joint, a front fork hook joint, and a shoulder joint.
  • the connecting piece is formed by casting and forging forming in a casting die, and the tubular member and the multifunctional plug head located in the pipe are used as inserts of the connecting piece, and are placed in the corresponding positions of the lower casting die and fastened. Thereby participating in the forming process of the connecting piece and realizing the high-strength connection of the connecting piece and the pipe piece.
  • the optimized connection structure of the present invention may include: a riser, an upper fork, a lower fork, and a front tube connecting the upper tube and the lower tube, and a riser joint for connecting the riser, the upper tube and the upper fork a five-way connecting the riser, the lower pipe and the lower fork, and a double plug and a hook joint connecting the upper and lower forks;
  • the optimized connection structure of the present invention may include: a front fork standpipe, a front fork pipe, a front fork claw plug, a shoulder joint for connecting the front fork standpipe and the front fork pipe, A front fork hook joint connecting the front fork tube and the front fork hook plug and a double plug of the shoulder cover.
  • the invention innovatively divides the traditional welded frame and the front fork parts into three categories: the first type is the pipe fitting, which retains most of the traditional welding process, and only changes the front pipe and the five-way to the connecting piece: second
  • the class is a hole in the end of each connected pipe fitting, a new multi-head plug is added:
  • the third type is a joint for connecting one or more pipe joints at each joint to replace the weld of the welding process; Therefore, in addition to changing the front tube and the five-way to the connecting piece, a new riser joint and two hook joints are added to the upper end of the riser and the connecting part of the hook; also in the front fork and front fork
  • Each of the fork hooks is provided with a shoulder joint and two front fork hook joints; for the casting and forging of the connecting piece, the PLC controlled cast forging machine, the heat preservation quantitative feeding furnace, the casting and forging die and the temperature control system can be adopted. With the cooperation of the equipment, each metal connecting piece is subjected to casting and
  • the invention relates to a method for realizing the optimal connection of the above metal pipe fittings, comprising the following steps:
  • One or more pipe fittings with multi-function plugs are placed at the corresponding positions of the casting and forging dies under the joints of the casting and forging machine table, and the molds are fastened and closed, in the PLC control, the heat preservation quantitative feeding furnace and In combination with the mold heating and cooling system, the laminar filling of the connecting part cavity is first filled, and the connecting piece and the tube part and the multi-function plug cavity which are involved in the casting and forging are fully filled, and later the metal melt is cooled in the semi-solid state. Casting and forging compound machine at temperature Under the control of the PLC, the final extrusion of the joint is subjected to the type processing, and the pressure is maintained until the processing is completed.
  • the connecting member forms an inner metal ring and an outer metal ring.
  • the inner and outer metal rings are connected by a plurality of radial and axial short metal columns, and one or more tubular members and multifunctional plugs are used.
  • the part where the head participates in the joint is wrapped in a three-dimensional direction and is integrally formed into a high-strength and tough joint structure.
  • connection point of the bicycle frame and the front fork of the invention is a mechanical connection, and can connect two different material parts together, thereby increasing the market value of the new frame and the front fork, and increasing safety. It also has the advantage of comfort: the premise is that all the connecting parts, pipe fittings, plugs and claws of the frame and the front fork are insulated; the upper and lower tubes of the frame, the left and right upper forks and The two forks of the lower fork and the front fork must be made of the same material; the metal with the melting point is not allowed to be used in the same frame or fork to avoid mutual interference between the heat treatment temperatures of the two materials. If the above principles are followed, the effects of stress caused by galvanic corrosion and linear expansion coefficients between different metal materials can be reduced to negligible levels.
  • connection structure of the bicycle frame comprises: an upper tube, a lower tube, a riser, an upper fork, a lower fork, and a front tube connecting the upper tube and the lower tube; connecting the riser, the upper tube and the upper fork a riser joint; a five-way connecting the riser, the lower and the lower fork; and a double plug and a hook joint connecting the upper and lower forks.
  • the front tube, the riser joint, the five-way joint, the hook joint and the double-plug head are made of magnesium alloy material; the upper tube, the lower tube, the riser tube, the upper fork and the lower fork are made of stainless steel.
  • the bicycle frame connection structure wherein the front tube, the riser joint, the five-way and the claw joint are made of a magnesium alloy material; the upper tube, the lower tube, the riser, the upper fork, and the lower The fork and the hook double plug are made of titanium alloy.
  • the bicycle frame connection structure wherein the front tube, the riser joint, the five-way and the claw joint are made of aluminum alloy; the upper tube, the lower tube, the riser, the upper fork, and the lower The fork and the hook double plug are made of titanium alloy.
  • the bicycle frame connection structure wherein the front tube, the riser joint, the five-way, the claw double plug, the claw joint, the riser, the upper fork and the lower fork are made of a magnesium alloy material;
  • the upper and lower tubes are made of a titanium alloy material.
  • connection structure of the bicycle front fork includes a front fork standpipe, a front fork pipe, and a front fork hook plug a head, a shoulder joint connecting the front fork standpipe and the front fork pipe, a front fork hook joint connecting the front fork pipe and the front fork hook plug, and a shoulder double plug participating in the connection.
  • the shoulder double plug, the shoulder joint, the front fork hook joint, the front fork claw plug are made of magnesium alloy material, and the front fork tube and the front fork standpipe are made of stainless steel.
  • the bicycle front fork connection structure wherein the shoulder double plug, the shoulder joint, the front fork hook joint, and the front fork claw plug are made of aluminum alloy; the front fork tube and The front fork standpipe is made of stainless steel.
  • the bicycle front fork connection structure wherein the shoulder double plug, the shoulder joint, the front fork hook joint, and the front fork claw plug are made of a magnesium alloy material; the front fork tube and The front fork standpipe is made of titanium alloy.
  • the bicycle front fork connection structure wherein the shoulder double plug, the shoulder joint, the front fork hook joint, and the front fork claw plug are made of aluminum alloy; the front fork tube and The front fork standpipe is made of titanium alloy.
  • the high rigidity and toughness connection structure of the bicycle frame and the front fork tube is simple. Only one multi-function plug head part is added at the connection point of each pipe fitting. Each time one joint piece is processed, 1 to 4 pieces of the connection can be completed.
  • the connection process of the pipe fittings can reach a length of 5.0 ⁇ 20.0mm.
  • the volume and structural strength of the metal involved in the connection cannot be compared with the welded structure; the obtained connecting piece is a forged dense structure with high strength and good toughness; the production method can be First realization: the production mode that is connected in the mold and completed under automatic control greatly reduces the production process of the frame and the front fork and saves a large number of employees and plant area, and the product quality is uniform.
  • Each connecting piece of the frame and the front fork has a short processing time, and the connected parts are: uniform heat, high position and dimensional precision between parts, beautiful connection appearance, and comparable in appearance to carbon fiber.
  • the connecting member can be processed by the direct liquid forging process, and the mechanical properties are easy to obtain and the mechanical properties are easy to obtain. Replace the product style and size, save the cost of the mold, and meet the needs of the current bicycle variety Mass production mode reduces production costs.
  • the high strength and toughness connection structure of the bicycle frame and the front fork of the invention is a mechanical connection, so that two different material parts can be combined and connected, and a variety of new frames and front forks can be added, so that The frame and front fork combine high safety and comfort to meet the most demanding needs of the modern bicycle market.
  • the invention is particularly suitable for the production of stainless steel and titanium alloy frames and front forks with ultra-high strength and toughness and thin wall thickness of 0.3-0.8 mm, which is low in cost compared with welding, and makes titanium alloy and stainless steel vehicles with great market prospects.
  • Frame and fork products can be quickly promoted and popularized.
  • Figure 1 is a schematic view of a typical cast-forged composite connection of a metal pipe
  • Figure 2 is a schematic view of the cast-forged composite joint assembly of each part of the bicycle frame
  • FIG. 3 is a schematic structural view of a bicycle frame and a front fork circular tube T-shaped connection plug according to the present invention
  • Figure 4 is a schematic view showing the structure of the angle connection plug of the bicycle frame of the present invention.
  • Figure 5 is a schematic view showing the angle connection plug of the flat tube of the bicycle frame of the present invention.
  • Figure 6 is a schematic view showing the connection structure of the double plug of the bicycle frame of the present invention.
  • Figure 7 is a schematic view of a cast-forged composite joint assembly of each part of the bicycle front fork
  • Figure 8 is a schematic view showing the structure of a circular double plug of a bicycle front fork shoulder cover according to the present invention.
  • Figure 9 is a schematic view showing the structure of a flat double plug of a bicycle front fork shoulder cover according to the present invention.
  • shoulder double round plug 38. shoulder double flat plug, 39. front fork claw plug, 40. front tube, 41. outer ring 42. inner ring, 43. radial connecting column, 44. axial connecting column, 45. connecting member outer flange, 46, front tube inner hole, 48. hook joint, 49. five-way, 50. riser Connector, 51. upper tube into the through hole, 52. upper fork into the through hole, 58. shoulder joint, 59. front fork hook joint, 60. front fork standpipe, 61. front fork tube, 62. front fork diameter To the through hole. .
  • Embodiment 1 Referring to FIG. 2, FIG. 3 and FIG. 4, the high-strength connection and the pipe material combination configuration of the front frame 40 of the frame and the upper tube 10 and the lower tube 14 are as follows:
  • the upper tube 10 and the lower tube 14 are respectively placed in the corresponding positions of the forging and pressing lower mold of the front tube 40 installed on the countertop of the casting and forging machine. At this time, the casting and forging die is insulated to 200-230 ° C, and the mold is clamped after tightening.
  • the magnesium alloy solution insulating at 680-730 °C is pumped through the pipeline to the barrel of the forging tube 40 forging, firstly laminar filling of the front tube 40 cavity: when magnesium The alloy melt passes through the upper tube 10, the radial through hole 13 of the lower tube 14 and the plug axial through hole 25, and enters the annular groove 23 of the plug to fill all the cavities; later when the magnesium alloy melt temperature drops to At 570 to 585 ° C, the front tube 40 is subjected to final extrusion forging under the control of the PLC of the casting and forging machine, and is kept at a pressure of 60 to 85 MPa until the processing is completed.
  • the front tube 40 forms a magnesium alloy inner ring 42 and an outer ring 41.
  • the inner and outer metal rings are connected by a radial magnesium alloy column 43 and an axial magnesium alloy column 44 to form a plug.
  • 20 and the connection between the upper tube 10 and the lower tube 14, wrapped in a three-dimensional direction A high-strength and tough connection structure.
  • the high-strength connection of the frame riser joint 50 with the upper pipe 10 and the upper fork 16 and the pipe material combination are configured:
  • the through holes 51 and 52 which allow the upper tube 10 and the upper fork 16 to enter respectively;
  • the inner hole width of the upper fork 16 is 12.1 mm
  • the thickness 30 of the end plug of the flat angle connector head 29 is 12.0. Mm
  • the sliding fit clearance of both is 0.1 mm, and the thickness of the end and the tip is 7.0 mm.
  • a Ti3AL2.5V titanium alloy seamless tube is used, and the remaining riser 15, the upper fork 16, and all the plugs are respectively made of 7050-T4, T6 aluminum alloy seamless pipes and rods.
  • the micro-isotification treatment is performed on the surface of the riser 15, the two upper forks and the plug head.
  • the inner and outer metal rings are connected by a radial aluminum alloy column 43 and an axial aluminum alloy column 44 to form
  • the connecting portion of the upper tube 10, the upper tube plug 20, the two upper forks 16, and the two flat corner plugs 29 is wrapped in a three-dimensional direction and integrated into a high-strength and tough joint structure.
  • Two front fork tubes 61 are made of Ti3AL2.5V titanium alloy seamless pipe, and the other standpipe 60, plug head 20, shoulder cap double plug head 38 and shoulder cover joint 58 are respectively made of 7050-T4, T6 aluminum alloy seamless pipe. , bars and ingots.
  • the aluminum alloy melt insulated at 690-720 °C is pumped through the pipeline, and pumped into the shoulder-joint joint 58 casting and forging die barrel, and the liquid laminar flow filling is performed on the shoulder joint 58 cavity first: the metal fluid at this time
  • the shoulder joint All the cavities in 58 are filled.
  • the melt temperature of the aluminum alloy drops to 580-595 °C
  • the final extrusion forging of the shoulder joint 58 is performed under the control of the PLC of the cast forging machine, and is 85.
  • the shoulder joint 58 forms a ring-shaped aluminum alloy inner ring 42 and an outer ring 41, the inner and outer layers of metal
  • the radial aluminum alloy column 43 and the axial aluminum alloy column 44 are connected to form a joint portion of the vertical pipe 60, the vertical pipe plug 20, the two front fork pipes 61 and the shoulder cover double plug 58 in the three-dimensional direction.
  • the package is forged into a high-strength and tough joint structure.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Steering Devices For Bicycles And Motorcycles (AREA)
  • Forging (AREA)
  • Automatic Cycles, And Cycles In General (AREA)

Abstract

一种金属管件的优化连接结构及其实现方法，该结构包括：管件（1）、置于管件（1）末端内孔的多功能塞头（2、20）和连接管件（1）的连接件（3），管件（1）在连接部位的周边设有径向通孔（13）；多功能塞头（2、20）包括：位于末端的堵塞体（21）、位于中端的凹槽（23）以及位于顶端的相连的大、小定位台阶（22、24）；连接件（3）采用铸锻复合结构，通过在铸锻模内成型加工，形成内、外两层金属圈（42、41）以及若干与之相连的径向和轴向金属柱（43、44），将参与铸锻加工的管件（1）和塞头（2、20）锻接部位在三维方向包裹锻接成一体化结构，使得自行车车架和前叉各管件（1）连接强韧。

Description

金属管件的优化连接结构及其实现方法 技术领域
本发明涉及的是一种金属管件连接技术领域，具体是一种用于各类车架管件的高强韧连接结构及其实现方法。
背景技术
世界目前在轻型机动或非机动车辆制造业，为追求节能减排和轻量化，大多选用轻质金属空心薄壁管材，通过焊接工艺连接成车架或其它产品，这种连接优点是设备简易、投资少、产品款式变新快，缺点是连接强度和韧性大幅下降，存在安全隐患。究其原因：是焊缝为铸态粗晶组织，易产生夹渣、缩孔、裂纹及参与连接的管件体积太小等问题，它破坏了无缝管件原来高强韧的锻态细晶组织。此外，焊接只能在相同材质间进行，无法在同一车架内采用两种不同材质管件进行焊接，从而获得多种优异性能。这在金属自行车车架和前叉制造业最充分、全面暴露出铝合金、镁合金、钛合金和不锈钢车架或前叉管件间的焊接诸多弊病；为解决上述问题，近几十年来，世界相关业者进行了许多替代焊接的实验和研发工作。
经过对现有技术的检索发现，中国专利文献号CN86106439，公开(公告)日1987.04.08，公开了一种自行车和类似装置的车架连接部包括短管衬套、连接零件、粘结剂和环状夹套。短管衬套包括管座、短管和环状台肩。短管伸出管座，环状台肩位于管座和短管之间；连接零件有管状端部，带环状端面，压配合在短管上；粘结剂把管状端部与短管粘结在一起；环状夹套装在端面和台肩之间的短管上。夹套包括内端和外端。内端包括第一凸起部，它沿圆周面延伸，和管座接近台肩处搭接；外端包括第二凸起部，具有中凹锥面；和连接零件的端面搭接与配合。该技术在自行车架前三角每个连接点使用了短管衬套、环状夹套、连接零件和粘结剂等多个零件才完成一个连接点的连接，虽解决了焊接车架前三角连接强度差，在同一车架内可使用二种不同材质构件难题，但该结构复杂、零件多、成本高、外形不美观、增加了车架重量、粘结剂易老化、还 无法解决车架的上叉和下叉的连接问题，发明至今仍未见业界应用。
中国专利文献号CN86101907公开(公告)日1986.12.17，公开了一种自行车架和自行车，该技术包括由上杆和下杆连接起来的坐椅杆和车头，并整体地用轻金属或合金，特别是镁铸成。至少下杆，最好还有坐椅杆被铸成有开放的截面，接着被第二铸件封闭，用黏接剂固定于开放截面上，最好再加机械性连接。机械性连接用倾斜布置在铸件长度方向上的嵌合件获得。上杆和下杆被结构桥在车头和坐椅杆之间的地连接。下杆连接在坐椅杆的中点。该技术采用镁合金一体铸出自行车架的上杆、下杆、坐椅杆和车头，其下杆和座椅杆铸有大C型开放截面，并用铸有小C型截面盖板用粘接剂封接；车架其余的成对后上叉和下叉、连接桥和轴颈等零部件，同样是用镁合金一体铸
Figure PCTCN2015075212-appb-000001
和用粘接剂加机械性辅助连接，完成车架连接加工；车架各部份金属厚度是5mm。这种铸件粘接总装车架的结构优点是：抗扭和抗弯能力强，参与连接的金属体积大，刚性好。不足之处是：模具投资大、各铸件很难控制配合间隙均匀、粘接剂老化等问题；这种生产方式很难适应目前车架市场要求尺寸和款式快速变化的难题。
问题的解决方案
技术解决方案
本发明针对现有金属管件焊接工艺易产生夹渣、缩孔、裂纹、连接强度和韧性大幅下降和连接体积太小等问题；提供一种金属管件的优化连接结构及其实现方法：它采用在管件末端周边设有径向通孔，并在该管末端内孔塞入一个多功能塞头；先将已塞入塞头的一支或多支管件，作为连接件的镶嵌件，预先置放在连接件下铸锻模的相应位置紧固后合模，然后在铸锻复合机的PLC控制下，对连接件型腔进行层流充型加工时，注入连接件型腔的金属流体，可通过管件的径向通孔和塞头轴向通孔流入塞头凹槽，当连接件经挤压锻造完工后，形成内层与外层两个金属圈，将待接管和塞头的连接部位，在三维方向包裹锻成一体的连接结构，从而完成连接件与管件的高强韧连接。由于自行车车架和前叉各管件的连接难度、复杂程度和高强韧要求都比其它轻型车的车架要高得多，因此本发明重点是解决自行车车架和前叉各管件的高强韧连接难题。
本发明的上述技术问题，通过下述技术方案得以解决：
本发明涉及一种金属管件的优化连接结构，包括：管件、置于管件末端内孔的多功能塞头和连接管件的连接件。
所述的管件在连接部位的周边设有径向通孔，通孔的中心连线与管件端面平行；
所述的多功能塞头包括：位于末端的堵塞体、位于中端的凹槽或通孔以及位于顶端的相连的大、小定位台阶，其中：大台阶外端面设有轴向通孔或通槽与凹槽相通，并设有与连接件内孔相交的相贯线圆弧面；
所述的连接件包括：内层金属圈、外层金属圈以及若干与之相连接的径向和轴向金属柱，所述的内、外层金属圈以及金属柱将参与铸锻成型加工的管件、多功能塞头锻接部位在三维方向包裹锻接成一体的高强韧连接结构。
所述的管件包括但不限于：自行车车架和前叉的上管、下管、立管、上叉、下叉、前叉管或竖管；
所述在立管上端连接部位设有一个用于连接上管和两支上叉立管接头，该立管上端连接部位设有经轴向长度和直径的局部扩管加工得到的内孔以及对向加工通孔，以实现上管和上叉能进入已扩径立管内孔，为立管接头成型加工提供空间位置。
所述的管件多功能塞头包括但不限于：上管二端塞头、下管二端塞头、立管塞头、上叉塞头、下叉塞头、勾爪双塞头、肩盖双塞头或前叉勾爪塞头；该多功能塞头可以是圆形、扁形或异形，其中：多功能塞头顶端小台阶和末端堵塞体的径向截面形状和尺寸相同且与所配管件内孔作滑动配合；
所述的扁形结构的多功能塞头的中端和顶端的径向截面厚度小于末端堵塞体径向截面厚度。
所述的勾爪双塞头为一体化结构，其塞头为圆形或扁形结构。
所述的肩盖双塞头为一体化结构，其塞头为圆形、扁形或异形，并且：在塞头连体上方设有前叉竖管的定位圆凹槽；在塞头连体上设有通孔，该通孔分别与前叉竖管塞头凹槽以及肩盖接头相通。
优选地，本发明所述的优化连接结构可以包括：前管、立管接头、五通、勾爪接头、前叉勾爪接头、肩盖接头。
所述的连接件经铸锻模内完成铸锻成型加工制成，所述的管件和位于管内的多功能塞头作为连接件的镶嵌件，通过预先放置在下铸锻模的相应位置并紧固从而参与连接件的成型加工并实现连接件与管件的高强韧连接。
优选地，本发明所述的优化连接结构可以包括：立管、上叉、下叉以及连接上管和下管的前管，用于连接所述立管、上管和上叉的立管接头，用于连接所述立管、下管和下叉的五通，连接上叉和下叉的勾爪双塞头和勾爪接头；
优选地，本发明所述的优化连接结构可以包括：前叉竖管、前叉管、前叉勾爪塞头、用于连接所述前叉竖管和前叉管的肩盖接头、用于连接所述前叉管和前叉勾爪塞头的前叉勾爪接头以及肩盖双塞头。
本发明创新地将传统焊接的车架和前叉零件改分为三类：第一类是管件，它保留了传统焊接工艺大多数管件，仅将前管和五通改为连接件：第二类是在每支连接的管件末端内孔，新增一个多功能塞头件：第三类是每个连接点用以连接一支或多支管件的连接件，以替代焊接工艺的焊缝；因此车架除将前管和五通改为连接件外，还要在立管上端和勾爪连接部位各增加一个立管接头和两个勾爪接头连接件；同样在前叉肩盖和前叉勾爪各增加一个肩盖接头和两个前叉勾爪接头连接件；对连接件的铸锻加工，可采用PLC控制铸锻复合机、保温定量供料炉、铸锻模具和温控***设备配合下，对各金属连接件逐一进行铸锻成型加工。此外金属连接件的加工，还可采用金属半固态成型设备和工艺完成。
本发明涉及上述金属管件的优化连接实现方法，包括以下步骤：
11以机床加工金属或非金属管件端面及通孔或通槽；
22以CNC机床加工多功能塞头；
33对管件和多功能塞头倒角、去毛刺、清洗、干燥；
44凡有两种不同材质的金属零件组合连接前，须进行表面微弧氧化绝缘处理；
55在管件连接端内孔，塞入相配的多功能塞头待连接；
66将塞有多功能塞头的一支或多支管件，置于铸锻复合机台面的连接件下铸锻模的相应位置，紧固后合模，在PLC控制、保温定量供料炉和模具加热与冷却***配合下，先对连接件型腔进行层流充型，将连接件和参与铸锻加工的管件及多功能塞头空腔全部充满，稍后当金属熔体冷却在半固态温度时，铸锻复合机 在PLC控制下，对连接件进行最后的挤压锻造成型加工，并保压至加工完成为止。此时连接件形成一个内层金属圈和一个外层金属圈，这内，外两层金属圈是由众多径向和轴向短小金属柱相连接，将一支或多支管件和多功能塞头参与连接的部位，在三维方向包裹锻成一体的高强韧连接结构。
至此，本发明工艺完成；余下操作可采用现有技术进一步处理及后续加工。
本发明自行车车架和前叉的每个连接点都属于机械性连接，可将两种不同材质零件组合连接在一起，从而增加许多有市场价值的车架和前叉新品种，有增加安全性又兼具舒适性的优点：前提是：车架和前叉的所有连接件、管件、塞头和勾爪均需绝缘处理；车架的上管和下管、左、右两支上叉和下叉以及前叉的两支前叉管，必须采用相同材质管材；熔点接近的金属不允许采用在同一车架或前叉中，以避免这两种材料热处理温度相互干扰。若遵守上述原则，可将不同金属材料间的电偶腐蚀和线膨胀系数不同产生的应力影响，降至忽略不计的程度。
作为优选，所述自行车车架的连接结构，包括：上管、下管、立管、上叉、下叉以及连接上管和下管的前管；连接所述立管、上管和上叉的立管接头；连接所述立管、下管和下叉的五通；连接上叉和下叉的勾爪双塞头和勾爪接头。其中所述的前管、立管接头、五通、勾爪接头和勾爪双塞头采用镁合金材料；所述的上管、下管、立管、上叉、下叉采用不锈钢材料。
作为优选，所述自行车车架的连接结构，其中所述的前管、立管接头、五通和勾爪接头采用镁合金材料；所述的上管、下管、立管、上叉、下叉和勾爪双塞头采用钛合金材料。
作为优选，所述自行车车架的连接结构，其中所述的前管、立管接头、五通和勾爪接头采用铝合金材料；所述的上管、下管、立管、上叉、下叉和勾爪双塞头采用钛合金材料。
作为优选，所述自行车车架的连接结构，其中的所述前管、立管接头、五通、勾爪双塞头、勾爪接头、立管、上叉和下叉采用镁合金材料；所述的上管和下管采用钛合金材料。
作为优选，所述自行车前叉的连接结构，包括前叉竖管、前叉管、前叉勾爪塞 头、连接所述前叉竖管和前叉管的肩盖接头、连接所述前叉管和前叉勾爪塞头的前叉勾爪接头、以及参与连接的肩盖双塞头。其中肩盖双塞头、肩盖接头、前叉勾爪接头、前叉勾爪塞头采用镁合金材料，所述的前叉管和前叉竖管采用不锈钢材料。
作为优选，所述自行车前叉的连接结构，其中所述的肩盖双塞头、肩盖接头、前叉勾爪接头、前叉勾爪塞头采用铝合金材料；所述的前叉管和前叉竖管采用不锈钢材料。
作为优选，所述自行车前叉的连接结构，其中所述的肩盖双塞头、肩盖接头、前叉勾爪接头、前叉勾爪塞头采用镁合金材料；所述的前叉管和前叉竖管采用钛合金材料。
作为优选，所述自行车前叉的连接结构，其中所述的肩盖双塞头、肩盖接头、前叉勾爪接头、前叉勾爪塞头采用铝合金材料；所述的前叉管和前叉竖管采用钛合金材料。
发明的有益效果
有益效果
本发明与现有的焊接自行车车架和前叉相比，其显着的进步和有益效果在于：
I.自行车车架和前叉的管件高强韧连接结构简单，在每支管件的连接点仅增加一个多功能塞头零件，每完成一个连接件加工的同时，可完成参与连接的1～4支管件的连接加工，连接长度可达5.0～20.0mm，参与连接的金属体积和结构强度是焊接结构无法相比的；制得的连接件是锻态致密组织，强度高、韧性好；生产方法可以首次实现：连接在模具内进行，并在自动控制下完成的生产模式，使车架和前叉的生产工序大幅减少并节省大量员工和厂房面积，产品质量划一标准。
II.车架和前叉的每个连接件加工时间短，被连接的零件：受热均匀、零件间的位置和尺寸精度高、连接外形美观，可与碳纤维连接的外形媲美。
III.将自行车车架和前叉各零件的连接工序和模具，分解为多工序、多模具的制造方法，可使连接件采用直接液锻工艺进行高强韧加工，容易取得优良的力学性能和易于更换产品款式与尺寸，节省模具费用，可满足时下自行车多品种小 批量生产模式，降低生产成本。
IV.用同一套生产设备和模具，可选择生产镁、铝、钛合金和不锈钢车架和前叉产品，对众多依赖采购管件的生产企业，可使产品变得空前丰富。
V.本发明的自行车车架和前叉的管件高强韧连接结构，属于机械性连接，因此可将两种不同材质的零件组合连接在一起，可增加多种车架和前叉新品种，使车架和前叉既有很高的安全性又兼具舒适性，可满足现代自行车市场绝大部分需求。
VI.本发明特别适用于生产超高强韧、管壁薄至0.3～0.8mm的不锈钢和钛合金车架和前叉，与焊接相比成本低，使极具市场发展前景的钛合金和不锈钢车架与前叉产品，可以迅速得到推广和普及。
对附图的简要说明
附图说明
图1是金属管件典型铸锻复合连接示意图；
图2自行车车架各零件铸锻复合连接总成示意图；
图3是本发明自行车车架和前叉圆管T型连接塞头结构示意图；
图4是本发明自行车车架圆管角度连接塞头结构示意图；
图5是本发明自行车车架扁形管角度连接塞头结示意图；
图6是本发明自行车车架勾爪双塞头连接结构示意图；
图7是自行车前叉各零件铸锻复合连接总成示意图；
图8是本发明自行车前叉肩盖圆双塞头结构示意图；
图9是本发明自行车前叉肩盖扁双塞头结构示意图；
图中：1.金属管件、2.多功能塞头件、3.连接件、10.上管、11.管件内孔、12.管件端面、13.管件径向通孔、14.下管、15.立管、16.上叉、17.下叉、18.立管扩径外圆、19.立管径向通孔、20.圆T接塞头、21.堵塞体、22.定位小台阶、23.圆塞环状凹槽、24.定位大台阶、25.塞头轴向通孔、26.相贯线圆弧面、27.塞头减重孔、28.圆形角接塞头、29.扁形角接塞头、30.扁塞堵塞体厚度、31.扁塞连接端厚度、32.扁塞连接通孔、34.勾爪双塞头、35.竖管定位凹槽、36.双塞头连体通孔、37.肩盖圆双塞头、38.肩盖扁双塞头、39.前叉勾爪塞头、40.前管、41.外环圈 、42.内环圈、43.径向连接柱、44.轴向连接柱、45.连接件外凸缘、46、前管内孔、48.勾爪接头、49.五通、50.立管接头、51.上管进入通孔、52.上叉进入通孔、58.肩盖接头、59.前叉勾爪接头、60.前叉竖管、61.前叉管、62.前叉径向通孔。。
发明实施例
本发明的实施方式
下面对本发明的实施例作详细说明，本实施例在以本发明技术方案为前提下进行实施，给出了详细的实施方式和具体的操作过程，但本发明的保护范围不限于下述的实施例。
实施例1
实施例1.参见图2、图3、图4，车架前管40与上管10和下管14的高强韧连接与管件材料组合配置：
1.1)上管10和下管14采用Ti3AL2.5V钛合金无缝圆管，壁厚＝0.8mm、内孔＝30.0mm；以机械或激光加工上管10和下管14连接端周边通孔＝7.0mm、数量＝6个；前管40、塞头20和28分别采用AZ80A-T4、T6镁锭和棒材，前者采用铸锻复合机加工，后者采用车床加工。
1.2)对管件和塞头的锐边倒角、去毛刺、清洗和干燥。
1.3)对塞头表面进行微孤氧化绝缘处理。
1.4)将塞头20和28分别塞入上管10和下管14连接末端内孔待连接。
1.5)将上管10、下管14分别置入安装在铸锻复合机台面的前管40铸锻下模相应位置，此时铸锻模保温至200～230℃，紧固后合模，在铸锻复合机PLC控制下，通过管道将保温在680～730℃的镁合金溶体泵送至前管40铸锻模的料筒内，先对前管40型腔进行层流充型：当镁合金熔体通过上管10、下管14的径向通孔13和塞头轴向通孔25，进入塞头的环形凹槽23将所有空腔充满；稍后当镁合金熔体温度下降至570～585℃时，在铸锻复合机PLC控制下，对前管40进行最后挤压锻造加工，并以60～85MPa比压保压至加工完成为止。此时前管40形成一层镁合金内圈42和一层外圈41，此内、外两层金属圈系由径向镁合金柱43和轴向镁合金柱44相连接，形成将塞头20和上管10、下管14的连接部位，在三维方向包裹锻 成一体的高强韧连接结构。
实施例2
参见图2、图3、图5，车架立管接头50与上管10和上叉16的高强韧连接与管件材料组合配置：
2.1)在立管15上端连接部位内孔，作轴向长度＝50.0mm，管厚度增厚＝1.0mm，扩径增加8.0mm的局部扩径加工：随后在连接上管10和上叉16的中心位置，对向加工可让上管10和上叉16分别进入的通孔51和52；上叉16的内孔宽度为12.1mm，扁角接塞头29其末端堵塞体的厚度30为12.0mm，二者的滑动配合间隙为0.1mm，其中端和顶端的厚度为7.0mm。除上管10采用Ti3AL2.5V钛合金无缝管，其余立管15、上叉16和所有塞头均分别采用7050-T4、T6铝合金无缝管材和棒材。
2.2)对管件和塞头的锐边倒角、去毛刺、清洗和干燥。
2.3)对立管15、两支上叉和塞头表面进行微孤氧化处理。
2.4)将塞头20和两个扁角塞头29分别塞入上管10和两支上叉管16连接端内孔待连接。
2.5)将扩径加工好的立管15、上管10塞入圆T接塞头20和上叉16塞入扁角接塞头29，分别置于安装在铸锻复合机台面的立管接头50的铸锻下模相应位置，此时铸锻模保温在200～250℃紧固后合模。在铸锻复合机PLC自动控制下，通过管道将保温在690～720℃的铝合金熔体泵送至立管接头50铸锻模料筒内，先对立管接头50型腔进行液态层流充型：当铝合金流体分别通过上叉16和上管10的径向通孔13，以及圆
Figure PCTCN2015075212-appb-000002
接塞头20和扁角接塞头29的轴向通孔25和33，将立管接头左、右两边的所有空腔充满；稍后当铝合金熔体温度下降至580～595℃时，在铸锻复合机PLC控制下，对立管接头50进行最后的挤压锻造成型加工，并以85～110MPa比压保压至完工为止。此时立管接头50形成一层环状铝合金内圈42和一层外圈41，此内、外两层金属圈系由径向铝合金柱43和轴向铝合金柱44相连接，形成将上管10、上管塞头20和两根上叉16、两个扁角接塞头29的连接部位，在三维方向包裹锻接成一体的高强韧连接结构。
实施例3
参见图7、图9，肩盖接头58与前叉竖管60和两根左，右前叉管62的高强韧连接与管件材料组合配置：
3.1)两支前叉管61采用Ti3AL2.5V钛合金无缝管材，其余竖管60、塞头20、肩盖双塞头38和肩盖接头58分别采用7050-T4、T6铝合金无缝管材、棒材和锭材。
3.2)对管件和塞头锐边倒角、去毛刺、清洗和干燥。
3.3)对管件和塞头表面进行微孤氧化绝缘处理。
3.4)将塞头20塞入竖管60连接端内孔，然后置于肩盖双塞头38的定位圆凹槽35内，并将塞头的轴向通孔25与肩盖双塞头38的通孔36对准后，在塞头20与肩盖双塞头38相交处对称点焊待连接。
3.5)在竖管60与肩盖双塞夹38完成点焊组件的左、右塞头，分别塞入已完成勾爪塞头连接的左、右两支前叉两支前叉管61的组件，置于安装在铸锻机台面上的肩盖接头58的下铸锻模的相应位置，此时铸锻模保温在200～250℃，紧固后合模，在铸锻复合机PLC自动控制下，通过管道将保温在690～720℃的铝合金熔体，泵送至肩盖接头58铸锻模料筒内，先对肩盖接头58型腔进行液态层流充型：此时金属流体通过竖管60径向通孔13和塞头20的轴向通孔25，以及左、右前叉管61的径向通孔62和肩盖双塞头38的横向通孔32，将肩盖接头58内的所有空腔充满，稍后当铝合金熔体温度下降至580～595℃时，在铸锻复合机PLC控制下，对肩盖接头58进行最后的挤压锻造成型加工，并以85～110MPa比压保压至完工为止；此时肩盖接头58形成一层环状铝合金内圈42和一层外圈41，此内、外两层金属圈系由径向铝合金柱43和轴向铝合金柱44相连接，形成将竖管60、竖管塞头20、两支前叉管61和肩盖双塞头58的连接部位，在三维方向包裹锻接成一体的高强韧连接结构。

Claims (12)

  1. 一种金属管件的优化连接结构，包括：管件、置于管件末端内孔的多功能塞头和连接管件的连接件，其特征在于：所述的管件在连接部位的周边设有径向通孔，通孔的中心连线与管件端面平行；所述的多功能塞头包括：位于末端的堵塞体、位于中端的凹槽或通孔以及位于顶端的相连的大、小定位台阶，其中：大台阶外端面设有轴向通孔或通槽与凹槽相通，并设有与连接件内孔相交的相贯线圆弧面；所述的连接件包括：内层金属圈、外层金属圈以及若干与之相连接的径向和轴向金属柱，所述的内、外层金属圈以及金属柱将参与铸锻成型加工的管件、多功能塞头锻接部位在三维方向包裹锻接成一体的高强韧连接结构。
  2. 根据权利要求1所述的金属管件的优化连接结构，其特征在于：所述的管件包括自行车车架和前叉的上管、下管、立管、上叉、下叉、前叉管或竖管；所述在立管上端连接部位设有一个用于连接上管和两支上叉立管接头，该立管上端连接部位设有经轴向长度和直径的局部扩管加工得到的内孔以及对向加工通孔，以实现上管和上叉能进入已扩径立管内孔，为立管接头成型加工提供空间位置。
  3. 根据权利要求2所述的金属管件的优化连接结构，其特征在于：所述的管件多功能塞头包括：上管二端塞头、下管二端塞头、立管塞头、上叉塞头、下叉塞头、勾爪双塞头、肩盖双塞头或前叉勾爪塞头；所述的多功能塞头为圆形、扁形或异形，其中：多功能塞头顶端小台阶和末端堵塞体的径向截面形状和尺寸相同且与所配管件内孔作滑动配合；所述的扁形结构的多功能塞头的中端和顶端的径向截面厚度小于末端堵塞体径向截面厚度。
  4. 根据权利要求3所述的金属管件的优化连接结构，其特征在于：所述的勾爪双塞头为一体化结构，其塞头为圆形或扁形结构。
  5. 根据权利要求3所述的金属管件的优化连接结构，其特征在于：所 述的肩盖双塞头为一体化结构，其塞头为圆形、扁形或异形，并且：在塞头连体上方设有前叉竖管的定位圆凹槽；在塞头连体上设有通孔，该通孔分别与前叉竖管塞头凹槽以及肩盖接头相通。
  6. 根据权利要求2所述的金属管件的优化连接结构，其特征在于：包括：前管、立管接头、五通、勾爪接头、前叉勾爪接头、肩盖接头；所述的连接件经铸锻模内完成铸锻成型加工制成，所述的管件和位于管内的多功能塞头作为连接件的镶嵌件，通过预先放置在下铸锻模的相应位置并紧固从而参与连接件的成型加工并实现连接件与管件的高强韧连接。
  7. 根据权利要求2所述的金属管件的优化连接结构，其特征在于：包括：立管、上叉、下叉以及连接上管和下管的前管，用于连接所述立管、上管和上叉的立管接头，用于连接所述立管、下管和下叉的五通，连接上叉和下叉的勾爪双塞头和勾爪接头；所述的前管、立管接头、五通、勾爪接头和勾爪双塞头采用铝合金制成；所述的上管、下管、立管、上叉和下叉采用不锈钢制成。
  8. 根据权利要求7所述的金属管件的优化连接结构，其特征在于：所述的前管、立管接头、五通和勾爪接头采用镁合金制成，所述的上管、下管、立管、上叉、下叉和勾爪双塞头采用钛合金制成，或者：所述的前管、立管接头、五通和勾爪接头采用铝合金制成，所述的上管、下管、立管、上叉、下叉和勾爪双塞头采用钛合金制成，或者：所述的前管、立管接头、五通、勾爪双塞头、勾爪接头、立管、上叉和下叉采用镁合金制成，所述的上管和下管采用钛合金制成。
  9. 根据权利要求2所述的金属管件的优化连接结构，其特征在于：包括：前叉竖管、前叉管、前叉勾爪塞头、用于连接所述前叉竖管和前叉管的肩盖接头、用于连接所述前叉管和前叉勾爪塞头的前叉勾爪接头以及肩盖双塞头，所述的肩盖双塞头、肩盖接头、前叉勾爪接头、前叉勾爪塞头采用镁合金制成，所述的前叉管和前 叉竖管采用不锈钢制成。
  10. 根据权利要求9所述的金属管件的优化连接结构，其特征在于：所述的肩盖双塞头、肩盖接头、前叉勾爪接头、前叉勾爪塞头采用铝合金制成，所述的前叉管和前叉竖管采用不锈钢制成，或者：所述的肩盖双塞头、肩盖接头、前叉勾爪接头、前叉勾爪塞头采用镁合金制成，所述的前叉管和前叉竖管采用钛合金制成，或者：所述的肩盖双塞头、肩盖接头、前叉勾爪接头、前叉勾爪塞头、采用铝合金制成，所述的前叉管和前叉竖管采用钛合金制成。
  11. 一种金属管件的优化连接实现方法，其特征在于：包括以下步骤：1)以机床加工金属或非金属管件端面及通孔或通槽；2)以CNC机床加工多功能塞头；3)对管件和多功能塞头倒角、去毛刺、清洗、干燥，且当两种不同金属零件组合连接前，须进行表面微弧氧化绝缘处理；4)在管件连接端内孔，塞入相配的多功能塞头待连接；5)将塞有多功能塞头的一支或多支管件，置于铸锻复合机台面的连接件下铸锻模的相应位置，紧固后合模，在PLC控制、保温定量供料炉和模具加热与冷却***配合下，先对连接件型腔进行金属熔体层流充型，将连接件和参与铸锻加工的管件及多功能塞头空腔全部充满，稍后当金属熔体冷却在半固态温度时，铸锻复合机在PLC自动控制下，对连接件进行最后的挤压锻造成型加工，并保压至加工完成为止；此时连接件形成一个内层金属圈和一个外层金属圈，这内，外两层金属圈是由众多径向和轴向短小金属柱相连接，将管件和多功能塞头参与连接的部位，在三维方向包裹锻成一体的高强韧连接结构。
  12. 一种根据权利要求1-11中的任意一项中所述的金属管件的优化连接结构的应用，其特征在于：将其用于自行车车架和前叉的连接、用于脚踏式和非脚踏式电动自行车车架和前叉的连接、用于电动或气动摩托车车架和前叉以及电动汽车车架的连接。
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CN104085485B (zh) 2016-05-04
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