WO2024038412A1 - Essieu et son procédé de fabrication - Google Patents

Essieu et son procédé de fabrication Download PDF

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Publication number
WO2024038412A1
WO2024038412A1 PCT/IB2023/058279 IB2023058279W WO2024038412A1 WO 2024038412 A1 WO2024038412 A1 WO 2024038412A1 IB 2023058279 W IB2023058279 W IB 2023058279W WO 2024038412 A1 WO2024038412 A1 WO 2024038412A1
Authority
WO
WIPO (PCT)
Prior art keywords
axle
bender
bias
preform
forging
Prior art date
Application number
PCT/IB2023/058279
Other languages
English (en)
Inventor
Babasaheb Neelkanth Kalyani
Basavraj Prabhakar KALYANI
Madan Umakant TAKALE
Sangameshwar PAWAR
Narsing BHOSALE
Manas NAG
Kedar PARANJAPE
Original Assignee
Bharat Forge Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bharat Forge Limited filed Critical Bharat Forge Limited
Publication of WO2024038412A1 publication Critical patent/WO2024038412A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B35/00—Axle units; Parts thereof ; Arrangements for lubrication of axles
    • B60B35/001—Axles of the portal type, i.e. axles designed for higher ground clearance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
    • B21D11/10—Bending specially adapted to produce specific articles, e.g. leaf springs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B21D53/90—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards axle-housings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D7/00—Bending rods, profiles, or tubes
    • B21D7/06—Bending rods, profiles, or tubes in press brakes or between rams and anvils or abutments; Pliers with forming dies
    • 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
    • B21K1/00—Making machine elements
    • B21K1/06—Making machine elements axles or shafts
    • B21K1/12—Making machine elements axles or shafts of specially-shaped cross-section
    • 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
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2310/00—Manufacturing methods
    • B60B2310/20—Shaping
    • B60B2310/224—Shaping by rolling

Definitions

  • the present invention relates to an axle beam used in a vehicle. More specifically, the present invention relates to manufacturing of a rear axle beam using a closed die hot forging process.
  • Rear Axle Beam is one of the critical components of a vehicle.
  • drive and electrical components are assembled/mounted on rear axle beam.
  • the rear axle beam has to be designed such that it should be able to withstand fatigue loads.
  • Various factors play a key role in enhancing the fatigue properties of the rear axle beam, the predominant one is the manufacturing process used for producing it.
  • One of the most common methods to produce a rear axle beam is hot forging. The microstructure and grain flow obtained during the hot forging process gives optimum fatigue strength to the rear axle beam. These properties are not achievable through other manufacturing processes, for example, casting method.
  • the typical rear axle beam is made up of plurality pad areas, a central area, and a plurality of spindles with or without stems and portions connecting to these areas.
  • the rear axle beam is symmetric from the central axis which divides equally it at its central area.
  • Each spindle is connected to each pad by a portion and each pad is connected to the central area by another portion.
  • the spindles (with or without stem), pad areas and central areas lie in three different planes.
  • the longitudinal axis is nothing but an axis of spindles.
  • the planes of pads, spindles and central areas are at an offset distance from each other in two different plane areas. i This kind of complex and intricate configuration of the rear axle beam has a significant effect on the hot forging process used to produce it.
  • rear axle beam forging process starts from a “rolled” round or rounded corner section (RCS) hot billet which is then subjected to various forging operations.
  • RCS rounded corner section
  • rear axle beam forging process consists of Reduce Rolling (RR) - Blocker Forging (BLK) - Finisher Forging (FIN).
  • RR Reduce Rolling
  • BLK Blocker Forging
  • FIN Finisher Forging
  • Reduce Rolling - Hot billet first undergoes a reduce rolling (RR) operation.
  • the RR operation reduces the cross-sectional dimension (diameter or RCS) of the billet at the locations where the material requirement is less while keeping these dimensions unchanged where the material requirement is more.
  • Blocker forging - The RR preform is further subjected to a blocker forging operation to produce a blocker preform.
  • the blocker dies have cavities in both top and bottom die which have rough external shape of the rear axle beam. Maximum material deformation and hence, material flow is produced in the blocker forging.
  • Finisher forging The blocker preform is next subjected to a finisher forging operation to produce final forged rear axle beam.
  • finisher dies are used which have cavities in both top and bottom dies which have shape exactly same as the external shape of the rear axle beam with machining allowances. Finisher operation produces the final shape of the forged rear axle beam.
  • This summary is provided to introduce concepts related to an axle which is used in an electric vehicle or any vehicle. More specifically, the present invention relates to manufacturing of the rear axle beam using closed die hot forging process.
  • the present disclosure describes an axle of a vehicle.
  • the axle may include of spindles, pads and central areas of the axle. Further, the axle may include a first bias and a second bias. The first bias may be symmetrically downwards at pads of the axle and the second bias may be symmetrically sidewards at spindles of the axle.
  • the present disclosure describes a method for manufacturing an axle of a vehicle.
  • the method may include steps of heating a billet, in a furnace. Further, reduce rolling the billet to form a Reduced Rolled (RR) preform. Furthermore, bending the RR preform, to form a bender preform.
  • the bender preform is bent in more than one plane in a multi-plane bender assembly.
  • the bending step is further described.
  • the bending may include steps of pressing the multi-plane bender assembly downwards to form a first bias.
  • the first bias may be symmetrically downwards at pad areas of the axle.
  • die of the multi-plane bender assembly slides sidewards to form a second bias.
  • the second bias may be symmetrically sidewards at spindle areas of the axle.
  • the first and the second bias are forged in a single forging stroke.
  • FIG. 1 A illustrates an axle (100) having spindles with steam, in accordance with an embodiment of the present subject matter
  • Figure IB illustrates an axle (120) having spindles without steam, in accordance with an embodiment of the present subject matter
  • Figure 2 illustrates a system (200) for manufacturing an axle (100) of a vehicle, in accordance with an embodiment of the present subject matter
  • FIG. 2A illustrates isometric view of a top bender die (211), in accordance with an embodiment of the present subject matter
  • FIG. 2B illustrates a bottom bender die (221), in accordance with an embodiment of the present subject matter
  • FIG. 2C illustrates top view of a top bender die (221), in accordance with an embodiment of the present subject matter
  • FIG. 2D illustrates a top bender die assembly (210), in accordance with an embodiment of the present subject matter
  • Figure 2E illustrates a bottom bender die assembly (220), in accordance with an embodiment of the present subject matter
  • Figure 3 illustrates a Reduce Rolled (RR) preform (300), in accordance with an embodiment of the present subject matter
  • Figure 4 illustrates a bender preform (400), in accordance with an embodiment of the present subject matter
  • Figure 4 A illustrates a blocker preform (410), in accordance with an embodiment of the present subject matter
  • Figure 5 illustrates a method (500) for manufacturing an axle (100) of a vehicle, in accordance with an embodiment of the present subject matter.
  • the present disclosure relates to an axle which is used in an electric vehicle or any vehicle. More specifically, the present invention relates to manufacturing of the rear axle beam using a closed die hot forging process.
  • Rear Axle Beams are shown.
  • the rear axle beams (100, 120) shown in the figures 1A & IB are used in electrical vehicles.
  • the Figure 1 A shows a rear axle beam (100) having spindles with steam.
  • Figure IB shows the rear axle beam (120) having spindles without stem.
  • These rear axle beams have a central axis (110, 130) as well as a longitudinal axis (108, 128).
  • the spindles (102, 122), a plurality of pads (104, 124)) and central area (106, 126) lie in three different planes respectively Plane A, D & G, Plane B, E & H and Plane C, F & I.
  • Plane A, B and C are having Y & Z as a coordinate axis.
  • Planes C, D and F are having X & Y as a coordinate axis.
  • Planes G, H and I are having X & Z as a coordinate axis.
  • Planes A, B and C are parallel to each other but are offset from each other by some specific distances.
  • Planes C, D and E are also parallel to each other but are offset from each other by some specific distances.
  • planes G, H and I are also parallel to each other but are offset from each other by some specific distances. These offset distances are different for different rear axle beams depending upon their capacity.
  • Planes A, D & G are perpendicular to each other
  • planes B, E & H are also perpendicular to each other
  • planes C, F & I are perpendicular to each other.
  • Figure 2 illustrates a system (200) to manufacture the axle (100), in accordance with an embodiment of the present disclosure. It should be understood that the system (200) may be used to manufacture both axle (100) and axle (120), with a slight change in the dimensions of the dies.
  • the system (200) may include a furnace (202), a reduce rolling equipment (203), a multi-plane bender assembly (201), blocker dies (204), finisher dies (205), one or more forging equipment (206), and one or more post-forging equipment (207).
  • the furnace (202) is configured to heat billet used as raw material.
  • the furnace (202) can be of different types such as oil-fired, gas-fired, electric, or induction heating. Additionally, the billet processed in the furnace (202) can have various forms such as forged, extruded, or rolled billets, enabling the furnace to cater to different manufacturing processes.
  • the billet may have a cylindrical shape or a rounded cross section (RCS), depending on the desired product.
  • the billet is composed of a steel alloy, providing strength and durability for applications that require high-performance materials.
  • the billet can be made of cast iron or any other suitable metal alloy, depending on the specific application and desired material properties.
  • the billet may be heated to reach the specific temperature required for further processing.
  • the furnace (202) is employed to facilitate this heating process.
  • the temperature range considered suitable for achieving the desired results is between 1000 °C to 1300 °C.
  • the processed billet may be transferred to reduce rolling equipment (203).
  • the reduce rolling equipment (203) performs reduce rolling operations.
  • a set of reduce rolling dies may be used for performing this operation.
  • the processed billet may be deformed into a stepped Reduced Rolled (RR) preform as shown in Figure 3.
  • the output of this process is an RR preform (300).
  • the multi-plane bender assembly (201) may be disclosed.
  • the multi-plane bender assembly (201) may be configured to bend the RR preform (300), the bending may not be restricted to one plane.
  • the multi-plane bender assembly (201) may include a top bender die (211), shown in Figure 2A and a bottom bender die (221), shown in Figure 2B.
  • the top die (211) and bottom die (221) may be configured to form contours for spindles, pads, and central areas of the axle.
  • the top bender die (211) may include one or more pins (215).
  • the one or more pins (215) may be configured to limit motion and maintain alignment of the multi-plane bender assembly (201) in the forging stroke.
  • the bottom bender die (221) may include one or more plungers (225).
  • the one or more plungers (225) may be configured to guide motion of the multi-plane bender assembly (201).
  • the top bender die (211) of the multi-plane bender assembly (201) may be pressed during forging stroke.
  • the one or more pins (215) may be configured to limit the motion and maintain alignment of the top bender die (211) and the bottom bender die (221) of the multi-plane bender assembly (201) in the forging stroke. Such limitation on the motion prohibits unwanted material displacement while forging.
  • Figure 2C illustrates top view of the top bender die (221), in accordance with an embodiment of the present subject matter.
  • the figure may further illustrate one or more depressions.
  • the one or more depressions may be configured to position the top die cassette (212) and the top die holder (213) on the top bender die (211). Further, the depressions may be rectangular, circular, or in any polygon shape, as per the bender assembly requirement.
  • the depressions may be further configured to limit motion of the top die cassette (212) and the top die holder (213) on the top bender die (211).
  • the bottom bender die (221) may include one or more depressions.
  • the one or more depressions may be further configured to position the bottom bender die (221) on the bottom die cassette (222) and the bottom die holder (223).
  • the depressions may be rectangular, circular, or in any polygon shape, as per the bender assembly requirement.
  • the depressions may be further configured to limit motion of the bottom bender die (221) on the bottom die cassette (222) and the bottom die holder (223).
  • the top die assembly (210) may further include a top bender die (211), a top cassette (212), and a top die holder (213).
  • the bottom die assembly (220) may include a bottom bender die (221), a bottom cassette (222), and a bottom die holder (223).
  • the top die assembly (210) and bottom die assembly (220) may be coupled with a forging equipment (not shown in figures), to enable forging process.
  • the forging equipment may be selected from any type of forging equipment like a mechanical press, screw press, wedge press, hydraulic press or hammer.
  • the multi-plane bender assembly (201) may be configured to bend the RR preform (300) into a bender preform (400) as shown in the figure 4. Further, the bending may not be restricted to one plane.
  • the bender preform (400) may include a first bias (401), a second bias (402) and an elongation (403) along the length of the axle (100).
  • the first bias (401) may be symmetrically downwards at pad areas of the axle (100) and the second bias (402) may be symmetrically sidewards at spindle areas of the axle (100). Further, the first bias (401) may be deformation of material at the pad areas of the axle (100) and the second bias (402) may be deformation of material at the spindle areas of the axle (100).
  • first bias (401) and second bias (402) may be in the range of 120 mm to 160 mm in length. Furthermore, the multiplane bender assembly (201) executes the bending and elongation in a single forging stroke of the forging equipment.
  • blocker dies (204) may be disclosed.
  • the bender preform (400) may be transferred to the blocker dies (204).
  • the blocker dies (204) are configured to perform blocker forging operations.
  • the blocker forging operation may produce a rough shape of the rear axle beam with maximum material flow, with some access material thrown out as a flash.
  • the output of this stage is the blocker preform (410).
  • the output of this operation is a blocker preform ( 10).
  • finisher dies (205) may be disclosed.
  • the blocker preform (410) may be transferred to the finisher dies (205).
  • the finisher dies (205) performs the finisher forging operation. In this operation, the final shape of the rear axle beam is formed with a small amount of material thrown in the form of flash. It is to be noted that the finisher operation produces the final as forged axle. Thus, the shape of the output the finisher forging step is exactly same as that of final axle.
  • finisher operation may be followed by post-forging operations which include but may not be limited to trimming, padding, shot blasting, heat treatment, machining etc.
  • postforging operations may be executed on one or more post-forging equipment (207). The postforging operations produce the final axle.
  • a method (500) for manufacturing an axle (100) may be disclosed.
  • the method may include various steps as described below.
  • the billet as raw material is heated, in the furnace (202).
  • the billet may be heated to the required temperature.
  • the required temperature may be 1000 °C to 1300 °C.
  • the billet may be a forged, extruded or rolled billet.
  • the billet can be cylindrical or rounded cross section (RCS) billet.
  • the billet material may be steel alloys or any other suitable metal alloy.
  • reduce rolling operation may be performed on the processed/heated billet to form the Reduced Rolled (RR) preform (300).
  • the reduce rolling equipment (203) may be used for performing this operation.
  • the processed billet may be deformed into a stepped Reduced Rolled (RR) preform (300) as shown in Figure 3.
  • bending operation may be performed on the RR preform (300), by the multi-plane bender assembly (201), to form the bender preform (400). Further, the bender preform (400) is bent in more than one plane in the multi -plane bender assembly (201).
  • blocker forging operation may be performed on the bender preform (400), to form a blocker preform (410).
  • the blocker forging operation may produce a rough shape of the rear axle beam with maximum material flow, with some access material thrown out as flash.
  • finisher forging operation may be performed on the blocker preform (410), to form the final shape of the axle (100).
  • the final shape of the rear axle beam is formed with small amount of material thrown in the form of flash. It is to be noted that the finisher operation produces the final as forged axle. Thus, the shape of the output of the finisher forging step is exactly the same as that of final axle.
  • post-forging operations may be performed to manufacture the final axle (100).
  • Postforging operations which include but are not limited to trimming, padding, shot blasting, heat treatment, machining etc.
  • Such post-forging operations may be executed on one or more postforging equipment (207).
  • the step (503) of bending the RR preform (300) may further include various steps as described below (not shown in figures).
  • the multi-plane bender assembly (201) may be pressed downwards to form the first bias (401).
  • the first bias (401) may be symmetrically downwards at pad areas of the axle (100).
  • die of the multi-plane bender assembly (201) may be further pressed downwards to form the second bias (402) and an elongation (403), along the length of the axle (100).
  • the second bias (402) may be symmetrically sidewards at spindle areas of the axle (100).
  • the preform material may slide sidewards to form the second bias (402).
  • first bias (401), the second bias (402) and the elongation (403) formed due to the multiplane bender assembly (201), are forged in a single forging stroke.
  • the invented forging process leads to better material distribution in the bender preform which leads to better die fill-up. This eliminates defects like underfill, cold shuts, die cracks etc.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)

Abstract

La présente divulgation concerne un essieu (100) et un procédé (500) de fabrication de l'essieu (100). L'essieu (100) comprend des broches (102), des patins (104) et des zones centrales (106). En outre, l'essieu comprend une première sollicitation (401) et une seconde sollicitation (402). La première sollicitation (401) est symétriquement orientée vers le bas au niveau de patins (104) de l'essieu (100) et la seconde sollicitation (402) est symétriquement orientée vers des broches (102) de l'essieu (100). Le procédé (500) de fabrication d'un essieu (100) d'un véhicule comprend les étapes consistant à chauffer (501) une billette dans un four (202). En outre, réduire le laminage (502) de la billette pour former une préforme laminée réduite (RR) (300). Par ailleurs, courber (503) la préforme RR (300) pour former une préforme de cintreuse (400). De plus, la préforme de cintreuse (400) est pliée dans plus d'un plan dans un ensemble de cintrage multi-plan (201).
PCT/IB2023/058279 2022-08-18 2023-08-18 Essieu et son procédé de fabrication WO2024038412A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN202221046899 2022-08-18
IN202221046899 2022-08-18

Publications (1)

Publication Number Publication Date
WO2024038412A1 true WO2024038412A1 (fr) 2024-02-22

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PCT/IB2023/058279 WO2024038412A1 (fr) 2022-08-18 2023-08-18 Essieu et son procédé de fabrication

Country Status (1)

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WO (1) WO2024038412A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IN201941051671A (fr) * 2019-12-13 2019-12-20
CN112846029A (zh) * 2020-12-18 2021-05-28 桂林福达重工锻造有限公司 一种采用u形展宽预成形结构的前轴压弯预成形工艺

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IN201941051671A (fr) * 2019-12-13 2019-12-20
CN112846029A (zh) * 2020-12-18 2021-05-28 桂林福达重工锻造有限公司 一种采用u形展宽预成形结构的前轴压弯预成形工艺

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