阅读说明：本技术 分水器模锻的工艺方法、分水器模具及模具挤压装置 (Water separator die forging process method, water separator die and die extrusion device ) 是由 辛绍杰 张栋 牛龙江 曹峰华 王佳茂 刘钊 于 2021-08-13 设计创作，主要内容包括：本发明公开了一种分水器模锻的工艺方法,其特征在于,包括如下步骤：S1:建立分水器模型,计算模型的各部分体积；S2：建立实心圆柱形棒料模型；S3:计算模锻时液压推杆的单边推进长度；S4:预先制造包括铜质分水器专用模锻模具、圆柱形棒料和生产线；S5:预加工准备；S6:加热圆柱形棒料；S7：初步挤压；S8：各分支型腔上模的形变检测；S9：步进式补充挤压；S10：脱模；S11：机加工修整。本发明根据计算机模拟计算,设计出一套包括原料定义、挤压策略、传感检测与反馈等工艺步骤在内的新的分水器模锻工艺方法,并基于该工艺方法创新设计了专用的模锻模具和挤压装置,可以提高产品质量,延长模具使用寿命,降低企业生产成本,提高了企业的效益与竞争力。(The invention discloses a die forging process method of a water separator, which is characterized by comprising the following steps of: s1, establishing a water separator model, and calculating the volume of each part of the model; s2: establishing a solid cylindrical bar model; s3, calculating the unilateral pushing length of the hydraulic push rod during die forging; s4, pre-manufacturing a special die forging die for the copper water separator, a cylindrical bar and a production line; s5, preprocessing preparation; s6, heating the cylindrical bar stock; s7: preliminary extrusion; s8: detecting the deformation of the upper die of each branch cavity; s9: step-by-step supplementary extrusion; s10: demolding; s11: and (6) machining and finishing. According to the invention, a set of novel water distributor die forging process method comprising the process steps of raw material definition, extrusion strategy, sensing detection, feedback and the like is designed according to computer simulation calculation, and a special die forging die and an extrusion device are innovatively designed based on the process method, so that the product quality can be improved, the service life of the die can be prolonged, the production cost of enterprises can be reduced, and the benefit and the competitiveness of the enterprises can be improved.)

1. A water separator die forging process method is characterized by comprising the following steps:

s1, establishing a water separator model, calculating the volume of each part of the model,

according to the parameters of the water segregator, establishing a water segregator model by utilizing computer three-dimensional modeling software, wherein the water segregator model comprises the following four parts: a main hollow pipe, a step section pipe, a solid branch pipe and an outer hexagonal section pipe;

the two ends of the main hollow pipe are provided with raised step section pipes, a plurality of solid branch pipes are uniformly distributed along the axial direction of the outer wall of the main hollow pipe, the solid branch pipes are vertical to the main hollow pipe, and the two ends of the step section pipes are provided with raised outer hexagonal section pipes; the volume of the main hollow pipe is set as A, the volume of the solid branch pipe is set as B, and the volume of the stepped section pipe and the outer hexagonal section pipe, which exceeds the diameter of the main hollow pipe, is set as C;

s2: establishing a solid cylindrical bar model,

the diameter of the cylindrical bar is equal to or slightly smaller than the outer diameter of the main hollow pipe, the length of the cylindrical bar is equal to the sum of the lengths of the main hollow pipe, the step section pipe and the outer hexagonal section pipe, and a copper material is selected;

s3, calculating the single-side pushing length of the hydraulic push rod during die forging,

the diameter of the hydraulic push rod is D, the unilateral pushing length E of the hydraulic push rod is (B + C)/D when die forging is carried out, and the volume of the hydraulic push rod entering the die cavity is equal to the sum of the volume B of the solid branch pipe and the volume C of the main hollow pipe added by the step section pipe and the outer hexagonal section pipe;

s4, pre-manufacturing a special die forging die for the copper water separator, a cylindrical bar and a production line;

s5, preprocessing preparation;

s6, heating the cylindrical bar stock;

s7: the extrusion is carried out for the first time,

transferring the heated cylindrical bar stock to a main cavity of a lower die of the die, then carrying out die assembly and plugging, extruding the cylindrical bar stock by a hydraulic push rod in two directions to deform the cylindrical bar stock, and enabling metal to flow into each branch cavity;

s8: the deformation of the upper die of each branch cavity is detected,

detecting by strain sensors mounted in the branch cavities of the upper dies;

s10: and (4) demoulding the mixture,

the hydraulic push rod retracts and the push plate retracts, the temperature of a water path in the upper die is reduced to be lower than that of the lower die, then the upper die is moved away, and the water separator is taken out of the lower die after being cooled;

s11: the processing and the finishing of the machine tool are carried out,

and (4) drilling and trimming the water distributor demoulding part through machining, and finally completely forming the product.

2. The process according to claim 1, characterized in that: s9 is also included between S8 and S10; wherein the content of the first and second substances,

s9: step-by-step supplemental extrusion

When the strain sensor in S8 detects that the branch cavities are not filled with copper materials, the hydraulic push rod continues to work, in order to prevent the excessive extrusion from causing mold damage or rigidity deterioration, the hydraulic push rod moves forward in a preset stepping mode, namely the hydraulic push rod at one end moves forward by 1mm and stops, the controller receives signals of the strain sensor, judges whether the tail ends of the branch cavities are deformed or not, then the hydraulic push rod at the other end moves forward by 1mm and stops, the controller detects whether the tail ends of the branch cavities are deformed or not again, the operation is repeatedly executed until the strain sensor at the tail end of each branch cavity detects obvious strain, the extrusion is qualified, and the water distributor product is formed.

3. The utility model provides a water knockout drum mould which characterized in that: the die forging die comprises an upper die and a lower die, wherein a main cavity matched with the shape of the water distributor die forging is formed in the upper die and the lower die along the length direction, a branch cavity is further formed in one side of the upper die along the length direction, and when the upper die and the lower die are closed along the opposite direction of the main cavity, a complete water distributor die forging die is formed.

4. A water divider mold as defined in claim 3, wherein: and a strain sensor is arranged on the branch cavity.

5. A water divider mold as defined in claim 4, wherein: the branch cavity is an L-shaped cavity, a first strain sensor and a second strain sensor are respectively arranged on the horizontal plane and the vertical plane of the L-shaped cavity, and the strain sensors comprise the first strain sensor and the second strain sensor.

6. The utility model provides an extrusion device of water knockout drum mould which characterized in that: the extrusion device comprises a hydraulic part, a movable hydraulic rod, a hydraulic push rod and a push plate; the hydraulic push rod is driven by the hydraulic component to move in the main cavity of the water distributor die forging die after passing through the round hole of the push plate, and a movable hydraulic rod is arranged between the hydraulic component and the water distributor die forging die.

7. The extrusion device of a water divider mold as defined in claim 6, wherein: the extrusion device is characterized by further comprising a cylindrical bar, the heated cylindrical bar is placed in a main cavity of the water distributor die forging die, and the hydraulic push rod in the extrusion device extrudes the cylindrical bar.

The technical field is as follows:

the invention relates to the technical field of water separator die forging, in particular to a water separator die forging process method, a water separator die and an extrusion device of the die.

Background art:

the water separator is one of the most important core parts in air-conditioning, floor heating manufacturing and other industrial equipment, and has the functions of mainly dividing liquid and gas in a main road into a plurality of different branches for output, or collecting the liquid and the gas on the different branches into one main road.

In addition, the working environment of the water separator is often accompanied by severe scenes such as high temperature and high pressure, so that the requirements on the reliability and durability of parts are high.

Meanwhile, higher requirements are also put forward on the reliability and the durability of the water separator processing equipment.

The water segregator which is widely applied at present mainly comprises a steel water segregator and a copper water segregator, and the production and manufacturing of the water segregator mainly comprises the methods of welding, casting, die forging and the like, and is assisted with certain machining for final finishing of products.

The prior art has the following technical problems:

(1) the water separator manufactured by adopting the welding mode is easy to damage the interface when encountering severe working environments such as high temperature, high pressure and the like because the welding flux is different from the raw material.

(2) The water separator manufactured by adopting the casting mode has loose texture and relatively poor mechanical property, and in order to improve the mechanical property, the defect of loose texture needs to be overcome by adopting a high-pressure casting mode, so the manufacturing cost is high.

(3) The water separator manufactured by adopting the die forging mode has relatively reliable quality, but when a steel raw material is used, on one hand, the forging temperature required by a steel piece is higher and generally needs to reach 1000-1200 ℃ or even higher, so the requirement on the performance of a die is higher, and the influence on the service life of the die is larger.

On the other hand, after the die forging of the steel piece is finished, oxide skin is generated on the surface of the steel piece, the steel piece needs to be repeatedly knocked off, when the outer surface of the steel piece is trimmed by machining, more waste is generated on materials, and metal grains can be changed at ultrahigh temperature, so that the final product performance is influenced.

(4) The water separator partially processed by using the copper raw material has the defects of the water separators in the steps (1) and (2), and due to the fact that the die forging process method is not optimized enough, even if the die forging mode is adopted for processing and manufacturing, the quality of a product is easy to have defects due to insufficient die forging, the die rigidity is easy to damage due to excessive die forging, and the service life of the die is shortened.

In view of the above, it is necessary to develop a better process and processing apparatus.

The invention content is as follows:

in order to overcome the defects and shortcomings in the prior art, the patent provides a water divider die forging process method and device. Based on the requirements of the water separator product manufacturing process, a set of novel water separator die forging process method comprising the process steps of raw material definition, extrusion strategy, sensing detection, feedback and the like is designed according to computer simulation calculation, and a special die forging device is innovatively designed based on the process method, so that the product quality can be improved, the service life of a die is prolonged, the production cost of an enterprise is reduced, and the benefit and the competitiveness of the enterprise are improved.

In order to solve the problems, the invention adopts the following novel technical scheme: a water separator die forging process method is characterized by comprising the following steps:

s1, establishing a water separator model, calculating the volume of each part of the model,

according to the parameters of the water segregator, establishing a water segregator model by utilizing computer three-dimensional modeling software, wherein the water segregator model comprises the following four parts: a main hollow pipe, a step section pipe, a solid branch pipe and an outer hexagonal section pipe;

the two ends of the main hollow pipe are provided with raised step section pipes, a plurality of solid branch pipes are uniformly distributed along the axial direction of the outer wall of the main hollow pipe, the solid branch pipes are vertical to the main hollow pipe, and the two ends of the step section pipes are provided with raised outer hexagonal section pipes; the volume of the main hollow pipe is set as A, the volume of the solid branch pipe is set as B, and the volume of the stepped section pipe and the outer hexagonal section pipe, which exceeds the diameter of the main hollow pipe, is set as C;

s2: establishing a solid cylindrical bar model,

the diameter of the cylindrical bar is equal to or slightly smaller than the outer diameter of the main hollow pipe, the length of the cylindrical bar is equal to the sum of the lengths of the main hollow pipe, the step section pipe and the outer hexagonal section pipe, and a copper material is selected;

s3, calculating the single-side pushing length of the hydraulic push rod during die forging,

the diameter of the hydraulic push rod is D, the unilateral pushing length E of the hydraulic push rod is (B + C)/D when die forging is carried out, and the volume of the hydraulic push rod entering the die cavity is equal to the sum of the volume B of the solid branch pipe and the volume C of the main hollow pipe added by the step section pipe and the outer hexagonal section pipe;

s4, pre-manufacturing a special die forging die for the copper water separator, a cylindrical bar and a production line;

s5, preprocessing preparation;

s6, heating the cylindrical bar stock;

s7: preliminary extrusion

Transferring the heated cylindrical bar stock to a main cavity of a lower die of the die, then carrying out die assembly and plugging, extruding the cylindrical bar stock by a hydraulic push rod in two directions to deform the cylindrical bar stock, and enabling metal to flow into each branch cavity;

s8: the deformation of the upper die of each branch cavity is detected,

detecting by strain sensors mounted in the branch cavities of the upper dies;

s10: and (4) demoulding the mixture,

the hydraulic push rod retracts and the push plate retracts, the temperature of a water path in the upper die is reduced to be lower than that of the lower die, then the upper die is moved away, and the water separator is taken out of the lower die after being cooled;

s11: the processing and the finishing of the machine tool are carried out,

and (4) drilling and trimming the water distributor demoulding part through machining, and finally completely forming the product.

In one embodiment, S9 is further included between steps S8 and S10; wherein the content of the first and second substances,

s9: the step-by-step supplementary extrusion is carried out,

when the strain sensor in S8 detects that the branch cavities are not filled with copper materials, the hydraulic push rod continues to work, in order to prevent the excessive extrusion from causing mold damage or rigidity deterioration, the hydraulic push rod moves forward in a preset stepping mode, namely the hydraulic push rod at one end moves forward by 1mm and stops, the controller receives signals of the strain sensor, judges whether the tail ends of the branch cavities are deformed or not, then the hydraulic push rod at the other end moves forward by 1mm and stops, the controller detects whether the tail ends of the branch cavities are deformed or not again, the operation is repeatedly executed until the strain sensor at the tail end of each branch cavity detects obvious strain, the extrusion is qualified, and the water distributor product is formed.

A water distributor die comprises an upper die and a lower die, wherein a main die cavity matched with the shape of a water distributor die is formed in the upper die and the lower die along the length direction, a branch die cavity is formed in one side of the upper die along the length direction, and when the upper die and the lower die are closed along the opposite direction of the main die cavity, a complete water distributor die forging die is formed.

In one embodiment, a strain sensor is provided on the branch cavity.

In one embodiment, the branch cavity is an L-shaped cavity, and a first strain sensor and a second strain sensor are respectively arranged on the horizontal plane and the vertical plane of the L-shaped cavity, and the strain sensors comprise the first strain sensor and the second strain sensor.

An extrusion device of a water separator die comprises a hydraulic part, a movable hydraulic rod, a hydraulic push rod and a push plate; the hydraulic push rod is driven by the hydraulic component to move in the main cavity of the water distributor die forging die after passing through the round hole of the push plate, and a movable hydraulic rod is arranged between the hydraulic component and the water distributor die forging die.

In one embodiment, the device further comprises a cylindrical bar stock, the heated cylindrical bar stock is placed in a main cavity of the water separator die forging die, and the cylindrical bar stock is extruded through the hydraulic push rod in the extrusion device.

Compared with the prior art, the invention has the main advantages or positive effects that:

the invention provides a water separator die forging process method, a water separator die and an extrusion device of the die, and is based on the water separator product manufacturing process requirements. According to computer simulation calculation, a set of novel water distributor die forging process method comprising the process steps of raw material definition, extrusion strategy, sensing detection, feedback and the like is designed, and a special die forging die and an extrusion device are innovatively designed based on the process method, so that the product quality can be improved, the service life of the die can be prolonged, the production cost of enterprises can be reduced, and the benefit and the competitiveness of the enterprises can be improved.

Description of the drawings:

FIG. 1 is a schematic diagram of an upper die and a lower die of a copper water knockout die in accordance with an embodiment of the present invention;

FIG. 2 is a schematic perspective view of a lower mold of a copper water separator die forging mold according to an embodiment of the present invention;

fig. 3 is a schematic perspective view of an upper die of a die forging die dedicated to a copper water separator according to an embodiment of the present invention;

fig. 4 is a schematic perspective view of an upper mold of a special die forging mold for a copper water knockout vessel from another perspective in accordance with an embodiment of the present invention;

FIG. 5 is a schematic view of a cylindrical bar being placed on a lower die in accordance with an embodiment of the present invention;

FIG. 6 is a schematic view of the installation of a cylindrical bar stock in accordance with one embodiment of the present invention;

FIG. 7 is a schematic diagram of the operation of the extrusion device of the copper water knockout die in accordance with an embodiment of the present invention;

FIG. 8 is a schematic perspective view of a cylindrical bar according to an embodiment of the present invention;

FIG. 9 is a schematic diagram of a theoretical calculation model of the water knockout vessel in an embodiment of the invention;

FIG. 10 is a schematic perspective view of a water knockout block according to an embodiment of the present invention;

FIG. 11 is a schematic perspective view of a water separator product according to an embodiment of the present invention;

FIG. 12 is a flow chart of a process for swaging a water trap in accordance with an embodiment of the present invention.

The specific implementation mode is as follows:

the following description of the embodiments of the present invention is provided for illustrative purposes, and other advantages and effects of the present invention will become apparent to those skilled in the art from the present disclosure. While the invention will be described in conjunction with the preferred embodiments, it is not intended that features of the invention be limited to these embodiments. On the contrary, the invention is described in connection with the embodiments for the purpose of covering alternatives or modifications that may be extended based on the claims of the present invention. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. The invention may be practiced without these particulars. Moreover, some of the specific details have been left out of the description in order to avoid obscuring or obscuring the focus of the present invention. It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.

In the description of the present embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings or orientations or positional relationships that are conventionally placed when the products of the present invention are used, and are only used for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the devices or elements indicated must have specific orientations, be configured in specific orientations, and operate, and thus, should not be construed as limiting the present invention.

The terms "first," "second," and the like are used solely to distinguish one from another and are not to be construed as indicating or implying relative importance.

In the description of the present embodiment, it should be further noted that, unless explicitly stated or limited otherwise, the terms "disposed," "connected," and "connected" are to be interpreted broadly, e.g., as a fixed connection, a detachable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present embodiment can be understood in specific cases by those of ordinary skill in the art.

Referring to fig. 1 in conjunction with fig. 2-11, in the embodiment of fig. 1, the copper water knockout die 1000 includes a lower die 1100 and an upper die 1200.

Referring to fig. 2, in the embodiment of fig. 2, the lower mold 1100 includes a middle section cavity 1101, stepped section cavities 1102 and 1103, hexagonal section cavities 1104 and 1105, branch cavities 1106, 1107, 1108, 1109 and 1110; the main cavity is formed by a middle section cavity 1101, step section cavities 1102 and 1103 and inner hexagonal section cavities 1104 and 1105.

Referring to fig. 3 in conjunction with fig. 4, in the embodiment of fig. 3 and 4, the upper die 1200 includes a mid-section cavity 1201, step section cavities 1202 and 1203, hexagonal section cavities 1204 and 1205, branch cavities 1206, 1207, 1208, 1209, 1210; first strain sensors 1211, 1212, 1213, 1214, 1215, second strain sensors 1216, 1217, 1218, 1219, 1220. The main cavity is formed by a middle section cavity 1201, step section cavities 1202 and 1203 and inner hexagonal section cavities 1204 and 1205.

The pasting area of the first strain sensor and the second strain sensor is formed by performing L-shaped hollowing on the outer side wall of the upper die 1200 to form an L-shaped cavity, so that the wall thickness between the L-shaped cavity and the branch cavity is reduced, and the sensors can better sense the strain change of the branch cavity at the tail end.

Referring to fig. 5 in conjunction with fig. 6, in the embodiment of fig. 5 and 6, a cylindrical billet 3000 is placed on the lower die 1100, and then the upper die 1200 is snapped and compressed to form a complete die.

Referring to fig. 7, in the embodiment of fig. 7, the pressing device includes a first pressing device 2100 and a second pressing device 2200, and the first pressing device 2100 includes a hydraulic component 2104, a moving hydraulic lever 2103, a hydraulic push rod 2102, and a push plate 2101. The second pressing device 2200 includes a hydraulic device 2204, a moving hydraulic rod 2203, a hydraulic push rod 2202, and a push plate 2201.

Referring to fig. 9, in the embodiment of fig. 9, the theoretical calculation model 4000 of the water knockout vessel includes a middle stage pipe 4001, step stage pipes 4002 and 4003, outer hexagonal stage pipes 4004 and 4005, first branch pipes 4006, 4007, 4008, 4009, 4010, and second branch pipes 4011, 4012, 4013, 4014, 4015, and a through hole 4016 in the main body pipe. A main body pipe is formed by the middle section pipe 4001, the step section pipes 4002 and 4003 and the outer hexagonal section pipes 4004 and 4005.

All internal bore diameters of the body tube are the same, i.e. only the external profile is not uniform throughout the body tube, but the internal bore diameters are the same and continuous, forming through bore 4016, and the bore diameter of through bore 4016 is the same as the bore diameter of the final product.

The first branch pipes 4006, 4007, 4008, 4009, 4010 and the second branch pipes 4011, 4012, 4013, 4014, 4015 are all solid.

Referring to fig. 10 in conjunction with fig. 7 and 9, fig. 10 shows a water knockout element 5000, which is a product after extrusion from a copper water knockout die 1000 after a cylindrical billet 3000 is swaged by extrusion devices 2100 and 2200. The through hole 5016 in fig. 10 is different from the through hole 4016 in fig. 9 in that the diameter of the through hole 5016 in fig. 10 is small, the through hole 5016 may not be punched by extrusion, and the through hole 5016 needs to be machined to the through hole 4016 by machining.

In addition, the rest of the diagram in fig. 10 corresponds exactly to the theoretical calculation model of the water separator in fig. 9, i.e. both the first branch pipe and the second branch pipe are solid.

Referring to fig. 11, fig. 11 is a final diverter product, which is compared to diverter stripper 5000 where the holes in the main pipe and each branch pipe are machined and punched through to form the final copper diverter product 6000.

It is understood that five branch cavities, five groups of the first strain sensor and the second strain sensor, may be used in this case, but the practical application scenario includes, but is not limited to, five, and the practical number may be set according to practical needs.

With continued reference to fig. 1 in conjunction with fig. 2-11, the diverter die and die press in one embodiment are connected as follows:

the lower die 1100 is fixed on a factory-designated work area floor, and the first and second pressing apparatuses 2100 and 2200 are similar. The upper mold 1200 is snap-fitted to the lower mold 1100 and guided through the holes and the cylinders (not shown).

The upper die 1200 is provided with an L-shaped cavity at the end of each branch cavity, and the thickness of the die wall at the end of each branch cavity is intentionally thinned to increase the sensitivity to strain sensing.

The ends of the branch cavities 1206, 1207, 1208, 1209, 1210 of the upper mold 1200 are provided with first strain sensors 1211, 1212, 1213, 1214, 1215 and second strain sensors 1216, 1217, 1218, 1219, 1220, respectively.

Referring to fig. 4, the first strain sensors 1211, 1212, 1213, 1214, 1215 are disposed on a vertical plane of the L-shaped cavity, and the second strain sensors 1216, 1217, 1218, 1219, 1220 are disposed on a horizontal plane of the L-shaped cavity.

A hydraulic push rod 2102 and a push plate 2101 in the first extrusion device 2100 are matched in a hole shaft mode capable of moving mutually, the diameter of the hydraulic push rod 2102 is smaller than the inner hole diameter of the water separator hollow main body pipe, the hydraulic push rod 2102 can extend into and withdraw from a main cavity of a die, and the push plate 2101 can be attached to the outer wall of the die.

The second pressing device 2200 operates in the same manner as the first pressing device 2100, and thus, will not be described in detail.

The concrete implementation mode of the water separator die forging process method is as follows:

1. establishing a model and calculating the volume of each part

And establishing a three-dimensional model according to the parameters such as the size of the actually required water separator by utilizing computer three-dimensional modeling software, and endowing the copper material with the properties.

The main pipe of the water separator model is in a hollow actual product state, and each branch pipeline is in a solid state before being opened, as shown in a water separator theoretical calculation model 4000 in fig. 9. And calculating the volume of the model, recording the volume of a hollow main pipe of the water separator model as A, recording the sum of the volumes of all solid branch pipelines as B, and obtaining the total volume of the water separator model by A + B. The volumes of the step section pipes 4002 and 4003 and the hexagonal section pipes 4004 and 4005 which are thicker than the outer diameter of the middle section pipe 4001 are marked as C, and a main cavity and each branch cavity of the mold are established according to the outline shape of the model. It may be desirable to have a thicker wall thickness in the main cavity and a thinner wall thickness at the end of each branch cavity, as shown in figures 3 and 4.

2. Establishing solid cylindrical bar model

The diameter of the main cavity is equal to or slightly smaller than the diameter of the main cavity of the mold (the outer diameter of the middle section tube 4001), the length of the main cavity of the mold is equal to or slightly smaller than the length of the main cavity of the mold, the length of the main cavity of the mold is the total length of the main body tube including the middle section tube 4001, the step section tubes 4002 and 4003 and the hexagonal section tubes 4004 and 4005), and the selected material is copper.

3. Calculating the single-side propulsion length of the hydraulic push rod during die forging

And if the diameter of the push rod is D, the pushing length is the sum of B + C divided by D and is recorded as E.

The volume of hydraulic rams 2102 and 2202 entering the die cavity is equal to the sum of the volume B of cylindrical billet 3000 extruded into each branch line and the volume C of the thicker section at the two ends of the water knockout vessel. Therefore, the push rod propelling length can be calculated accurately, so that the product quality defect caused by insufficient extrusion can be prevented, and the die can be prevented from being damaged excessively by extrusion.

4. The special die forging die 1000 for the copper water separator, the cylindrical bar 3000, the production line and the like are manufactured in advance according to the parameters.

5. Preparation for preprocessing

The lower die 1100 is fixedly arranged on the ground of a work area designated by a factory, the first extrusion device 2100 and the second extrusion device 2200 are fixedly arranged as above, and meanwhile, the hydraulic component 2104 in the first extrusion device 2100 works to drive the movable hydraulic rod 2103, the hydraulic push rod 2102 and the push plate 2101 to retract to a preparation work position.

6. Heating cylindrical bar

Heating the copper cylindrical bar stock to 600 ℃ to reach the preset optimal die forging temperature, then heating to 650 ℃, and keeping the constant temperature range at 650 +/-10 ℃. Therefore, the temperature of the forged piece during formal die forging can be reduced to about 600 ℃, the die forging effect is guaranteed, meanwhile, oxide skin cannot fall off due to high-temperature oxidation of the copper material, material loss is less, and therefore high matching of theoretical data and actual products is guaranteed.

7. Preliminary extrusion

The heated cylindrical bar 3000 of copper is quickly transferred into the main cavity of the lower die 1100 as shown in fig. 5, and then closed and blocked. The upper die 1200 snaps onto the lower die 1100 and compresses, as shown in fig. 6.

The hydraulic component 2104 of the first extrusion device 2100 works to drive the movable hydraulic rod 2103, the hydraulic push rod 2102 and the push plate 2101 to move forward, the push plate 2101 is tightly attached to the side wall of the mold, the front end of the hydraulic push rod 2102 is flush with the front end surface of the push plate 2101, and the second extrusion device 2200 has the same principle. The hydraulic rams 2102 and 2202, which have been located at the ends of the main cavity of the die, are then operated to bi-directionally compress the cylindrical billet 3000 to deform it, and the metal slowly flows into the various branch cavities, etc.

During extrusion, the advancing speeds of the push rods on the two sides are consistent, and the lengths of the push rods entering the main cavity are also consistent. When the total length of the pushing distance of the push rods reaches E, namely the length of pushing E/2 of each push rod at two sides, the extrusion is temporarily stopped.

8. Deformation detection of upper die of each branch cavity

At the end of each branch cavity 1206, 1207, 1208, 1209, 1210 of the upper mould 1200 a first strain sensor 1211, 1212, 1213, 1214, 1215 and a second strain sensor 1216, 1217, 1218, 1219, 1220 are arranged respectively, in the primary extrusion process, the copper material is extruded and flows into each branch cavity, under the action of gravity, the branch cavities 1106, 1107, 1108, 1109 and 1110 of the lower die 1100 are firstly and most easily filled with flowing copper, the branch cavities 1206, 1207, 1208, 1209, 1210 of the upper die 1200 are not necessarily completely filled, mainly because the initial cylindrical billet 3000 cannot be made to absolute zero volume, for example, the dimensions of the cylindrical bar stock raw material are subject to tolerance, the length or diameter may be slightly smaller than the theoretical dimension, therefore, when the volume is slightly smaller, there is a possibility that the individual branch cavities cannot be filled with copper during extrusion. This detection step is therefore required.

Because the wall thickness of each branch cavity is thin, the branch cavities are relatively easy to deform when stressed.

When the strain sensor at the end of each branch cavity of the upper die 1200 detects a significant strain, it indicates that the extrusion is acceptable and the water separator product is formed.

When the strain sensors at the end of one or more of the branch cavities do not detect strain, it is indicated that the branch cavities are not filled with copper, and therefore, the extrusion is required to be continued.

9. Step-by-step supplemental extrusion

When copper materials which are not filled in the branch cavities are detected in the step 8, the hydraulic push rods 2102 and 2202 continue to work, in order to prevent the die damage or rigidity deterioration caused by excessive extrusion, the hydraulic push rods need to advance in a preset stepping mode, namely the hydraulic push rod 2102 at one end advances for 1mm and then stops, the controller receives signals of the strain sensors, judges whether the tail ends of the branch cavities are deformed or not, then the hydraulic push rod 2202 at the other end advances for 1mm and stops, the controller detects whether the tail ends of the branch cavities are deformed or not again, and the operation is repeatedly executed until the strain sensors at the tail ends of the branch cavities detect obvious strain, the extrusion is qualified, and the water distributor product is formed.

10. Demoulding

The hydraulic push rods 2102 and 2202 and the push plates 2101 and 2201 are retracted to reduce the temperature of a water path inside the upper die 1200 and lower than that of the lower die 1100, so that the extrusion degree of the water separator and the upper die is weakened, the upper die is separated conveniently, the water separator is prevented from being brought out together due to adhesion or extrusion and the like when the upper die is removed, and the water separator is taken out of the lower die after being cooled gradually.

At this time, the state of the sample is as shown in fig. 10, the through hole 5016 has a small diameter, and needs to be subjected to machining, reaming and punching;

in addition, each branch pipe can be solid, so drilling and opening are needed.

11. Machining finishing

The final product is completely formed by machining the knockout piece 5000 of the water separator by operations such as drilling, trimming and the like, and as shown in fig. 11, the final copper water separator product 6000 can be obtained.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.