Integrated head punching plate blank near-net forming aid, integrated head

Abstract

The utility model discloses integrated head punch shape uses the blank near net shape forming auxiliary, integrated head belongs to the technical field of head manufacturing, the existing technology in which at least one of integrated head manufacturing's demoulding difficulty, production cycle, material utilization rate, complex structure forming difficulty etc.

Description

Technical Field

[0001] This utility model relates to the field of end cap manufacturing technology, and in particular to a near-net-shape forming tool for slab blanks used in the punching of integrated end caps and an integrated end cap. Background Technology

[0002] As equipment in my country's energy, chemical, aerospace, and marine engineering industries develops towards integration and large-scale production, the performance requirements for large container heads (such as pressure vessel heads for nuclear power plants and large chemical containers) are increasing. To meet the extreme demands for stability and reliability in harsh service environments, modern large heads are generally adopting integrated complex structures, that is, manufacturing the head body and multiple accessories such as nozzles and manholes of different specifications as a single forging.

[0003] However, the manufacturing of such large integrated heads requires first forging a shaped slab blank (i.e., a stamping blank) for subsequent stamping. This slab blank is not a simple disc shape, but rather requires pre-forming multiple protrusions that correspond one-to-one with the nozzles, manholes, and other features on the final head. It is precisely this "integrated" characteristic of the product structure that leads to the enormous difficulties in manufacturing its stamping blank: traditional free forging combined with machining methods not only have long production cycles, but also result in extremely low material utilization due to the huge machining allowance, and it is difficult to guarantee the forming quality of the complex protrusions; while the die forging technology adopted in recent years can improve material utilization and forming consistency, it faces huge obstacles in the product demolding process—the multiple protrusions of different shapes and complex distribution on the slab blank cause severe interlocking and interference with the mold cavity, resulting in huge demolding resistance. Forced demolding can lead to surface scratches or even internal damage to the product, which seriously restricts the efficient and high-quality manufacturing of large integrated head products. Utility Model Content

[0004] Based on the above analysis, this utility model aims to provide a near-net-shape forming tool for slab blanks for integrated head punching and an integrated head, in order to solve at least one of the problems in the manufacturing of integrated heads, especially large integrated heads with nozzles of different specifications, such as high demolding difficulty, long production cycle, low material utilization rate, and difficulty in forming complex structures.

[0005] The objective of this utility model is mainly achieved through the following technical solutions:

[0006] This utility model provides an integrated near-net-shape forming tool for end cap punching, including a top block assembly and a lower die;

[0007] The top block assembly includes a top block region and a top block recessed cavity region, the top block recessed cavity region being arranged around the top block region and sinking in a stepped manner; the top block region includes an open inner cavity;

[0008] The lower mold includes a hollow area and a lower mold cavity area, and the lower mold cavity area is arranged around the hollow area and sinks in a stepped manner.

[0009] An elastic reset mechanism is provided between the top block assembly and the lower mold;

[0010] When the mold is closed, the top block area extends into the hollow area, and the lower mold recess area and the open inner cavity together form the forming chamber of the blank to be formed.

[0011] Furthermore, the elastic reset mechanism is disposed within the cavity region of the top block.

[0012] Furthermore, the top block area includes an upper boss structure and a lower column structure; the open inner cavity is formed within the boss structure; the maximum outline dimension of the outer peripheral wall of the boss structure is not greater than the outline dimension of the outer peripheral wall of the column structure.

[0013] Furthermore, the inner peripheral wall of the hollowed-out area of ​​the lower mold and the outer peripheral wall of the column structure follow each other and slide relative to each other.

[0014] Furthermore, the inner peripheral wall of the outermost recessed cavity in the top block cavity area can accommodate the outer peripheral wall of the lower mold, and when the mold is closed, the bottom of the lower mold abuts against the bottom of the outermost recessed cavity in the top block cavity area.

[0015] Furthermore, the inner peripheral wall of the outermost recessed cavity in the lower mold cavity area along the radial direction is conformal to the outer peripheral wall of the blank to be formed.

[0016] Furthermore, the blank to be formed includes a first protrusion located in the middle and second protrusions distributed around the first protrusion;

[0017] The lower mold recessed cavity area includes a third recessed cavity and a fourth recessed cavity in the radial direction from the outside to the inside;

[0018] The inner peripheral wall of the fourth recessed cavity conforms to the outer peripheral wall of the second protrusion;

[0019] The outer peripheral wall of the boss structure at the top of the top block area conforms to the inner peripheral wall of the second protrusion.

[0020] The inner peripheral wall of the open cavity conforms to the outer peripheral wall of the first protrusion;

[0021] The inner peripheral wall of the third sinking cavity conforms to the outer peripheral wall of the slab.

[0022] Furthermore, the depth of the open cavity of the boss structure at the top of the top block area is equal to the depth of the innermost recessed cavity in the lower mold recess area along the radial direction.

[0023] Furthermore, the difference between the height of the column structure at the bottom of the top block area and the depth of the innermost recessed cavity in the radial direction of the top block cavity area is equal to the depth of the hollow area of ​​the lower mold.

[0024] This utility model provides an integrated end cap, which is formed by punching and enveloping a blank made by the near-net-shape forming tool. The blank is formed in a forming cavity jointly enclosed by the lower die cavity area of ​​the near-net-shape forming tool and the open inner cavity.

[0025] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0026] This invention achieves near-net-shape forming of slabs for integrated head punching. Through the coordinated operation of the top block assembly and the lower die, as well as the setting of the elastic reset mechanism, the demolding difficulty is significantly reduced. The traditional multi-stage free forging is optimized into in-die upsetting, which effectively shortens the production cycle and improves material utilization. Furthermore, through the conformal fit between the open inner cavity of the top block area and the recessed cavity area of ​​the lower die, high-precision and consistent forming of slabs with complex structures and integrated heads is achieved.

[0027] (1) This utility model addresses the common problem of demolding difficulties in the manufacturing of integrated head punching blanks using existing die forging processes. Through innovative mold structure design, it provides a near-net-shape forming auxiliary tool, effectively solving the technical problems of high demolding resistance, low efficiency, and easy damage to the blank surface. Specifically, through the coordinated design of the cavity of the top block assembly and the lower die, the top block area is set as a structure with an open inner cavity, which together with the lower die recess area forms the blank forming chamber, realizing the precision forming of complex protruding structures. On this basis, by setting an elastic reset mechanism between the top block assembly and the lower die, after in-die upsetting, the lower die along with the intermediate blank can be automatically and quickly separated from the top block assembly, significantly reducing the demolding difficulty and avoiding product defects that may be caused by forced demolding.

[0028] (2) This utility model optimizes the complex slab forming process, which requires multiple forging passes and multiple steps in traditional free forging, into in-die upsetting by using the cooperative structure of the top block assembly and the lower die. Specifically, through the cooperative structure of the top block area extending into the hollow area, and the forming chamber formed by the lower die recess area and the open inner cavity, near-net-shape forming of complex slab structures is achieved, significantly reducing the number of forging passes and process steps, effectively shortening the production cycle, and improving material utilization.

[0029] (3) This utility model uses the open inner cavity of the top block area and the stepped structure of the lower mold cavity area to form a complete forming chamber when the mold is closed, thus decomposing the complex protruding structure onto the corresponding cavity. Through the simple axial movement of the top block area extending into the hollow area, the complex three-dimensional features on the blank can be formed simultaneously and precisely, ensuring forming quality and dimensional accuracy, and effectively solving the problem of difficult blank forming for complex structures.

[0030] (4) In some preferred embodiments, the present invention further addresses the problems of high demolding difficulty, long production cycle, low material utilization and difficulty in forming complex structures through structural optimization and matching design:

[0031] a) By setting the elastic reset mechanism in the cavity area of ​​the top block, the lower mold and the top block assembly can be automatically and quickly separated after molding, which significantly reduces the difficulty of demolding and avoids product damage caused by forced demolding.

[0032] b) Through the precise fit between the top block area and the lower die, the traditional multi-fire and multi-step free forging process is optimized into near-net-shape forming in the die, which greatly shortens the production cycle, reduces material waste, and improves material utilization.

[0033] c) By adapting the open inner cavity of the top block area to the recessed cavity of the lower mold, the complex protruding structure is decomposed into the corresponding cavity, realizing the synchronous and precise forming of multiple complex three-dimensional features on the blank, effectively solving the problem of difficult forming of complex structures.

[0034] d) By controlling the outer peripheral wall contour dimension of the boss structure in the top block area to be no greater than the outer peripheral wall contour dimension of the column structure, and by making the outer peripheral wall of the column structure slide in a conformal fit with the inner peripheral wall of the lower mold hollow area, the demolding resistance is further reduced and the demolding smoothness is improved.

[0035] e) By designing the fit between the top block recess area and the outer peripheral wall of the lower mold, the mold closing stroke is limited, improving the control precision of the forming process and ensuring the consistency of complex structure forming;

[0036] f) By precisely setting the depth of the open inner cavity of the top block area to be equal to the depth of the innermost recessed cavity of the lower mold cavity area, and the difference between the height of the column structure and the depth of the top block cavity area to be equal to the depth of the lower mold hollow area, the integrity and coordination of the forming cavity are ensured, further improving material utilization and forming accuracy.

[0037] In this invention, the above-described technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of this invention will be set forth in the following description, and some advantages may become apparent from the description or be learned by practicing the invention. The objectives and other advantages of this invention can be realized and obtained through the embodiments described and the accompanying drawings, which are particularly pointed out. Attached Figure Description

[0038] The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0039] Figure 1 (a) is a structural schematic diagram of the top block assembly of the near-net-shape forming tooling provided in this embodiment of the present invention, (b) is a top view of the top block assembly, and (a) is a schematic diagram of the top block assembly. Figure 1 (b) sectional view of section AA, (c) three-dimensional view of the top block assembly;

[0040] Figure 2 for Figure 1 (a) Enlarged schematic diagram;

[0041] Figure 3 (a) is a structural schematic diagram of the lower mold of the near-net-shape forming tooling provided in the embodiment of this utility model, (b) is a top view of the lower mold, and (a) is... Figure 3 (b) A cross-sectional view of section AA in the middle, and (c) A three-dimensional view of the lower mold;

[0042] Figure 4 for Figure 3 (a) Enlarged schematic diagram;

[0043] Figure 5 A schematic diagram of the top block assembly and the lower mold after mold closing for the near-net-shape forming tooling provided in this embodiment of the utility model (the spring is not placed in the recessed cavity);

[0044] Figure 6 The diagram shows the top block assembly and the lower mold after mold closing of the near-net-shape forming tool provided in this embodiment of the utility model (the spring is placed in the recessed cavity). (a) is a cross-sectional view, and (b) is a three-dimensional view.

[0045] Figure 7 (a) is a schematic diagram of the edge-opening hammer head of the near-net-shape forming tooling provided in the embodiment of this utility model, (b) is a top view of the edge-opening hammer head, and (a) is... Figure 7 (b) Schematic sectional view of section AA;

[0046] Figure 8The diagram shows the in-mold upsetting process during the manufacturing of an integrated head punching blank using the near-net-shape forming tooling provided in this embodiment of the invention. (a) is before mold closing, (b) after in-mold upsetting is completed, and (c) after demolding.

[0047] Figure 9 The diagram shows the in-mold edge opening process during the manufacturing of an integrated end cap punching blank using the near-net-shape forming tool provided in this embodiment of the present invention. (a) is before rotating the edge opening, (b) is after the in-mold edge opening is completed, and (c) is after demolding.

[0048] Figure 10 The following are schematic diagrams of the intermediate blank and the integrated head stamping blank obtained in the process of manufacturing the integrated head stamping blank using the near-net-shape forming tool provided in the embodiments of this utility model: (a) is a cross-sectional view of the intermediate blank, (b) is a three-dimensional view of the intermediate blank, (c) is a cross-sectional view of the integrated head stamping blank, and (d) is a three-dimensional view of the integrated head stamping blank.

[0049] Figure 11 (a) is a schematic diagram of an integrated head obtained by manufacturing a stamping slab using the near-net-shape forming fixture provided in this embodiment of the invention, and (b) is a top view of the integrated head. Figure 11 (b) Schematic sectional view of section AA;

[0050] Figure label:

[0051] 10-Slab to be formed, 10a-Outer peripheral wall of slab, 11-First protrusion of slab, 11a-Outer peripheral wall of the first protrusion in slab, 12-Second protrusion of slab, 121-Bulge on the second protrusion, 121A-Centripetal bulging section, 121B-Centrifugal bulging section, 12a-Inner peripheral wall of the second protrusion in slab, 12b-Outer peripheral wall of the second protrusion in slab; 20-Top block assembly, 2 0a - Outer peripheral wall of the top block assembly, 21 - Top block area, 211 - Boss structure, 211a - Open inner cavity, 211a-1: Inner peripheral wall of the open inner cavity, 211b - Outer peripheral wall of the boss structure, 211b-1: Centripetal concave section provided on the outer peripheral wall of the boss structure, 212 - Column structure, 212b - Outer peripheral wall of the column structure, 22 - Top block recessed cavity area, 22a - First recessed cavity, 22 a1 - Inner peripheral wall of the first sunken cavity, 22b - First step surface, 22c - Second sunken cavity, 22c1 - Inner peripheral wall of the second sunken cavity, 23 - Spring, 30 - Lower mold, 30a - Outer peripheral wall of the lower mold, 31 - Hollowed-out area, 31a - Inner peripheral wall of the hollowed-out area, 32 - Lower mold sunken cavity area, 32a - Third sunken cavity, 32a1 - Inner peripheral wall of the third sunken cavity, 32b - Second step surface, 32c - Fourth sunken cavity, 32c1 - Inner peripheral wall of the fourth sunken cavity, 32c1-1: Centrifugal concave section provided on the inner peripheral wall of the fourth sunken cavity, 40 - Opening hammer, 40a - End of the opening hammer, 50 - Initial blank, 60 - Intermediate blank, 70 - Rotating platform, 90 - Unloading platform, 00 - Integrated end cap, 01 - First end cap nozzle, 02 - Second end cap nozzle, 03 - End cap manhole. Detailed Implementation

[0052] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which constitute a part of the present invention and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0053] This utility model provides an integrated near-net-shape forming tool for end cap punching, including a top block assembly 20 and a lower die 30;

[0054] The top block assembly 20 includes a top block region 21 and a top block recessed cavity region 22. The top block recessed cavity region 22 is arranged around the top block region 21 and sinks in a stepped manner. The top block region 21 includes an open inner cavity 211a.

[0055] The lower mold 30 includes a hollow area 31 and a lower mold cavity area 32. The lower mold cavity area 32 is arranged around the hollow area 31 and sinks in a stepped manner.

[0056] An elastic reset mechanism is provided between the top block assembly 20 and the lower mold 30;

[0057] When the mold is closed, the top block area 21 extends into the hollow area 31, and the lower mold recess area 32 and the open inner cavity 211a together form the forming chamber of the blank 10 to be formed.

[0058] It is understood that the hollowed-out area 31 is located in the middle of the lower mold 30 and is used to accommodate the top block area 21. The hollowed-out area is a through-hole structure.

[0059] Specifically, the elastic reset mechanism is located within the top block recessed cavity 22.

[0060] In one embodiment, the top block recessed cavity region 22 includes, from the outside to the inside in the radial direction, a first recessed cavity 22a and a second recessed cavity 22c.

[0061] In one embodiment, the lower mold recessed cavity region 32 includes a third recessed cavity 32a and a fourth recessed cavity 32c in a radial direction from the outside to the inside.

[0062] In one embodiment, the elastic reset mechanism is a spring 23, which is disposed in the second recessed cavity 22c. The top end of the spring 23 abuts against the bottom surface of the lower mold 30 and is compressed when the mold is closed.

[0063] For example, the top block recessed cavity region 22 is concentrically arranged around the top block region 21 and sinks in a stepped manner. The top block recessed cavity region 22 includes, from the outside to the inside in the radial direction, the following:

[0064] The first sinking cavity 22a is distributed in a ring shape.

[0065] The second recessed cavity 22c is arranged in a ring shape, and its bottom surface extends to the root of the top block area 21 and then terminates.

[0066] The first step surface 22b is located between the first sinking cavity 22a and the second sinking cavity 22c, forming a rigid limiting surface when the lower mold 30 moves downward.

[0067] For example, the lower mold recessed cavity area 32 is concentrically arranged around the hollowed-out area 31 and recessed in a stepped manner, and includes, from the outside to the inside in the radial direction:

[0068] The third sunken cavity 32a is arranged in a ring shape;

[0069] The fourth recessed cavity 32c is distributed in a ring shape, and the bottom surface of the fourth recessed cavity 32c extends to the boundary of the hollow area 31 and then terminates.

[0070] The second step surface 32b is located between the third sinking cavity 32a and the fourth sinking cavity 32c.

[0071] Specifically, the top block area 21 includes an upper boss structure 211 and a lower column structure 212; the open inner cavity 211a is formed inside the boss structure 211; the maximum outline dimension of the outer peripheral wall of the boss structure 211 is not greater than the outline dimension of the outer peripheral wall of the column structure 212.

[0072] Specifically, the inner peripheral wall of the outermost recessed cavity in the lower mold cavity area 32 along the radial direction is conformal to the outer peripheral wall of the blank 10 to be formed.

[0073] Specifically, the blank to be formed 10 includes a first protrusion 11 located in the middle and a second protrusion 12 distributed around the first protrusion 11;

[0074] The lower mold recessed cavity area 32 includes, from the outside to the inside in the radial direction, a third recessed cavity 32a and a fourth recessed cavity 32c;

[0075] The inner peripheral wall 32c1 of the fourth recessed cavity 32c conforms to the outer peripheral wall 12b of the second protrusion 12;

[0076] The outer peripheral wall 211b of the boss structure 211 on the upper part of the top block area 21 conforms to the inner peripheral wall 12a of the second protrusion 12;

[0077] The inner peripheral wall 211a-1 of the open inner cavity 211a conforms to the outer peripheral wall 11a of the first protrusion 11.

[0078] The inner peripheral wall 32a1 of the third recessed cavity 32a conforms to the outer peripheral wall 10a of the slab 10.

[0079] Specifically, the inner peripheral wall 31a of the hollow area 31 of the lower mold 30 and the outer peripheral wall of the column structure 212 follow each other and slide relative to each other.

[0080] Specifically, the boss structure 211 is an annular boss structure. The outer peripheral wall of the annular boss structure has a draft angle (e.g., 1 to 7 degrees). The radial dimension of the outer peripheral wall of the annular boss structure decreases monotonically along the demolding direction to form a conical outer wall with a small top and a large bottom, which is conducive to demolding. The maximum dimension of the bottom of the annular boss (the end closest to the column structure) is not greater than the outer peripheral wall contour dimension of the column structure 212.

[0081] For example, the column structure 212 is a cylinder.

[0082] For example, the height 2H3 of the column structure 212 is greater than the depth 2H2 of the second recessed cavity 22c, and the height portion (2H3-2H2) of the column structure 212 that extends beyond the second recessed cavity 22c is adapted to the shape of the inner peripheral wall 31a of the hollow area 31 of the lower mold 30 and can achieve a sliding fit.

[0083] For example, see Figures 1-6 The column structure 212 is a cylinder with a diameter of 2D2. The hollow area 31 is a cylindrical hollow structure with a diameter of 3D3. The above dimensions satisfy the following relationship: 3D3-2D2=δ, where δ is the sliding fit clearance in the mechanical field. For example, the value of δ ranges from 0.0015 inches to 0.0040 inches, and for high-precision fits, 0.0001 inches≤δ≤0.0020 inches.

[0084] For example, the top block region 21 and the top block recessed cavity region 22 are coaxially arranged on the central axis of the top block assembly 20. Specifically, the first recessed cavity 22a and the second recessed cavity 22c included in the top block recessed cavity region 22 are coaxially arranged on the central axis of the top block assembly 20. It can be understood that the top block assembly 20 is a coaxially combined rotating body with a central axis.

[0085] For example, the inner peripheral walls of the third recessed cavity 32a and / or the fourth recessed cavity 32c and / or the open inner cavity 211a extend from the opening end toward the bottom wall and have draft angles, such as draft angles of 1° to 7°. The radial dimensions of the inner peripheral walls of the third recessed cavity 32a and / or the fourth recessed cavity 32c and / or the open inner cavity 211a increase monotonically along the demolding direction to form a conical cavity with a large opening and a small bottom, which is conducive to demolding.

[0086] For example, the inner peripheral walls of the first recessed cavity 22a and / or the second recessed cavity 22c are parallel to the central axis of the top block assembly 20. The first stepped surface 22b is perpendicular to the central axis of the top block assembly 20.

[0087] For example, the bottom of the open inner cavity 211a conforms to the top surface of the first protrusion 11 in the blank 10 to be formed (the complete surface of the first protrusion 11 that is furthest from the base of the blank 10).

[0088] The spring 23 is disposed within the second recessed cavity 22c, and the top end of the spring 23 abuts against the bottom surface of the lower mold 30 during mold closing. The spring 23 is configured to provide flexible floating support during mold closing and drive the lower mold 30 and intermediate blank to reset during demolding, thereby achieving rapid and non-destructive demolding.

[0089] Preferably, there are multiple springs 23, which are evenly distributed within the second sinking cavity 22c.

[0090] In one embodiment, the hollow area 31 and the lower mold cavity area 32 are coaxially arranged on the central axis of the lower mold 30. Specifically, the lower mold cavity area 32 includes a third recessed cavity 32a and a fourth recessed cavity 32c, which are coaxially arranged on the central axis of the lower mold 30. It can be understood that the lower mold 30 is a coaxially combined rotating body with a central axis.

[0091] Specifically, the inner peripheral wall of the outermost recessed cavity in the top block cavity area 22 along the radial direction can accommodate the outer peripheral wall of the lower mold 30, and when the mold is closed, the bottom of the lower mold 30 abuts against the bottom of the outermost recessed cavity in the top block cavity area 22 along the radial direction.

[0092] For example, the contour dimension defined by the inner peripheral wall 22a1 of the first recessed cavity 22a is not less than the contour dimension defined by the outer peripheral wall 30a of the lower mold 30; and the contour dimension defined by the outer peripheral wall 30a of the lower mold 30 is greater than the contour dimension defined by the inner peripheral wall 22c1 of the second recessed cavity 22c. This dimensional design provides guidance and motion tolerance for the downward movement of the lower mold, ensuring its smooth introduction into the top block assembly; based on this, after the lower mold smoothly enters the first recessed cavity 22a, it continues to descend and compress the spring 23. This process causes the blank to be gradually pushed out (reverse extrusion) on the top block area 21, thereby sequentially forming the first protrusion 11. The compression of the spring 23 provides the necessary flexible pressure to ensure sufficient material filling. When the lower mold 30 descends to its final position (such as the first step surface 22b limit), the inner peripheral wall of the fourth recessed area 32c on the lower mold 30 and the outer peripheral wall of the top block area 21 cooperate to precisely form the second protrusion 12, thereby completing the synchronous precision forming of complex features with axial movement. See also Figures 1-6 When the outline defined by the inner peripheral wall 22a1 of the first recessed cavity 22a is circular, its diameter is 2D1. When the outline defined by the inner peripheral wall 22c1 of the second recessed cavity 22c is circular, its diameter is 2D3. The outline defined by the outer peripheral wall 30a of the lower mold 30 is circular, its diameter is 3D1. The above diameters satisfy the following relationship: 2D1 ≥ 3D1 > 2D3.

[0093] For example, the second step surface 22b conforms to the region (such as an annular region) between the root of the second protrusion 12 and the outer peripheral wall 10a of the slab 10 to be formed.

[0094] For example, the bottom of the fourth recessed cavity 32c conforms to the top surface of the second protrusion 12 in the blank 10 to be formed (the complete surface of the second protrusion 12 itself that is furthest from the blank 10 base).

[0095] In one embodiment, the blank 10 to be formed includes a first protrusion 11 located in the middle of the blank 10, and a second protrusion 12 distributed in a ring around the first protrusion 11.

[0096] Specifically, the second protrusion 12 and the first protrusion 11 are radially spaced.

[0097] Specifically, the second protrusion 12 in the blank 10 to be formed has a plurality of bulges 121 in the circumferential direction, and each bulge 121 has a radially concentric outer bulge section 121A and a centrifugal outer bulge section 121B.

[0098] Optionally, the outer peripheral wall contour of the slab 10 to be formed can be a regular shape or an irregular shape. For example, the outer peripheral wall contour of the slab 10 can be a centrally symmetrical shape, such as a circle or an ellipse.

[0099] It can be understood that the "centripetal bulging section 121A" refers to the section that bulges outward toward the central area of ​​the slab, and the "centrifugal bulging section 121B" refers to the section that bulges outward away from the central area of ​​the slab. When the outer peripheral wall contour of the slab 10 is a centrally symmetrical figure, the central area is specifically the center of the centrally symmetrical figure.

[0100] Preferably, the plurality of bulges 121 are arranged symmetrically in pairs about the center of the slab 10. Specifically, the bulges 121 are manhole seats used for forming manholes during slab stamping. By setting the manhole seats in pairs symmetrically arranged, it is ensured that the load does not become eccentric during the slab stamping process, thereby ensuring the machining accuracy and product yield of the manhole in the final integrated head. See also Figure 10 and Figure 11 The integrated end cap 00 includes multiple end cap nozzles 01 and 02 and an end cap manhole 03. Correspondingly, a pair of bulges 121 are symmetrically arranged on the second protrusion 12 of the preformed or unformed slab 10 about the center of the slab 10. The bulges 121 can also be called manhole seats, which are used to ensure uniform load distribution and avoid uneven load during the punching process.

[0101] More preferably, the plurality of bulges 121 are distributed at equal angular intervals around the second protrusion 12 in the circumferential direction of the blank 10. Exemplarily, the plurality of bulges 121 have the same shape.

[0102] For example, the first protrusion 11 is located in the central region of the slab 10 and is shaped as a protruding cylinder.

[0103] For example, the first protrusion 11 and the second protrusion 12 are arranged coaxially about the central axis of the blank 10 to be formed.

[0104] For example, the second protrusion 12 is an annular protrusion distributed around the first protrusion 11. On the second protrusion 12, the non-bulging area has a uniform thickness, and the centripetal outward bulging section 121A and centrifugal outward bulging section 121B of each bulge 121 are symmetrical arcs. Specifically, the centripetal outward bulging section 121A and centrifugal outward bulging section 121B of each bulge 121 are symmetrical about the central axis of the bulge 121, which is located on the middle ring of the annular protrusion. It can be understood that the middle ring is the ring exactly between the inner and outer rings of the annular protrusion.

[0105] Furthermore, the top block assembly 20 and the lower mold 30 cooperate to form the bulges 121 of the second protrusion 12 on the blank 10.

[0106] Specifically, the outer peripheral wall 211b of the annular boss structure 211 of the top block area 21 is provided with a plurality of concentric concave sections 211b-1. The number, circumferential position and concave contour of the concentric concave sections 211b-1 correspond one-to-one with the concentric bulging sections 121A of each bulge 121 and follow the shape.

[0107] The inner peripheral wall 32c1 of the fourth sinking cavity 32c is provided with a plurality of centrifugal concave sections 32c1-1. The number, circumferential position and concave surface contour of the centrifugal concave sections 32c1-1 correspond one-to-one with the centrifugal outer bulge section 121B of each bulge 121 and follow its shape.

[0108] It should be noted that the ingenuity of this utility model's auxiliary tooling design lies in its clever decomposition of the complex first protrusion and the second protrusion containing multiple bulges on the blank to be formed into a top block area and a stepped-down top block cavity area on the top block assembly, as well as a hollow area and a stepped-down lower mold cavity area on the lower mold. By utilizing the centripetal concave section of the top block area in the top block assembly, the centrifugal concave section on the lower mold, and the stepped multi-level sinking cavity and the open cavity of the top block area, the cavities of the two mold components together form a complete protrusion and bulge forming space after mold closing. The cavities of the mold components and each concave section strictly conform to the corresponding sections of the target feature in terms of quantity, circumferential position, and surface contour, thus achieving near-net-shape forming of complex three-dimensional features with simple axial mold opening and closing actions. This solution not only effectively solves the demolding problem of multi-protrusion and multi-bulge structures through complementary surface decomposition and clever setting of elastic structure, but also significantly improves the reliability and service life of mold operation by avoiding the use of complex mechanisms such as side core pulling. While ensuring forming accuracy, it reduces manufacturing difficulty and maintenance costs and improves forming efficiency. Especially for complex integrated end caps, the auxiliary tool provided by this utility model shows significant advantages of reduced manufacturing difficulty, reduced costs and improved efficiency while ensuring product quality.

[0109] Specifically, the depth of the open cavity 211a of the boss structure on the upper part of the top block area 21 is equal to the depth of the innermost recessed cavity in the lower mold recess area 32 along the radial direction.

[0110] For example, the depth of the open cavity 211a of the annular boss structure in the upper part of the top block area 21 is equal to the depth of the fourth recessed cavity 32c of the lower die 30; this ensures that the first protrusion 11 and the second protrusion 12 in the formed slab have the same height (vertical distance from the root to the top of the protrusion), which is beneficial for a more reasonable stress distribution during subsequent slab forming and service, reducing stress concentration caused by sudden changes in thickness, and improving product fatigue life. See also Figures 1-6 When the bottom of the open inner cavity 211a is a plane, the depth of the open inner cavity 211a of the annular boss structure 211 on the top block area 21 is 2H4. When the bottom surface of the fourth recessed cavity 32c is a plane, the depth of the fourth recessed cavity 32c of the lower mold 30 is 3H2. When the tops of the first protrusion 11 and the second protrusion 12 of the blank 10 to be formed are flush and the height of both is 1H2; the above dimensions satisfy the following relationship: 2H4=3H2=1H2.

[0111] Specifically, the difference between the height of the column structure 212 at the bottom of the top block area 21 and the depth of the innermost recessed cavity in the radial direction of the top block cavity area 22 is equal to the depth of the hollow area 31 of the lower mold 30.

[0112] For example, the difference between the height of the column structure 212 at the lower part of the top block area 21 and the depth of the second recessed cavity 22c of the top block recessed cavity area 22 is equal to the depth of the hollowed-out area 31. See also Figures 1-6 When the bottom of the second recessed cavity 22c is a plane, the height of the column structure 212 at the bottom of the top block area 21 (relative to the bottom plane of the second recessed cavity 22c) is 2H3, and the depth of the second recessed cavity 22c (relative to the bottom plane of the second recessed cavity 22c) is 2H2. The depth of the hollow area 31 is 3H3; the above dimensions satisfy the following relationship: 3H3 = 2H3 - 2H2, so as to ensure that when the bottom of the lower mold 30 abuts against the first step surface 22b, the bottom of the fourth recessed cavity 32c of the lower mold 30 is flush with the root of the annular boss structure 211, together forming the top surface of the second protrusion 12 on the blank 10.

[0113] It can be understood that "the depth of the hollow area 31" refers to the vertical distance from the top surface of the hollow area 31 (e.g., the surface that is level with the fourth recessed cavity 32c in the lower mold) to the bottom surface of the hollow area (e.g., the surface that is level with the bottom of the lower mold).

[0114] Specifically, the near-net-shape forming tooling further includes: an edge-opening hammer head 40, the two ends 40a of which conform to the outer peripheral wall of the lower mold 30. See also Figure 7The outer peripheral wall 30a of the lower mold 30 has a circular outline, and the two ends of the edge-opening hammer head 40 are arc-shaped edges that conform to the outer peripheral wall of the lower mold 30. In the prior art, the two ends of the edge-opening hammer head are straight edges. The edge-opening cone head of this invention adopts an end profile designed to conform to the outer peripheral wall of the lower mold 30, such as an arc-shaped profile, ensuring that the edge-opening hammer head 40 and the outer ring of the lower mold 30 can effectively fit together. This improves the dimensional accuracy and quality uniformity of the outer ring portion between the outer peripheral wall 12b of the second protrusion 12 and the outer peripheral wall 10a of the slab after forming.

[0115] This invention achieves near-net-shape forming of slabs for integrated head punching. Through the coordinated operation of the top block assembly and the lower die, as well as the setting of the elastic reset mechanism, the demolding difficulty is significantly reduced. The traditional multi-stage free forging is optimized into die forming, which effectively shortens the production cycle and improves material utilization. Through the conformal fit between the open inner cavity of the top block area and the recessed cavity area of ​​the lower die, high-precision and consistent forming of complex structure slabs and integrated heads is achieved.

[0116] It should be noted that the motion principle of the near-net-shape forming tool provided by this utility model is as follows: The forming process of the near-net-shape forming tool begins with in-mold upsetting: After assembling the top block assembly 20 and the lower mold 30 included in the near-net-shape forming tool, the heated initial blank is placed in the lower mold 30, and the press drives the lower mold and the top block assembly to produce a mold closing movement. The lower mold compresses the elastic reset structure (such as spring 23), and the top block area 21 of the top block assembly 20 extends into the hollow area 31 of the lower mold 30. During this process, the blank moves between the open inner cavity 211a of the top block area 21 and the lower mold 30. Plastic flow occurs within the closed cavity formed by the mold cavity area 32, which precisely conforms to the complex protruding structure of the target slab blank, simultaneously forming the protruding structure of the slab blank 10 to be formed (e.g., the first protrusion in the middle of the slab blank and the surrounding second protrusion); when the bottom of the lower mold contacts the bottom of the outermost recessed cavity in the top block cavity area 22 of the top block assembly (e.g., the first step surface 22b), the upsetting terminates, forming the intermediate blank; subsequently, the press returns, and the elastic reset structure (e.g., spring 23) releases the elastic force, automatically lifting the lower mold and the intermediate blank, achieving non-destructive demolding from the top block area. Then, in-mold edge forming is performed: the lower mold with the intermediate blank is transferred to the rotating platform, and an edge-opening hammer (such as an edge-opening hammer whose end conforms to the outer wall of the lower mold) is used to rotate and hammer, so that the outer diameter of the blank continues to expand until its outer edge completely fills the outermost radial recess (such as the third recess 32a) in the lower mold recess area 32 of the lower mold and fits against the inner peripheral wall, thereby obtaining a near-net-shape integrated end cap punching blank.

[0117] Before manufacturing an integrated head using the near-net-shape forming fixture designed in this utility model, the dimensions of the blank for punching are calculated based on the dimensions of the integrated head. For example, if the integrated head is a curved head, the outer diameter of the blank for punching is (3.14×SR+t) / drawing rate, where SR is the inner sphere radius of the integrated head, t is the wall thickness of the integrated head, and the drawing rate is 1.06-1.08.

[0118] This utility model provides an integrated end cap, which is formed by punching and enveloping a blank made of a near-net-shape forming tool as described above. The blank is formed in a forming cavity jointly enclosed by the lower die cavity area 32 of the near-net-shape forming tool and the open inner cavity 211a.

[0119] The near-net-shape forming tool provided by this utility model is particularly suitable for forming and processing large-sized, complex multi-nozzle integrated heads.

[0120] In some embodiments, the integrated head of this invention is a large-size, complex multi-nozzle integrated head, wherein "large-size" refers to an inner sphere radius SR ≥ 1000 mm; further, the wall thickness t ≥ 100 mm. "Complex multi-nozzle" refers to the number of nozzles ≥ 4 and the number of manholes ≥ 1 on the integrated head; further, the multi-nozzle includes at least two different sizes of nozzles. For example, see... Figure 11 The integrated end cap 00 includes two different specifications of end cap nozzles and one end cap manhole 03. The first specification of end cap nozzles (i.e., first end cap nozzles 01) comprises five units, and the second specification of end cap nozzles (i.e., second end cap nozzles 02) comprises one unit. Specifically, the second end cap nozzle 02 is located at the top center of the integrated end cap, and is formed by punching and completely enclosing the first protrusion 11 of the slab blank 10. The five first end cap nozzles 01 and the end cap manhole 03 are evenly distributed on a ring coaxial with the center of the second end cap nozzle 02. The five first end cap nozzles 01 and the end cap manhole 03 are formed by punching and completely enclosing the second protrusion 12 of the slab blank 10. Specifically, the manhole 03 is formed by a bulge 121 punched on the second protrusion 12 and its overall envelopment, and a first nozzle 01 symmetrically distributed with respect to the manhole 03 is formed by another bulge 121 punched on the second protrusion 12 and its overall envelopment.

[0121] The technical solution of this utility model will be further described in detail below with reference to specific embodiments and comparative examples.

[0122] Example 1:

[0123] This embodiment provides a near-net-shape forming fixture for an integrated end cap punching blank 10, the near-net-shape forming fixture comprising: a top block assembly 20 and a lower die 30; see also Figures 1 to 7 ;

[0124] The top block assembly 20 includes a top block region 21 and a top block recessed cavity region 22; the top block recessed cavity region 22 is arranged around the top block region 21 and sinks in a stepped manner, and the top block region 21 includes an open inner cavity 211a;

[0125] The lower mold 30 includes a hollow area 31 and a lower mold cavity area 32. The lower mold cavity area 32 is arranged around the hollow area 31 and sinks in a stepped manner. The hollow area 31 is a through hollow structure.

[0126] An elastic reset mechanism, namely a spring 23, is provided between the top block assembly 20 and the lower mold 30;

[0127] When the mold is closed, the top block area 21 extends into the hollow area 31, and the lower mold recess area 32 and the open inner cavity 211a together form the forming chamber of the blank 10 to be formed.

[0128] In this embodiment, the outer peripheral wall 10a of the blank 10 to be formed has a circular outline. The blank 10 includes a first protrusion 11 located in the middle of the blank 10, and a second protrusion 12 distributed in a ring around the first protrusion 11. The first protrusion and the second protrusion have the same height. The second protrusion 12 has two bulges 121 in the ring direction. Each bulge 121 has a radially concentric bulging section 121A and a centrifugal bulging section 121B. The first protrusion 11 and the second protrusion 12 are arranged coaxially about the central axis of the blank 10. The first protrusion 11 is a protruding cylinder. The two bulges 121 are symmetrically arranged about the center of the blank 10 and along the diameter direction. On the second protrusion 12, the non-bulge area has a uniform thickness. The concentric bulging section 121A and the centrifugal bulging section 121B of each bulge 121 are symmetrical arcs, and the two bulges have the same shape.

[0129] In this embodiment, the top block recessed cavity region 22 is concentrically arranged around the top block region 21 and sinks in a stepped manner. The top block recessed cavity region 22 includes, from the outside to the inside in the radial direction:

[0130] The first sinking cavity 22a is distributed in a ring shape.

[0131] The second recessed cavity 22c is arranged in a ring shape, and its bottom surface extends to the root of the top block area 21 and then terminates.

[0132] The first step surface 22b is located between the first sinking cavity 22a and the second sinking cavity 22c, forming a rigid limiting surface when the lower mold 30 moves downward.

[0133] In this embodiment, the lower mold recessed cavity area 32 is concentrically arranged around the hollowed-out area 31 and sinks in a stepped manner, and includes the following in the radial direction from the outside to the inside:

[0134] The third sunken cavity 32a is arranged in a ring shape;

[0135] The fourth recessed cavity 32c is distributed in a ring shape, and the bottom surface of the fourth recessed cavity 32c extends to the boundary of the hollow area 31 and then terminates.

[0136] The second step surface 32b is located between the third sinking cavity 32a and the fourth sinking cavity 32c.

[0137] In this embodiment, to form the shape of the slab, the inner peripheral wall 32c1 of the fourth recessed cavity 32c conforms to the outer peripheral wall 12b of the second protrusion 12; the outer peripheral wall 211b of the boss structure 211 on the top block area 21 conforms to the inner peripheral wall 12a of the second protrusion 12; the inner peripheral wall 211a-1 of the open inner cavity 211a conforms to the outer peripheral wall 11a of the first protrusion 11; and the inner peripheral wall 32a1 of the third recessed cavity 32a conforms to the outer peripheral wall 10a of the slab 10. The second step surface 22b conforms to the region (such as the annular region) between the root of the second protrusion 12 and the outer peripheral wall 10a of the slab 10 to be formed. The bottom of the open inner cavity 211a conforms to the top surface of the first protrusion 11 in the slab 10 to be formed (the complete surface of the first protrusion 11 that is furthest from the slab 10 base). The bottom of the fourth recessed cavity 32c conforms to the top surface of the second protrusion 12 in the blank 10 to be formed (the complete surface of the second protrusion 12 that is furthest from the base of the blank 10).

[0138] The top block assembly 20 and the lower mold 30 cooperate to form the bulges 121 of the second protrusion 12 on the blank 10.

[0139] Specifically, the outer peripheral wall 211b of the annular boss structure 211 of the top block area 21 is provided with a plurality of concentric concave sections 211b-1. The number, circumferential position and concave contour of the concentric concave sections 211b-1 correspond one-to-one with the concentric bulging sections 121A of each bulge 121 and follow the shape.

[0140] The inner peripheral wall 32c1 of the fourth sinking cavity 32c is provided with a plurality of centrifugal concave sections 32c1-1. The number, circumferential position and concave surface contour of the centrifugal concave sections 32c1-1 correspond one-to-one with the centrifugal outer bulge section 121B of each bulge 121 and follow its shape.

[0141] Specifically, the top block assembly 20 is a coaxial rotating body with a central axis. The top block region 21 and the top block recessed cavity region 22 are coaxially arranged on the central axis of the top block assembly 20. The inner peripheral walls of the first recessed cavity 22a and / or the second recessed cavity 22c are parallel to the central axis of the top block assembly 20. The first step surface 22b is perpendicular to the central axis of the top block assembly 20. The top block region 21 includes an upper boss structure 211 and a lower column structure 212. The open inner cavity 211a is formed within the boss structure 211. The boss structure 211 is an annular boss structure. The column structure 212 is a cylinder.

[0142] To facilitate demolding, the outer peripheral wall of the annular boss structure has a draft angle (e.g., 1 to 7 degrees). The radial dimension of the outer peripheral wall of the annular boss structure decreases monotonically along the demolding direction to form a conical outer wall with a small top and a large bottom. The maximum dimension of the bottom of the annular boss structure (the end closest to the column structure) is equal to the outline dimension of the outer peripheral wall of the column structure 212. The inner peripheral walls of the third recessed cavity 32a, the fourth recessed cavity 32c, and the open inner cavity 211a extend from the opening end toward the bottom wall and have draft angles, for example, a draft angle of 1° to 7°. The radial dimension of the inner peripheral walls of the third recessed cavity 32a, the fourth recessed cavity 32c, and the open inner cavity 211a increases monotonically along the demolding direction to form a conical cavity with a large opening and a small bottom.

[0143] The inner peripheral walls of the first recessed cavity 22a and / or the second recessed cavity 22c are parallel to the central axis of the top block assembly 20. The first stepped surface 22b is perpendicular to the central axis of the top block assembly 20.

[0144] The height 2H3 of the column structure 212 is greater than the depth 2H2 of the second recessed cavity 22c, and the height portion of the column structure 212 that extends beyond the second recessed cavity 22c (2H3-2H2) is adapted to the shape of the inner peripheral wall 31a of the hollow area 31 of the lower mold 30 and can achieve sliding fit.

[0145] The contour dimension defined by the inner peripheral wall 22a1 of the first recessed cavity 22a is not less than the contour dimension defined by the outer peripheral wall 30a of the lower mold 30; and the contour dimension defined by the outer peripheral wall 30a of the lower mold 30 is greater than the contour dimension defined by the inner peripheral wall 22c1 of the second recessed cavity 22c, ensuring that the inner peripheral wall of the outermost recessed cavity (i.e., the first recessed cavity 22a) in the top block recessed cavity area 22 can accommodate the outer peripheral wall of the lower mold 30, and when the mold is closed, the bottom of the lower mold 30 abuts against the bottom of the outermost recessed cavity (i.e., the first recessed cavity 22a) in the top block recessed cavity area 22.

[0146] Specifically, the lower mold 30 is a coaxial rotating body with a central axis, and the hollow area 31 and the lower mold cavity area 32 are coaxially arranged on the central axis of the lower mold 30.

[0147] In this embodiment, the depth of the open cavity 211a of the annular boss structure in the upper part of the top block area 21 is equal to the depth of the fourth recessed cavity 32c of the lower mold 30, ensuring that the first protrusion 11 and the second protrusion 12 in the formed blank have the same height (vertical distance from the root to the top of the protrusion). The difference between the height of the column structure 212 in the lower part of the top block area 21 and the depth of the second recessed cavity 22c of the top block recessed cavity area 22 is equal to the depth of the hollow area 31.

[0148] In this embodiment, the elastic reset structure consists of eight springs 23 evenly arranged in the second recessed cavity 22c, with the top of each spring 23 abutting against the bottom surface of the lower mold 30 when the mold is closed.

[0149] In this embodiment, the integrated end cap 00 to be processed is a curved end cap with the following dimensions: SR = 1230mm, wall thickness t = 100mm. Based on (3.14×SR+t) / drawing rate, and drawing rate = 1.07, the outer diameter dimensions of the blank 10 for punching are calculated as follows: 1D1 = 3700mm, 1H1 = 200mm, 1H2 = 260mm; see [link to documentation]. Figure 1 2D1 = 4000mm, 2D2 = 2400mm, 2D3 = 3000mm, 2H1 = 300mm, 2H2 = 500mm, 2H3 = 600mm, 2H4 = 260mm; see also Figure 3 , 3D1=4000mm, 3D2=3700mm, 3D3=2400mm, 3H1=200mm, 3H2=260mm, 3H3=100mm.

[0150] Example 2

[0151] Example 2 is the same as Example 1, except that the near-net-shape forming fixture further includes an edge-opening hammer head 40, the two ends of which are arc-shaped edges that conform to the outer peripheral wall of the lower mold 30; see also Figure 7 .

[0152] Under the premise of achieving the same size and specifications for the integrated head stamping slab, the near-net-shape forming fixture described in this embodiment of the invention not only shortens the manufacturing cycle to less than 2 / 3 of the traditional "free forging + machining" method, but also results in an integrated head manufactured by existing technology with superior dimensional accuracy, overall quality, and comprehensive performance of the final integrated head. In particular, the near-net-shape forming fixture described in this embodiment of the invention enables efficient and high-quality manufacturing of complex integrated large heads (such as structures with multiple nozzles of different specifications) that are difficult to form or have excessively long cycles using existing technologies.

[0153] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present utility model should be included within the protection scope of the present utility model.

Claims

1. An integrated near-net-shape forming fixture for end cap punching, characterized in that, Includes top block assembly (20) and lower mold (30); The top block assembly (20) includes a top block region (21) and a top block recessed cavity region (22), the top block recessed cavity region (22) is arranged around the top block region (21) and sinks in a stepped manner; the top block region (21) includes an open inner cavity (211a); The lower mold (30) includes a hollow area (31) and a lower mold cavity area (32), wherein the lower mold cavity area (32) is arranged around the hollow area (31) and sinks in a stepped manner; An elastic reset mechanism is provided between the top block assembly (20) and the lower mold (30); When the mold is closed, the top block area (21) extends into the hollow area (31), and the lower mold recess area (32) and the open inner cavity (211a) together form the forming chamber of the blank (10) to be formed.

2. The near-net-shape forming aid according to claim 1, characterized in that, The elastic reset mechanism is located in the top block cavity area (22).

3. The near-net-shape forming aid according to claim 1, characterized in that, The top block area (21) includes an upper boss structure (211) and a lower column structure (212); the open inner cavity (211a) is formed in the boss structure (211); the maximum outline dimension of the outer peripheral wall of the boss structure (211) is not greater than the outline dimension of the outer peripheral wall of the column structure (212).

4. The near-net-shape forming aid according to claim 3, characterized in that, The inner peripheral wall of the hollow area (31) of the lower mold (30) and the outer peripheral wall of the column structure (212) follow each other and slide relative to each other.

5. The near-net-shape forming aid according to claim 1, characterized in that, The inner peripheral wall of the outermost recessed cavity in the top block cavity area (22) can accommodate the outer peripheral wall of the lower mold (30), and when the mold is closed, the bottom of the lower mold (30) abuts against the bottom of the outermost recessed cavity in the top block cavity area (22).

6. The near-net-shape forming aid according to claim 1, characterized in that, The inner peripheral wall of the outermost recessed cavity in the lower mold cavity area (32) along the radial direction is conformed to the outer peripheral wall of the blank to be formed (10).

7. The near-net-shape forming aid according to claim 3, characterized in that, The blank to be formed (10) includes a first protrusion (11) located in the middle and a second protrusion (12) distributed around the first protrusion (11); The lower mold recessed cavity area (32) includes a third recessed cavity (32a) and a fourth recessed cavity (32c) in the radial direction from the outside to the inside; The inner peripheral wall (32c1) of the fourth recessed cavity (32c) conforms to the outer peripheral wall (12b) of the second protrusion (12); The outer peripheral wall of the boss structure (211) on the upper part of the top block area (21) conforms to the inner peripheral wall (12a) of the second protrusion (12); The inner peripheral wall (211a-1) of the open inner cavity (211a) conforms to the outer peripheral wall (11a) of the first protrusion (11); The inner peripheral wall (32a1) of the third recessed cavity (32a) conforms to the outer peripheral wall (10a) of the slab (10).

8. The near-net-shape forming aid according to claim 3, characterized in that, The depth of the open cavity (211a) of the boss structure (211) on the upper part of the top block area (21) is equal to the depth of the innermost recessed cavity in the lower mold cavity area (32) along the radial direction.

9. The near-net-shape forming aid according to claim 3, characterized in that, The difference between the height of the column structure (212) at the bottom of the top block area (21) and the depth of the innermost recessed cavity in the radial direction of the top block cavity area (22) is equal to the depth of the hollow area (31) of the lower mold (30).

10. An integrated end cap, characterized in that, The integrated end cap is formed by punching and enveloping a blank made from a near-net-shape forming tool according to any one of claims 1-9, wherein the blank is formed in a forming chamber formed by the lower die recess area (32) of the near-net-shape forming tool and the open inner cavity (211a).

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