Continuous extrusion-forging composite forming device and method

Abstract

This invention discloses a continuous extrusion forging composite forming apparatus and method. The continuous extrusion forging composite forming apparatus includes a punch, an extrusion cylinder, an extrusion die core, a floating lower die, an elastic component, a lower die assembly, and an ejector rod. The punch is slidably placed in a first cavity of the extrusion cylinder, which is used to hold the blank. The extrusion die core is installed at the bottom end of the first cavity and has an extrusion through hole. The bottom end of the extrusion cylinder has a first channel communicating with the extrusion through hole. The floating lower die is slidably connected to a second cavity of the lower die assembly, and the floating lower die is connected to the bottom end of the second cavity through the elastic component. The floating lower die has a second channel. The ejector rod is vertically mounted on the lower die assembly, and its top end can be slidably connected to the second channel. This invention simplifies the traditional multi-step complex forming process by extruding the blank, solving the problems of poor microstructure consistency, low material utilization, and low production efficiency caused by traditional multi-stage forming of the disc and rod regions separately.

Description

Technical Field

[0001] This invention relates to the field of hot working technology, and in particular to a continuous extrusion forging composite forming apparatus and method. Background Technology

[0002] In aero engines, the bolted connection between the disc and shaft not only increases the engine weight but also easily leads to problems such as disc deformation, thread damage, and low bolt preload accuracy. This increases the risk of core rotor collision and ultimately results in poor reliability and stability of the disc-shaft components. Therefore, integrated disc-shaft structures have become an inevitable choice for advanced aero engine rotor structure design.

[0003] The integrated disc-shaft structure of an aero-engine is a complex structural component that incorporates both disc-type and journal-type integral structural features.

[0004] Currently, domestic manufacturers of integrated disc-shaft components mostly employ a step-by-step forming process. The disc portion typically utilizes free forging, die forging, or axial closed-circuit rolling techniques, while the long shaft portion generally uses free forging or hot extrusion. Forming the disc and shaft separately in different heats inevitably leads to uneven grain structure in some areas due to "air burning" or minor deformation. Furthermore, these traditional manufacturing processes are lengthy, have long production cycles, and are complex, making it impossible to complete the forming process in a single heat. The blanking process requires multiple grinding and finishing operations, resulting in reduced material utilization. Moreover, multi-heat forming not only poses serious challenges to process control but also makes it difficult to guarantee alloy fibers (streamlines), leading to poor product quality consistency.

[0005] These types of components are mostly made of high-temperature alloys or titanium alloys and other difficult-to-deform alloys. High alloying leads to poor hot working performance of the materials and narrow process window. The billets are prone to cracking during conventional casting and forging processes, making it difficult to complete the large deformation billet opening and forging of fine-grained billets. Summary of the Invention

[0006] In view of this, the first objective of the present invention is to provide a continuous extrusion forging composite forming apparatus that can solve the problems of poor microstructure consistency, low material utilization and low production efficiency caused by traditional multi-pass forming of the disc and rod regions separately.

[0007] The second objective of this invention is to provide a continuous extrusion forging composite forming method.

[0008] To achieve the first objective mentioned above, the present invention provides the following solution:

[0009] A continuous extrusion forging composite forming device includes a punch, an extrusion cylinder, an extrusion die core, a floating lower die, an elastic component, a lower die assembly, and an ejector pin;

[0010] The punch can be slidably placed in the first cavity of the extrusion cylinder. The first cavity is used to hold the blank. The extrusion die core is installed at the bottom end of the first cavity. The extrusion die core is provided with an extrusion through hole. The bottom end of the extrusion cylinder is provided with a first channel communicating with the extrusion through hole.

[0011] The floating lower die is slidably connected to the second cavity of the lower die assembly, and the floating lower die is connected to the bottom end of the second cavity through the elastic component. The extrusion cylinder is installed at the top of the lower die assembly to limit and abut against the top of the floating lower die. The floating lower die has a second channel, which communicates with the first channel, and the diameter of the second channel is smaller than the diameter of the first channel. The push rod is vertically mounted on the lower die assembly, and the top end of the push rod can be slidably connected to the second channel.

[0012] When the floating lower die abuts against the bottom wall of the second cavity, the second cavity, the punch, the extrusion die core, the floating lower die, and the top of the ejector pin can form a forming cavity that matches the shape of the part to be formed, and the punch can press the blank into the forming cavity.

[0013] In one specific implementation, the pressing rate of the punch is adjustable;

[0014] During the initial extrusion stage, when the blank is extruded, the downward pressing rate of the punch is a first rate value;

[0015] After the head of the extruded blank contacts the ejector pin, the downward pressing rate of the punch is reduced to the second rate value;

[0016] After the blank has fully contacted the inner wall of the cavity of the floating lower die, the pressing rate of the punch is the third rate value;

[0017] The first rate value is greater than the second rate value, and the second rate value is greater than the third rate value.

[0018] In another specific embodiment, the continuous extrusion forging composite forming apparatus further includes a glass pad and a process material pad;

[0019] The process pad and the glass pad are sequentially disposed between the punch and the blank. When the blank is completely extruded into the forming cavity, the glass pad and the process pad fill the space enclosed by the bottom end of the punch, the extrusion die core and the top end of the forming cavity.

[0020] In another specific implementation, the top end of the extrusion die core is provided with a first conical hole that communicates with and is coaxial with the top end of the extrusion through hole, and the bottom end of the extrusion die core is provided with a second conical hole that communicates with and is coaxial with the bottom end of the extrusion through hole;

[0021] and / or

[0022] The punch includes a punch body and an extrusion steel pad disposed at the bottom end of the punch body. The extrusion steel pad is slidably connected to the first cavity and is used to extrude the blank.

[0023] and / or

[0024] The lower mold assembly includes a lower mold outer sleeve, a lower module, and a lower mold base;

[0025] Both the lower mold outer sleeve and the lower module are mounted on the lower mold base, and the lower module is fitted inside the lower mold outer sleeve. The push rod can slide through the lower mold base and the lower module, and the bottom end of the elastic component is connected to the lower module.

[0026] In another specific embodiment, the lower mold assembly further includes a washer ring disposed on the lower mold module and fitted over the ejector pin.

[0027] In another specific embodiment, the elastic component includes a screw and a compression spring;

[0028] The bottom end of the lower module has a first groove, the nut of the screw is stuck in the bottom of the first groove, the screw passes through the lower module and is connected to the floating lower mold, the compression spring is sleeved on the outside of the screw, and its two ends abut against the floating lower mold and the lower module respectively.

[0029] In another specific implementation, a second groove is provided at the top of the lower module, the bottom end of the compression spring abuts against the bottom end of the second groove, and when the floating lower mold abuts against the lower module, the compression spring is completely accommodated in the second groove.

[0030] In another specific implementation, the process pad is a pad made of stainless steel;

[0031] and / or

[0032] The glass pad is a pad made of the glass powder lubricant;

[0033] and / or

[0034] The difference between the diameter of the first channel and the diameter of the second channel is greater than or equal to 20 mm;

[0035] and / or

[0036] The initial restoring force of the compression spring is 1 / 3 to 2 / 3 of the initial extrusion force of the punch;

[0037] and / or

[0038] The inner wall of the extrusion cylinder is coated with a first lubricant layer;

[0039] and / or

[0040] The outer wall of the blank is coated with a second lubricant layer.

[0041] The various embodiments of the present invention can be combined arbitrarily as needed, and the resulting embodiments are also within the scope of the present invention and are part of the specific implementation of the present invention.

[0042] To achieve the second objective mentioned above, the present invention provides the following solution:

[0043] A continuous extrusion forging composite forming method, comprising:

[0044] Step S1: Provide a continuous extrusion forging composite forming apparatus as described in any one of the above;

[0045] Step S2: Heat the lubricant-coated blank to a first preset temperature and hold it at that temperature for a first preset time;

[0046] Step S3: Heat the extrusion cylinder to a second preset temperature and keep it at that temperature. After the billet has been kept at that temperature, install the extrusion cylinder onto the continuous extrusion and forging composite forming device.

[0047] Step S4: The heated blank is quickly transferred to the preheated and graphite-lubricated extrusion cylinder, and the punch is activated to extrude and deform the blank. After the bottom end of the billet extruded from the extrusion die core contacts the ejector pin, pressure is continued to be applied to cause the blank to undergo upsetting deformation. The punch is driven to continue to move downward, and the blank is upsetting to fill the entire first cavity and react on the floating lower die. The axial flow deformation resistance of the metal continuously increases. The pressure difference of the cavity cross section between the first channel and the second channel forces the elastic component to be compressed. The floating lower die slides downward and forms a disc cavity between itself and the bottom end of the extrusion cylinder. The punch is driven to continue to move downward, so that the metal flows uniformly in the radial direction to form the disc part of the part to be formed.

[0048] Step S5: After extrusion is completed, lift the punch and remove the extrusion cylinder, the extrusion die core, and the extruded part together using the ejector pin.

[0049] In a specific implementation, step S4, which involves activating the punch to extrude and deform the blank, specifically includes: during the initial extrusion stage, when extruding the blank, setting the punch's downward pressing rate to a first rate value; after the head of the extruded blank contacts the ejector pin, reducing the punch's downward pressing rate to a second rate value for roughing deformation; and after the blank fully contacts the inner wall of the cavity of the floating lower die, reducing the punch's downward pressing rate to a third rate value to complete the forming of the disc body portion.

[0050] and / or

[0051] The step S4, after transferring the blank to the extrusion cylinder and before starting the punch to extrude and deform the blank, also includes: placing a glass pad, a process pad, and an extrusion steel pad on top of the blank in sequence;

[0052] and / or

[0053] The first preset time in step S2 is T = D × (0.8~1.3) min / mm, where D is the diameter of the billet.

[0054] and / or

[0055] Before heating the billet in step S2, the billet is further encased in a stainless steel sleeve.

[0056] and / or

[0057] The step S5 is followed by step S6: heat treatment is performed on the part obtained in step S5 after processing.

[0058] The continuous extrusion forging composite forming apparatus provided by this invention involves heating the billet and the extrusion cylinder separately, placing the heated billet into the extrusion cylinder, and then installing the extrusion cylinder onto the continuous extrusion forging composite forming apparatus. The punch is driven to move downward to extrude the billet, causing it to deform. After the bottom end of the billet extruded from the extrusion die core contacts the ejector rod, pressure continues to be applied, causing the billet to undergo upsetting deformation. The punch continues to move downward, and the billet is upsetting to fill the entire first cavity and reacts against the floating lower die. The axial flow deformation resistance of the metal continuously increases. The pressure difference between the cavity sections of the first and second channels forces the elastic component to be compressed. The floating lower die slides downward and forms a disc-shaped cavity between itself and the bottom end of the extrusion cylinder. The punch continues to move downward, causing the metal to flow uniformly in the radial direction to form the disc-shaped part of the part to be formed. After extrusion is completed, the punch is lifted, and the extrusion cylinder, extrusion die core, and extruded part are removed together by the ejector rod.

[0059] This invention simplifies the traditional multi-step complex forming process by extruding blanks. It produces a one-time forming of a disc-shaft integrated forging blank through extrusion, rod forging, and disc forging. The metal flow lines are smooth and continuous, reducing the number of heating steps and forming processes in traditional methods. This improves the control of microstructure and product consistency, shortens the production cycle, and reduces manufacturing costs. During forging, the floating die provides radial constraint on the extruded blank, increasing the deformation and resulting in a uniform and fine deformed microstructure. Furthermore, the floating die provides flexible back pressure, meeting the needs of producing a variety of products and rapid production.

[0060] This invention solves the problems of poor microstructure consistency, low material utilization and low production efficiency caused by traditional multi-fire forming of the disc and rod regions separately. Attached Figure Description

[0061] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any novel effort.

[0062] Figure 1 A cross-sectional view of the continuous extrusion and forging composite forming device provided by the present invention when a blank is placed in it.

[0063] Figure 2 A cross-sectional view of the continuous extrusion and forging composite forming device provided by the present invention when the extruded billet has not yet come into contact with the top rod.

[0064] Figure 3 A cross-sectional view of the continuous extrusion and forging composite forming device provided by the present invention when the extruded billet is started and contacts the push rod.

[0065] Figure 4 A cross-sectional view of the continuous extrusion and forging composite forming device provided by the present invention when the extruded billet is started up to the top of the floating lower die;

[0066] Figure 5 A cross-sectional view of the continuous extrusion and forging composite forming device provided by the present invention when the extruded billet is started and enters the top of the floating lower die;

[0067] Figure 6 A cross-sectional view of the continuous extrusion and forging composite forming device provided by the present invention from the start of extruding the billet to completion.

[0068] Figure 7 This is a schematic diagram of the structure of the finished product processed by the present invention.

[0069] in, Figures 1-7 middle:

[0070] The continuous extrusion forging composite forming device includes: a punch 100, an extrusion cylinder 200, an extrusion die core 300, a floating lower die 400, an elastic component 500, a lower die assembly 600, an ejector pin 700, a first cavity 201, a blank 2000, an extrusion through hole 301, a first channel 202, a second cavity 601, a second channel 401, a glass pad 800, a process material pad 900, a first tapered hole 302, a second tapered hole 303, an extrusion steel pad 102, a lower die outer sleeve 602, a lower die module 603, a lower die base 604, a washer ring 605, a screw 501, a compression spring 502, a first groove 603a, a second groove 603b, and an upper die base 103. Detailed Implementation

[0071] The following will refer to the appendices in the embodiments of the present invention. Figures 1-7 The technical solutions in the embodiments of the present invention are clearly and completely described herein. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0072] In the description of this invention, it should be understood that the terms "upper," "lower," "top surface," "bottom surface," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the indicated position or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0073] like Figure 1 As shown, the first aspect of the present invention provides a continuous extrusion forging composite forming apparatus 1000 to solve the problems of poor microstructure consistency, low material utilization and low production efficiency caused by traditional multi-pass forming of the disc body and rod region separately.

[0074] The continuous extrusion forging composite forming device 1000 includes a punch 100, an extrusion cylinder 200, an extrusion die core 300, a floating lower die 400, an elastic component 500, a lower die assembly 600, and an ejector pin 700.

[0075] Specifically, the punch 100, extrusion cylinder 200, extrusion die core 300, floating lower die 400, lower die assembly 600 and ejector pin 700 are all coaxially arranged.

[0076] The extrusion cylinder 200 has a first cavity 201, and the punch 100 can be slidably placed in the first cavity 201 of the extrusion cylinder 200, that is, the punch 100 can slide up and down along the first cavity 201.

[0077] To facilitate the extrusion deformation of the billet 2000 within the extrusion cylinder 200, this invention discloses that the inner wall of the extrusion cylinder 200 is coated with a first lubricant layer, and the outer wall of the billet 2000 is coated with a second lubricant layer. It should be noted that the first and second lubricant layers can be coating layers formed by spraying graphite lubricant.

[0078] The first cavity 201 is used to hold the billet 2000. It should be noted that the billet 2000 is an alloy ingot, which can be a smelted steel ingot that has not been roughened or a bar after roughening. In this embodiment, the billet 2000 is an alloy ingot, and the extrusion ratio of the alloy ingot is 3:1 to 10:1.

[0079] The extrusion die core 300 is installed at the bottom end of the first cavity 201. The extrusion die core 300 is provided with an extrusion through hole 301. The bottom end of the extrusion cylinder 200 is provided with a first channel 202 that communicates with the extrusion through hole 301. Specifically, the extrusion through hole 301 and the extrusion die core 300 are coaxially arranged, and the first channel 202 and the extrusion cylinder 202 are coaxially arranged, that is, the first channel 202 and the extrusion through hole 301 are coaxially arranged to achieve uniformity of the blank 2000 entering the first channel 202 through the extrusion through hole 301.

[0080] The floating lower mold 400 and the second cavity 601 of the lower mold assembly 600 are slidably connected. Specifically, the fit between the floating lower mold 400 and the second cavity 601 is a clearance fit.

[0081] The floating lower die 400 is connected to the bottom end of the second cavity 601 via the elastic component 500, and the extrusion cylinder 200 is installed at the top of the lower die assembly 600 to limit and abut against the top of the floating lower die 400. Specifically, the number of elastic components 500 is not limited, but there are at least two, and they are evenly distributed around the axis of the lower die assembly 600.

[0082] A second channel 401 is provided on the floating lower mold 400. The second channel 401 communicates with the first channel 202, and the diameter of the second channel 401 is smaller than the diameter of the first channel 202. Specifically, this invention discloses that the difference between the diameter of the first channel 202 and the diameter of the second channel 401 is greater than or equal to 20 mm. It should be noted that the difference between the diameters of the first channel 202 and the second channel 401 is not limited to the above range and can be set according to specific needs.

[0083] The ejector rod 700 can be lifted and installed on the lower mold assembly 600, and the top end of the ejector rod 700 can be slidably connected to the second channel 401.

[0084] When the floating lower die 400 abuts against the bottom wall of the second cavity 601, the top of the second cavity 601, the punch 100, the extrusion die core 300, the floating lower die 400 and the ejector pin 700 can form a forming cavity that matches the shape of the part to be formed, and the punch 100 can press the blank 2000 into the forming cavity.

[0085] The continuous extrusion forging composite forming apparatus 1000 provided by this invention, when in use, such as... Figures 1-6 As shown, the billet 2000 and the extrusion cylinder 200 are heated separately, and the heated billet 2000 is placed into the extrusion cylinder 200. The extrusion cylinder 200 is then installed on the continuous extrusion forging composite forming device 1000, and the punch 100 is driven to move downward to extrude the billet 2000. The billet 2000 is deformed by extrusion, and after the bottom end of the bar extruded from the extrusion die core 300 contacts the ejector pin 700, pressure is continued to be applied, causing the billet 2000 to undergo upsetting deformation. The punch 100 is driven to move downward, and the billet 2000 is upsetting until it fills the entire first cavity 201 and reacts on the float. As the lower die 400 moves, the axial flow deformation resistance of the metal continuously increases. The pressure difference between the cavity sections of the first channel 202 and the second channel 401 forces the elastic component 500 to be compressed. The floating lower die 400 slides downwards, simultaneously forming a disc-shaped cavity between itself and the bottom end of the extrusion cylinder 200. This drives the punch 100 to continue moving downwards, causing the metal to flow radially and uniformly to form the disc-shaped portion of the part to be formed. After extrusion, the punch 100 is lifted, and the extrusion cylinder 200, extrusion die core 300, and the extruded part are removed together via the ejector pin 700. The finished part is as follows: Figure 7 As shown.

[0086] This invention simplifies the traditional multi-step complex forming process by forming a blank 2000 through extrusion. It achieves a one-time forming of a disc-shaft integrated forging blank through extrusion, rod forging, and disc forging. The metal flow lines are smooth and continuous, reducing the number of heating steps and forming processes in traditional forming methods. This improves the control of microstructure and product consistency, shortens the production cycle, and reduces manufacturing costs. During the forging process, the floating die provides radial constraint on the extruded blank 2000, allowing for a forging height-to-diameter ratio exceeding that of slender bar blanks. This further increases the deformation of the blank 2000 during forging, which is beneficial for obtaining a uniform and fine deformed microstructure. Furthermore, the flexible back pressure achieved by the floating die can meet the production needs of multiple product varieties and rapid production launch.

[0087] This invention solves the problems of poor microstructure consistency, low material utilization and low production efficiency caused by traditional multi-fire forming of the disc and rod regions separately.

[0088] In some embodiments, the pressing rate of the punch 100 is adjustable; specifically, the punch 100 is fixed on the upper die holder 103.

[0089] During the initial extrusion stage, when extruding the blank 2000, the downward pressing rate of the punch 100 is the first rate value; after the head of the extruded blank 2000 contacts the ejector pin 700, the downward pressing rate of the punch 100 is reduced to the second rate value; after the blank 2000 is in complete contact with the inner wall of the cavity of the floating lower die 400, the downward pressing rate of the punch 100 is the third rate value; the first rate value is greater than the second rate value, and the second rate value is greater than the third rate value.

[0090] Specifically, the first velocity value is greater than or equal to 10 mm / s and less than or equal to 100 mm / s, the second velocity value is greater than or equal to 1 mm / s and less than or equal to 10 mm / s, and the third velocity value is greater than or equal to 0.01 mm / s and less than or equal to 1 mm / s.

[0091] It should be noted that the first rate value, the second rate value, and the third rate value are not limited to the values ​​in the above range, and can also be set to values ​​outside the above range, depending on the specific needs.

[0092] This invention employs segmented speed control during the forming process. Specifically, rapid forming is used in the initial extrusion stage and the roughing deformation stage to prevent the billet 2000 from cracking due to excessively rapid temperature drop. Finally, slow forming is used in the disc forming stage to allow sufficient time for the alloy grains that have not undergone complete dynamic recrystallization after rapid extrusion to complete full sub-dynamic and static recrystallization during slow deformation, thereby obtaining a disc-shaft integral forging blank with uniform and fine grains.

[0093] In some embodiments, the continuous extrusion forging composite forming apparatus 1000 further includes a glass pad 800 and a process pad 900. Specifically, the process pad 900 and the glass pad 800 are sequentially disposed between the punch 100 and the blank 2000. When the blank 2000 is completely extruded into the forming cavity, the glass pad 800 and the process pad 900 fill the space enclosed by the bottom end of the punch 100, the extrusion die core 300 and the top end of the forming cavity.

[0094] Specifically, the present invention discloses that the process pad 900 is a pad made of stainless steel and the glass pad 800 is a pad made of glass powder lubricant.

[0095] This invention prevents the two alloys from "welding" after extrusion by placing a glass pad 800, made of glass powder lubricant, between the billet 2000 and the process pad 900.

[0096] Furthermore, the present invention discloses that the top end of the extrusion die core 300 is provided with a first conical hole 302 that communicates with and is coaxial with the top end of the extrusion through hole 301, and the bottom end of the extrusion die core 300 is provided with a second conical hole 303 that communicates with and is coaxial with the bottom end of the extrusion through hole 301. The arrangement of the first conical hole 302 and the second conical hole 303 provides guidance for the blank 2000 to enter and exit the extrusion through hole 301.

[0097] In order to avoid the blank 2000 coming out of the second conical hole 303 from generating an axial force on the extrusion cylinder 200, the present invention discloses that the diameter of the connection between the second conical hole 303 and the first channel 202 is the same as the diameter of the first channel 202.

[0098] In some embodiments, the punch 100 includes a punch 100 body and an extrusion steel pad 102 disposed at the bottom end of the punch 100 body. The extrusion steel pad 102 is slidably connected to the first cavity 201 and is used to extrude the blank 2000.

[0099] In some embodiments, the lower mold assembly 600 includes a lower mold outer sleeve 602, a lower module 603, and a lower mold base 604. The lower mold outer sleeve 602 and the lower module 603 are both mounted on the lower mold base 604, and the lower module 603 is fitted inside the lower mold outer sleeve 602. The push rod 700 can slide through the lower mold base 604 and the lower module 603. The bottom end of the elastic component 500 is connected to the lower module 603.

[0100] Furthermore, the present invention discloses that the lower die assembly 600 also includes a washer ring 605, which is disposed on the lower module 603 and fitted outside the ejector rod 700. The washer ring 605 can adjust the cavity height H between the floating lower die 400 and the extrusion cylinder 200, which can meet the manufacturing requirements of integrated disc-shaft components with different disc rim thicknesses.

[0101] In some embodiments, the elastic component 500 includes a screw 501 and a compression spring 502. The bottom end of the lower module 603 is provided with a first groove 603a. The nut of the screw 501 is stuck at the bottom of the first groove 603a. The screw 501 passes through the lower module 603 and is connected to the floating lower mold 400. The compression spring 502 is sleeved on the outside of the screw 501, and its two ends abut against the floating lower mold 400 and the lower module 603 respectively.

[0102] Furthermore, this invention discloses that the initial restoring force of the compression spring 502 is 1 / 3 to 2 / 3 of the initial extrusion breakthrough force of the punch 100. It should be noted that the initial restoring force of the compression spring 502 refers to the restoring force when the continuous extrusion forging composite forming device 1000 is assembled and the punch 100 has not yet moved downwards. The initial extrusion breakthrough force of the punch 100 refers to the initial force required when the punch 100 presses down on the blank 2000 and causes it to move downwards.

[0103] Furthermore, the present invention discloses that the top of the lower module 603 is provided with a second groove 603b, the bottom end of the compression spring 502 abuts against the bottom end of the second groove 603b, and when the floating lower mold 400 abuts against the lower module 603, the compression spring 502 is completely contained in the second groove 603b, thus preventing the compression spring 502 from being crushed.

[0104] A second aspect of the present invention provides a continuous extrusion forging composite forming method, comprising:

[0105] Step S1: Provide a continuous extrusion forging composite forming apparatus 1000 as described in any of the above embodiments.

[0106] Step S2: Heat the lubricant-coated blank 2000 to a first preset temperature and keep it at that temperature for a first preset time.

[0107] Specifically, the lubricated blank 2000 is placed in a resistance heating furnace for heating. The first preset time is T = D × (0.8 ~ 1.3) min / mm, where D is the diameter of the blank 2000.

[0108] In order to reduce the temperature drop during extrusion and deformation and improve the plasticity of the alloy, the present invention discloses that the billet 2000 is further encased in stainless steel before heating, and the stainless steel is removed after the forging is formed.

[0109] It should be noted that the first preset temperature is the temperature value set as needed.

[0110] Step S3: Heat the extrusion cylinder 200 to the second preset temperature and keep it at that temperature. After the billet 2000 has been kept at that temperature, install the extrusion cylinder 200 onto the continuous extrusion forging composite forming device 1000.

[0111] Specifically, the extrusion cylinder 200 is placed in a resistance heating furnace for preheating and heat preservation, with the second preset temperature being 300℃~400℃.

[0112] Step S4: The heated blank 2000 is quickly transferred to the preheated extrusion cylinder 200 coated with graphite lubricant, and the punch 100 is activated to extrude and deform the blank 2000. After the bottom end of the bar extruded from the extrusion die core 300 contacts the ejector pin 700, pressure is continued to be applied to cause the blank 2000 to undergo upsetting deformation. The punch 100 is driven to move downward, and the blank 2000 is upsetting to fill the entire first cavity 201 and reacts on the floating lower die 400. The resistance of the metal axial flow deformation continuously increases. The pressure difference of the cavity section between the first channel 202 and the second channel 401 forces the elastic component 500 to be compressed. The floating lower die 400 slides downward and forms a disc cavity between itself and the bottom end of the extrusion cylinder 200. The punch 100 is driven to move downward, so that the metal flows uniformly in the radial direction to form the disc part of the part to be formed.

[0113] Specifically, the extrusion deformation of the blank 2000 by the punch 100 includes: during the initial extrusion stage, the downward pressing rate of the punch 100 is set to a first rate value; after the head of the extruded blank 2000 contacts the ejector pin 700, the downward pressing rate of the punch 100 is reduced to a second rate value for roughing deformation; after the blank 2000 is in complete contact with the inner wall of the cavity of the floating lower die 400, the downward pressing rate of the punch 100 is reduced to a third rate value, completing the forming of the disc body. That is, segmented speed control is used during the forming process. Rapid forming during the initial extrusion and roughing deformation stages prevents the blank 2000 from cracking due to excessively rapid temperature drop. Finally, slow forming during the disc body forming stage allows sufficient time for the alloy grains, which have not undergone complete dynamic recrystallization after rapid extrusion, to complete adequate sub-dynamic and static recrystallization during slow deformation, thereby obtaining a uniformly fine-grained, integrally forged disc-shaft blank.

[0114] Furthermore, the present invention discloses that after transferring the blank 2000 to the extrusion cylinder 200 and before the punch 100 is activated to extrude and deform the blank 2000, the invention further includes: sequentially placing a glass pad 800, a process pad 900, and an extrusion steel pad 102 above the blank 2000. The present invention prevents the two alloys from “welding” after extrusion by placing a glass pad 800, made of glass powder lubricant, between the blank 2000 and the process pad 900.

[0115] Step S5: After extrusion is completed, lift the punch 100 and remove the extrusion cylinder 200, extrusion die core 300 and the extruded part together through the ejector pin 700.

[0116] Furthermore, the present invention discloses that after step S5, it also includes step S6: heat treatment to strengthen the part obtained in step S5 after processing.

[0117] Example 1

[0118] In this embodiment, taking the cavity height H between the floating lower die 400 and the extrusion cylinder 200 as 65mm, the single-sided gap between the floating lower die 400 and the lower die outer sleeve 602 as 0.6mm, the diameter of the first channel 202 as 370mm, the diameter of the second channel 401 as 300mm, and the billet 2000 as a GH4169 alloy ingot as an example.

[0119] Continuous extrusion and forging composite forming methods include:

[0120] Step A1: Place the GH4169 alloy ingot coated with lubricant into a resistance heating furnace and heat it at 1050℃±10℃ and hold it at that temperature. The holding time is T=D×(0.8~1.3)min / mm, where D is the diameter of the ingot 2000.

[0121] Step A2: Place the extrusion cylinder 200 into the resistance heating furnace, preheat it to 360°C and keep it at that temperature. After the GH4169 alloy billet has been kept at that temperature, install the extrusion cylinder 200 onto the lower die assembly 600.

[0122] Step A3: After being thoroughly heated, the GH4169 alloy billet is quickly transferred to the preheated extrusion cylinder 200, which is sprayed with graphite lubricant. Then, the glass pad 800, the process material pad 900, and the extrusion steel pad 102 are placed in sequence, and the punch 100 is activated to extrude and deform it. The pressing speed of the punch 100 is set to 60 mm / s. After the head of the GH4169 alloy billet first extruded from the extrusion die core 300 contacts the ejector pin 700, the pressing speed of the punch 100 is adjusted to 5 mm / s to continue applying pressure, so that the billet 2000 undergoes upsetting deformation.

[0123] Step A4: The punch 100 continues to descend, and the blank 2000 is shaped to fill the entire cavity and reacts on the floating lower die 400. The resistance of the metal to axial flow deformation continues to increase. The pressing speed of the punch 100 is adjusted to 0.5 mm / s. The pressure difference between the cavity sections of the first channel 202 and the second channel 401 is used to force the compression spring 502 to be compressed. The floating lower die 400 slides downward and forms a disc cavity between itself and the bottom end face of the extrusion cylinder 200. The punch 100 continues to descend, so that the metal flows uniformly in the radial direction to form the disc part of the component.

[0124] Step A5: After extrusion, lift the punch 100, and remove the extrusion cylinder 200, extrusion die core 300 and the integrated disc and shaft blank forging together through the ejection action of the mechanical device and the ejector rod 700 to obtain the GH4169 alloy integrated disc and shaft forging blank.

[0125] Step A6: After machining the GH4169 alloy disc shaft integral forging blank, perform solution treatment and aging heat treatment.

[0126] Example 2

[0127] In this embodiment, taking the cavity height H between the floating lower die 400 and the extrusion cylinder 200 as 65mm, the single-sided gap between the floating lower die 400 and the lower die outer sleeve 602 as 0.6mm, the diameter of the first channel 202 as 340mm, the diameter of the second channel 401 as 270mm, and the billet 2000 as a TC17 titanium alloy bar billet after blanking deformation as an example.

[0128] Continuous extrusion and forging composite forming methods include:

[0129] Step B1: After the TC17 titanium alloy billet has been deformed, it is coated with lubricant, placed in a resistance heating furnace, heated at 10°C above the phase transformation point, and held at that temperature for a duration of T. 保温时间 =D×1.0min / mm, where D is the diameter of the billet (2000 mm);

[0130] Step B2: Place the extrusion cylinder 200 into the resistance heating furnace, preheat it to 380°C and keep it at that temperature. After the billet has been kept at that temperature, install the extrusion cylinder 200 onto the lower die assembly 600.

[0131] Step B3: After being heated through, the TC17 titanium alloy billet is quickly transferred to the preheated extrusion cylinder 200, which is sprayed with graphite lubricant. Then, the glass pad 800, the stainless steel process pad 900, and the extrusion steel pad 102 are placed in sequence, and the punch 100 is activated to extrude and deform it. The pressing speed of the punch 100 is set to 30 mm / s. After the head of the TC17 titanium alloy billet first extruded from the extrusion die core 300 contacts the ejector pin 700, the pressing speed of the punch 100 is adjusted to 3 mm / s to continue applying pressure, so that the billet 2000 undergoes upsetting deformation.

[0132] Step B4: The punch 100 continues to descend, and the blank 2000 is shaped to fill the entire cavity and reacts on the floating lower die 400. The resistance of the metal to axial flow deformation continues to increase. The pressing speed of the punch 100 is adjusted to 0.8 mm / s. The pressure difference between the cavity sections of the first channel 202 and the second channel 401 is used to force the compression spring 502 to be compressed. The floating lower die 400 slides downward and forms a disc cavity between itself and the bottom end face of the extrusion cylinder 200. The punch 100 continues to descend, so that the metal flows uniformly in the radial direction to form the disc part of the component.

[0133] Step B5: After extrusion, lift the punch 100, and remove the extrusion cylinder 200, extrusion die core 300 and the integrated disc shaft blank forging together through the ejection action of the mechanical device and the ejector pin 700 to obtain the TC17 titanium alloy integrated disc shaft forging blank.

[0134] Step B6: After machining the TC17 titanium alloy disc shaft integral forging blank, perform solution and aging heat treatment.

[0135] It should be noted that words indicating direction in this article, such as "up" and "down," are all in the format of "upper" and "lower." Figure 1 The orientation settings in the text are for ease of description only and have no other specific meaning.

[0136] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0137] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0138] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0139] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A continuous extrusion forging composite forming device, characterized in that, The device comprises a punch, an extrusion cylinder, an extrusion core, a floating lower die, an elastic assembly, a lower die assembly and a top rod. The punch is slidably arranged in a first cavity of the extrusion cylinder, the first cavity is used for containing a blank, the extrusion core is arranged at the bottom end of the first cavity, the extrusion core is provided with an extrusion through hole, and the bottom end of the extrusion cylinder is provided with a first channel communicated with the extrusion through hole. The floating lower die is slidably connected with a second cavity of the lower die assembly, the floating lower die is connected with the bottom end of the second cavity through the elastic assembly, the extrusion cylinder is arranged at the top end of the lower die assembly to limit the abutment of the top end of the floating lower die, the floating lower die is provided with a second channel, the second channel is communicated with the first channel, the diameter of the second channel is smaller than that of the first channel, the top rod is arranged on the lower die assembly in a lifting manner, and the top end of the top rod is slidably connected with the second channel. When the floating lower die abuts against the bottom wall of the second cavity, the second cavity, the punch, the extrusion core, the floating lower die and the top end of the top rod can be surrounded to form a forming cavity matched with the shape of a part to be formed, and the punch can press the blank into the forming cavity. The elastic assembly is compressed by the pressure difference of the cavity section between the first channel and the second channel, the floating lower die slides downward to form a disc cavity between the bottom end of the extrusion cylinder, and the punch is driven to continue to move downward to make the metal flow uniformly in the radial direction to form a disc part of the part to be formed. The top end of the extrusion core is provided with a first tapered hole communicated with and coaxial with the top end of the extrusion through hole, and the bottom end of the extrusion core is provided with a second tapered hole communicated with and coaxial with the bottom end of the extrusion through hole. The elastic assembly comprises a screw rod and a compression spring. The lower die assembly comprises a lower die block, the bottom end of the lower die block is provided with a first groove, the nut of the screw rod is clamped at the groove bottom of the first groove, the screw rod passes through the lower die block and is connected with the floating lower die, the compression spring is sleeved outside the screw rod and abuts against the floating lower die and the lower die block at two ends. The pressing speed of the punch is adjustable. In the initial extrusion stage, the pressing speed of the punch is a first speed value. After the head of the blank contacts the top rod, the pressing speed of the punch is reduced to a second speed value. After the blank fully contacts the inner wall of the cavity of the floating lower die, the pressing speed of the punch is a third speed value. The first speed value is greater than the second speed value, and the second speed value is greater than the third speed value.

2. The continuous extrusion-forging composite forming apparatus according to claim 1, wherein The device further comprises a glass pad and a process material pad. The process material pad and the glass pad are sequentially arranged between the punch and the blank, and when the blank is fully extruded into the forming cavity, the glass pad and the process material pad are filled in the space surrounded by the bottom end of the punch, the extrusion core and the top end of the forming cavity.

3. The continuous extrusion-forging composite forming device according to claim 2, wherein The punch comprises a punch body and an extrusion steel pad arranged at the bottom end of the punch body, the extrusion steel pad being slidably connected with the first cavity for extruding the blank; and / or The lower die assembly comprises a lower die jacket, a lower die block and a lower die seat; The lower die jacket and the lower die block are both mounted on the lower die seat, and the lower die block is sleeved in the lower die jacket, the ejector rod being slidably penetrating through the lower die seat and the lower die block, the bottom end of the elastic assembly being connected with the lower die block.

4. The continuous extrusion-forging composite forming apparatus according to claim 3, wherein The lower die assembly further comprises a gasket ring arranged on the lower die block and sleeved outside the ejector rod.

5. The continuous extrusion-forging composite forming apparatus according to claim 1, wherein The top end of the lower die block is provided with a second groove, the bottom end of the compression spring abutting against the bottom end of the second groove, and when the floating lower die abuts against the lower die block, the compression spring is completely accommodated in the second groove.

6. The continuous extrusion-forging composite forming apparatus according to claim 2, wherein The process pad is a pad made of stainless steel; and / or The glass pad is a pad made of glass powder lubricant; and / or The diameter difference between the first channel and the second channel is greater than or equal to 20 mm; and / or The initial return force of the compression spring is 1 / 3-2 / 3 of the initial extrusion breakthrough force of the punch; and / or The inner wall of the extrusion cylinder is coated with a first lubricant layer; and / or The outer wall of the blank is coated with a second lubricant layer.

7. A continuous extrusion-forging composite forming method characterized by, Comprise: Step S1: providing the continuous extrusion-forging composite forming device according to any one of claims 1-6; Step S2: heating the blank coated with lubricant to a first preset temperature and keeping the temperature for a first preset time; Step S3: heating the extrusion cylinder to a second preset temperature and keeping the temperature, and after the keeping temperature of the blank ends, mounting the extrusion cylinder on the continuous extrusion-forging composite forming device; Step S4: quickly transferring the hot penetrated blank into the preheated extrusion cylinder sprayed with graphite lubricant, and driving the punch to extrude and deform the blank, after the bottom end of the rod blank extruded from the extrusion core contacts with the ejector rod, continuing to press, so that the blank is upset deformed, continuing to drive the punch to move downward, the blank is upset to fill the entire first cavity and reacts on the floating lower die, the metal axial flow deformation resistance continuously increases, the elastic assembly is forced to be compressed by using the cavity cross section pressure difference between the first channel and the second channel, the floating lower die slides downward while forming a disc cavity between the bottom end of the extrusion cylinder, driving the punch to continue to move downward, so that the metal uniformly flows in the radial direction to form the disc part of the part to be formed; Step S5: after the extrusion is completed, lifting the punch, and taking out the extrusion cylinder, the extrusion core and the extruded part together through the ejector rod. Step S1: providing the continuous extrusion-forging composite forming device according to any one of claims 1-6; Step S2: heating the blank coated with lubricant to a first preset temperature and keeping the temperature for a first preset time; Step S3: heating the extrusion cylinder to a second preset temperature and keeping the temperature, and after the keeping temperature of the blank ends, mounting the extrusion cylinder on the continuous extrusion-forging composite forming device; Step S4: quickly transferring the hot penetrated blank into the preheated extrusion cylinder sprayed with graphite lubricant, and driving the punch to extrude and deform the blank, after the bottom end of the rod blank extruded from the extrusion core contacts with the ejector rod, continuing to press, so that the blank is upset deformed, continuing to drive the punch to move downward, the blank is upset to fill the entire first cavity and reacts on the floating lower die, the metal axial flow deformation resistance continuously increases, the elastic assembly is forced to be compressed by using the cavity cross section pressure difference between the first channel and the second channel, the floating lower die slides downward while forming a disc cavity between the bottom end of the extrusion cylinder, driving the punch to continue to move downward, so that the metal uniformly flows in the radial direction to form the disc part of the part to be formed; Step S5: after the extrusion is completed, lifting the punch, and taking out the extrusion cylinder, the extrusion core and the extruded part together through the ejector rod.

8. The continuous extrusion-forging composite forming method according to claim 7, wherein The extrusion deformation of the blank by the punch in the step S4 specifically includes: in the initial extrusion stage, setting the pressing speed of the punch as a first speed value, reducing the pressing speed of the punch to a second speed value for upsetting deformation after the head of the blank contacts the ejector rod, reducing the pressing speed of the punch to a third speed value after the blank fully contacts the inner wall of the cavity of the floating lower die, and completing the forming of the disc part; and / or The step S4 further includes: sequentially placing a glass pad, a process material pad and an extrusion steel pad above the blank before the blank is transferred into the extrusion cylinder and before the extrusion deformation of the blank by the punch. and / or The first preset time T in the step S2 is T = D x (0.8-1.3) min / mm, and D is the diameter of the blank. and / or The step S2 further includes: surrounding the blank with a stainless steel sleeve before heating the blank. and / or The step S5 is followed by a step S6 of performing heat treatment strengthening on the part after machining.

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