Ultra-large heavy-load high-temperature arc-shaped feeding forging follow-up compliance device and forging method thereof

Abstract

The present invention provides an ultra-large, heavy-load, high-temperature arc-shaped feeding forging follow-up and compliance device and a forging method thereof, wherein the device includes two upper platforms, a plurality of pressure sensors, a plurality of hydraulic cylinders, a plurality of guide mechanisms, two lower platforms and a controller; the upper platform and the lower platform are arc-shaped; the two lower platforms are arranged opposite to each other with a gap to form a ring; the upper platforms are respectively arranged above the lower platforms and are arranged opposite to each other with a gap to form a ring; the pressure sensors are arranged on the upper platforms; the hydraulic cylinders and the guide mechanisms are respectively arranged between the corresponding upper and lower platforms; the pressure sensors and the hydraulic cylinders are connected to the controller. The ultra-large, heavy-load, high-temperature arc-shaped feeding forging follow-up and compliance device and a forging method thereof of the present invention can reduce and eliminate the ten-thousand-ton pressure of the press on the feeding equipment, thereby realizing the integral forging of ultra-large arc-shaped forgings.

Description

Technical Field

[0001] The present invention relates to the field of forging devices, and in particular to an ultra-large heavy-load high-temperature arc-shaped feeding forging follow-up compliance device and a forging method thereof. Background Art

[0002] The arc-shaped forging has an outer diameter of over 10 meters, an inner diameter of 6 meters, a maximum angle of 180 degrees, and a blank thickness of only 0.3 meters. It also has symmetrical bosses on the upper and lower surfaces, making it an extremely heavy, large, irregular, and thin forging. Due to the special material requirements, it must possess excellent mechanical properties.

[0003] Arc-shaped forgings are made of austenitic stainless steel, requiring short forging times. Two-fire forging is preferred, with single-fire forging typically taking no more than 30 minutes. The forging press is a 16,500-ton press. Using arc-feed forging, the cross-sectional area is less than 2 meters by 1 meter, and near the final forging temperature, the press becomes virtually immobile. Forging in one piece would be impossible. The internal dimensions of the 16,500-ton press are 6 meters, making in-press forging impossible.

[0004] The so-called integral forging refers to step-by-step feeding and local compaction, but the whole is a forging, which is different from segmented forging and then welding, and its overall performance is excellent.

[0005] Currently, curved forgings are primarily forged in sections, which are then welded or assembled using other connection methods. This method has significant drawbacks: welding results in substandard mechanical properties and a complex process. Other connection methods, such as bolting or riveting, lack sufficient rigidity to meet the requirements of complex curved products.

[0006] However, if integral forging is adopted, the 10,000-ton pressure of the press will be applied to the feeding equipment, which will instantly cause damage to the feeding equipment. Currently, there is still a lack of a follow-up compliance device that can reduce and remove the 10,000-ton pressure of the press on the feeding equipment. Summary of the Invention

[0007] In response to the above-mentioned deficiencies in the prior art, the present invention provides an ultra-large heavy-load high-temperature arc-shaped feeding forging following and compliance device and a forging method thereof, which can reduce and eliminate the 10,000-ton pressure of the press on the feeding equipment, thereby realizing the integral forging of ultra-large arc-shaped forgings.

[0008] In order to achieve the above-mentioned objectives, the present invention provides an ultra-large heavy-load high-temperature arc-shaped feeding forging following and compliance device, comprising two upper platforms, a plurality of pressure sensors, a plurality of hydraulic cylinders, a plurality of guide mechanisms, two lower platforms and a controller; the upper platform and the lower platform are arc-shaped; the two lower platforms are arranged opposite to each other with a gap to form a ring; the upper platforms are respectively arranged above the lower platforms and are arranged opposite to each other with a gap to form a ring; the pressure sensor is arranged on the upper platform; the hydraulic cylinder and the guide mechanism are respectively arranged between the corresponding upper platform and the lower platform; the pressure sensor and the hydraulic cylinder are connected to the controller.

[0009] Preferably, four hydraulic cylinders are included, and the hydraulic cylinders are respectively arranged in pairs between the corresponding upper platform and the lower platform; and the connecting line of the two hydraulic cylinders connected to the same upper platform is located on the center of gravity line of the corresponding upper platform.

[0010] Preferably, a guide mechanism is provided on both sides of each hydraulic cylinder.

[0011] Preferably, each of the guide mechanisms includes a guide post and a guide sleeve, the guide sleeve and the guide post are respectively connected to the corresponding upper platform and the lower platform, and the guide sleeve is sleeved outside the guide post.

[0012] Preferably, the controller is provided with an active compliance mode and a passive compliance mode; in the active compliance mode, the hydraulic cylinder controls the upper platform to move synchronously with the movable crossbeam of a press; in the passive compliance mode, when the pressure value of the pressure sensor exceeds a preset threshold, the hydraulic cylinder controls the upper platform to move downward following the movable crossbeam of the press.

[0013] A forging method based on the ultra-large heavy-load high-temperature arc-shaped feeding forging following compliance device of the present invention comprises the following steps:

[0014] S1: A feeding device is provided on the upper platform, an upper anvil is connected to the bottom of the movable crossbeam of a press, and a lower anvil is provided in the gap between the two upper platforms and the two lower platforms and is located directly below the upper anvil; after the feeding device feeds the casting and forging part between the upper anvil and the lower anvil, the feeding device stops moving; the movable crossbeam of the press drives the upper anvil to move downward;

[0015] S2: The movable crossbeam is fed rapidly, and when it is 200 mm above the casting, the speed is reduced;

[0016] S3: the movable crossbeam continues to move downward, and when the pressure of the pressure sensor exceeds the preset threshold, the upper anvil and the upper platform move downward synchronously and gradually approach the upper surface of the lower anvil;

[0017] S4: the movable crossbeam continues to feed, and after the forging contacts the lower anvil, the upper anvil and the upper platform continue to move downward, and the upper anvil and the lower anvil begin to forge the forging;

[0018] S5: After forging is completed, the movable crossbeam starts to move upward. When the pressure of the pressure sensor is less than the preset threshold, the upper platform starts to move upward under the action of the hydraulic cylinder to lift the formed casting and forging to separate from the lower anvil and move upward, and the upper platform returns to its initial position.

[0019] S6: The movable crossbeam continues to move upward, and the movable crossbeam returns to its initial position.

[0020] The present invention adopts the above technical solution, so it has the following beneficial effects:

[0021] The follow-up compliance mechanism utilizes both active and passive compliance systems when the press is pressed downward. In active mode, the upper platform moves downward synchronously with the press's crossbeam, moving faster as the crossbeam moves. During forging, the upper platform moves slower as the crossbeam advances. In passive mode, the hydraulic cylinder of the follow-up compliance mechanism passively moves downward after exceeding a certain pressure until forging is complete. The follow-up compliance mechanism enables integrated external feeding of curved forgings at pressures exceeding 10,000 tons, preventing the ring feed mechanism from instantly collapsing under these pressures. Eight guide posts and guide sleeves ensure smooth and consistent up and down movement. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a front view of an ultra-large, heavy-load, high-temperature arc-shaped feeding forging follow-up compliance device according to an embodiment of the present invention;

[0023] Figure 2 This is a top view of an ultra-large, heavy-load, high-temperature arc-shaped feeding forging following and compliance device according to an embodiment of the present invention. DETAILED DESCRIPTION

[0024] Below according to the attached drawings Figure 1 and Figure 2 , gives the preferred embodiment of the present invention, and describes it in detail so that the functions and features of the present invention can be better understood.

[0025] See also Figure 1 and Figure 2An embodiment of the present invention provides an ultra-large, heavy-load, high-temperature arc-shaped feeding forging following and compliance device, comprising two upper platforms 1, a plurality of pressure sensors, a plurality of hydraulic cylinders 2, a plurality of guide mechanisms 3, two lower platforms 4 and a controller; the upper platform 1 and the lower platform 4 are arc-shaped; the two lower platforms 4 are arranged opposite to each other with a gap to form a ring; the upper platforms 1 are respectively arranged above the lower platforms 4 and are arranged opposite to each other with a gap to form a ring; the pressure sensors are arranged on the upper platform 1; the hydraulic cylinders 2 and the guide mechanisms 3 are respectively arranged between the corresponding upper platform 1 and the lower platform 4; the pressure sensors and the hydraulic cylinders 2 are connected to the controller.

[0026] It includes four hydraulic cylinders 2 , which are respectively arranged in pairs between the corresponding upper platform 1 and the lower platform 4 ; and the connecting line of the two hydraulic cylinders 2 connected to the same upper platform 1 is located on the center of gravity line of the corresponding upper platform 1 .

[0027] A guide mechanism 3 is provided on both sides of each hydraulic cylinder 2 .

[0028] Each guide mechanism 3 includes a guide post and a guide sleeve. The guide sleeve and the guide post are respectively connected to the corresponding upper platform 1 and lower platform 4, and the guide sleeve is sleeved outside the guide post.

[0029] The controller is provided with an active compliance mode and a passive compliance mode; in the active compliance mode, the hydraulic cylinder 2 controls the upper platform 1 to move synchronously with the movable crossbeam of a press; in the passive compliance mode, when the pressure value of the pressure sensor exceeds a preset threshold, the hydraulic cylinder 2 controls the upper platform 1 to move downward following the movable crossbeam of the press.

[0030] Active compliance means that when there is an external load, the interference position is detected by the monitoring device, and the signal is fed back to the controller. The controller issues an instruction to control the hydraulic cylinder 2 to avoid the external load.

[0031] Passive compliance means that when the pressure generated by the external load exceeds the system's preset threshold, the safety valve (relief valve) will open to release pressure to ensure system safety and avoid interference. When the external load falls below the preset threshold, the system will increase the hydraulic pressure to drive the device back to its original position. For example, when a large manipulator is clamping a workpiece to extend, the manipulator must be able to follow the press's downward movement to cooperate with the press to complete the process requirements while protecting the manipulator from damage.

[0032] This equipment must be used with a 10,000-ton press and a compliance system must be set up, otherwise it will not be able to withstand the huge pressure of the press.

[0033] A forging method for an ultra-large, heavy-load, high-temperature arc-shaped feeding forging follower compliance device according to an embodiment of the present invention includes the following steps:

[0034] S1: A feeding device is installed on the upper platform 1, an upper anvil is connected to the bottom of a movable crossbeam of a press, and a lower anvil is installed in the gap between the two upper platforms 1 and the two lower platforms 4 and is located directly below the upper anvil; when the feeding device sends the casting and forging part between the upper and lower anvils, the feeding device stops moving; the movable crossbeam of the press drives the upper anvil to move downward;

[0035] S2: The movable crossbeam feeds quickly, and when it is 200mm above the casting and forging, the speed is reduced;

[0036] S3: The movable crossbeam continues to move downward. When the pressure of the pressure sensor exceeds the preset threshold, the upper anvil and the upper platform 1 move downward synchronously and gradually approach the upper surface of the lower anvil.

[0037] S4: The movable crossbeam continues to feed. After the casting contacts the lower anvil, the upper anvil and the upper platform 1 continue to move downward, and the upper anvil and the lower anvil begin to forge the casting;

[0038] S5: After forging is completed, the movable crossbeam starts to move upward. When the pressure of the pressure sensor is less than the preset threshold, the upper platform 1 starts to move upward under the action of the hydraulic cylinder 2, lifting the formed casting and forging from the lower anvil and moving upward, and the upper platform 1 returns to its initial position.

[0039] S6: The movable crossbeam continues to move upward and returns to its initial position.

[0040] An embodiment of the present invention is an ultra-large heavy-load high-temperature arc-shaped feed forging follow-up compliance device that can move the casting from the feed track to the forging position and move it downward in parallel, cooperating with the press to complete the forging of the blank in each pass and each step. The eight guide pillars and guide sleeves can ensure the stability and consistency of the up and down movement. The four hydraulic cylinders 2 are synchronous. The hydraulic cylinders 2 of the left and right platforms are set on the center of gravity line of the upper platform 1. Although there is a huge eccentric load when the press is pressed down, the adjustment threshold can effectively avoid damage to the left and right platforms due to pressure. The compliance device is the core device to ensure the normal operation of the entire forging equipment.

[0041] The present invention has been described in detail above with reference to the embodiments of the accompanying drawings. A person skilled in the art can make various modifications to the present invention based on the above description. Therefore, certain details in the embodiments should not be construed as limiting the present invention. The scope of protection of the present invention shall be determined by the scope defined in the appended claims.

Claims

1. A forging method based on an ultra-large, heavy-load, high-temperature arc-shaped feeding forging follow-up compliance device; The following compliance device comprises two upper platforms, a plurality of pressure sensors, a hydraulic cylinder (2), a plurality of guide mechanisms (3), two lower platforms (4) and a controller; the upper platform (1) and the lower platform (4) are arc-shaped; the two lower platforms (4) are arranged opposite to each other with a gap to form a ring; the upper platforms (1) are respectively arranged above the lower platforms (4) and are arranged opposite to each other with a gap to form a ring; the pressure sensor is arranged on the upper platform (1); the hydraulic cylinder (2) and the guide mechanism (3) are respectively arranged between the corresponding upper platform (1) and the lower platform (4); the pressure sensor and the hydraulic cylinder (2) are connected to the controller; The following compliance device comprises four hydraulic cylinders (2), wherein the hydraulic cylinders (2) are respectively arranged between the corresponding upper platform (1) and the lower platform (4); and the connecting line of the two hydraulic cylinders (2) connected to the same upper platform (1) is located on the center of gravity line of the corresponding upper platform (1); A guide mechanism (3) is provided on both sides of each hydraulic cylinder (2); Each of the guide mechanisms (3) comprises a guide post and a guide sleeve, wherein the guide sleeve and the guide post are respectively connected to the corresponding upper platform (1) and the lower platform (4), and the guide sleeve is sleeved outside the guide post; The controller is provided with an active compliance mode and a passive compliance mode; in the active compliance mode, the hydraulic cylinder (2) controls the upper platform (1) to move synchronously with the movable crossbeam of a press; in the passive compliance mode, when the pressure value of the pressure sensor exceeds a preset threshold, the hydraulic cylinder (2) controls the upper platform (1) to move downward with the movable crossbeam of the press; The forging method comprises the steps of: S1: A feeding device is provided on the upper platform (1), an upper anvil is connected to the bottom of the movable crossbeam of a press, and a lower anvil is provided in the gap between the two upper platforms (1) and the two lower platforms (4) and is located directly below the upper anvil; after the feeding device sends the casting and forging part between the upper anvil and the lower anvil, the feeding device stops moving; the movable crossbeam of the press drives the upper anvil to move downward; S2: The movable crossbeam is fed rapidly, and when it is 200 mm above the casting, the speed is reduced; S3: the movable crossbeam continues to move downward, and when the pressure of the pressure sensor exceeds the preset threshold, the upper anvil and the upper platform (1) move downward synchronously and gradually approach the upper surface of the lower anvil; S4: the movable crossbeam continues to feed, and after the casting contacts the lower anvil, the upper anvil and the upper platform (1) continue to move downward, and the upper anvil and the lower anvil begin to forge the casting; S5: After the forging is completed, the movable crossbeam starts to move upward. After the pressure of the pressure sensor is less than the preset threshold, under the action of the hydraulic cylinder (2), the upper platform (1) starts to move upward to lift the formed casting and forging to separate from the lower anvil and move upward, and the upper platform (1) returns to its initial position. S6: The movable crossbeam continues to move upward, and the movable crossbeam returns to its initial position.

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