A fan-shaped forging step displacement die and manufacturing process

Abstract

The present application belongs to the technical field of die forging, and particularly relates to a stepped offset die for a fan-shaped forging and a manufacturing process. The process comprises the following steps: after welding lug ears on both ends of the fan-shaped forging, the fan-shaped forging is heated in a furnace; the fan-shaped forging after being discharged from the furnace is hoisted into a lower die, a wide arc segment of an upper die is covered on a step of the fan-shaped forging, and then full coverage is pressed down; the upper die is rotated by 180 degrees, a narrow arc segment of the upper die is covered on the step of the fan-shaped forging, and then the fan-shaped forging is continuously pressed down until the lower segment of the fan-shaped forging is tightly attached to the lower die, and a fan-shaped stepped forging blank is obtained after demolding; subsequently, heat treatment and machining processes are performed, and the finished product manufacturing of the fan-shaped stepped forging is completed. The present application reduces material loss and energy consumption, reduces the manufacturing cost of the wind power flange, improves the manufacturing flexibility, and increases the market competitiveness of the enterprise.

Description

Technical Field

[0001] This invention belongs to the field of die forging technology, specifically relating to a staggered die for a fan-shaped forging and its manufacturing process. Background Technology

[0002] Fan-shaped arc segment stepped forgings, as a component form for reducing transportation costs in large forgings, remain the preferred form in the fields of mining machinery and construction engineering. Because the overall size and weight of these forgings approach the limits of equipment manufacturing both nationally and globally, most of them are assembled in a uniformly segmented manner to achieve their original design purpose. However, compared with the die forging staggered transfer process, the traditional free forging process for this type of forging has the following problems:

[0003] 1) Using free forging, the forging allowance will be greatly increased compared to the offset forming allowance of die forging. In addition, during the forming process, the hydraulic press and manipulator are easily operated manually, which can easily cause the fan-shaped forging allowance to be too small, resulting in failure to form or rework.

[0004] 2) The lack of flexibility in free forging greatly affects the production efficiency of this type of product;

[0005] 3) In the heat treatment process of forgings, the traditional cooling media are quenching liquid, oil or other cooling media, which bring great environmental pollution problems in the quenching process of forgings;

[0006] Therefore, there is a need to develop a staggered die and manufacturing process for fan-shaped forgings to solve the above-mentioned problems in the existing manufacturing process of fan-shaped stepped forgings, so as to reduce material loss and energy consumption, reduce the manufacturing cost of such forgings, improve manufacturing flexibility, and increase the market competitiveness of enterprises. Summary of the Invention

[0007] This invention discloses a fan-shaped forging stepped misalignment mold and manufacturing process. This step reduces material loss and energy consumption, lowers the manufacturing cost of wind power flanges, improves manufacturing flexibility, and enhances the market competitiveness of enterprises.

[0008] The technical solution of this invention to solve the technical problem is:

[0009] A fan-shaped forging stepped misalignment mold and its manufacturing process include the following steps:

[0010] (1) Weld lifting lugs to both ends of the stepped sector forging and then load it into the furnace for heating;

[0011] The fan-shaped forging has an outer arc radius of 4390mm, an inner arc radius of 3500mm, an inner diameter of 4020mm for the step, a total height of 400mm, a step height of 290mm, and an angle of 30° between the two sides and the vertical plane.

[0012] (2) Hoist the fan-shaped forging after it comes out of the furnace into the lower mold, cover the step of the fan-shaped forging with the wide arc section of the upper mold, and then press it down to fully cover it;

[0013] The lower mold includes a base plate with a length and width of 2.4 meters and a thickness of 300 mm. The upper part of the base plate is welded with a concave plate and a convex plate that are adapted to the size of the fan-shaped forging. Both the concave plate and the convex plate have a certain draft angle. Multiple stiffening plates are welded to the outside of the concave plate.

[0014] (3) Rotate the upper mold 180° and cover the narrow arc segment of the upper mold onto the step of the fan-shaped forging. Continue to press down until the lower section of the fan-shaped forging is tightly fitted with the lower mold. After demolding, a fan-shaped step forging blank is obtained.

[0015] The upper mold includes a top plate that is 3.3m long, 2.4m wide, and 300mm thick. A wide lower pressure plate and a narrow lower pressure plate, which are adapted to the size of the fan-shaped forging, are welded to the lower end of the top plate. The wide lower pressure plate is 465mm wide and the narrow lower pressure plate is 255mm wide.

[0016] (4) The obtained fan-shaped stepped forging blank is subjected to heat treatment, wherein the heat treatment includes at least one or more of normalizing and tempering;

[0017] The normalizing temperature is 860℃-910℃, and the tempering temperature is 630℃-680℃.

[0018] (5) Roughly machine the heat-treated fan-shaped stepped forging blank;

[0019] The surface roughness of the fan-shaped forging after rough machining is Ra6.3-12.5.

[0020] (6) Perform performance heat treatment on the rough-machined fan-shaped stepped forging blank;

[0021] During the performance heat treatment, the rough-machined fan-shaped stepped forging blank is heated to a certain temperature and immediately suspended into a water tank. Water cooling and air cooling are alternated to achieve the quenching process in the performance heat treatment process of the fan-shaped forging, and then tempering is performed.

[0022] The quenching temperature in the performance heat treatment is 840℃-890℃, and the tempering temperature is 570℃-620℃.

[0023] (7) The fan-shaped stepped forging blank after performance heat treatment is semi-finished and subjected to ultrasonic testing;

[0024] The surface roughness of the fan-shaped forging after performance heat treatment is Ra6.3-12.5; existing ultrasonic testing procedures are used to check whether there are defects in the internal quality of the fan-shaped forging.

[0025] (8) The fan-shaped stepped forging blank after ultrasonic testing is precision machined and magnetic particle testing is performed to obtain the fan-shaped stepped forging;

[0026] The surface roughness of the fan-shaped forging after finishing is Ra3.2-6.3; magnetic particle testing is used to check whether there are any defects in the surface quality of the fan-shaped forging.

[0027] The beneficial effects achieved by this application after adopting the above technical solution are as follows:

[0028] 1. The fan-shaped forging step misalignment mold of the present invention can achieve precise misalignment of the steps of the fan-shaped forging by using the upper mold and the lower mold in cooperation. It can realize the misalignment process of multiple fan-shaped step forgings with one mold, solve the shortcomings of free forging that cannot misalign the steps of the billet, insufficient forming degree and insufficient allowance, avoid the billet that cannot be repaired or scrapped, reduce the cost of subsequent processes and improve the efficiency of subsequent processing.

[0029] 2. The manufacturing process of the present invention enables flexible manufacturing of fan-shaped forgings; by using an upper die with a wide lower pressure plate and a narrow lower pressure plate, the fan-shaped stepped billet can be flexibly clamped and pressed down by a forging manipulator. This method can flexibly realize that the steps of the fan-shaped stepped forging are fed according to the die design and completely fill the die.

[0030] 3. The manufacturing process of this invention enables the green manufacturing of fan-shaped forgings; the present invention performs performance heat treatment on the billet, which can not only meet the mechanical properties of the forgings, but also avoid the environmental pollution problems caused by the use of quenching fluid, oil or other cooling media, thus realizing the green manufacturing of forgings. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the lower mold in an embodiment of the present invention.

[0032] Figure 2 This is a schematic diagram of the upper mold in an embodiment of the present invention.

[0033] Figure 3 This is a schematic diagram of the manufacturing process for the misalignment of the fan-shaped stepped forging in an embodiment of the present invention.

[0034] Figure 4 This is a physical image of the product manufactured according to the present invention.

[0035] Figure 5 This is a bottom view of the actual product manufactured according to the present invention.

[0036] In the diagram: 11- Rib plate; 12- Concave plate; 13- Bottom plate; 14- Convex plate; 21- Wide lower pressure plate; 22- Top plate; 23- Narrow lower pressure plate. Detailed Implementation

[0037] To facilitate understanding of the embodiments of the present invention, the following provides a further description of the fan-shaped forging step misalignment mold and its manufacturing process as exemplified by the embodiments of the present invention.

[0038] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit and scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0039] In addition, the accompanying drawings are provided to further understand the invention and constitute a part of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0040] Example 1

[0041] Combination Figure 1 This embodiment provides a fan-shaped forging stepped misalignment mold and manufacturing process, including the following steps:

[0042] (1) Weld lifting lugs to both ends of the stepped sector forging and then load it into the furnace for heating;

[0043] The fan-shaped forging has an outer arc radius of 4390mm, an inner arc radius of 3500mm, an inner diameter of 4020mm for the step, a total height of 400mm, a step height of 290mm, and an angle of 30° between the two sides and the vertical plane.

[0044] (2) Hoist the fan-shaped forging after it comes out of the furnace into the lower mold, cover the step of the fan-shaped forging with the wide arc section of the upper mold, and then press it down to fully cover it;

[0045] The lower mold includes a base plate with a length and width of 2.4 meters and a thickness of 300 mm. The upper part of the base plate is welded with a concave plate and a convex plate that are adapted to the size of the fan-shaped forging. Both the concave plate and the convex plate have a certain draft angle. Multiple stiffening plates are welded to the outside of the concave plate.

[0046] (3) Rotate the upper mold 180° and cover the narrow arc segment of the upper mold onto the step of the fan-shaped forging. Continue to press down until the lower section of the fan-shaped forging is tightly fitted with the lower mold. After demolding, a fan-shaped step forging blank is obtained.

[0047] The upper mold includes a top plate that is 3.3m long, 2.4m wide, and 300mm thick. A wide lower pressure plate and a narrow lower pressure plate, which are adapted to the size of the fan-shaped forging, are welded to the lower end of the top plate. The wide lower pressure plate is 465mm wide and the narrow lower pressure plate is 255mm wide.

[0048] (4) The obtained fan-shaped stepped forging blank is subjected to heat treatment, wherein the heat treatment includes at least one or more of normalizing and tempering;

[0049] The normalizing temperature is 860℃, and the tempering temperature is 630℃.

[0050] (5) Roughly machine the heat-treated fan-shaped stepped forging blank;

[0051] The surface roughness of the fan-shaped forging after rough machining is Ra6.3.

[0052] (6) Perform performance heat treatment on the rough-machined fan-shaped stepped forging blank;

[0053] During the performance heat treatment, the rough-machined fan-shaped stepped forging blank is heated to a certain temperature and immediately suspended into a water tank. Water cooling and air cooling are alternated to achieve the quenching process in the performance heat treatment process of the fan-shaped forging, and then tempering is performed.

[0054] The quenching temperature in the performance heat treatment is 840℃, and the tempering temperature is 570℃.

[0055] (7) The fan-shaped stepped forging blank after performance heat treatment is semi-finished and subjected to ultrasonic testing;

[0056] The surface roughness of the fan-shaped forging after performance heat treatment is Ra6.3; the existing ultrasonic testing procedure is used to check whether there are defects in the internal quality of the fan-shaped forging; ultrasonic testing is an important process in the forging manufacturing process, which can check whether there are defects in the internal quality of the forging and whether it can meet the preset specification requirements.

[0057] (8) The fan-shaped stepped forging blank after ultrasonic testing is precision machined and magnetic particle testing is performed to obtain the fan-shaped stepped forging;

[0058] The surface roughness of the fan-shaped forging after finishing is Ra3.2; magnetic particle testing is used to check whether there are defects on the surface of the fan-shaped forging; magnetic particle testing is an important process in the manufacturing process of fan-shaped stepped forgings, which can check whether there are defects on the surface of the forging and whether it can meet the pre-set specifications.

[0059] Example 2

[0060] A fan-shaped forging stepped misalignment mold and its manufacturing process include the following steps:

[0061] (1) Weld lifting lugs to both ends of the stepped sector forging and then load it into the furnace for heating;

[0062] The fan-shaped forging has an outer arc radius of 4390mm, an inner arc radius of 3500mm, an inner diameter of 4020mm for the step, a total height of 400mm, a step height of 290mm, and an angle of 30° between the two sides and the vertical plane.

[0063] (2) Hoist the fan-shaped forging after it comes out of the furnace into the lower mold, cover the step of the fan-shaped forging with the wide arc section of the upper mold, and then press it down to fully cover it;

[0064] The lower mold includes a base plate with a length and width of 2.4 meters and a thickness of 300 mm. The upper part of the base plate is welded with a concave plate and a convex plate that are adapted to the size of the fan-shaped forging. Both the concave plate and the convex plate have a certain draft angle. Multiple stiffening plates are welded to the outside of the concave plate.

[0065] (3) Rotate the upper mold 180° and cover the narrow arc segment of the upper mold onto the step of the fan-shaped forging. Continue to press down until the lower section of the fan-shaped forging is tightly fitted with the lower mold. After demolding, a fan-shaped step forging blank is obtained.

[0066] The upper mold includes a top plate that is 3.3m long, 2.4m wide, and 300mm thick. A wide lower pressure plate and a narrow lower pressure plate, which are adapted to the size of the fan-shaped forging, are welded to the lower end of the top plate. The wide lower pressure plate is 465mm wide and the narrow lower pressure plate is 255mm wide.

[0067] (4) The obtained fan-shaped stepped forging blank is subjected to heat treatment, wherein the heat treatment includes at least one or more of normalizing and tempering;

[0068] The normalizing temperature is 910℃, and the tempering temperature is 680℃.

[0069] (5) Roughly machine the heat-treated fan-shaped stepped forging blank;

[0070] The surface roughness of the fan-shaped forging after rough machining is Ra12.5.

[0071] (6) Perform performance heat treatment on the rough-machined fan-shaped stepped forging blank;

[0072] During the performance heat treatment, the rough-machined fan-shaped stepped forging blank is heated to a certain temperature and immediately suspended into a water tank. Water cooling and air cooling are alternated to achieve the quenching process in the performance heat treatment process of the fan-shaped forging, and then tempering is performed.

[0073] The quenching temperature in the performance heat treatment is 890℃, and the tempering temperature is 620℃.

[0074] (7) The fan-shaped stepped forging blank after performance heat treatment is semi-finished and subjected to ultrasonic testing;

[0075] The surface roughness of the fan-shaped forging after performance heat treatment is Ra12.5; existing ultrasonic testing procedures are used to check whether there are defects in the internal quality of the fan-shaped forging.

[0076] (8) The fan-shaped stepped forging blank after ultrasonic testing is precision machined and magnetic particle testing is performed to obtain the fan-shaped stepped forging;

[0077] The surface roughness of the fan-shaped forging after finishing is Ra6.3; magnetic particle testing is used to check whether there are any defects in the surface quality of the fan-shaped forging.

[0078] Example 3

[0079] A fan-shaped forging stepped misalignment mold and its manufacturing process include the following steps:

[0080] (1) Weld lifting lugs to both ends of the stepped sector forging and then load it into the furnace for heating;

[0081] The fan-shaped forging has an outer arc radius of 4390mm, an inner arc radius of 3500mm, an inner diameter of 4020mm for the step, a total height of 400mm, a step height of 290mm, and an angle of 30° between the two sides.

[0082] (2) Hoist the fan-shaped forging after it comes out of the furnace into the lower mold, cover the step of the fan-shaped forging with the wide arc section of the upper mold, and then press it down to fully cover it;

[0083] The lower mold includes a base plate with a length and width of 2.4 meters and a thickness of 300 mm. The upper part of the base plate is welded with a concave plate and a convex plate that are adapted to the size of the fan-shaped forging. Both the concave plate and the convex plate have a certain draft angle. Multiple stiffening plates are welded to the outside of the concave plate.

[0084] (3) Rotate the upper mold 180° and cover the narrow arc segment of the upper mold onto the step of the fan-shaped forging. Continue to press down until the lower section of the fan-shaped forging is tightly fitted with the lower mold. After demolding, a fan-shaped step forging blank is obtained.

[0085] The upper mold includes a top plate that is 3.3m long, 2.4m wide, and 300mm thick. A wide lower pressure plate and a narrow lower pressure plate, which are adapted to the size of the fan-shaped forging, are welded to the lower end of the top plate. The wide lower pressure plate is 465mm wide and the narrow lower pressure plate is 255mm wide.

[0086] (4) The obtained fan-shaped stepped forging blank is subjected to heat treatment, wherein the heat treatment includes at least one or more of normalizing and tempering;

[0087] The normalizing temperature is 890℃, and the tempering temperature is 650℃.

[0088] (5) Roughly machine the heat-treated fan-shaped stepped forging blank;

[0089] The surface roughness of the fan-shaped forging after rough machining is Ra10.5.

[0090] (6) Perform performance heat treatment on the rough-machined fan-shaped stepped forging blank;

[0091] During the performance heat treatment, the rough-machined fan-shaped stepped forging blank is heated to a certain temperature and immediately suspended into a water tank. Water cooling and air cooling are alternated to achieve the quenching process in the performance heat treatment process of the fan-shaped forging, and then tempering is performed.

[0092] The quenching temperature in the performance heat treatment is 870℃, and the tempering temperature is 600℃.

[0093] (7) The fan-shaped stepped forging blank after performance heat treatment is semi-finished and subjected to ultrasonic testing;

[0094] The surface roughness of the fan-shaped forging after performance heat treatment is Ra10.5; existing ultrasonic testing procedures are used to check whether there are defects in the internal quality of the fan-shaped forging.

[0095] (8) The fan-shaped stepped forging blank after ultrasonic testing is precision machined and magnetic particle testing is performed to obtain the fan-shaped stepped forging;

[0096] The surface roughness of the fan-shaped forging after finishing is Ra4.3; magnetic particle testing is used to check whether there are any defects in the surface quality of the fan-shaped forging.

[0097] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various variations or substitutions within the technical scope disclosed in the present invention, and these should all be covered within the scope of protection of the present invention.

[0098] Furthermore, while this invention provides examples of various specific processes and materials, those skilled in the art will recognize the application of other processes and / or the use of other materials.

Claims

1. A manufacturing process for producing sector-shaped forgings using a stepped offset die, characterized in that, Includes the following steps: (1) Weld lifting lugs to both ends of the stepped sector forging and then load it into the furnace for heating; (2) Hoist the fan-shaped forging after it comes out of the furnace into the lower mold, cover the step of the fan-shaped forging with the wide arc section of the upper mold, and then press it down to fully cover it; (3) Rotate the upper mold 180° and cover the narrow arc segment of the upper mold onto the step of the fan-shaped forging. Continue to press down until the lower section of the fan-shaped forging is tightly fitted with the lower mold. After demolding, a fan-shaped step forging blank is obtained. (4) The obtained fan-shaped stepped forging blank is subjected to heat treatment, wherein the heat treatment includes at least one or more of normalizing and tempering; (5) Roughly machine the heat-treated fan-shaped stepped forging blank; (6) Perform performance heat treatment on the rough-machined fan-shaped stepped forging blank; (7) The fan-shaped stepped forging blank after performance heat treatment is semi-finished and subjected to ultrasonic testing; (8) The fan-shaped stepped forging blank after ultrasonic testing is precision machined and magnetic particle testing is performed to obtain the fan-shaped stepped forging; The upper mold includes a top plate that is 3.3m long, 2.4m wide, and 300mm thick. A wide lower pressure plate and a narrow lower pressure plate adapted to the size of the fan-shaped forging are welded to the lower end of the top plate. The wide lower pressure plate is 465mm wide and the narrow lower pressure plate is 255mm wide. The fan-shaped forging described in step (1) has an outer arc radius of 4390mm, an inner arc radius of 3500mm, an inner diameter of 4020mm, a total height of 400mm, a step height of 290mm, and an angle of 30° between the two sides and the vertical plane.

2. The manufacturing process for producing fan-shaped forgings using a stepped offset die according to claim 1, characterized in that, The lower mold mentioned in step (2) includes a base plate with a length and width of 2.4 meters and a thickness of 300 mm. The upper part of the base plate is welded with a concave plate and a convex plate that are adapted to the size of the fan-shaped forging. Both the concave plate and the convex plate have a certain draft angle. Multiple stiffeners are welded on the outer side of the concave plate.

3. The manufacturing process for producing fan-shaped forgings using a stepped offset die according to claim 1, characterized in that, The normalizing temperature in step (4) is 860℃-910℃, and the tempering temperature is 630℃-680℃.

4. The manufacturing process for producing a fan-shaped forging using a stepped offset die according to claim 1, characterized in that, The surface roughness of the fan-shaped stepped forging blank after rough machining in step (5) is Ra6.3-12.

5.

5. The manufacturing process for producing a fan-shaped forging using a stepped offset die according to claim 1, characterized in that, In step (6), the quenching temperature in the heat treatment is 840℃-890℃, and the tempering temperature is 570℃-620℃.

6. The manufacturing process for producing a fan-shaped forging using a stepped offset die according to claim 1, characterized in that, The surface roughness of the fan-shaped stepped forging blank after the performance heat treatment in step (7) is Ra6.3-12.5; the ultrasonic testing step is used to check whether there are defects in the internal quality of the fan-shaped forging.

7. The manufacturing process for producing a fan-shaped forging using a stepped offset die according to claim 1, characterized in that, The surface roughness of the fan-shaped stepped forging blank after finishing in step (8) is Ra3.2-6.3; the surface quality of the fan-shaped forging is checked for defects by magnetic particle testing.

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