Method of manufacturing a disc-shaped article and mould

Abstract

The application relates to a disc-shaped part manufacturing method and a die, the disc-shaped part manufacturing method comprising the following steps: placing a blank in the center of a die cavity of a lower die module; controlling an upper die module and a pressing rod to synchronously move towards the lower die module at a first linear velocity, and controlling the upper die module and the lower die module to reversely rotate at a first angular velocity respectively, so that a first pushing groove and a second pushing groove provide a radial outward pushing force acting on the blank; when the upper die module and the lower die module contact each other, controlling the pressing rod and a top rod to clampingly fix the blank to avoid rotation of the blank; controlling the upper die module and the lower die module to reversely rotate at a second angular velocity respectively, so that the first pushing groove and the second pushing groove roll the end face of the blank until the end face of the blank reaches a preset flatness. The disc-shaped part manufacturing method and the die can simplify a process flow, improve production efficiency, and ensure the performance stability of a forged part.

Description

Technical Field

[0001] This application relates to the field of disc-shaped component manufacturing technology, and in particular to a method for manufacturing disc-shaped components and a mold. Background Technology

[0002] Disc-shaped parts are widely used in power, nuclear energy, and aerospace industries, especially as core components of aircraft and aerospace engines, where their forming quality significantly impacts engine performance. Currently, the manufacturing method for disc-shaped parts involves forming the target part from a bar-shaped billet through a pre-forging and final forging process. In related technologies, to ensure full filling of the forging and improve forming defects, a multi-step forming method is employed, designing two different sets of dies specifically for the forming characteristics of the pre-forging and final forging steps, thereby ensuring sufficient deformation of the billet in each step. However, multi-step forming has a long process flow, low production efficiency, and the complex thermal deformation history makes it difficult to control the performance stability of the forging. Summary of the Invention

[0003] Therefore, it is necessary to provide a method and mold for manufacturing disc-shaped parts to simplify the process, improve production efficiency, and ensure the performance stability of the forgings.

[0004] According to a first aspect of this application, embodiments of this application provide a method for manufacturing a disc-shaped component, including:

[0005] The blank is placed in the center of the mold cavity of the lower module;

[0006] The upper module and the pressure rod are controlled to move synchronously toward the lower module at a first linear velocity, and the upper module and the lower module are controlled to rotate in opposite directions at a first angular velocity, so that the first push groove and the second push groove provide a radially outward thrust acting on the billet;

[0007] When the upper module and the lower module are in contact with each other, the pressure rod and the top rod are controlled to clamp and fix the billet to prevent the billet from rotating.

[0008] The upper module and the lower module are controlled to rotate in opposite directions at a second angular velocity, so that the first pusher groove and the second pusher groove roll the end face of the billet until the end face of the billet reaches a preset flatness.

[0009] In one embodiment, a plane perpendicular to the first axis and tangent to the inner wall of the upper module's mold cavity is defined as a first tangent plane, and a plane perpendicular to the first axis and tangent to the inner wall of the lower module's mold cavity is defined as a second tangent plane.

[0010] The upper module has multiple first spiral lines distributed circumferentially around the first axis on the first cross-section, and a first push groove is formed between two adjacent first spiral lines.

[0011] The lower module has multiple second spiral lines circumferentially distributed around the first axis on the second cross-section, and a second push groove is formed between two adjacent second spiral lines;

[0012] The first helix rotates in the opposite direction to the upper module, and the second helix rotates in the opposite direction to the lower module.

[0013] In one embodiment, the first spiral and the second spiral are configured to be one of an Archimedean spiral, an involute, or a first preset curve.

[0014] The parametric equation of the first preset curve with respect to the parameter θ and coordinates x and y is as follows:

[0015] x = e -dθ cosθ

[0016] y = e -dθ sinθ

[0017] The first angular velocity ω1 is a function of the deformation time t:

[0018]

[0019] Where v1 is the first linear velocity, d is the first preset constant, and L0 is the initial height of the billet.

[0020] In one embodiment, the value of the first preset constant d satisfies the following condition:

[0021] d = 0.5

[0022] d=1

[0023] d=2

[0024] in, The diameter of the disc-shaped component.

[0025] In one embodiment, a cylindrical surface with the first axis as its central axis is defined as a reference cylindrical surface;

[0026] The intersection lines of the first and second pusher grooves with the reference cylindrical surface are smooth arcs.

[0027] In one embodiment, the intersection of the first pusher groove and the second pusher groove with the reference cylindrical surface is a second preset curve;

[0028] The equation of the second preset curve with respect to coordinates s and p is:

[0029]

[0030] 0≤s≤l

[0031] Where a is a second preset constant, and l is the distance between two intersection points of two adjacent first or second helical lines and the reference cylindrical surface.

[0032] In one embodiment, the value of the second preset constant a satisfies the following condition:

[0033] a = (0.25 ~ 0.4)D min

[0034] Among them, D min It is the distance between the starting points of two adjacent first spirals or second spirals.

[0035] In one embodiment, the first linear velocity ranges from 1 to 10 mm / s; and / or

[0036] The second angular velocity ranges from 0.01 to 0.02 rad / s.

[0037] In one embodiment, controlling the pressure rod and the top rod to clamp and fix the billet to prevent the billet from rotating when the upper module and the lower module are in contact with each other specifically includes:

[0038] When the upper module and the lower module are in contact with each other, the pressure rod is controlled to apply a preset pressure to the blank to clamp and fix the blank.

[0039] According to a second aspect of this application, embodiments of this application also provide a mold for manufacturing disc-shaped parts, including an upper module, a pressure rod, a lower module, and a push rod;

[0040] The pressure rod and the top rod are constructed as rotating bodies and are coaxially arranged with the first axis as the center of rotation.

[0041] The pressure rod passes through the upper module and extends into the mold cavity of the upper module, and the push rod passes through the lower module and extends into the mold cavity of the lower module;

[0042] The upper module has a die cavity with a plurality of first push grooves extending outward from the center, and the lower module has a die cavity with a plurality of second push grooves extending outward from the center.

[0043] When the upper module and the lower module rotate in opposite directions, the first pusher groove and the second pusher groove can provide a radially outward thrust acting on the billet.

[0044] In the above-mentioned method and mold for manufacturing disc-shaped parts, a plurality of first push grooves extending outward from the center are provided in the mold cavity of the upper module, and a plurality of second push grooves extending outward from the center are provided in the mold cavity of the lower module. In the pre-forging step, while the upper module and the pressure rod move synchronously toward the lower module, the upper module and the lower module are controlled to rotate in opposite directions at the same speed, so that the billet at the end flows into the first push groove and the second push groove. The first push groove and the second push groove are used to apply a radially outward pushing force to the billet, so as to reduce the influence of the friction between the mold and the billet on the radial flow velocity of the billet at the end, so that the radial flow velocity of the billet at the end is close to the radial flow velocity in the middle, avoiding the billet from bulging and cracking, improving the forming limit of the material, and ensuring that the billet is fully deformed in the pre-forging step. In the final forging step, while the pressure rod and the push rod clamp the billet, the upper module and the lower module are controlled to rotate in opposite directions at the same speed, so that the billet flows out from the first push groove and the second push groove, and the end face of the billet is rolled flat by the first push groove and the second push groove to ensure that the billet is fully deformed in the final forging step.

[0045] The aforementioned method and mold for manufacturing disc-shaped parts utilize a single mold to complete both the pre-forging and final forging of the billet, ensuring sufficient deformation of the billet in each step. This eliminates the need to transfer the billet between different molds, reducing processing steps, simplifying the process, and improving production efficiency. Furthermore, it eliminates the need for repeated heating and holding of the billet, ensuring the performance stability of the forging. In addition, the billet metal deforms circumferentially under the pushing action of the first and second pusher grooves, increasing the amount of material deformation, refining the microstructure, and improving the overall mechanical properties of the forging. Attached Figure Description

[0046] Figure 1 This is a schematic flowchart of a method for manufacturing a disc-shaped component according to an embodiment of this application;

[0047] Figure 2 This is a schematic diagram of the mold structure in one embodiment of this application;

[0048] Figure 3 for Figure 2 A magnified view of a section at point A in the middle;

[0049] Figure 4 This is a schematic diagram of the mold structure before the forming process begins in one embodiment of this application;

[0050] Figure 5 This is a schematic diagram of the initial shape of the blank in one embodiment of this application;

[0051] Figure 6 This is a schematic diagram of the mold structure in the pre-forging step of one embodiment of this application;

[0052] Figure 7 This is a schematic diagram of the structure of the intermediate form of the billet in one embodiment of this application;

[0053] Figure 8 This is a schematic diagram of the mold structure in the final forging step in one embodiment of this application;

[0054] Figure 9 This is a schematic diagram of the final form of the blank in one embodiment of this application;

[0055] Figure 10 This is a schematic diagram of the structure of the mold cavity of the lower module in one embodiment of this application;

[0056] Figure 11 for Figure 10 The diagram shows the structure of the lower module's cavity from another perspective;

[0057] Figure 12 This is a coordinate graph of the first preset curve in one embodiment of this application;

[0058] Figure 13 for Figure 10 The diagram shows a cross-sectional view of the die cavity of the lower module on the reference cylindrical surface.

[0059] Figure 14 This is a coordinate graph of the second preset curve in one embodiment of this application.

[0060] Explanation of reference numerals in the attached figures:

[0061] 100. Mold;

[0062] 101. Upper module; 1011. First pusher groove; 1012. First spiral; 1013. First flash groove; 102. Pressure rod; 103. Lower module; 1031. Second pusher groove; 1032. Second spiral; 1033. Second flash groove; 1034. Gear ring; 104. Push rod; 105. First drive component; 106. Second drive component; 107. Gear ring component; 108. First gear; 109. Second gear; 110. Upper template; 111. Fixing sleeve; 112. First bearing; 113. Fixing base; 114. Second bearing;

[0063] 10. Billet; 10a. Billet in its initial form; 10b. Billet in its intermediate form; 10c. Billet in its final form;

[0064] O, First axis; B, First tangent plane; C, Second tangent plane; D, Reference cylindrical surface. Detailed Implementation

[0065] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0066] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0067] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0068] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0069] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0070] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0071] Disc-shaped parts are widely used in power, nuclear energy, and aerospace industries, especially as core components of aircraft and aerospace engines, where their forming quality significantly affects engine performance. In recent years, with the rapid development of various fields, the demand for large-size disc-shaped parts has been increasing daily. Currently, the manufacturing method for disc-shaped parts involves using a flat die to form a bar-shaped billet, and then shaping the billet into the target part through pre-forging and final forging processes.

[0072] When forging bar-shaped billets, the deformation of the metal billet is similar to compression deformation. Due to the friction between the die and the billet, the radial flow velocity in the middle of the billet is faster than that at the ends, resulting in a bulging shape. Meanwhile, disc-shaped parts used in engines often use high-temperature alloys and titanium alloys, which are difficult-to-deform alloys with high resistance to high-temperature deformation and small hot working windows. During forging, defects such as incomplete filling or edge cracking are prone to occur. Furthermore, the long high-temperature forging time for these disc-shaped parts means that the grain refinement rate obtained from deformation is insufficient to offset the grain growth rate, resulting in coarse grains. This significantly reduces the performance of the final forging, making it difficult to meet the high-temperature tensile properties, creep resistance, and fatigue resistance requirements of large-sized disc-shaped parts under long-term harsh working conditions.

[0073] Since the formation defects of disc-shaped parts are closely related to the filling flow and deformation degree of metal in the mold cavity, current research mainly focuses on improving the cavity structure and forming process, or using multi-step forming to ensure full filling of the forging. For example, one related patent uses spherical protrusions in the upper and lower molds to reduce the contact area between the billet and the mold during instantaneous contact, thus slowing down the cooling rate of the workpiece and increasing metal fluidity. However, existing processes for forging high-temperature alloys and titanium alloys often use isothermal forging methods, where the temperature difference between the mold and the billet is small. Therefore, reducing the contact area to decrease the temperature difference between the billet and the mold has a very limited effect on improving the fluidity of the billet. In another related patent, two different molds are designed for the forming characteristics of the pre-forging and final forging steps, thereby ensuring that the billet is fully deformed in each step. However, multi-step forming has a long process flow, low production efficiency, and the complex thermal deformation history makes it difficult to control the performance stability of the forging. Therefore, further research is needed on the manufacturing methods and molds for disc-shaped parts.

[0074] To address the problems existing in the aforementioned related technologies, this application provides a method and mold for manufacturing disc-shaped parts, which simplifies the process flow, improves production efficiency, and ensures the performance stability of forgings.

[0075] Figure 1 A schematic flowchart of a method for manufacturing a disc-shaped component according to an embodiment of this application is shown; Figure 2 A schematic diagram of the mold structure in one embodiment of this application is shown; Figure 3 It shows Figure 2 A magnified view of a portion of point A in the middle.

[0076] In some embodiments, see Figures 1 to 3 This application provides a method for manufacturing a disc-shaped part, using a specially designed mold 100 to process a blank. The mold 100 includes an upper module 101, a pressure rod 102, a lower module 103, and a push rod 104. The pressure rod 102 and the push rod 104 are constructed as rotating bodies and are coaxially arranged with a first axis O as the center of rotation. The pressure rod 102 passes through the upper module 101 and extends into the mold cavity of the upper module 101, while the push rod 104 passes through the lower module 103 and extends into the mold cavity of the lower module 103. The mold cavity of the upper module 101 has a plurality of first push grooves 1011 extending outward from the center, and the mold cavity of the lower module 103 has a plurality of second push grooves 1031 extending outward from the center. The method includes the following steps:

[0077] S101. Place the blank in the center of the mold cavity of the lower module.

[0078] Figure 4 This invention provides a schematic diagram of the mold structure before the start of molding in one embodiment of the present application. Figure 5A schematic diagram of the initial form of the blank is shown in one embodiment of this application.

[0079] This step is a preparatory step before the forming process begins. The explanation of this step is provided in conjunction with the accompanying drawings. For details, please refer to... Figure 4 and Figure 5 First, the mold 100 is installed on a press (not shown). The press drives the upper module 101 and the pressure rod 102 upward to open the mold, thus reserving operating space for placing the bar-shaped billet (the initial billet 10a). Then, the billet 10 is placed in the center of the mold cavity of the lower module 103, ensuring that the lower module 103 is aligned with the center of the billet 10 so that the billet 10 can flow evenly from the center outward throughout the forming process. Optionally, before placing the billet 10, a lubricant is sprayed into the mold cavity to reduce friction and adhesion between the billet 10 and the mold 100, thereby extending the mold life, reducing energy consumption, and improving the quality of the forging.

[0080] S102. Control the upper module and the pressure rod to move synchronously toward the lower module at a first linear velocity, and control the upper module and the lower module to rotate in opposite directions at a first angular velocity, so that the first pusher groove and the second pusher groove provide radial outward thrust acting on the billet.

[0081] Figure 6 This invention provides a schematic diagram of the mold structure in the pre-forging step according to an embodiment of the present application. Figure 7 A schematic diagram of the structure of an intermediate form of the blank is shown in one embodiment of this application.

[0082] This step corresponds to the pre-forging step in the billet forming process, used to obtain a billet 10b with an intermediate shape similar in size and shape to the target forging (disc-shaped part). This step is explained in conjunction with the accompanying drawings. Specifically, see... Figure 6 and Figure 7 The upper module 101 and the pressure rod 102 are driven to move downward synchronously at a first linear velocity v1 by a press, while the upper module 101 and the lower module 103 are controlled to rotate in opposite directions at a first angular velocity ω1, until the upper module 101 and the lower module 103 contact each other to close the mold 100. Optionally, the value of the first linear velocity v1 is in the range of 1 to 10 mm / s to ensure that the billet 10 undergoes superplastic deformation at a lower strain rate and reduces the deformation resistance.

[0083] During the synchronous downward movement of the upper module 101 and the pressure rod 102, both ends of the billet 10 are pressed into the first push groove 1011 and the second push groove 1031. Since the first push groove 1011 and the second push groove 1031 are constructed to extend outward from the center, when the upper module 101 and the lower module 103 rotate relative to the billet 10, the extrusion force of the first push groove 1011 and the second push groove 1031 on the billet metal inside will have a radially outward component, that is, a radially outward pushing force acting on the billet 10. This reduces the influence of the friction between the mold 100 and the billet 10 on the radial flow velocity of the billet 10 at the end, so that the radial flow velocity of the billet 10 at the end is close to the radial flow velocity in the middle, avoiding the billet 10 from bulging and cracking, improving the forming limit of the material, ensuring that the billet is fully deformed in the pre-forging step, and obtaining the intermediate-shaped billet 10b.

[0084] S103. When the upper and lower modules are in contact with each other, control the pressure rod and the push rod to clamp and fix the billet to prevent the billet from rotating.

[0085] S104. Control the upper and lower modules to rotate in opposite directions at the second angular velocity, so that the first and second pusher grooves can roll the end face of the billet until the end face of the billet reaches the preset flatness.

[0086] Figure 8 This invention provides a schematic diagram of the mold structure in the final forging step according to one embodiment of the present application. Figure 9 A schematic diagram of the final form of the blank is shown in one embodiment of this application.

[0087] These two steps correspond to the final forging step in the billet forming process, used to obtain the target forging, i.e., the final form of the billet 10c. This step is explained with reference to the accompanying drawings. See details below. Figure 8 and Figure 9 With the upper module 101 and lower module 103 in contact with each other, the press controls the pressure rod 102 and the push rod 104 to clamp and fix the billet 10. Then, the upper module 101 and lower module 103 are controlled to rotate in opposite directions with a second angular velocity ω2. Optionally, the value of the second angular velocity ω2 is in the range of 0.01 to 0.02 rad / s. A smaller rotation speed helps to reduce the forming force during rolling, increase the amount of deformation, refine the grains, and improve the forming quality of the two end faces of the forging.

[0088] During the rotation of the upper module 101 and the lower module 103 relative to the billet 10, the billet metal flows out from the first push groove 1011 and the second push groove 1031. The first push groove 1011 and the second push groove 1031 flatten the end face of the billet 10, ensuring that the billet is fully deformed in the final forging step to obtain the final billet 10c. The purpose of clamping and fixing the billet 10 with the pressure rod 102 and the push rod 104 is to prevent the billet 10 from rotating together with the module in contact with another surface after one surface of the billet 10 has been flattened, causing slippage and affecting the forming of the billet. Optionally, the preset flatness can be set according to the surface quality requirements of the target forging, which is not limited in this application.

[0089] Therefore, the above-mentioned method for manufacturing disc-shaped parts can complete the pre-forging and final forging of the billet using a single set of molds, ensuring sufficient deformation of the billet in each step. This eliminates the need to transfer the billet between different molds, reducing processing steps, simplifying the process, and improving production efficiency. Furthermore, it eliminates the need for repeated heating and holding of the billet, ensuring the performance stability of the forging. In addition, the billet metal deforms circumferentially under the pushing action of the first pusher groove 1011 and the second pusher groove 1031, increasing the amount of material deformation, refining the microstructure, and improving the overall mechanical properties of the forging.

[0090] It should be noted that the manufacturing method and mold of this application have significant advantages over traditional manufacturing methods and molds when manufacturing large disc-shaped parts with a small height-to-diameter ratio and a flat shape.

[0091] Figure 10 A schematic diagram of the structure of the mold cavity of the lower module in one embodiment of this application is shown; Figure 11 It shows Figure 10 The diagram below shows the structural schematic of the mold cavity of the lower module from another perspective.

[0092] In some embodiments, see Figure 3 , Figure 9 and Figure 10A plane perpendicular to the first axis O and tangent to the inner wall of the mold cavity of the upper module 101 is defined as the first tangential plane B, and a plane perpendicular to the first axis O and tangent to the inner wall of the mold cavity of the lower module 103 is defined as the second tangential plane C. The upper module 101 has multiple first spirals 1012 circumferentially distributed around the first axis O on the first tangential plane B, with a first pusher groove 1011 formed between two adjacent first spirals 1012. The lower module 103 has multiple second spirals 1032 circumferentially distributed around the first axis O on the second tangential plane C, with a second pusher groove 1031 formed between two adjacent second spirals 1032. The rotation direction of the first spirals 1012 is opposite to that of the upper module 101, and the rotation direction of the second spirals 1032 is opposite to that of the lower module 103. Thus, the multiple first push grooves 1011 of the upper module 101 and the multiple second push grooves 1031 of the lower module 103 are all arranged in a continuous circumferential spiral groove, and the spiral direction of the grooves is opposite to the direction of rotation of the module they belong to. This allows the first push grooves 1011 and the second push grooves 1031 to apply force evenly to both ends of the billet 10 in the circumferential direction, thereby ensuring the billet forming effect in the pre-forging and final forging steps. Optionally, the number of first spiral lines 1012 and second spiral lines 1032 are both 20, with 20 first push grooves 1011 in the die cavity of the upper module 101 and 20 second push grooves 1031 in the die cavity of the lower module 103.

[0093] Figure 12 The coordinate graph of the first preset curve in one embodiment of this application is shown.

[0094] In some specific embodiments, see Figure 5 , Figure 6 , Figure 11 and Figure 12 The shapes of the first helix 1012 and the second helix 1032 are constructed as a first preset curve, and the first preset curve is defined by the parametric equation of parameter θ with respect to coordinates x and y as follows:

[0095] x = e -dθ cosθ

[0096] y = e -dθ sinθ

[0097] The first angular velocity ω1 is a function of the deformation time t:

[0098]

[0099] Where v1 is the first linear velocity, d is the first preset constant, and L0 is the initial height of the billet.

[0100] Specifically, the first preset curve is derived from the relationship between the cylinder radius, the radial velocity at the front edge of the billet, and the deformation time. When the first helix 1012 and the second helix 1032 are constructed as the first preset curve, and the first angular velocity ω1 varies with the deformation time t according to the above function, it can be ensured that the radial velocity at the end of the billet 10 is consistent with the radial velocity at the middle of the billet 10, maximizing the equality between the outer diameter at the end of the billet 10 and the outer diameter at the middle of the billet 10, thereby causing the billet 10 to bulge and crack. Optionally, the value of the first preset constant d and the range of the parameter θ are determined according to actual needs, and this application does not limit them. Figure 12 The curve shown represents the shape of the first preset curve when d = 0.5 and θ ∈ (-3π, 3π). Figure 11 The second spiral 1032 on the lower module 103 is Figure 12 A portion of the first preset curve shown.

[0101] In other specific embodiments, the shapes of the first helix 1012 and the second helix 1032 can also be constructed as Archimedean spirals or involutes similar to the shape of the first preset curve.

[0102] Analysis of the parametric equations of the first preset curve reveals that the larger the constant d, the smaller the curvature of the curve. Furthermore, the value of the first preset constant d satisfies the following condition:

[0103] d = 0.5

[0104] d=1

[0105] d=2

[0106] in, The diameter of the disc-shaped component.

[0107] Figure 13 It shows Figure 10 The diagram shows a cross-sectional view of the die cavity of the lower module on the reference cylindrical surface. Figure 14 The coordinate graph of the second preset curve in one embodiment of this application is shown.

[0108] In some embodiments, see Figure 10 and Figure 13 A cylindrical surface with the first axis O as its central axis is defined as the reference cylindrical surface D, and the intersection of the first pusher groove 1011 and the second pusher groove 1031 with the reference cylindrical surface D is a smooth arc. This ensures that the billet flows smoothly in the first pusher groove 1011 and the second pusher groove 1031. Optionally, the shape of the smooth arc can be constructed as a parabola, a sine curve, or a circular arc.

[0109] In some embodiments, the intersection of the first pusher groove 1011 and the second pusher groove 1031 with the reference cylindrical surface D is a second preset curve. The shape of the second preset curve is a sine curve, and the equation of the second preset curve with respect to coordinates s and p is:

[0110]

[0111] 0≤s≤l

[0112] Where a is a second preset constant, and l is the distance between the two intersection points of the two adjacent first helical lines 1012 and the second helical line 1032 with the reference cylindrical surface D.

[0113] Combining the equations of the second preset curve Figure 10 and Figure 13 Structural analysis reveals that the value of the second preset constant 'a' is equal to half the depth of the first pusher groove 1011 and the second pusher groove 1031. A greater groove depth (i.e., a larger value of the second preset constant 'a') results in more billet metal within the first pusher groove 1011 and the second pusher groove 1031, leading to higher efficiency in pushing the billet metal outward. However, this also increases the risk of metal shear deformation. Therefore, the groove depth needs to be controlled within a suitable range. A suitable groove depth improves the efficiency of the first pusher groove 1011 and the second pusher groove 1031 in pushing the billet metal radially outward during the pre-forging step, and avoids metal shear deformation caused by the billet metal flowing out during the final forging step.

[0114] Furthermore, the value of the second preset constant a satisfies the following condition:

[0115] a = (0.25 ~ 0.4)D min

[0116] Among them, D min It is the distance between the starting points of two adjacent first helixes 1012 and second helixes 1032.

[0117] In some embodiments, see Figure 3 and Figure 10 The upper module 101 has a first flash groove 1013 on the outer periphery of the die cavity, and the lower module 103 has a second flash groove 1033 on the outer periphery of the die cavity. In this way, the total volume of the billet 10 can be set to be slightly larger than the total volume of the target forging, so as to ensure that in the final forging step, the billet metal flowing out from the first push groove 1011 and the second push groove 1031 can completely fill the die cavity, and the excess billet metal can flow into the flash groove, thereby ensuring that the forging is formed in place.

[0118] In some embodiments, see Figure 8Step S103 specifically includes: with the upper module 101 and the lower module 103 in contact with each other, the control lever 102 applies a preset pressure P to the blank 10 to clamp and fix the blank 10. In this way, the frictional resistance provided by the preset pressure P is greater than the difference in torque applied by the upper module 101 and the lower module 103 to deform the blank 10, thereby preventing the blank 10 from rotating with the upper module 101 or the lower module 103.

[0119] Specifically, the value of the preset pressure P satisfies the following conditions:

[0120] P = (2 ~ 3.5)F

[0121] Where P is in kN, and F is the projected area of ​​the forging, including the flash bridge, in cm². 2 .

[0122] As an optional implementation, the mold 100 is mounted on a double-action press. The double-action press has an outer slider and an inner slider that can move and apply pressure independently of each other. The upper module 101 is connected to the outer slider, and the pressure rod 102 is connected to the inner slider. The outer slider drives the upper module 101 to move up and down, and the inner slider 102 drives the pressure rod 102 to move up and down. This enables the upper module 101 and the pressure rod 102 to move down synchronously in the pre-forging step, and the pressure rod 102 to apply further pressure in the final forging step.

[0123] In some embodiments, prior to step S101, the upper module 101, lower module 103, and blank 10 need to be heated to a preset temperature, and the blank 10 needs to be held at that temperature for a preset duration. Heating and holding the blank 10 helps improve the metal fluidity of the blank 10 to ensure that the blank 10 is fully deformed in the subsequent forming process. Preheating the mold 100 helps protect the mold 100 and improve the efficiency of the mold 100.

[0124] Furthermore, when the billet 10 is made of a high-temperature alloy, the preset temperature is 50–150°C lower than the complete dissolution temperature of the γ' phase of the high-temperature alloy, and the preset time is 2–3 hours. This preset temperature is within the range where the high-temperature alloy has good plasticity, which can effectively reduce the deformation resistance during the forming process. At the same time, the γ' phase exists in the high-temperature alloy at this preset temperature, which effectively inhibits grain growth by pinning grain boundaries, resulting in a fine-grained structure. When the billet 10 is made of a titanium alloy, the preset temperature is 20–50°C lower than the β phase transformation temperature of the titanium alloy, and the preset time is 1–2 hours. This preset temperature is within the two-phase region of the titanium alloy, where the α phase can inhibit grain growth, resulting in a biphasic structure with superior performance after forging.

[0125] Based on the same inventive concept, see [link to inventive concept] Figure 2 and Figure 3This application also provides a mold 100 for manufacturing disc-shaped parts, including an upper module 101, a pressure rod 102, a lower module 103, and a push rod 104. The pressure rod 102 and the push rod 104 are constructed as rotating bodies and are coaxially arranged with a first axis O as the center of rotation. The pressure rod 102 passes through the upper module 101 and extends into the mold cavity of the upper module 101, and the push rod 104 passes through the lower module 103 and extends into the mold cavity of the lower module 103. The mold cavity of the upper module 101 has a plurality of first push grooves 1011 extending outward from the center, and the mold cavity of the lower module 103 has a plurality of second push grooves 1031 extending outward from the center. When the upper module 101 and the lower module 103 rotate in opposite directions, the first push grooves 1011 and the second push grooves 1031 can provide a radially outward pushing force acting on the blank 10. Using mold 100 enables the above-mentioned disc-shaped part manufacturing method to be implemented, thereby simplifying the process flow, improving production efficiency, and ensuring the performance stability of the forging.

[0126] In some embodiments, see continue to see Figure 2 The mold 100 also includes a first driving member 105 and a second driving member 106. The first driving member 105 is driven to the upper module 101 to drive the upper module 101 to rotate. The second driving member 106 is driven to the lower module 103 to drive the lower module 103 to rotate in the opposite direction relative to the upper module 101. In this way, during the pre-forging and final forging steps, the first driving member 105 and the second driving member 106 can drive the upper module 101 and the lower module 103 to rotate in opposite directions at the same speed, thereby realizing the pushing action and the rolling action.

[0127] Specifically Figure 2 In the illustrated embodiment, the mold 100 further includes a gear ring 107, a first gear 108, and a second gear 109. The upper outer wall of the lower module 103 has a gear ring portion 1034. The gear ring 107 is fixed to the lower outer wall of the upper module 101. The first drive member 105 is configured as a first motor, and the first gear 108 is fixed to the drive shaft of the first motor. The gear ring 107 meshes with the first gear 108 to achieve a transmission connection between the first drive member 105 and the upper module 101. The second drive member 106 is configured as a second motor, and the second gear 109 is fixed to the drive shaft of the second motor. The gear ring portion 1034 meshes with the second gear 109 to achieve a transmission connection between the second drive member 106 and the lower module 103.

[0128] In some embodiments, the mold 100 further includes an upper template 110, a fixed sleeve 111, and a first bearing 112. The fixed sleeve 111 is fixedly connected to the upper template 110, and the upper module 101 is rotatably disposed in the fixed sleeve 111 by means of the first bearing 112. The first bearing 112 can reduce the coefficient of friction during the rotation of the upper module 101 and ensure rotational accuracy. Optionally, there are two first bearings 112, which are configured as two tapered roller bearings arranged opposite each other along the first axis O, thereby providing sufficient axial and radial support force to the upper module 101 in the pre-forging and final forging steps.

[0129] In some embodiments, the mold 100 further includes a fixed base 113 and a second bearing 114. The lower module 103 is rotatably disposed in the fixed base 113 by means of the second bearing 114. The second bearing 114 can reduce the coefficient of friction during the rotation of the lower module 103 and ensure rotational accuracy. Optionally, the second bearing 114 is configured as a tapered roller bearing to provide sufficient axial and radial support force to the lower module 103 during the pre-forging and final forging steps.

[0130] Specifically, the operation steps of the mold 100 installed on the double-action press are as follows: The upper module 101 is connected to the outer slider via the upper template 110, and the pressure rod 102 is connected to the inner slider, thereby enabling the outer slider and the inner slider to drive the upper module 101 and the pressure rod 102 to move up and down. The lower module 103 is installed on the worktable via the fixed seat 113. The ejector rod 104 is connected to the ejection device, thereby ejecting the target forging after forming is completed via the ejector rod 104.

[0131] In summary, the aforementioned method and mold for manufacturing disc-shaped parts can complete both the pre-forging and final forging of the billet using a single mold, ensuring sufficient deformation of the billet in each step. This eliminates the need to transfer the billet between different molds, reducing processing steps, simplifying the process, and improving production efficiency. Furthermore, it eliminates the need for repeated heating and holding of the billet, ensuring the performance stability of the forging. In addition, the billet metal deforms circumferentially under the pushing action of the first pusher groove 1011 and the second pusher groove 1031, increasing the amount of material deformation, refining the microstructure, and improving the overall mechanical properties of the forging.

[0132] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0133] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent should be determined by the appended claims.

Claims

1. A method for manufacturing a disc-shaped component, characterized in that, A mold is used to process the blank. The mold includes an upper module, a pressure rod, a lower module, and a push rod. The pressure rod and the push rod are constructed as rotating bodies and are coaxially arranged with a first axis as the center of rotation. The pressure rod passes through the upper module and extends into the mold cavity of the upper module. The push rod passes through the lower module and extends into the mold cavity of the lower module. The mold cavity of the upper module has a plurality of first push grooves that bend outward from the center. The mold cavity of the lower module has a plurality of second push grooves that bend outward from the center. The method for manufacturing the disc-shaped component includes: The blank is placed in the center of the mold cavity of the lower module; The upper module and the pressure rod are controlled to move synchronously toward the lower module at a first linear velocity, and the upper module and the lower module are controlled to rotate in opposite directions at a first angular velocity, so that the first push groove and the second push groove provide a radially outward thrust acting on the billet; When the upper module and the lower module are in contact with each other, the pressure rod and the top rod are controlled to clamp and fix the billet to prevent the billet from rotating. The upper module and the lower module are controlled to rotate in opposite directions at a second angular velocity, so that the first pusher groove and the second pusher groove roll the end face of the billet until the end face of the billet reaches a preset flatness.

2. The method for manufacturing a disc-shaped part according to claim 1, characterized in that, A plane perpendicular to the first axis and tangent to the inner wall of the mold cavity of the upper module is defined as the first tangent plane, and a plane perpendicular to the first axis and tangent to the inner wall of the mold cavity of the lower module is defined as the second tangent plane. The upper module has multiple first spiral lines distributed circumferentially around the first axis on the first cross-section, and a first push groove is formed between two adjacent first spiral lines. The lower module has multiple second spiral lines circumferentially distributed around the first axis on the second cross-section, and a second push groove is formed between two adjacent second spiral lines; The first helix rotates in the opposite direction to the upper module, and the second helix rotates in the opposite direction to the lower module.

3. The method for manufacturing a disc-shaped part according to claim 2, characterized in that, The first spiral and the second spiral are constructed in the shape of one of an Archimedean spiral, an involute, or a first preset curve; The first preset curve is composed of parameters Regarding coordinates The parametric equation is: First angular velocity Regarding deformation time The function is: in, For the first linear velocity, This is the first preset constant. The initial height of the blank is given.

4. The method for manufacturing a disc-shaped part according to claim 3, characterized in that, The first preset constant The value of satisfies the following conditions: in, The diameter of the disc-shaped component.

5. The method for manufacturing a disc-shaped part according to claim 2, characterized in that, Define the cylindrical surface with the first axis as its central axis as the reference cylindrical surface; The intersection lines of the first and second pusher grooves with the reference cylindrical surface are smooth arcs.

6. The method for manufacturing a disc-shaped part according to claim 5, characterized in that, The intersection of the first pusher groove and the second pusher groove with the reference cylindrical surface is a second preset curve; The second preset curve about coordinates The equation is: in, This is the second preset constant. The distance is the distance between two adjacent intersection points of the first or second helix and the reference cylindrical surface.

7. The method for manufacturing a disc-shaped part according to claim 6, characterized in that, The second preset constant The value of satisfies the following conditions: in, It is the distance between the starting points of two adjacent first spirals or second spirals.

8. The method for manufacturing a disc-shaped part according to claim 1, characterized in that, The first linear velocity ranges from 1 to 10 mm / s; and / or The second angular velocity ranges from 0.01 to 0.02 rad / s.

9. The method for manufacturing a disc-shaped part according to claim 1, characterized in that, When the upper module and the lower module are in contact with each other, controlling the pressure rod and the top rod to clamp and fix the billet to prevent the billet from rotating specifically includes: When the upper module and the lower module are in contact with each other, the pressure rod is controlled to apply a preset pressure to the blank to clamp and fix the blank.

10. A mold for manufacturing disc-shaped parts, characterized in that, Applied to the method for manufacturing disc-shaped parts according to any one of claims 1-9.

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