A forging fixture and forging method for a large frame-type integral forging.

Abstract

This invention discloses a forging fixture for large frame-type integral forgings, comprising an upper die system and a lower die system, which are respectively installed on the upper die base and lower die base of a press. The upper die system includes an upper anvil, an upper anvil, a pad, an upper anvil connector, a push rod, a steel ball, and a cover plate. The lower die system includes a lower anvil and a limiting block. A forging method for large frame-type integral forgings includes the following steps: Step 1, free forging and drawing; Step 2, installing the forging fixture; Step 3, placing the billet; Step 4, forging the billet; Step 5, forging and widening. This invention reduces the number of forging passes, increases forging efficiency, and significantly shortens the product production cycle; it has low energy consumption, significantly reducing the production cost of forgings; it has a high degree of automation and does not generate derivative labor, significantly reducing the labor load of workers; it does not require any process consumables or auxiliary materials, simplifying operation and reducing costs.

Description

Technical Field

[0001] This invention relates to the field of forging hot working technology, and in particular to a forging tooling and forging method for large frame-type integral forgings. Background Technology

[0002] So-called spectacle frame forgings, as the name suggests, refer to a type of forging whose shape and outline resemble those of eyeglasses. Currently, spectacle frame forgings used in advanced aircraft tend to be integral, characterized by large size, complex shape, multiple high-rib and thin-rib structures, and high forging difficulty. Because these forgings are mostly made of high-strength, high-toughness advanced titanium alloys, the raw materials are particularly expensive. Therefore, to save costs and minimize raw material input, the billet is usually designed as a slab with a cross-section of equal thickness, with a length and width much smaller than the forging. Then, through specific forging operations, the billet is gradually deformed, and the raw material is spatially distributed to obtain a rough shape with dimensions and a similar shape and structure to the final forging. The rough shape is then placed in a mold for pressing to obtain the final forging.

[0003] Forging is a crucial step in the entire process from raw material to final die forging. Whether the forging process is reasonable and advanced directly affects the quality of subsequent die forging and determines the efficiency and stability of the entire forging process.

[0004] Currently, the existing forging process for integral forging parts of eyeglass frames is: free forging drawing and widening + die forging widening + die forging shaping.

[0005] 1. Free forging lengthening and widening: The billet is drawn in length to a size similar to the final forging. Then, with the repeated pressing of the free forging press, the worker moves the small hammer anvil back and forth to make the billet grow in width.

[0006] 2. Due to the limited capacity of the free forging press, the billet width cannot be increased to the required size. In this case, the billet needs to be transferred to the die forging press for further widening, i.e., die forging widening. Special anvils are used to locally forge the billet while restricting the material flow in the length direction, so that it can only flow in the width direction, thereby increasing the width of the billet. By repeatedly forging the same part in multiple heats, the billet is gradually increased to a width size similar to the final forging.

[0007] 3. The forging and widening process is a local forging process, which will cause large warping deformation in the non-forging parts. This requires the billet to be reshaped to restore its flatness, so that it can be quickly and accurately positioned on the die during subsequent forging. This process of restoring the flatness of the billet is called reshaping.

[0008] Existing forging processes are lengthy and complex. Free forging widening is limited by equipment capacity (low pressure) and small tool size (requiring four people to lift, maximum weight 200 kg); while die forging widening can only repeatedly press the same position, resulting in weak driving effect on the material in the width direction; and it causes significant warping deformation of the billet, requiring an additional forging pass. All of these factors contribute to the low widening efficiency and numerous forging passes of existing methods. During die forging widening, steel plates need to be continuously laid on the forging position as fodder to assist in pushing the material flow in the width direction, which consumes a large amount of steel plates. Because existing die forging widening methods need to constrain the material flow in the length direction, severe pinching damage occurs between the material driven out of the forging position and the material whose flow is restricted.

[0009] In summary, the existing forging process has the following shortcomings:

[0010] 1. The forging process involves multiple passes, resulting in low efficiency and a long manufacturing cycle. The existing forging process requires 10 passes to complete, and the rough shape has serious forming defects (clamping marks). These defects will then require an additional 2 to 3 passes in the subsequent die forging process.

[0011] 2. Due to the multiple forging processes, energy consumption is high, resulting in high production costs;

[0012] 3. It generates a large amount of derivative labor. In order to eliminate the pinch marks on the rough shape, a lot of repeated polishing is required between the initial forging and subsequent multiple forging cycles, which is time-consuming and labor-intensive;

[0013] 4. Low level of automation, heavy workload for workers, requiring strong physical strength to complete the forging process;

[0014] 5. It requires a large amount of auxiliary materials and consumables. The forging process requires a large amount of steel plates to complete, and each forging requires about 1 ton of steel plates. Summary of the Invention

[0015] The purpose of this invention is to provide a forging fixture and forging method for large frame-type integral forgings, which solves the problems of multiple forging passes and poor shape quality in existing forging methods.

[0016] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0017] This invention discloses a forging fixture for large frame-type integral forgings, comprising an upper die system and a lower die system, which are respectively mounted on an upper die base and a lower die base of a press. The upper die system includes an upper anvil base, a movable upper anvil is disposed in the middle of the bottom surface of the upper anvil base, pads are disposed on both sides of the width of the upper anvil, upper anvil base connectors are disposed at both ends of the length of the upper anvil base, and push rods are disposed at both ends of the upper anvil. The upper anvil base connectors are provided with mounting grooves for the upper anvil to pass through, and a plurality of steel balls are disposed on the bottom surface of the mounting grooves. A cover plate is disposed in the mounting grooves to prevent the steel balls from falling out. The lower die system includes a lower anvil and limiting blocks, the limiting blocks being disposed in corresponding slots at the four corners of the lower anvil.

[0018] Furthermore, the upper anvil and the lower anvil are both connected to the upper and lower die seats of the press through multiple first fastening components, and positioning keys are provided between the upper anvil and the upper die seat, and between the lower anvil and the lower die seat.

[0019] Furthermore, the first fastening assembly uses T-bolts, nuts, and washers.

[0020] Furthermore, the number of pads is set to four, and the four pads are symmetrically arranged at the four corners of the bottom surface of the upper anvil.

[0021] Furthermore, the pad is connected to the bottom surface of the upper anvil via a third fastening assembly, and the upper anvil connector is connected to the upper anvil via a fourth fastening assembly.

[0022] Furthermore, the third fastening component uses M42 screws and washers; the fourth fastening component uses M56 bolts and washers.

[0023] Furthermore, the side of the upper anvil 1 is engraved with numerical markings representing the anvil positions.

[0024] Furthermore, the bottom surface of the mounting groove is evenly provided with a plurality of ball grooves, the steel ball is placed in the ball groove, the cover plate is provided with a through hole at the corresponding position of the steel ball, and the diameter of the through hole is smaller than the diameter of the steel ball. The cover plate covers the steel ball and is connected to the upper anvil connector through a second fastening assembly.

[0025] Furthermore, the second fastening assembly uses M10 screws and washers.

[0026] A forging method for a large frame-type integral forging, comprising the following steps, using the forging fixture for large frame-type integral forgings as described above:

[0027] Step 1, Free forging and drawing: The billet is drawn on a free forging hydraulic press using conventional forging anvils, so that the billet is similar in length to the final forging size;

[0028] Step 2, install the forging fixture: install the upper die system and the lower die system on the upper die seat and lower die seat of the press respectively. Then, operate the press to move downwards, so that the upper anvil connecting piece in the upper die system presses on the limit block in the lower die system. Set this state as the zero position state of the press.

[0029] Step 3, Placing the blank: The press moves upward, and the upper die holder drives the upper die system upward. At this time, the upper anvil will fall on the steel ball embedded in the upper anvil holder connector, placing the blank into the cavity of the lower anvil.

[0030] Step 4, forging the billet: The upper die system descends, the upper anvil contacts the billet, and then the billet is pressed under the pressure applied by the upper anvil, causing the billet to flow in the width direction, thereby widening the billet; at this time, the edge of the billet will curl upward, and the pad plate is in the process of descending with the upper die system. The pad plate will touch the billet that has curled upward, and then press it back to a flat state. In this way, the billet is flattened while it is being widened.

[0031] Step 5, forging widening: After the upper die system descends and presses to the zero position, it is then lifted and moved upwards, stopping at a position of about 200mm. At this time, the upper anvil is pushed to move to the next anvil position; then the upper die system descends again to press the billet to the next position; then the upper die system moves upwards again and moves the upper anvil again, and so on, to complete the billet widening.

[0032] Compared with the prior art, the beneficial technical effects of the present invention are as follows:

[0033] This invention not only widens the billet but also flattens it. Therefore, using this tooling to widen the billet requires only one forging pass to complete the work of seven forging passes in the existing process. The billet forged using this tooling flows only in the width direction, with virtually no flow in the length direction. This avoids the severe pinching damage caused by the constraint of material flow in the length direction in the existing process. Furthermore, the upper anvil is designed with a transition slope and rounded corners, preventing forming defects in the width direction. Therefore, the resulting rough shape has excellent dimensions and surface quality, which is highly beneficial for subsequent die forging, thus reducing the number of forging passes by 2-3. Using the forging process proposed in this invention, both the free forging drawing and die forging widening processes are completed by automated or semi-automated machines and equipment, greatly reducing the labor load on workers. In summary, the present invention has the following advantages: 1) fewer forging passes and higher forging efficiency, which can significantly shorten the production cycle of products; 2) lower energy consumption, which significantly reduces the production cost of forgings; 3) higher degree of automation, and no additional labor is generated, which significantly reduces the labor load of workers; 4) no process consumables or auxiliary materials are required, which simplifies operation and reduces costs. Attached Figure Description

[0034] The present invention will be further described below with reference to the accompanying drawings.

[0035] Figure 1 This is a front view of the forging tooling for the large frame-type integral forging of the present invention;

[0036] Figure 2 This is a side view of the forging tooling for the large frame-type integral forging of the present invention;

[0037] Figure 3 This is a top view of the forging tooling for the large frame-type integral forging of the present invention;

[0038] Figure 4 This is a cross-sectional view along direction AA of the forging tooling for the large frame-type integral die forging of the present invention;

[0039] Figure 5 This is a schematic diagram of the upper mold system and lower mold system of the present invention in their open states;

[0040] Figure 6 This is a schematic diagram of the upper mold system and lower mold system in their closed states according to the present invention;

[0041] Figure 7 This is a schematic diagram of the side structure of the upper mold system and the lower mold system of the present invention;

[0042] Explanation of reference numerals in the attached drawings: 1. Upper anvil; 2. Upper anvil connector; 3. Upper anvil; 4. Lower anvil; 5. Pad; 6. Steel ball; 7. Limiting block; 8. First fastening assembly; 9. Positioning key; 10. Push rod; 11. Cover plate; 12. Second fastening assembly; 13. Third fastening assembly; 14. Fourth fastening assembly; 15. Billet. Detailed Implementation

[0043] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0044] It should be noted that 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 indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. "Several" means one or more, unless otherwise explicitly specified.

[0045] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention 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. Therefore, they should not be construed as limitations on this invention.

[0046] like Figure 1-7 As shown, a forging fixture for a large frame-type integral forging part includes an upper die system and a lower die system. The upper die system and the lower die system are respectively installed on the upper die base and the lower die base of the press. The upper die system includes an upper anvil 1, a movable upper anvil 3 is provided in the middle of the bottom surface of the upper anvil 1, pads 5 are provided on both sides of the width of the upper anvil 3, upper anvil connecting parts 2 are provided at both ends of the length of the upper anvil 1, and push rods 10 are provided at both ends of the upper anvil 3. The upper anvil connecting parts 2 are provided with an installation groove for the upper anvil 3 to pass through. Several steel balls 6 are provided on the bottom surface of the installation groove, and a cover plate 11 is provided in the installation groove to prevent the steel balls 6 from falling. The lower die system includes a lower anvil 4 and a limiting block 7. The limiting block 7 is provided in the corresponding slots at the four corners of the lower anvil 4.

[0047] Specifically, the upper anvil seat 1 and the lower anvil 4 are both connected to the upper and lower die seats of the press through multiple first fastening components 8. Positioning keys 9 are provided between the upper anvil seat 1 and the upper die seat, and between the lower anvil 4 and the lower die seat. The first fastening components 8 are T-bolts, nuts and washers.

[0048] The number of pads 5 is set to four, and the four pads 5 are symmetrically arranged at the four corners of the bottom surface of the upper anvil 1; the pads 5 are connected to the bottom surface of the upper anvil 1 by a third fastening assembly 13; the third fastening assembly 13 uses M42 screws and washers.

[0049] The upper anvil connector 2 is connected to the upper anvil 1 via a fourth fastening assembly 14; the fourth fastening assembly 14 uses M56 bolts and washers.

[0050] The bottom surface of the mounting groove is evenly provided with several ball grooves. The steel ball 6 is placed in the ball groove. The cover plate 11 is provided with a through hole at the corresponding position of the steel ball 6, and the diameter of the through hole is smaller than the diameter of the steel ball 6. The cover plate 11 covers the steel ball 6 and is connected to the upper anvil connector 2 through the second fastening component 12. The second fastening component 12 adopts M10 screws and washers. The cover plate 11 covers the steel ball 6 and limits the steel ball 6 to prevent the steel ball 6 from falling. When the upper anvil 3 moves, the steel ball 6 rolls in its respective ball groove, reducing the frictional resistance of the upper anvil movement.

[0051] The upper anvil 1 is marked with numbers 1, 2, 3, 4, and 5, each number representing an anvil position. When in use, the upper anvil 3 moves one anvil position at a time.

[0052] The installation process of the forging tooling for the above-mentioned large frame-type integral forging is as follows:

[0053] First, install the mold system:

[0054] 1) Secure the four pads 5 to the upper anvil 1 using the third fastening assembly 13;

[0055] 2) Place the steel ball 6 into the ball groove on the upper anvil connector 2, cover it with the cover plate 11, and fasten it with the second fastening component 12;

[0056] 3) Place both ends of the upper anvil 3 onto the installed upper anvil seat connector 2;

[0057] 4) Secure the upper anvil 1 and the upper anvil connector 2 together at the four corners of the upper anvil 1 using the fourth fastening assembly 14;

[0058] After the above four steps, the upper mold system is basically installed. Then, use the first fastening component 8 to install it on the upper mold base of the press, and use the positioning key 9 for installation and positioning. Finally, insert the push rod 10 into the corresponding mounting holes at both ends of the upper anvil 3, and the upper anvil 3 can be pushed to move back and forth along the width direction in the upper mold system.

[0059] Then, install the lower die system: The lower die system consists of two parts: the lower anvil 4 and the limiting block 7. Different specifications of eyeglass frame blanks need to be matched with the limiting block 7. During operation, the limiting block 7 is placed into the corresponding slots at the four corners of the lower anvil 4. Similar to the upper die system, the lower die system is also installed on the lower die base of the press using the first fastening component 8, and the positioning key 9 is used in the middle for installation and positioning.

[0060] A forging method for a large frame-type integral forging, comprising the following steps, using the forging fixture for large frame-type integral forgings as described above:

[0061] Step 1, free forging and drawing: The billet 15 is drawn on a free forging hydraulic press using conventional forging anvils, so that the billet 15 is similar in length to the final forging size;

[0062] Step 2, install the forging fixture: install the upper die system and the lower die system on the upper die seat and lower die seat of the press respectively. Then, operate the press to move downwards, so that the upper anvil connecting piece 2 in the upper die system presses on the limiting block 7 in the lower die system. Set this state as the zero position state of the press.

[0063] Step 3, Placing the blank: The press moves upward, and the upper die holder drives the upper die system upward. At this time, the upper anvil 3 will fall on the steel ball 6 embedded in the upper anvil holder connector 2, placing the blank 15 into the cavity of the lower anvil 4.

[0064] Step 4, forging the billet: The upper die system descends, the upper anvil 3 contacts the billet 15, and then presses the billet 15 under the pressure applied by the upper anvil seat 1, causing the billet 15 to flow in the width direction, thereby widening the billet; at this time, the edge of the billet 15 will curl upward, and the pad 5 is in the process of descending with the upper die system. The pad 5 will touch the billet 15 that has curled upward, and then press it back to a flat state. In this way, the billet is flattened while it is being widened.

[0065] Step 5, forging widening: After the upper die system descends and presses to the zero position, it is immediately lifted and moved upwards, stopping at a position of about 200mm. At this time, the upper anvil 3 is pushed to move to the next anvil position; then the upper die system descends again to press the billet 15 to the next position; then the upper die system moves upwards again and moves the upper anvil 3 again, and so on, to complete the billet widening.

[0066] The forging fixture described in this invention is applied to the die forging widening process. This fixture is a semi-automated equipment with high work efficiency and requires no strenuous physical labor from workers. Compared to existing forging processes, the advanced feature of the forging process proposed in this invention lies in its widening of the billet. Using the forging fixture proposed in this invention, the three processes of free forging widening (2 forging passes), die forging widening (4 forging passes), and die forging shaping (1 forging pass) in the existing process can be simplified into one process (die forging widening), which can be completed in only one forging pass, saving 6 passes. Furthermore, the billet produced by this method has better shape and size control and is free from forming defects such as pinch marks, allowing subsequent die forging processes to proceed more smoothly and efficiently, thus saving another 2-3 die forging passes. In summary, compared with existing forging processes, the forging process proposed in this invention can reduce the forging process of integral die forging parts such as eyeglass frames by 7 to 8 forging passes, which translates to a reduction of 15 to 20 days in production cycle time per batch.

[0067] In addition, this forging process can significantly reduce energy consumption; the entire process requires no consumables; there are basically no grinding or repairs needed if there are no forming defects; and it is basically automated, which significantly reduces the labor load of workers and has very considerable comprehensive benefits.

[0068] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A forging method for large frame-type integral forgings, wherein the forging method utilizes forging fixtures for forging processing, characterized in that: The forging fixture includes an upper die system and a lower die system. The upper die system and the lower die system are respectively installed on the upper die seat and the lower die seat of the press. The upper die system includes an upper anvil seat (1). A movable upper anvil (3) is provided in the middle of the bottom surface of the upper anvil seat (1). Pads (5) are provided on both sides of the width of the upper anvil (3). Upper anvil seat connectors (2) are provided at both ends of the length of the upper anvil seat (1). Push rods (10) are provided at both ends of the upper anvil (3). An installation groove is provided on the upper anvil seat connector (2) so that the upper anvil (3) can pass through. Several steel balls (6) are provided on the bottom surface of the installation groove. A cover plate (11) is provided in the installation groove to prevent the steel balls (6) from falling. The lower die system includes a lower anvil (4) and a limiting block (7). The limiting block (7) is provided in the corresponding slots at the four corners of the lower anvil (4). The forging method includes the following steps: Step 1, free forging and drawing: The billet (15) is drawn on a free forging hydraulic press using conventional forging anvils, so that the billet (15) is similar in length to the final forging size; Step 2, install forging tooling: install the upper die system and the lower die system on the upper die seat and lower die seat of the press respectively, and then operate the press to move downward so that the upper anvil seat connector (2) in the upper die system presses on the limit block (7) in the lower die system, and set this state as the zero position state of the press; Step 3, placing the blank: The press moves upward, and the upper die holder drives the upper die system upward. At this time, the upper anvil (3) will fall on the steel ball (6) embedded in the upper anvil holder connector (2), and the blank (15) will be placed in the cavity of the lower anvil (4). Step 4, forging the billet: The upper die system moves downward, the upper anvil (3) contacts the billet (15), and then presses the billet (15) under the pressure applied by the upper anvil seat (1), so that the billet (15) flows in the width direction, thereby widening the billet; at this time, the edge of the billet (15) will be turned up, and the pad (5) is in the process of moving downward with the upper die system. The pad (5) will touch the billet (15) that is turned up, and then press it back to a flat state. In this way, the billet is flattened while being widened. Step 5, forging widening: After the upper die system descends and presses to the zero position, it is then lifted and moved upwards, stopping at the 200mm position. At this time, the upper anvil (3) is pushed to move to the next anvil position; then the upper die system descends again to press the billet (15) to the next position; then the upper die system moves upwards again and moves the upper anvil (3) again, and so on, to complete the billet widening.

2. The forging method for large frame-type integral forgings according to claim 1, characterized in that: The upper anvil (1) and the lower anvil (4) are connected to the upper and lower die seats of the press by multiple first fastening components (8). Positioning keys (9) are provided between the upper anvil (1) and the upper die seat, and between the lower anvil (4) and the lower die seat.

3. The forging method for large frame-type integral forgings according to claim 2, characterized in that: The first fastening assembly (8) uses T-bolts, nuts and washers.

4. The forging method for large frame-type integral forgings according to claim 1, characterized in that: The number of pads (5) is set to four, and the four pads (5) are symmetrically arranged at the four corners of the bottom surface of the upper anvil (1).

5. The forging method for large frame-type integral forgings according to claim 4, characterized in that: The pad (5) is connected to the bottom surface of the upper anvil (1) by a third fastening assembly (13), and the upper anvil connector (2) is connected to the upper anvil (1) by a fourth fastening assembly (14).

6. The forging method for large frame-type integral forgings according to claim 5, characterized in that: The third fastening component (13) uses an M42 screw and a washer; the fourth fastening component (14) uses an M56 bolt and a washer.

7. The forging method for large frame-type integral forgings according to claim 1, characterized in that: The side of the upper anvil (1) is engraved with a number representing the anvil position.

8. The forging method for large frame-type integral forgings according to claim 1, characterized in that: The bottom surface of the mounting groove is evenly provided with a number of ball grooves. The steel ball (6) is placed in the ball groove. The cover plate (11) is provided with a through hole at the corresponding position of the steel ball (6), and the diameter of the through hole is smaller than the diameter of the steel ball (6). The cover plate (11) covers the steel ball (6) and is connected to the upper anvil connector (2) through the second fastening assembly (12).

9. The forging method for large frame-type integral forgings according to claim 8, characterized in that: The second fastening assembly (12) uses M10 screws and washers.

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