A die flash groove structure for asymmetric forging

Abstract

The application discloses a die flash groove structure for asymmetric forging, which can be applied to the forging of circumferential asymmetric class and axial thin-wall deep cavity forgings, can reasonably distribute materials, effectively increase the outflow resistance of the flash, improve the filling capacity of the forgings, improve the quality of the forgings, reduce material consumption and reduce production cost. The upper die and the lower die are used for being mounted on a forging press, the middle part of the upper die and the lower die forms a forging cavity, the edge part of the upper die and the lower die is provided with a flash groove, the flash groove comprises a bridge part and a bin part, the cavity is a non-symmetrical deep cavity, the bin part is horizontally arranged, and the upper end of the bridge part is outwardly inclined.

Description

Technical Field

[0001] This invention relates to the field of forging technology, and in particular to a die flash groove structure for asymmetric forging. Background Technology

[0002] There are generally four types of flash groove designs for forging dies, or closed forging without flash grooves for symmetrical forgings. However, for some circumferentially asymmetrical, axially thin-walled deep-cavity forgings, if normal flash is used, material easily flows out, forming flash, and the deep cavity is difficult to fill during forging. Using a resistance groove type flash groove also makes it difficult for the forging to fill completely. If closed forging is used, uneven material distribution will cause areas with less material to fill first, creating significant resistance, preventing the die from reaching the intended position, resulting in incomplete punching in other areas. Therefore, how to develop a new flash groove structure to solve the problem of incomplete punching in asymmetrical deep-cavity forgings without increasing material consumption has become a pressing technical problem for those skilled in the art. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a die flash groove structure for asymmetric forging. It can be applied to the forging of circumferentially asymmetric and axially thin-walled deep cavity forgings. It can not only reasonably distribute the material, but also effectively increase the flash flow resistance, improve the filling capacity of the forging, improve the quality of the forging, reduce material consumption, and reduce production costs.

[0004] The objective of this invention is achieved as follows:

[0005] A flash groove structure for asymmetric forging includes an upper die and a lower die, which are mounted on a forging press. The middle part of the upper die and the lower die forms a forging cavity. A flash groove is provided between the edge parts of the upper die and the lower die. The flash groove includes a bridge part and a cavity part. The cavity is an asymmetric deep cavity. The cavity part is horizontally arranged. The upper end of the bridge part is inclined outward.

[0006] When the upper die contacts the material and continues to move downward, because the forging has an asymmetrical deep structure, less material is needed in the thin-walled part of the forging and more material is needed in the thick-walled part of the forging. The excess material in the thin-walled part of the forging needs to be discharged from the die. The bridge gap and the bin form a passage. The bridge gap has enough space to allow the excess material in the thin-walled part to be discharged from the die, while the material in the thick-walled part flows downward to form the forging.

[0007] After the material distribution is completed, both the thin-walled and thick-walled parts of the forging receive sufficient material supply. The upper die continues to move downward, the bridge gap gradually decreases, and the resistance formed by the bridge gap on the material gradually increases, effectively preventing the material from flowing out of the forging cavity, and allowing the material to continue to flow into the forging cavity with less resistance, thus forming the forging.

[0008] When the upper and lower dies are fitted together, and the upper die finishes moving downwards, the bridge gap and the height of the cavity reach their minimum values. The bridge gap creates a huge resistance to the material flow, reaching its maximum value, and the material flows to the deepest part of the thin wall of the forging.

[0009] Preferably, before the upper mold finishes its downward movement, the gap between the bridge sections is less than the height of the storage section.

[0010] Preferably, when the upper mold finishes its downward movement, the gap between the bridge section and the height of the chamber section are the same.

[0011] Preferably, the lower end of the bridge portion adjacent to the forging cavity is a plane, and this plane is on the same horizontal plane as the parting surface of the forging.

[0012] Due to the adoption of the above technical solution, the present invention has the following beneficial effects:

[0013] This invention can generate sufficiently large forging resistance to ensure the forming of forgings, while also allowing excess metal to be discharged from asymmetric forgings and achieving low material consumption, thus satisfying the production of radially asymmetric, thin-walled, deep-cavity forgings.

[0014] This invention allows excess circumferential material to flow out of the mold cavity, effectively solving the problem of uneven material distribution caused by circumferential asymmetry in forgings. Simultaneously, it creates good resistance in the closed half of the mold, ensuring good punching performance for axially thin-walled deep cavities. At the end of the mold's life, reduced bridge wear lowers flash material loss by 30-40%, saving material. This specially designed flash groove mold has been validated in batches on different types of forging presses, all of which produce qualified forgings, meeting the requirements for mass production. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention;

[0016] Figures 2-4 This is a diagram illustrating the usage process of the present invention.

[0017] Figure Labels

[0018] In the attached diagram, 1 is the upper mold, 2 is the lower mold, and 3 is the forging cavity. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to the accompanying drawings.

[0020] First, the upper and lower dies are installed on the forging press. The hot billet is placed inside the die, and then the upper die moves downward under the drive of the equipment.

[0021] Figure 2 — Figure 3This refers to the process from when the upper die just touches the billet during its downward movement to when the die is halfway through its travel. Because the forging is asymmetrical, the thin-walled sections require less material, while the thick-walled sections require more. Excess material from the thin-walled sections needs to be expelled from the die. During this process, the large bridge gap B1 provides sufficient space for this excess material to exit the die, while the material from the thick-walled sections flows downwards to form the forging. This special flash structure allows the required material to flow into the die cavity while simultaneously allowing excess waste to flow out, solving the problem of improper material distribution in circumferentially asymmetrical forgings.

[0022] Figure 3 — Figure 4 This refers to the process where the mold continues to move downwards after material distribution is complete. After the first process, material distribution is essentially finished, and the mold continues to move downwards. At this point, both the thin-walled and thick-walled sections of the mold receive an effective supply of material. As the upper mold descends, the bridge gap B2 gradually decreases, and the resistance to the material gradually increases to 5-10 times its original value. This effectively prevents the material from flowing out of the mold cavity, allowing it to continue flowing into the mold cavity where the resistance is lower, thus forming the forging. This process ensures that the vast majority of the material flows into the mold cavity, providing a foundation for the subsequent step of forming a qualified forging.

[0023] Figure 4 This refers to the end of the equipment operation and the final bonding of the upper and lower molds. At this point, the bridge gap B3 is at its minimum, creating significant resistance to material flow, approximately 20-30 times that of the second stage. The deepest part of the thin-walled section is the most difficult to form because the resistance to material flow there is very high. Figure 4 The significant increase in resistance at the bridge section makes it greater than the resistance to material flow to the deepest part of the thin-walled section. This ensures that material flows to the deepest part of the thin-walled section when the mold reaches its final state, guaranteeing sufficient material flow to the most difficult-to-form areas and ensuring the final shape and dimensions of the forging meet requirements. The bridge height and the bin height (i.e., bin space) are also at their minimum at this point, resulting in less flash and reduced material consumption.

[0024] Compared to other flash groove structures, this special flash groove structure allows excess metal to flow out of the mold cavity during the initial contact stage with the material, and increases the resistance to material flow out of the mold cavity as the mold descends to a certain stage. Furthermore, the increased resistance lasts for a longer period than the four conventional flash structures. Simultaneously, the bridge gap and the cavity are smaller when the mold is in contact, reducing flash material consumption. This special flash structure combines the advantages of both open and closed forging processes: it effectively distributes uneven forging material, creates sufficient resistance for a long time at the end of the mold's movement to ensure forging formation, and allows for flash removal after forging.

[0025] Asymmetric deep cavities refer to forgings whose sides have asymmetrical wall structures and uneven wall thickness.

[0026] The bridge section consists of two parts. The lower part is adjacent to the forging part, sharing the same plane as the forging parting surface, and is relatively short (≤5mm in this embodiment). The upper part slopes outward, forming an angle A with the mold parting plane (angle A can be adjusted during mold design based on the circumferential thickness ratio and axial height-to-thickness ratio of the part). This angle creates resistance to material flow during forging and is removed in the subsequent trimming process. The storage compartment is parallel to the mold parting plane, without any slope or other features, and is mainly used to accommodate excess metal during forging. Both the bridge section and the storage compartment are removed in the subsequent trimming process. The storage compartment is parallel to the parting surface and can be open or closed depending on the type of equipment used.

[0027] Finally, it should be noted that the above preferred embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail through the above preferred embodiments, those skilled in the art should understand that various changes can be made to it in form and detail without departing from the scope defined by the claims of the present invention.

Claims

1. An asymmetric forging method, comprising a die flash groove structure, the die flash groove structure comprising an upper die and a lower die, the upper die and the lower die being mounted on a forging press, the middle portion of the upper die and the lower die forming a forging cavity, a flash groove being provided between the edge portions of the upper die and the lower die, the flash groove comprising a bridge portion and a cavity portion, characterized in that: The cavity is an asymmetrical deep cavity, the compartment is horizontally arranged, and the upper end of the bridge is inclined outward; The forging method is as follows: When the upper die contacts the material and continues to move downward, because the forging has an asymmetrical deep structure, less material is needed in the thin-walled part of the forging and more material is needed in the thick-walled part of the forging. The excess material in the thin-walled part of the forging needs to be discharged from the die. The bridge gap and the bin form a passage. The bridge gap has enough space to allow the excess material in the thin-walled part to be discharged from the die, while the material in the thick-walled part flows downward to form the forging. After the material distribution is completed, both the thin-walled and thick-walled parts of the forging receive sufficient material supply. The upper die continues to move downward, the bridge gap gradually decreases, and the resistance formed by the bridge gap on the material gradually increases, effectively preventing the material from flowing out of the forging cavity, and allowing the material to continue to flow into the forging cavity with less resistance, thus forming the forging. When the upper and lower dies fit together, and the upper die finishes moving downwards, the bridge gap and the height of the cavity reach their minimum values. The bridge gap creates a huge resistance to the material flow, reaching its maximum value, and the material flows to the deepest part of the thin wall of the forging. Before the upper mold finishes its downward movement, the gap between the bridge sections is always less than the height of the storage section; When the upper mold finishes moving downwards, the gap between the bridge section and the height of the chamber section are the same.

2. The asymmetric forging method according to claim 1, characterized in that: The lower end of the bridge portion adjacent to the forging cavity is a plane, and this plane is on the same horizontal plane as the parting surface of the forging.

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