A method for producing a monolithic conical head forging for aerospace applications

Abstract

The application relates to a production method of a whole type conical head forging for aerospace. The application aims to solve the technical problem of difficult production of the whole type conical head forging. The method comprises the following steps: 1, heating an aluminum alloy ingot; 2, free forging blanking; 3, punching; 4, ring forging; and 5, eccentric forging. The whole type conical head forging manufactured by the application not only meets the standard requirements, but also improves the problem of local strength reduction caused by welding seams in the original split structure which needs to be formed by welding, and the whole manufacturing period is reduced without the process of releasing stress by welding, and the service life is increased. Since the welding seams are cancelled, the whole structure strength is increased by 20%. The whole type conical head forging manufactured by the application solves the problems of unable ring rolling due to the small hole diameter (less than or equal to 500 mm) and the high height (greater than or equal to 400 mm), and the problem of large material investment in the conventional whole type forging process, and the material investment can be reduced by more than 40%. The whole type conical head forging prepared by the application is used in aerospace technology.

Description

Technical Field

[0001] This invention relates to a method for manufacturing an integral conical forging for aerospace applications. Background Technology

[0002] With the development of the aerospace industry, in order to adapt to increasingly complex aerospace missions, the quality requirements for related products are getting higher and higher. A domestic company has an order for a type of integral conical forging for aerospace use. The manufacturing of this integral conical forging is extremely difficult. In the past, it was always done by forging in parts and then welding them together. It was very difficult to produce integral conical forging products that meet the user's requirements. Summary of the Invention

[0003] The present invention aims to solve the technical problem of difficult production of integral conical forgings, and provides a method for producing integral conical forgings for aerospace applications.

[0004] A method for preparing an integral conical forging for aerospace applications, comprising the following steps:

[0005] I. Heating aluminum alloy ingots:

[0006] The aluminum alloy ingot is heated to a temperature of 400℃~460℃ and held at that temperature for 10h~12h.

[0007] 2. The aluminum alloy ingot heated in step 1 is uprooted four times on a vertical forging machine and then drawn three times to form a round billet. The initial forging temperature is controlled at 400-460℃ and the final forging temperature is controlled at 380-440℃.

[0008] 3. Punch the center hole of the round blank formed in step 2 using a punch with a diameter of 260mm, then cut the hole with a cutting die with a diameter of 300mm, and then heat and hold it at a temperature of 400℃~460℃ for 10h~12h to obtain the forging.

[0009] 4. Insert the forgings processed in step 3 onto a mandrel with a diameter of 260mm and perform ring forging and hole enlargement on a vertical forging machine to the small diameter size. The forging ring obtained after hole enlargement is a common straight cylindrical forging ring. Control the initial forging temperature to be 400~460℃ and the final forging temperature to be 380~440℃.

[0010] Fifth, the forging ring processed in step four is eccentrically forged on a non-circular shaft, and the final forging temperature is controlled at 350-400℃. The other end is enlarged to the large diameter of the forging ring, thus obtaining the integral conical forging for aerospace use, and the preparation is completed.

[0011] Beneficial effects of this invention:

[0012] The aerospace-grade integral conical forging manufactured by this invention not only meets standard requirements but also improves the overall structural strength of the conical forging, eliminates the user's welding process, shortens the manufacturing cycle, and increases the product's service life. It also solves the problem of high production costs.

[0013] This invention manufactures an integral conical forging for aerospace applications that not only meets standard requirements but also improves upon the problem of localized strength reduction caused by welds in traditional split structures that require welding. Furthermore, it eliminates the stress-relieving process of welding, reducing overall manufacturing time and increasing service life. By eliminating welds, the overall structural strength increases by 20%. This invention also solves the problem of not being able to perform ring rolling for small hole diameters (≤Φ500mm) and heights (≥400mm). It also addresses the issue of large material input in conventional integral forging processes, reducing material input by more than 40%.

[0014] The aerospace integral conical forging manufactured by this invention has a tensile strength of 324MPa to 353MPa, a yield strength of 160MPa to 170MPa, an elongation of 15% to 25%, and other requirements in accordance with the GJB2351 standard.

[0015] 1. Welding process eliminated, resulting in high overall forging performance;

[0016] 2. The yield rate is more than 20% higher than that of traditional integral forging;

[0017] 3. The actual production requires more than 40% less equipment capacity than die forging.

[0018] The integral conical forging prepared by this invention is used in aerospace technology. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the integral conical forging for aerospace applications obtained in Example 1;

[0020] Figure 2 This is a schematic diagram of the irregular shaft in step five of Example 1. Detailed Implementation

[0021] Specific Implementation Method 1: This implementation method describes a method for preparing an integral conical forging for aerospace applications, which is carried out according to the following steps:

[0022] I. Heating aluminum alloy ingots:

[0023] The aluminum alloy ingot is heated to a temperature of 400℃~460℃ and held at that temperature for 10h~12h.

[0024] 2. The aluminum alloy ingot heated in step 1 is uprooted four times on a vertical forging machine and then drawn three times to form a round billet. The initial forging temperature is controlled at 400-460℃ and the final forging temperature is controlled at 380-440℃.

[0025] 3. Punch the center hole of the round blank formed in step 2 using a punch with a diameter of 260mm, then cut the hole with a cutting die with a diameter of 300mm, and then heat and hold it at a temperature of 400℃~460℃ for 10h~12h to obtain the forging.

[0026] 4. Insert the forgings processed in step 3 onto a mandrel with a diameter of 260mm and perform ring forging and hole enlargement on a vertical forging machine to the small diameter size. The forging ring obtained after hole enlargement is a common straight cylindrical forging ring. Control the initial forging temperature to be 400~460℃ and the final forging temperature to be 380~440℃.

[0027] Fifth, the forging ring processed in step four is eccentrically forged on a non-circular shaft, and the final forging temperature is controlled at 350-400℃. The other end is enlarged to the large diameter of the forging ring, thus obtaining the integral conical forging for aerospace use, and the preparation is completed.

[0028] Specific Implementation Method Two: This implementation method differs from Specific Implementation Method One in that the mass percentage content of the elements in the aluminum alloy ingot mentioned in step one is:

[0029] The composition is as follows: Si 0.05%–0.2%, Fe 0.05%–0.3%, Cu ≤0.1%, Mn 0.5%–0.8%, Mg 5.9%–6.7%, Ni ≤0.15%, Zn ≤0.30%, Ti ≤0.10%, individual impurities ≤0.05%, total impurities ≤0.10%, and the remainder is Al. Other aspects are the same as in Specific Embodiment 1.

[0030] Specific Implementation Method Three: This implementation method differs from Specific Implementation Method One or Two in that the size of the aluminum alloy ingot mentioned in step one is Φ500mm. Everything else is the same as in Specific Implementation Method One or Two.

[0031] Specific Implementation Method Four: This implementation method differs from Specific Implementation Methods One to Three in that the size of the circular dough in step two is Φ500mm. Everything else is the same as in Specific Implementation Methods One to Three.

[0032] Specific Implementation Method Five: This implementation method differs from Specific Implementation Methods One to Four in that: in step three, the heating is controlled to reach a temperature of 430℃, and the temperature is maintained for 10 to 12 hours. Everything else is the same as in Specific Implementation Methods One to Four.

[0033] Specific Implementation Method Six: This implementation method differs from Specific Implementation Methods One to Five in that the vertical forging machine described in step four is a 3000-ton hydraulic press. Everything else is the same as in Specific Implementation Methods One to Five.

[0034] Specific Implementation Method Seven: This implementation method differs from Specific Implementation Methods One to Six in that: in step four, the initial forging temperature is controlled at 430℃, and the final forging temperature is controlled at 410℃. Everything else is the same as in Specific Implementation Methods One to Six.

[0035] Specific Implementation Method Eight: This implementation method differs from Specific Implementation Methods One to Seven in that: the irregular shaft described in step five consists of a frustum of a cone and a cylinder. The bottom surface of the cylinder is the same as the bottom surface of the frustum of the cone, and the bottom surface of one end of the cylinder is connected to the bottom surface of the frustum of the cone. The diameter of the top surface of the frustum of the cone is Φ500mm, and the diameter of the bottom surface of the frustum of the cone is Φ900mm. Everything else is the same as in Specific Implementation Methods One to Seven.

[0036] Specific Implementation Method Nine: This implementation method differs from Specific Implementation Methods One to Eight in that the final forging temperature is controlled at 375℃ in step five. Everything else is the same as in Specific Implementation Methods One to Eight.

[0037] Specific Implementation Method Ten: This implementation method differs from Specific Implementation Methods One to Nine in that the minor diameter of the aerospace integral conical forging described in step five is φ500mm, the major diameter is φ900mm, and the height is 450mm. Everything else is the same as in Specific Implementation Methods One to Nine.

[0038] The scope of this invention is not limited to the above-described embodiments; a combination of one or more specific embodiments can also achieve the purpose of the invention.

[0039] Example 1:

[0040] A method for preparing an integral conical forging for aerospace applications, comprising the following steps:

[0041] I. Heating aluminum alloy ingots:

[0042] The aluminum alloy ingot was heated to 430℃ and held at 430℃ for 10 hours.

[0043] 2. The aluminum alloy ingot heated in step 1 is uprooted four times on a vertical forging machine and then drawn three times to form a round billet. The initial forging temperature is controlled at 430℃ and the final forging temperature is 410℃.

[0044] 3. Punch the center hole of the round blank formed in step 2 using a punch with a diameter of 260mm, then cut the hole using a cutting die with a diameter of 300mm, and then heat and hold it at 430℃ for 10 hours to obtain the forging.

[0045] 4. After processing in step 3, insert the forging through a mandrel with a diameter of 260mm and perform ring forging and hole enlargement on a vertical forging machine to the small diameter size. The forging ring obtained after hole enlargement is a common straight cylindrical forging ring. The initial forging temperature is controlled at 430℃ and the final forging temperature is controlled at 410℃.

[0046] Fifth, the forging ring processed in step four is eccentrically forged on a non-circular shaft, and the final forging temperature is controlled at 375℃. The other end is enlarged to the large diameter of the forging ring, thus obtaining the integral conical forging for aerospace use, and the preparation is completed.

[0047] The aerospace integral cone forging prepared in this embodiment has a tensile strength of 324MPa to 353MPa, a yield strength of 160MPa to 170MPa, an elongation of 15% to 25%, and other requirements in accordance with the GJB2351 standard.

Claims

1. A method of producing a monolithic tapered head forging for aerospace applications, characterized by This method is performed according to the following steps: I. Heating aluminum alloy ingots: The aluminum alloy ingot is heated to a temperature of 400℃~460℃ and held at that temperature for 10h~12h. The mass percentage of elements in the aluminum alloy ingot mentioned in step one is: Si is 0.05%~0.2%, Fe is 0.05%~0.3%, Cu is ≤0.1%, Mn is 0.5%~0.8%, Mg is 5.9%~6.7%, Ni is ≤0.15%, Zn is ≤0.30%, Ti is ≤0.10%, individual impurities are ≤0.05%, total impurities are ≤0.10%, and the remainder is Al; 2. The aluminum alloy ingot heated in step 1 is uprooted four times on a vertical forging machine and then drawn three times to form a round billet. The initial forging temperature is controlled at 400~460℃ and the final forging temperature is controlled at 380~440℃.

3. Punch the center hole of the round blank formed in step 2 using a punch with a diameter of 260mm, then cut the hole with a cutting die with a diameter of 300mm, and then heat and hold it at a temperature of 400℃~460℃ for 10h~12h to obtain the forging.

4. Insert the forgings processed in step 3 onto a mandrel with a diameter of 260mm and perform ring forging and hole enlargement on a vertical forging machine to the small diameter size. The forging ring obtained after hole enlargement is a common straight cylindrical forging ring. Control the initial forging temperature to be 400~460℃ and the final forging temperature to be 380~440℃.

5. The forging ring processed in step 4 is eccentrically forged on a non-circular shaft. The final forging temperature is controlled at 350~400℃. The other end is enlarged to the large diameter of the forging ring, thus obtaining the integral conical forging for aerospace use, and the preparation is completed. The aluminum alloy ingot mentioned in step one has a size of Φ500mm; The circular dough blank mentioned in step two has a size of Φ500mm; The irregular shaft mentioned in step five consists of a frustum and a cylinder. The bottom surface of the cylinder is the same as the bottom surface of the frustum, and the bottom surface of one end of the cylinder is connected to the bottom surface of the frustum. The diameter of the top surface of the frustum is Φ500mm, and the diameter of the bottom surface of the frustum is Φ900mm. The aerospace integral cone forging mentioned in step five has a minor diameter of φ500mm, a major diameter of φ900mm, and a height of 450mm.

2. A method of producing a monoblock tapered head forging for aerospace applications as claimed in claim 1, wherein Step 3: Control the heating to 430℃ and keep it at that temperature for 10-12 hours.

3. The method of producing a monoblock tapered head forging for aerospace applications of claim 1, wherein The vertical forging machine mentioned in step four is a 3000-ton hydraulic press.

4. The method of producing a monolithic tapered head forging for aerospace applications of claim 1, wherein Step four: control the initial forging temperature to 430℃ and the final forging temperature to 410℃.

5. The method of producing a monolithic tapered head forging for aerospace applications of claim 1, wherein In step five, the final forging temperature is controlled at 375℃.

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