High-precision rolling and bulging method for asymmetric outer double-groove machine ring forging and product
Patent Information
- Application Number
- CN202410567469.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-09
- Publication Date
- 2026-09-22
- Estimated Expiration
- 2044-05-09
AI Technical Summary
[0003]目前，非对称外双沟槽机匣环锻件的工艺方法无法保证环锻件足够的椭圆度，无法防止环锻件大小端的出现，通常能达到的外包络环件椭圆度为环件外径的0.5%，必须保留较大的机加工余量，从而造成材料利用率低和机加工周期长，一般需要三个月的机加工周期
本方法将非对称外双沟槽机匣环锻件的轧制过程分步进行，并且在异型截面轧制后配合胀形工艺对轧制后环件尺寸进行校正，并且预先设计计算出非对称外双沟槽环锻件成形过程各道次的关键控制参数，降低了最终环锻件轴向两端端面的尺寸差异，消除了大小端问题，能够确保最终机匣环锻件椭圆度达到外径尺寸的0.1%以内。
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Abstract
Description
Technical Field
[0001] This invention relates to the manufacture of aero-engine casings, specifically to a high-precision rolling and bulging method and product for asymmetric external double-groove casing ring forgings. Background Technology
[0002] The manufacturing process of titanium alloy casings for aero engines includes ring rolling and machining. The final rolled ring forging must not only meet the performance requirements of the casing component matrix, but also encompass the outer contour of the final casing component and ensure sufficient machining allowance for the next step. In particular, for asymmetric double-groove casing ring forgings, if the rolled ring forging has a problem with large and small ends (i.e., the outer diameters of the two axial end faces are inconsistent), it further increases the volume required to encompass the outer contour of the final casing component.
[0003] Currently, the manufacturing process for asymmetric external double-groove casing ring forgings cannot guarantee sufficient ellipticity and cannot prevent the occurrence of large and small ends. The achievable ellipticity of the outer envelope ring is typically 0.5% of the ring's outer diameter, necessitating a large machining allowance. This results in low material utilization and a long machining cycle, generally requiring three months. Therefore, the forming accuracy of ring forgings is currently a bottleneck restricting the rapid iteration of titanium alloy casing manufacturing for aero-engines. Summary of the Invention
[0004] The purpose of this invention is to provide a high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings and the products obtained based on this method. This method divides the rolling process of asymmetric external double-groove casing ring forgings into steps. After rolling the irregular cross-section, the bulging process is used to correct the size of the rolled ring, eliminating the problem of large and small ends, and ensuring that the ellipticity of the final casing ring forging reaches within 0.1% of the outer diameter.
[0005] The technical solution adopted in this invention is: A high-precision rolling and bulging method for asymmetric double-groove casing ring forgings involves first rolling a rectangular cross-section ring billet into an irregular cross-section multiple times, followed by bulging, to obtain an asymmetric double-groove ring forging. Then, the asymmetric double-groove ring forging is heat-treated and subjected to residual heat bulging to obtain the final ring forging. For the forming process of the asymmetric double-groove ring forging, the number of irregular cross-section rolling passes, the number of bulging passes, the bulging amount during the residual heat bulging process, the bulging amount after each pass of irregular cross-section rolling, and the outer diameter of the irregular cross-section ring forging after each pass of rolling are pre-designed and calculated, thereby reducing the dimensional differences and ellipticity of the axial end faces of the final ring forging.
[0006] Furthermore, when designing the forming process of an asymmetric external double-groove ring forging, the rolling number n and bulging number m of the irregular cross-section are first determined based on the dimensional information of the final ring forging and the rectangular cross-section ring blank, and the bulging amount of the residual heat bulging process is also determined. Then, the outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling and bulging is determined sequentially. , the amount of bulging after the nth pass of irregular cross-section rolling The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling Then, the outer diameter of the irregular cross-section ring forging after the previous irregular cross-section rolling and bulging, the bulging amount after the previous irregular cross-section rolling, and the outer diameter of the irregular cross-section ring forging after the previous irregular cross-section rolling are determined sequentially. After calculating sequentially to the previous pass, the outer diameter of the irregular cross-section ring forging after all passes of irregular cross-section rolling and bulging, the bulging amount after all passes of irregular cross-section rolling, and the outer diameter of the irregular cross-section ring forging after all passes of irregular cross-section rolling are obtained.
[0007] Furthermore, the formula for calculating the number of rolling passes n for irregular cross-sections is as follows:
[0008] Where n is a value rounded up; The minimum rectangular envelope area of the final irregular cross-section of the ring forging; This refers to the cross-sectional area of the final ring forging. , These are the maximum and minimum wall thicknesses of the final ring forging's irregular cross-section, respectively. , These are the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively. This refers to the final outer diameter of the ring forging; The outer diameter of the rectangular cross-section ring blank.
[0009] Furthermore, the formula for calculating the number of bulging cycles, m, is as follows: When n=1, m=1; When n > 1, we have:
[0010] When m=n, the rolling and bulging of the irregular section are carried out alternately; when m=n-1, the last pass of the irregular section rolling must have bulging, the previous passes of the irregular section rolling do not have bulging, and the remaining passes of the irregular section rolling all have one bulging.
[0011] Furthermore, the amount of expansion during the waste heat expansion process The calculation formula is as follows: = ×
[0012] in, This refers to the final outer diameter of the ring forging; For the relative bulge amount of the final ring forging outer diameter, select 0.002≤ ≤0.01.
[0013] Furthermore, the outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling and bulging... The calculation formula is as follows: = -
[0014] The bulging amount after the nth pass of irregular cross-section rolling The calculation formula is as follows: =0.01
[0015] The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling The calculation formula is as follows: = -
[0016] in, This refers to the final outer diameter of the ring forging; , These represent the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively.
[0017] Furthermore, the outer diameter of the irregular cross-section ring forging after the i-th pass of irregular cross-section rolling and bulging... The calculation formula is as follows: = (1≤i<n) The bulging amount after the i-th pass of irregular cross-section rolling The calculation formula is as follows: =0.01 (1≤i<n) The outer diameter of the irregular cross-section ring forging after the i-th pass of irregular cross-section rolling The calculation formula is as follows: = - (1≤i<n) in, The outer diameter of the ring forging after the (i+1)th pass of irregular cross-section rolling and bulging; Let be the cross-sectional area of the rectangular cross-section ring blank; This refers to the cross-sectional area of the final ring forging. The wall thickness of the rectangular cross-section ring blank; , These are the maximum and minimum wall thicknesses of the final ring forging's irregular cross-section, respectively. , These represent the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively.
[0018] Preferably, the asymmetric outer double groove casing ring forging is made of titanium alloy.
[0019] An asymmetric double-groove casing ring forging is manufactured using the above method.
[0020] The beneficial effects of this invention are: This method divides the rolling process of the asymmetric external double-groove casing ring forging into steps, and after rolling the irregular cross-section, it uses an expansion forming process to correct the size of the rolled ring. Furthermore, it pre-designs and calculates the key control parameters for each pass of the asymmetric external double-groove ring forging process, which reduces the dimensional difference between the two end faces of the axial direction of the final ring forging, eliminates the problem of large and small ends, and ensures that the ellipticity of the final casing ring forging reaches within 0.1% of the outer diameter. Attached Figure Description
[0021] Figure 1 This is a process flow diagram of the high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings in an embodiment of the present invention.
[0022] Figure 2 This is a schematic diagram of the dimensions of the asymmetric external double-groove casing ring forging in an embodiment of the present invention.
[0023] Figure 3 This is a finished product diagram from an embodiment of the present invention. Detailed Implementation
[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments.
[0025] Example 1 This embodiment discloses a high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings, such as... Figure 1As shown, it includes three main processes: the fabrication process of the rectangular cross-section ring blank, the forming process of the asymmetric double-groove ring forging, and the residual heat bulging process. The fabrication process of the rectangular cross-section ring blank and the residual heat bulging process are conventional, while the forming process of the asymmetric double-groove ring forging is the core focus of this application. Specifically, the fabrication process of the rectangular cross-section ring blank generally involves: first, upsetting and punching the bar to obtain the ring blank, and then rolling the ring blank into a rectangular cross-section to obtain the rectangular cross-section ring blank; the forming process of the asymmetric double-groove ring forging involves: first, rolling the rectangular cross-section ring blank into an irregular cross-section multiple times and then bulging it after rolling to obtain the asymmetric double-groove ring forging; the residual heat bulging process involves heat treating the asymmetric double-groove ring forging and then performing residual heat bulging to obtain the final ring forging.
[0026] For the forming process of asymmetric external double groove ring forgings, it is necessary to pre-design and calculate the number of rolling passes, the number of bulging passes, the bulging amount during the residual heat bulging process, the bulging amount after each pass of rolling the irregular cross section, and the outer diameter of the irregular cross section ring forging after each pass of rolling the irregular cross section, so as to reduce the dimensional difference and ellipticity of the axial end faces of the final ring forging.
[0027] Based on the above design requirements for the forming process of asymmetric external double-groove ring forgings, in this embodiment, the design process involves: first determining the number of rolling operations n and the number of bulging operations m for the irregular cross-section based on the dimensional information of the final ring forging and the rectangular cross-section ring blank, and then determining the bulging amount during the residual heat bulging process. Then, the outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling and bulging is determined sequentially. , the amount of bulging after the nth pass of irregular cross-section rolling The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling Then, the outer diameter of the irregular cross-section ring forging after the previous irregular cross-section rolling and bulging, the bulging amount after the previous irregular cross-section rolling, and the outer diameter of the irregular cross-section ring forging after the previous irregular cross-section rolling are determined sequentially. After calculating sequentially to the previous pass, the outer diameter of the irregular cross-section ring forging after all passes of irregular cross-section rolling and bulging, the bulging amount after all passes of irregular cross-section rolling, and the outer diameter of the irregular cross-section ring forging after all passes of irregular cross-section rolling are obtained.
[0028] Specifically, based on the above design concept, the design flow of the forming process of the asymmetric external double groove ring forging in this embodiment is as follows.
[0029] The first step is to determine the number of rolling cycles, n, for irregular cross-sections. The formula for calculating the number of rolling passes n for irregular cross-sections is as follows:
[0030] Where n is a value rounded up; The minimum rectangular envelope area of the final irregular cross-section of the ring forging; This refers to the cross-sectional area of the final ring forging. , These are the maximum and minimum wall thicknesses of the final ring forging's irregular cross-section, respectively. , These are the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively. This refers to the final outer diameter of the ring forging; The outer diameter of the rectangular cross-section ring blank.
[0031] The second step is to determine the number of bulging cycles, m. The formula for calculating the number of bulging cycles, m, is as follows: When n=1, m=1; When n > 1, we have:
[0032] When m=n, the rolling and bulging of the irregular section are carried out alternately; when m=n-1, the last pass of the irregular section rolling must have bulging, the previous passes of the irregular section rolling do not have bulging, and the remaining passes of the irregular section rolling all have one bulging.
[0033] The third step is to determine the amount of expansion during the waste heat expansion process.
[0034] Expansion amount during waste heat expansion process The calculation formula is as follows: = ×
[0035] in, This refers to the final outer diameter of the ring forging; For the relative bulge amount of the final ring forging outer diameter, select 0.002≤ ≤0.01.
[0036] The fourth step is to determine the outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling and bulging. , the amount of bulging after the nth pass of irregular cross-section rolling The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling
[0037] The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling and bulging The calculation formula is as follows: = -
[0038] The bulging amount after the nth pass of irregular cross-section rolling The calculation formula is as follows: =0.01
[0039] The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling The calculation formula is as follows: = -
[0040] in, This refers to the final outer diameter of the ring forging; , These represent the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively.
[0041] Step 5: Determine the outer diameter of the irregular cross-section ring forging after the i-th pass of irregular cross-section rolling and bulging. , the amount of bulging after the i-th pass of irregular cross-section rolling The outer diameter of the irregular cross-section ring forging after the i-th pass of irregular cross-section rolling
[0042] The outer diameter of the irregular cross-section ring forging after the i-th pass of irregular cross-section rolling and bulging The calculation formula is as follows: = (1≤i<n) The bulging amount after the i-th pass of irregular cross-section rolling The calculation formula is as follows: =0.01 (1≤i<n) The outer diameter of the irregular cross-section ring forging after the i-th pass of irregular cross-section rolling The calculation formula is as follows: = - (1≤i<n) in, The outer diameter of the ring forging after the (i+1)th pass of irregular cross-section rolling and bulging; Let be the cross-sectional area of the rectangular cross-section ring blank; This refers to the cross-sectional area of the final ring forging. The wall thickness of the rectangular cross-section ring blank; , These are the maximum and minimum wall thicknesses of the final ring forging's irregular cross-section, respectively. , These represent the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively.
[0043] In this embodiment: the symmetrical outer double-groove casing ring forging is made of titanium alloy, specifically TC4 titanium alloy; the specific dimensions of the symmetrical outer double-groove casing ring forging are as follows... Figure 2 As shown; based on the above information and design process, the rolling number of irregular cross-sections is n=2, the bulging number is m=2, and the bulging amount of the residual heat bulging process is determined. =8mm, outer diameter of the irregular cross-section ring forging after the second pass of irregular cross-section rolling and bulging. =1492mm, bulging amount after the second pass of irregular section rolling. =22mm, outer diameter of the irregular cross-section ring forging after the second pass of irregular cross-section rolling. =1470mm, outer diameter of the irregular section ring forging after the first pass of irregular section rolling and bulging. =1058mm, bulging amount after the first pass of irregular section rolling =16mm, outer diameter of the irregular cross-section ring forging after the first pass of irregular cross-section rolling. =1042mm.
[0044] Example 2 This embodiment discloses an asymmetric external double-groove casing ring forging, manufactured using the above-described method; as follows: Figure 3 As shown, the product obtained after manufacturing according to Example 1 has an ellipticity of 1.5 mm, which is within 0.1% of the outer diameter.
[0045] This method divides the rolling process of asymmetric external double-groove casing ring forging into steps, and after rolling the irregular cross-section, it uses an expansion forming process to correct the size of the rolled ring. Furthermore, it pre-designs and calculates the key control parameters for each pass of the asymmetric external double-groove ring forging forming process, thereby reducing the dimensional difference and ellipticity of the axial end faces of the final ring forging and eliminating the problem of large and small ends.
[0046] The embodiments described above are some, but not all, of the embodiments of this application. The detailed description of the embodiments of this application is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.
Claims
1. A high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings, characterized in that: First, the rectangular cross-section ring billet is subjected to multiple passes of irregular cross-section rolling and subsequent bulging to obtain an asymmetric external double-groove ring forging. Then, the asymmetric external double-groove ring forging is heat-treated and subjected to residual heat bulging to obtain the final ring forging. For the forming process of the asymmetric external double-groove ring forging, the number of irregular cross-section rolling passes, the number of bulging passes, the bulging amount during the residual heat bulging process, the bulging amount after each pass of irregular cross-section rolling, and the outer diameter of the irregular cross-section ring forging after each pass of irregular cross-section rolling are designed and calculated in advance, thereby reducing the dimensional difference and ellipticity of the axial end faces of the final ring forging. For the forming process of asymmetric external double-groove ring forgings, the design process first determines the number of rolling operations (n) and the number of bulging operations (m) for the irregular cross-section based on the dimensional information of the final ring forging and the rectangular cross-section ring blank, and then determines the bulging amount during the residual heat bulging process. Then, the outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling and bulging is determined sequentially. , the amount of bulging after the nth pass of irregular cross-section rolling The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling Then, the outer diameter of the irregular cross-section ring forging after the previous irregular cross-section rolling and bulging, the bulging amount after the previous irregular cross-section rolling, and the outer diameter of the irregular cross-section ring forging after the previous irregular cross-section rolling are determined sequentially. After calculating sequentially to the previous pass, the outer diameter of the irregular cross-section ring forging after all passes of irregular cross-section rolling and bulging, the bulging amount after all passes of irregular cross-section rolling, and the outer diameter of the irregular cross-section ring forging after all passes of irregular cross-section rolling are obtained. The formula for calculating the number of rolling passes n for irregular cross-sections is as follows: Where n is a value rounded up; The minimum rectangular envelope area of the final irregular cross-section of the ring forging; This refers to the cross-sectional area of the final ring forging. , These are the maximum and minimum wall thicknesses of the final ring forging's irregular cross-section, respectively. , These are the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively. This refers to the final outer diameter of the ring forging; The outer diameter of the rectangular cross-section ring blank; The formula for calculating the number of bulging cycles, m, is as follows: When n=1, m=1; When n > 1, we have: When m=n, the rolling and bulging of the irregular section are carried out alternately; when m=n-1, the bulging must be carried out after the rolling of the irregular section in the last pass, and the bulging can be omitted after the rolling of the irregular section in a previous pass, while the bulging must be carried out once after the rolling of the irregular section in the remaining passes.
2. The high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings as described in claim 1, characterized in that, Expansion amount during waste heat expansion process The calculation formula is as follows: = × in, This refers to the final outer diameter of the ring forging; For the relative bulge amount of the final ring forging outer diameter, select 0.002≤ ≤0.
01.
3. The high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings as described in claim 1, characterized in that, The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling and bulging The calculation formula is as follows: = - The bulging amount after the nth pass of irregular cross-section rolling The calculation formula is as follows: =0.01 The outer diameter of the irregular cross-section ring forging after the nth pass of irregular cross-section rolling The calculation formula is as follows: = - in, This refers to the final outer diameter of the ring forging; , These represent the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively.
4. The high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings as described in claim 1, characterized in that, The outer diameter of the irregular cross-section ring forging after the i-th pass of irregular cross-section rolling and bulging. The calculation formula is as follows: = ,(1≤i<n) The bulging amount after the i-th pass of irregular cross-section rolling The calculation formula is as follows: =0.01 ,(1≤i<n) The outer diameter of the irregular cross-section ring forging after the i-th pass of irregular cross-section rolling The calculation formula is as follows: = - ,(1≤i<n) in, The outer diameter of the ring forging after the (i+1)th pass of irregular cross-section rolling and bulging; Let be the cross-sectional area of the rectangular cross-section ring blank; This refers to the cross-sectional area of the final ring forging. The wall thickness of the rectangular cross-section ring blank; , These are the maximum and minimum wall thicknesses of the final ring forging's irregular cross-section, respectively. , These represent the larger and smaller groove cross-sectional areas of the final ring forging's irregular cross-section, respectively.
5. The high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings as described in claim 1, characterized in that, The asymmetric outer double groove casing ring forging is made of titanium alloy.
6. An asymmetric external double-groove casing ring forging, characterized in that: It is manufactured using the high-precision rolling and bulging method for asymmetric external double-groove casing ring forgings as described in any one of claims 1 to 5.