A large whole frame forging forging and drawing forming die and forming method

Abstract

The present application mainly relates to a large whole frame forging drawing forming die and forming method, the die includes the upper die and the lower die which are oppositely arranged; the lower surface of the upper die is provided with a convex rectangular workbench, the transition area between the workbench and the lower surface of the upper die is a slope transition section with inclined surface structure, the metal plate blank can move horizontally between the upper die and the lower die to change the contact area of the metal plate blank with the die. The method for drawing forming processing by using the die includes determining the drawing forming processing times of the forging, then drawing forming processing the metal plate blank multiple times until the metal plate blank is processed into a large whole frame forging. By using the large whole frame forging drawing forming die and forming method provided by the present application, the forming load of the large whole frame forging in the overall forming process can be significantly reduced, and the low-load overall forging forming of the large whole frame forging on the existing press equipment can be realized. Meanwhile, the machining amount can be effectively reduced, and the production cost can be greatly reduced.

Description

Technical Field

[0001] This invention belongs to the field of metal material plastic forming technology, and particularly relates to a large-scale integral frame forging forging and drawing forming mold and forming method. Background Technology

[0002] The large frame forging in this invention refers to a "U-shaped" forging with a concave upper plane forming a central web with a small height and a large outer perimeter. Its structural schematic diagram is shown below. Figure 1 As shown. These large, integral frame forgings are commonly used in aerospace components. Due to their enormous size, manufacturing them is extremely difficult. Traditional processing methods involve machining a metal slab with a maximum height equal to that of the large frame forging. This method results in low material utilization and low processing efficiency, thus increasing manufacturing costs. When forging is used, the overall structural size of the large frame forging is so large that the forging pressure exceeds 100,000 tons, exceeding the manufacturing capacity of existing press equipment worldwide. Summary of the Invention

[0003] To address the shortcomings of existing technologies, the large integral frame forging die and forming method proposed in this invention can not only achieve low-load forming of large integral frame forgings within the manufacturing capabilities of existing press equipment, but also significantly reduce the amount of machining required for large integral frame forgings, thereby improving material utilization and processing efficiency.

[0004] This invention provides a large-scale integral frame forging and drawing forming die, the die comprising an upper die and a lower die arranged opposite to each other; a rectangular worktable protruding from the lower surface of the upper die is provided, the top surface of the worktable contacting the top of the metal slab, forming a first working area; the transition area between the first working area of ​​the worktable and the lower surface of the upper die is a sloping transition section with an inclined structure, all four sides of the worktable being sloping transition sections, the vertical projection width of the sloping transition section being the sloping width value; the metal slab can move horizontally between the upper and lower dies to change the contact area between the metal slab and the die, the axial direction on the die coinciding with the movement direction of the metal slab is the first axial direction, and the axial direction on the die perpendicular to the movement direction of the metal slab is the second axial direction;

[0005] The structural dimensions of the first working area in the second axial direction are the same as the concave structural dimensions of the large frame forging after processing. The width of the first working area in the first axial direction is the working width value. Edge plane structures are provided on both sides of the worktable on the lower surface of the upper die along the first axial direction, ensuring the upper surface of the metal slab remains flat during forging and drawing. The width of the edge plane structure along the first axial direction is the edge width value. Two boss structures are provided at one end of the lower surface of the upper die facing the moving direction of the metal slab. These boss structures are evenly distributed along the second axial direction, enabling the shaping of the already formed forging parts and preventing warping deformation. The lower surface of the upper die... The two sides of the lower die are provided with raised frame edges, the height of which is the same as the height of the worktable. The surface of the lower die that contacts the bottom of the metal slab is the second working area. The top of the lower die is provided with a concave planar structure that is high on both sides and low in the middle in the second axial direction, so that the second working area is located at the bottom of the concave planar structure. This not only facilitates the positioning of the metal slab, but also constrains the flow of metal around the forging during the forging and drawing process, so that the long sides of the large frame forging are deformed regularly. The second working area of ​​the lower die is unconstrained in the first axial direction, and the metal material can flow along the first axial direction during the forging and drawing process, so that the planar structure remains flat and does not bend or deform.

[0006] A method for forging and drawing forming using the forging and drawing forming die includes the following steps:

[0007] Step 1: After preheating the upper and lower molds, install them onto the upper and lower worktables of the press, respectively.

[0008] Step 2: Place the heated metal slab into the cavity of the lower die. Determine the number of times the forging is to be forged and drawn along the first axial direction based on the length, working width and slope width of the concave area of ​​the large frame forging. Then, forge and draw the metal slab sequentially along the first axial direction until the metal slab is processed into a large frame forging.

[0009] Step 3: After completing the forging and drawing process of the entire large frame forging, remove the large frame forging formed in Step 2 from the cavity of the lower die.

[0010] Preferably, the method for each forging and drawing process in step 2 includes the following steps:

[0011] Step 21: Place the heated unprocessed metal slab or the metal slab that has completed the previous forging and drawing process into the cavity of the lower die;

[0012] Step 22: Control the press to drive the upper die to move downwards and perform forging and drawing processing on the metal slab. When the press reaches the pressing amount set by the forming process, control the press to drive the upper die to stop moving downwards. At this time, the metal slab will form a locally concave planar structure with high sides and low middle in the second axial direction, and a concave section with a length value of the working width value and a slope structure with a width value of the slope width value in the first axial direction.

[0013] Step 23: Control the press to lift the upper die during the return stroke, and then move the metal slab to the placement position for the next forging and drawing process; during each forging and drawing process, the position of the slope structure of the metal slab must be within the pressing range of the first working area of ​​the upper die.

[0014] The forging and drawing forming die and method for large integral frame forgings proposed in this invention, compared with existing technologies, reduces the effective contact area between the metal slab and the die during the integral forging process from the entire projected area of ​​the forging to a small local contact area in the center of the forging. This significantly reduces the forming load of large integral frame forgings during the integral forming process, enabling low-load integral forging on existing press equipment. Simultaneously, the forging and drawing forming die and method for large integral frame forgings proposed in this invention effectively reduces the amount of machining required for large integral frame forgings, improves material utilization and processing efficiency, and thus greatly reduces production costs. Attached Figure Description

[0015] Figure 1 This is a top view structural diagram of a large integral frame forging according to an embodiment of the present invention;

[0016] Figure 2 This is a schematic diagram of the cross-sectional structure of a large integral frame forging in the AA direction according to an embodiment of the present invention;

[0017] Figure 3 This is a three-dimensional schematic diagram of the installation structure of the forging and drawing forming die according to an embodiment of the present invention;

[0018] Figure 4 This is a schematic cross-sectional view of the forging and drawing forming die installation structure in the BB direction according to an embodiment of the present invention;

[0019] Figure 5 This is a schematic diagram of the cross-sectional structure of the forging and drawing forming die mounting structure according to an embodiment of the present invention, taken in the CC direction.

[0020] Figure 6 This is a schematic diagram of the forging process of the forging and drawing forming method of the present invention;

[0021] In the figure, 1 is the upper mold, 2 is the metal blank, 3 is the lower mold, 4 is the first working area, 5 is the boss structure, 6 is the second working area, 7 is the worktable, W1 is the working width value, W2 is the edge width value, W3 is the slope width value, CC is the first axial direction, and BB is the second axial direction. Detailed Implementation

[0022] This invention provides a large-scale integral frame forging and drawing forming die, comprising an upper die 1 and a lower die 3 arranged opposite to each other; a rectangular worktable 7 protruding from the lower surface of the upper die 1 is provided, and the top surface of the worktable 7 contacts the top of the metal slab 2, forming a first working area 4. The transition area between the first working area 4 of the worktable 7 and the lower surface of the upper die 1 is a sloping transition section with an inclined structure. All four sides of the worktable 7 are set as sloping transition sections, and the vertical projection width of the sloping transition section is the sloping width value W3. The metal slab 2 can move horizontally between the upper die 1 and the lower die 3 to change the contact area between the metal slab 2 and the die. The axial direction on the die that coincides with the moving direction of the metal slab 2 is the first axial direction CC, and the axial direction on the die that is perpendicular to the moving direction of the metal slab 2 is the second axial direction BB. The structural dimensions of the first working area 4 in the second axial direction are the same as the concave structural dimensions of the processed large-scale integral frame forging, and the width of the first working area 4 in the first axial direction is the working width value W1. The worktable 7 on the lower surface of the upper die 1 has edge planar structures on both sides along the first axial direction, which keeps the upper surface of the metal slab 2 flat during forging and drawing. The width of the edge planar structure along the first axial direction is the edge width value W2. Two boss structures 5 are provided on the lower surface of the upper die 1 at one end facing the moving direction of the metal slab 2. The boss structures 5 are evenly distributed along the second axial direction, which can shape the already formed forging parts and prevent them from warping and deforming. The lower surface of the upper die 1 has raised frame edges on both sides along the first axial direction. The height of the frame edges is the same as the height of the worktable 7. The surface of the lower die 3 that contacts the bottom of the metal slab 2 is the second working area 6. The top of the lower die 3 has a concave planar structure with high sides and low middle in the second axial direction, so that the second working area 6 is located at the bottom of the concave planar structure. This not only facilitates the positioning of the metal slab 2, but also restricts the flow of metal around the forging during the forging and drawing process, making the long sides of the large frame forging deform regularly. The second working area 6 of the lower die 3 is unrestrained in the first axial direction, and the metal material can flow along the first axial direction of the lower die 3 during the forging and drawing process, so that the planar structure remains flat and does not produce bending deformation.

[0023] A method for forging and drawing forming using the forging and drawing forming die includes the following steps:

[0024] Step 1: After preheating the upper mold 1 and the lower mold 3, install them onto the upper and lower worktables of the press respectively;

[0025] Step 2: Place the heated metal slab 2 into the cavity of the lower die 3. Determine the number of forging and drawing operations based on the length of the concave area along the first axial direction, the working width W1, and the slope width W3 of the large frame forging. Then, sequentially perform forging and drawing operations on the metal slab 2 along the first axial direction until the metal slab 2 is processed into a large frame forging. Each forging and drawing forming method includes the following steps:

[0026] Step 21: Place the heated unprocessed metal slab 2 or the metal slab 2 that has completed the previous forging and drawing process into the cavity of the lower die 3;

[0027] Step 22: Control the press to drive the upper die 1 to move downwards and perform forging and drawing processing on the metal blank 2. When the press reaches the pressing amount set by the forming process, control the press to drive the upper die 1 to stop moving downwards. At this time, the metal blank 2 will form a locally concave planar structure with high sides and low middle in the second axial direction, and a concave section with a length value of the working width value W1 and a sloping structure with a width value of the slope width value W3 in the first axial direction.

[0028] Step 23: Control the press to lift the upper die 1 during the return stroke, and then move the metal slab 2 to the placement position for the next forging and drawing process; during each forging and drawing process, the position of the slope structure of the metal slab 2 must be within the pressing range of the first working area 4 of the upper die 1.

[0029] Step 3: After completing the forging and drawing process of the entire large frame forging, remove the large frame forging formed in Step 2 from the cavity of the lower die 3.

[0030] The present invention will be further described below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments presented herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0031] Example

[0032] like Figure 1As shown, the dimensions of the large frame forging to be processed in this embodiment are: length 2148mm, width 1452mm, and height 52mm; the dimensions of the bottom web of the concave structure at the center of the large frame forging are: length 1800mm, width 1097mm, and thickness 22mm, and the distance between the surface of the bottom web and the top plane of the large frame forging is 30mm. The processing material of the large frame forging is 7075 aluminum alloy, and the dimensions of the unprocessed metal slab 2 are: length 1650mm, width 1450mm, and height 52mm. In this embodiment, the length values ​​of both the large frame forging and the metal slab 2 are along the first axial direction, while the width values ​​are along the second axial direction.

[0033] like Figure 2 and Figure 3 As shown, the mold used for forging and drawing large frame forgings in this embodiment includes an upper mold 1 and a lower mold 3 arranged opposite each other. The length of the upper mold 1 and the lower mold 3 along the first axial direction is 1000mm, and the length along the second axial direction is 2000mm. The length of the first working area 4 of the upper mold 1 in the second axial direction is the same as the length of the concave structure of the large frame forging in the same direction. The working width W1 of the first working area 4 of the upper mold 1 in the first axial direction is designed to be 300mm. The first working area 4 of the upper mold 1 has edge plane structures with an edge width W2 of 300mm on both sides in the first axial direction, so that the forging remains straight and does not bend during the forging and drawing process. The worktable 7 of the upper mold 1 has a ramp transition section with a ramp width W3 of 50mm on all four sides. Two identical boss structures 5 with dimensions of 350mm in length, 120mm in width, and 30mm in height are provided on one end of the lower surface of the upper mold 1 facing the moving direction of the metal slab 2. The boss structures 5 are evenly distributed along the second axial direction and can shape the already formed forging parts to prevent them from warping and deforming.

[0034] The surface of the lower die 3 that contacts the bottom of the metal slab 2 is the second working area 6. The top of the lower die 3 has a concave planar structure with higher sides and a lower middle in the second axial direction, so that the second working area 6 is located at the bottom of the concave planar structure. This not only facilitates the positioning of the metal slab 2, but also constrains the flow of metal around the forging during the forging and drawing process, making the long sides of the large frame forging deform regularly. The second working area 6 of the lower die 3 is unconstrained in the first axial direction, and the metal material can flow along the first axial direction during the forging and drawing process, keeping the planar structure flat without bending deformation.

[0035] like Figure 4 As shown, in this embodiment, a large integral frame forging die is used for forging and drawing large integral frame forgings. The specific method includes the following steps:

[0036] Step 1: After preheating the upper mold 1 and the lower mold 3, install them onto the upper and lower worktables of the press respectively;

[0037] Step 2: In this embodiment, the concave length of the forging along the first axial direction is 1800mm, the working width W1 of the upper die 1 is 300mm, and the slope width W3 on the four sides of the upper die 1 worktable 7 is 50mm. Calculations determine that 7 forging and drawing processes are required. The specific steps for each forging and drawing process are as follows:

[0038] Step 201: Place the heated metal slab 2 into the cavity of the lower mold 3;

[0039] Step 202: Control the press to drive the upper die 1 to move downward to perform the first forging and drawing process. When the press reaches the pressing amount of 30mm set by the forming process, control the press to drive the upper die 1 to stop moving downward. At this time, the metal blank 2 will form a local concave planar structure with a height of 52mm on both sides and a height of 22mm in the middle in the second axial direction, and a concave section with a length of 300mm and a slope structure with a width of 50mm in the first axial direction.

[0040] Step 203: After the first forging and drawing process is completed, control the press to lift the upper die 1 during the return stroke, and then operate the robot to hold the metal blank 2 and move it forward 250mm to the placement position for the second forging and drawing process. The placement position for the second forging and drawing process must ensure that the position of the slope structure formed by the metal blank 2 after the first forging and drawing process is still within the pressing range of the forging and drawing forming die.

[0041] Step 204: Control the press to drive the upper die 1 to move downward for the second forging and drawing process. When the press reaches the pressing amount of 30mm set by the forming process, control the press to drive the upper die 1 to stop moving downward. At this time, the metal slab 2 will form a new local concave planar structure with a height of 52mm on both sides and 22mm in the middle in the second axial direction, and a concave section with a length of 550mm and a new slope structure with a width of 50mm in the first axial direction.

[0042] Step 205: After the second forging and drawing process is completed, control the press to lift the upper die 1 during the return stroke, and then operate the robot to hold the metal blank 2 and move it forward 250mm to the placement position for the third forging and drawing process. The placement position for the third forging and drawing process must ensure that the position of the slope structure formed by the metal blank 2 after the second forging and drawing process is still within the pressing range of the forging and drawing forming die.

[0043] Step 206: Control the press to drive the upper die 1 to move downwards for the third forging and drawing process. When the press reaches the pressing amount of 30mm set by the forming process, control the press to drive the upper die 1 to stop moving downwards. At this time, the metal slab 2 will form a new local concave planar structure with a height of 52mm on both sides and 22mm in the middle in the second axial direction, and a concave section with a length of 800mm and a new slope structure with a width of 50mm in the first axial direction.

[0044] Step 207: After the third forging and drawing process is completed, control the press to lift the upper die 1 during the return stroke, and then operate the robot to hold the metal blank 2 and move it forward 250mm to the placement position for the fourth forging and drawing process. The placement position for the fourth forging and drawing process must ensure that the position of the slope structure formed by the metal blank 2 after the third forging and drawing process is still within the pressing range of the forging and drawing forming die.

[0045] Step 208: Control the press to drive the upper die 1 to move downwards for the fourth forging and drawing process. When the press reaches the pressing amount of 30mm set by the forming process, control the press to drive the upper die 1 to stop moving downwards. At this time, the metal slab 2 will form a new local concave planar structure with a height of 52mm on both sides and 22mm in the middle in the second axial direction, and a concave section with a length of 1050mm and a new slope structure with a width of 50mm in the first axial direction.

[0046] Step 209: After the fourth forging and drawing process is completed, control the press to lift the upper die 1 during the return stroke, and then operate the robot to hold the metal blank 2 and move it forward 250mm to the placement position for the fifth forging and drawing process. The placement position for the fifth forging and drawing process must ensure that the position of the slope structure formed by the metal blank 2 after the fourth forging and drawing process is still within the pressing range of the forging and drawing forming die.

[0047] Step 210: Control the press to drive the upper die 1 to move downward to perform the 5th forging and drawing process. When the press reaches the pressing amount of 30mm set by the forming process, control the press to drive the upper die 1 to stop moving downward. At this time, the metal slab 2 will form a new local concave planar structure with a height of 52mm on both sides and 22mm in the middle in the second axial direction, and a concave section with a length of 1300mm and a new slope structure with a width of 50mm in the first axial direction.

[0048] Step 211: After the 5th forging and drawing process is completed, control the press to lift the upper die 1 during the return stroke, and then operate the robot to hold the metal blank 2 and move it forward 250mm to the placement position for the 6th forging and drawing process. The placement position for the 6th forging and drawing process must ensure that the position of the slope structure formed by the metal blank 2 after the 5th forging and drawing process is still within the pressing range of the forging and drawing forming die.

[0049] Step 212: Control the press to drive the upper die 1 to move downward to perform the 6th forging and drawing process. When the press reaches the pressing amount of 30mm set by the forming process, control the press to drive the upper die 1 to stop moving downward. At this time, the metal slab 2 will form a new local concave plane structure with a height of 52mm on both sides and 22mm in the middle in the second axial direction, and a concave section with a length of 1550mm and a new slope structure with a width of 50mm in the first axial direction.

[0050] Step 213: After the 6th forging and drawing process is completed, control the press to lift the upper die 1 during the return stroke, and then operate the robot to hold the metal blank 2 and move it forward 250mm to the placement position for the 7th forging and drawing process. The placement position for the 7th forging and drawing process must ensure that the position of the slope structure formed by the metal blank 2 after the 6th forging and drawing process is still within the pressing range of the forging and drawing forming die.

[0051] Step 214: Control the press to drive the upper die 1 downward to perform the 7th forging and drawing process. When the press reaches the pressing amount of 30mm set by the forming process, control the press to drive the upper die 1 to stop moving downward. At this time, the overall forming of the large frame forging is completed.

[0052] Step 3: Control the press to lift the upper die 1 during the return stroke, and take the large frame forging after integral forming out of the cavity of the lower die 3, thus completing the overall forming process of the forging.

[0053] In this embodiment, the maximum load during the forging and drawing process of large frame forgings using a large frame forging die is 10,000 tons, which is only 1 / 12 of the maximum load of overall forging and can also achieve overall forging on existing press equipment.

[0054] Secondly, in this embodiment, compared with directly machining a metal slab 2 with a length of 2148mm, a width of 1452mm, and a height of 52mm to manufacture a large frame forging, the large frame forging drawing method reduces the amount of machining by 39%, increases the material utilization rate by 26%, and significantly reduces the manufacturing cost of the large frame forging.

[0055] The above embodiments are merely illustrative examples to clearly illustrate the present invention and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all embodiments here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A drawing and forming die for a large monoblock forging, characterized by, The mold comprises an upper die and a lower die arranged opposite to each other; the lower surface of the upper die is provided with a rectangular workbench protruding from the lower surface, the top surface of the workbench is in contact with the top of the metal slab, which is a first working area; the transition area between the first working area of the workbench and the lower surface of the upper die is a slope transition section with a slope structure, the four sides of the workbench are all provided with the slope transition section, the vertical projection width value of the slope transition section is a slope width value; the metal slab can move horizontally between the upper die and the lower die to change the contact area of the metal slab with the mold, the axial direction of the mold coinciding with the moving direction of the metal slab is a first axial direction, and the axial direction of the mold perpendicular to the moving direction of the metal slab is a second axial direction; the structural size of the first working area in the second axial direction is the same as the size of the concave structure of the large whole-frame forged piece after processing, and the width value of the first working area in the first axial direction is a working width value; the workbench on the lower surface of the upper die is provided with an edge plane structure on both sides in the first axial direction, so that the upper surface of the metal slab remains flat during the forging and drawing forming process, and the width value of the edge plane structure in the first axial direction is an edge width value; one end of the lower surface of the upper die towards the moving direction of the metal slab is provided with two boss structures uniformly distributed in the second axial direction, which can reshape the forged part that has been formed and prevent it from being warped; the edges of the lower surface of the upper die in the first axial direction are provided with raised frames, and the height of the frame is the same as the height of the workbench; the surface of the lower die in contact with the bottom of the metal slab is a second working area, and the top of the lower die is provided with a concave plane structure with high sides and low middle in the second axial direction, so that the second working area is located at the bottom of the concave plane structure, which not only facilitates the positioning of the metal slab, but also constrains the flow of the peripheral metal of the forged piece during the forging and drawing forming process, so that the two long sides of the large whole-frame forged piece are deformed regularly; the second working area of the lower die is unconstrained in the first axial direction, and the metal material can flow along the first axial direction during the forging and drawing forming process, so that the plane structure remains flat without bending deformation.

2. A method for performing a swaging and stretch forming process using the swaging and stretch forming die according to claim 1, characterized by, The method comprises the following steps: Step 1: preheat the upper die and the lower die and then install them on the upper workbench surface and the lower workbench surface of the press respectively; Step 2: place the heated metal slab into the cavity of the lower die, determine the number of times of forging and drawing processing of the forged piece according to the length value of the concave area of the large whole-frame forged piece in the first axial direction, the working width value and the slope width value, and then sequentially process the metal slab in the first axial direction until the metal slab is processed into a large whole-frame forged piece; Step 3: after the forging and drawing processing of the whole large whole-frame forged piece is completed, take out the large whole-frame forged piece processed in step 2 from the cavity of the lower die.

3. The method of swaging and stretch forming processing according to claim 2, wherein, The method of each time of forging and drawing processing in step 2 comprises the following steps: Step 21: place the heated unprocessed metal slab or the metal slab after the last time of forging and drawing processing into the cavity of the lower die; Step 22: control the press to drive the upper die to move downward to perform the forging and drawing process on the metal slab, and when the press reaches the set reduction amount of the forming process, control the press to drive the upper die to stop moving downward, at this time, the metal slab will form a local concave plane structure with high on both sides and low in the middle in the second axial direction, and form a concave section with a length value of the working width value and a slope structure with a width value of the slope width value in the first axial direction; Step 23: control the press to return to lift the upper die, and then move the metal slab to the placement position for the next forging and drawing process. During each forging and drawing process, the position of the slope structure of the metal slab must be within the pressing range of the first working area of the upper die.

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