Shape correcting tool for end socket forge piece

Abstract

The invention discloses a shape correcting tool for a seal head forge piece, belongs to the technical field of seal head forge piece manufacturing, and solves the technical problems that an existing shape correcting tool is complex in structure and needs to be welded with auxiliary facilities such as a lifting lug for side standing and the like, so that the shape of the seal head forge piece cannot be effectively corrected. The end socket forge piece shape correcting tool comprises a bearing assembly, a first end socket supporting assembly, a second end socket supporting assembly, a fixing assembly and a force applying assembly. The supporting assembly is arranged in the long axis direction of the end socket forge piece, and the end socket forge piece is placed on the supporting assembly. The first end socket supporting assembly and the second end socket supporting assembly are located at the two ends of the end socket forge piece in the long axis direction and fixedly connected with the bearing assembly. The force applying assembly is used for applying shape correcting force to the end socket forge piece, and the fixing assembly is used for keeping the shape-corrected state of the end socket forge piece. According to the method, accurate shape correction of the deformed end socket forge piece is achieved, and the method can be used for shape correction of end socket forge pieces with different diameters.

Description

Technical Field

[0001] The invention relates to the technical field of head forging manufacturing, in particular to a shape correction tool for head forging. Background Art

[0002] Head forgings are mostly used in pressure vessel equipment. As the size of pressure vessel equipment increases, the size of the head forgings required also increases. In order to meet the performance requirements of the equipment, the head forgings need to be subjected to performance heat treatment. During the performance heat treatment of the head forgings, due to heating expansion, uneven cooling or lack of flatness and solidity when loading the furnace, the head forgings will be severely deformed. Common deformation is the appearance of obvious long and short axes. For head forgings, the larger the diameter (especially the diameter exceeds 4000mm) and the smaller the wall thickness (especially the wall thickness is less than 180mm), the greater the deformation tendency during the heat treatment process.

[0003] For deformed head forgings, if the deformation exceeds the machining allowance of the head forgings, it will result in the inability to meet the subsequent finishing dimensions and requires correction. For head correction, press punching correction can be used. Punching correction requires the design of special punches and lower dies and other auxiliary tools according to the actual size of the head, which is costly and not very versatile. For head forgings, the forgings can also be shaped by a press on the side. If side correction is required, auxiliary facilities such as side-standing lugs need to be welded on the head and head fixing aids need to be designed. At the same time, temporary accessories such as welding lugs on the head will affect the performance of the head forgings to a certain extent and increase the risk of cracking of the head. In short, there is currently no simple and universal correction tooling for head forgings. Summary of the invention

[0004] In view of the above analysis, the present invention aims to provide a shaping tool for head forgings to solve the technical problem that the existing shaping tool has a complex structure and requires temporary auxiliary facilities such as welding side lifting ears, resulting in the inability to effectively shape the head forgings.

[0005] The purpose of the present invention is mainly achieved through the following technical solutions:

[0006] The present invention provides a shape-correcting tool for a head forging, which includes a supporting assembly, a first head supporting assembly, a second head supporting assembly, a fixing assembly and a force-applying assembly;

[0007] The support assembly is arranged along the long axis direction of the head forging, and the head forging is placed on the support assembly;

[0008] The first head support assembly and the second head support assembly are located at both ends of the head forging in the long axis direction, and the bottom of the first head support assembly and the second head support assembly are fixedly connected to the supporting assembly; the force-applying assembly and the fixing assembly are both arranged in the long axis direction of the head forging and located between the outer circle of the head forging and the second head support assembly, the force-applying assembly is used to apply a shaping force to the head forging, and the fixing assembly is used to maintain the head forging in a state after being shaped.

[0009] In one possible design, a round electric stove is also included;

[0010] The supporting assembly, the first end cover supporting assembly, the second end cover supporting assembly, the fixing assembly and the force applying assembly are all arranged in the circular electric furnace;

[0011] The circular electric furnace is used to heat treat the head forgings to eliminate stress.

[0012] In a possible design, a plurality of supporting shims are also included;

[0013] A plurality of support washers are arranged along the long axis direction of the head forging, and the support washers are used to support the bearing assembly to ensure its stability.

[0014] In a possible design, the support assembly includes a support steel plate, and the support steel plate is a rectangular parallelepiped steel plate;

[0015] The supporting steel plate is arranged on the supporting pad iron; the length of the supporting steel plate is greater than the long axis length of the head forging.

[0016] In a possible design, the first head support assembly includes a first vertical plate and a first conformal steel plate;

[0017] The bottom surface of the first vertical plate is welded and fixed to the supporting steel plate; the first conformal steel plate is provided with an arc surface; the arc surface of the first conformal steel plate is conformal to the part in contact with the head forging; when the head forging is calibrated, the first vertical plate provides support force to the head forging through the first conformal steel plate.

[0018] In a possible design, the first head support assembly further includes a plurality of first ribs;

[0019] A plurality of first ribs are arranged parallel to each other; the plurality of first ribs are arranged at one end of the first vertical plate away from the first conformal steel plate and are fixedly connected to the vertical plate;

[0020] The bottom of the first rib plate is welded and fixed to the supporting steel plate, and the first rib plate is used to provide support for the first vertical plate.

[0021] In one possible design, the fixing assembly includes a second conformal steel plate;

[0022] Along the long axis direction of the head forging, the second conformal steel plate is located at the opposite end of the first conformal steel plate; the arc surface of the second conformal steel plate is conformal at the contact portion with the head forging; the force application component applies a correction force to the head forging through the second conformal steel plate.

[0023] In one possible design, the second head support assembly includes a second vertical plate;

[0024] The second vertical plate is a rectangular steel plate; the second vertical plate is welded to the supporting steel plate along the vertical direction.

[0025] In a possible design, the second head support assembly further includes a plurality of second ribs;

[0026] The plurality of second ribs are arranged parallel to each other; the plurality of second ribs are arranged at one end of the second vertical plate away from the second conformal steel plate, and one end of the second rib is fixedly connected to the second vertical plate;

[0027] The bottom of the second rib plate is welded and fixed to the supporting steel plate, and the second rib plate is used to provide support for the second vertical plate.

[0028] In a possible design, the fixing assembly further includes a first supporting steel plate and a second supporting steel plate arranged in parallel; after the force-applying assembly applies a correcting force to the head forging, the first supporting steel plate and the second supporting steel plate are arranged between the second conformal steel plate and the second vertical plate; one end of the first supporting steel plate and the second supporting steel plate are welded to the second conformal steel plate, and the other end thereof is against the second vertical plate;

[0029] The first supporting steel plate and the second supporting steel plate are used to fix the size of the head forging after correction.

[0030] The present invention also provides a method for correcting the shape of a head forging, the method comprising the following steps:

[0031] Step 1: Before loading into the furnace, measure the size of the head forging, and mark the major axis and minor axis orientation of the head forging on its outer surface;

[0032] Step 2, welding the first end support assembly and the second end support assembly on the supporting steel plate;

[0033] Step 3: When loading the furnace, open the furnace door and install the supporting pad iron and supporting steel plate on the working table of the circular electric furnace in sequence;

[0034] Step 4, placing the end head forging on the supporting steel plate in a calibrated position, wherein the end head forging is located between the first end head support assembly and the second end head support assembly;

[0035] Step 5: Place the fixed components;

[0036] The fixing assembly is located in the gap between the outer circle of the head forging and the second head supporting assembly;

[0037] Step 6: Place the force-applying component, and the force-applying component calibrates the head forging through the fixing component;

[0038] Step 7: Before removing the force-applying component, use the fixing component to fix the size of the head forging after the shape adjustment;

[0039] Step 8: Uninstall the force-applying component;

[0040] Remove the force-applying component and set a support block in its place;

[0041] Step 9, performing stress relief heat treatment;

[0042] Step 10: After cooling to room temperature, remove the shape correction tooling;

[0043] Step 11: Re-check the inner hole size of the head forging. After the shaped head forging meets the requirements, the shaped head forging is completed.

[0044] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0045] (1) The present invention utilizes a first head support assembly, a fixing assembly, and a second head support assembly to fix the head forging, and utilizes a large-tonnage hydraulic jack as a force source to apply force to the long axis direction of the outer circle of the head forging, so that the head forging undergoes elastic deformation in the radial direction, the long axis shrinks, and the short axis lengthens, thereby achieving the purpose of precise shape correction.

[0046] (2) The present invention can evenly transmit the force generated by the hydraulic jack to the surface of the head forging by providing the first conformal steel plate and the second conformal steel plate, thereby avoiding large local deformation of the head forging resulting in the size not meeting the requirements.

[0047] In the present invention, the above-mentioned technical solutions can also be combined with each other to achieve more preferred combination solutions. Other features and advantages of the present invention will be described in the subsequent description, and some advantages can become obvious from the description, or can be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained through the contents particularly pointed out in the embodiments of the description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The drawings are only for the purpose of illustrating particular embodiments and are not to be considered limiting of the present invention. Like reference symbols denote like components throughout the drawings.

[0049] Figure 1 It is a structural schematic diagram of the head forging of the present invention;

[0050] Figure 2 yes Figure 1 A top view of

[0051] Figure 3 Schematic diagram of the shape correction of the present invention (taking a circular furnace bottom as an example);

[0052] Figure 4 A top view of the shape correction tool of the present invention;

[0053] Figure 5 It is a front view of the shape correction tool of the invention;

[0054] Figure 6 It is a schematic diagram of the stress relief heat treatment process.

[0055] Reference numerals:

[0056] 1-first vertical plate; 2-first rib plate; 3-first conformal steel plate; 4-supporting steel plate; 5-second conformal steel plate; 6-first supporting steel plate; 7-second supporting steel plate; 8-jack; 9-second vertical plate; 10-second rib plate; 11-supporting pad; 12-head forging. DETAILED DESCRIPTION

[0057] The preferred embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of the present invention and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not used to limit the scope of the present invention.

[0058] The head forging 12 of the present invention has a diameter greater than 4000 mm, a wall thickness less than 180 mm, and a weight of 10-75 tons. For this type of forging, the larger the diameter and the smaller the wall thickness, the greater the deformation tendency during the heat treatment process. The existing shaping tooling cannot meet the shaping requirements.

[0059] In order to solve the problem of deformation of the end cap forging 12 to produce a major axis and a minor axis, the present invention provides a shape-correcting tool for the end cap forging 12, which includes a supporting assembly, a first end cap supporting assembly, a second end cap supporting assembly, a fixing assembly and a force-applying assembly; the supporting assembly is arranged along the major axis direction of the end cap forging 12, and the end cap forging 12 is placed on the supporting assembly; the first end cap supporting assembly and the second end cap supporting assembly are located at both ends of the major axis direction of the end cap forging 12, and the bottom of the first end cap supporting assembly and the bottom of the second end cap supporting assembly are both fixedly connected to the supporting assembly; the force-applying assembly and the fixing assembly are both arranged in the major axis direction of the end cap forging 12 and between the outer circle of the end cap forging 12 and the second end cap supporting assembly, the force-applying assembly is used to apply a shape-correcting force to the end cap forging 12, and the fixing assembly is used to maintain the shape-corrected state of the end cap forging 12 through the reaction force generated by the second end cap supporting assembly.

[0060] Specifically, since the deformed end cap forging 12 will have a major axis and a minor axis, it is necessary to measure the size of the forging before loading it into the furnace for shape correction, and mark the major axis and minor axis orientations of the end cap forging 12 on its outer surface; then, install the shape correction tooling: first, fix the first end cap support assembly and the second end cap support assembly on the support assembly, the support assembly is arranged in the heat treatment equipment according to the shape correction orientation, and the end cap forging 12 is placed on the support assembly according to the shape correction orientation, wherein the first end cap support assembly and the second end cap support assembly are respectively Located at both ends of the long axis direction of the end cap forging 12, and the first end cap support assembly is in contact with the outer circle of the end cap forging 12; a certain gap is set between the second end cap support assembly and the outer circle of the end cap forging 12, and the gap is used to set the fixing assembly and the force-applying assembly; during the shape correction, the force-applying assembly applies a certain force to the end cap forging 12 along the long axis direction through the fixing assembly, so that the end cap forging 12 undergoes elastic deformation in the long axis direction (radial direction), that is, the long axis of the end cap forging 12 shrinks and the short axis elongates, thereby achieving the purpose of precise shape correction. When the deformation of the end cap forging 12 reaches the predetermined target value, the fixing assembly fixes the end cap forging 12 to maintain the deformation, and then the force-applying assembly is removed, and the fixing assembly provides the support force to it through the second end cap support assembly to ensure the deformation of the end cap forging 12; finally, the end cap forging 12 is heat-treated by heat treatment equipment to eliminate stress, so that the end cap forging 12 is permanently deformed and the shape correction is completed.

[0061] Compared with the prior art, the present invention fixes the head forging 12 by utilizing a first head support assembly, a fixing assembly and a second head support assembly, and utilizes a force-applying assembly to apply force to the head forging 12 along the long axis direction, thereby achieving the purpose of shape correction, and ultimately realizing precise shape correction of the head forging 12.

[0062] It should be pointed out that the force-applying assembly of the present invention includes a large-tonnage hydraulic jack 8, for example, a 500-ton hydraulic jack 8. The hydraulic jack 8 is used as a force source to apply force to the long axis direction of the outer circle of the head forging 12, so that the head forging 12 undergoes elastic deformation in the radial direction, shortens the long axis, and lengthens the short axis, thereby achieving the purpose of shape correction.

[0063] It should be noted that the above-mentioned shaping tooling also includes a circular electric furnace; during shaping, the supporting assembly, the first head support assembly, the second head support assembly, the fixing assembly and the force-applying assembly are all arranged in the circular electric furnace; the circular electric furnace is used to heat treat the head forging 12 that applies the shaping force to eliminate stress.

[0064] Alternatively, the heat treatment equipment of the present invention adopts a rectangular electric furnace or a rectangular gas furnace. When an electric furnace of other shapes is adopted, the shapes of other components can be adjusted according to actual conditions.

[0065] It should be pointed out that the shape correction tool of the present invention also includes a plurality of support washers 11; the plurality of support washers 11 are arranged along the long axis direction of the head forging 12, and the support washers 11 are all used to support the bearing assembly to ensure its stability.

[0066] Compared with the prior art, the present invention supports the supporting assembly by means of the supporting washer 11 to ensure the stable placement of the supporting assembly, thereby ensuring the stability of the head forging 12 during shape correction.

[0067] In order to further ensure the stability of the head forging 12 during shape adjustment, the support assembly of the present invention includes a support steel plate 4, which is a rectangular steel plate; the support steel plate 4 is arranged on the support pad 11; the length of the support steel plate 4 is greater than the long axis length of the head forging 12.

[0068] Specifically, during the shape adjustment, the head forging 12 needs to be placed between the first head support assembly and the second head support assembly on the supporting steel plate 4. Along the long axis direction of the head forging 12, one end of the outer circle of the head forging 12 is against the first head support assembly, and the other end is in contact with the hydraulic jack 8 through the fixing assembly. When the hydraulic jack 8 applies force to it, the first head support assembly can provide supporting force to the head forging 12. Setting the length of the supporting steel plate 4 to be greater than the length of the long axis of the head forging 12 is to provide sufficient operating space to ensure that the head forging 12 is shaped on its top surface.

[0069] It should be noted that the upper and lower end surfaces of the supporting washer 11 are both flat end surfaces, and the other side surfaces can be any shape that is convenient for lifting and placement; similarly, the upper and lower end surfaces of the supporting steel plate 4 are both flat end surfaces so that it can be placed horizontally on the supporting washer.

[0070] In order to provide supporting force for the outer circle of the head forging 12, the first head supporting assembly of the present invention includes a first vertical plate 1 and a first conformal steel plate 3; the bottom surface of the first vertical plate 1 is welded and fixed to the supporting steel plate 4; the first conformal steel plate 3 is provided with an arcuate surface; the arcuate surface of the first conformal steel plate 3 is conformal to the part in contact with the head forging 12; when the head forging 12 is calibrated, the first vertical plate 1 provides supporting force to the head forging 12 through the first conformal steel plate 3.

[0071] Specifically, the first vertical plate 1 is a vertically arranged rectangular steel plate, the bottom surface of the first vertical plate 1 is welded and fixed to the supporting steel plate 4, and a first conformal steel plate 3 is provided on the side close to the head forging 12. One side of the arc surface of the first conformal steel plate 3 conforms to the outer circle of the corresponding head forging 12, and the other side rests on the first vertical plate 1; when calibrating, the hydraulic jack 8 acts as a force source to apply force to the long axis direction of the outer circle of the head forging 12. At this time, the first vertical plate 1 can generate a reaction force on the head forging 12 through the first conformal steel plate 3, thereby achieving the purpose of calibration.

[0072] Compared with the prior art, the present invention arranges a first conformal steel plate 3 between the first vertical plate 1 and the outer circle of the head forging 12, which can evenly transmit the reaction force generated by the first vertical plate 1 to the surface of the head forging 12, thereby avoiding large local deformation of the head forging 12 resulting in the size not meeting the requirements.

[0073] In order to ensure the firmness of the first vertical plate 1, the first head support assembly of the present invention also includes a plurality of first rib plates 2; the plurality of first rib plates 2 are arranged parallel to each other; the plurality of first rib plates 2 are arranged at one end of the first vertical plate 1 away from the first conformal steel plate 3 and are fixedly connected to the first vertical plate 1; the bottom of the first rib plate 2 is welded and fixed to the supporting steel plate 4, and the first rib plate 2 is used to provide support for the first vertical plate 1 to ensure that the first vertical plate 1 does not deform under the action of the hydraulic jack 8.

[0074] Specifically, the first rib plate 2 is a rectangular steel plate arranged in the vertical direction. Multiple first rib plates 2 are arranged parallel to each other and are fixed to the first vertical plate 1 by welding and are perpendicular to each other; the bottom of the first rib plate 2 is welded and fixed to the supporting steel plate 4.

[0075] Compared with the prior art, the present invention arranges a plurality of first ribs 2 and fixes the first ribs 2 to the first vertical plate 1 by welding. When the head forging 12 is shaped, the first ribs 2 can provide support for the first vertical plate 1, thereby ensuring that the first vertical plate 1 provides stable support for the first conformal steel plate 3.

[0076] In order to prevent indentations from occurring on the outer circle of the forging during the shaping process, the fixing assembly of the present invention includes a second conformal steel plate 5; along the long axis direction of the head forging 12, the second conformal steel plate 5 is located at the opposite end of the first conformal steel plate 3; the part where the second conformal steel plate 5 contacts the head forging 12 is conformal; and the force-applying assembly applies a shaping force to the head forging 12 through the second conformal steel plate 5.

[0077] Specifically, the second conformal steel plate 5 is provided with a curved surface, which matches the outer diameter of the head forging 12 that needs to be shaped, and the other surfaces are flat surfaces; during shaping, the second conformal steel plate 5 can evenly transmit the force generated by the hydraulic jack 8 to the surface of the head forging 12, thereby avoiding large local deformation of the head forging 12 resulting in the size not meeting the requirements.

[0078] It should be noted that the second end cover support assembly of the present invention includes a second vertical plate 9 ; the second vertical plate 9 is a rectangular parallelepiped steel plate; the second vertical plate 9 is welded to the supporting steel plate 4 along the vertical direction.

[0079] It should be noted that the first vertical plate 1 and the second vertical plate 9 of the present invention are both flat rectangular steel plates. The two vertical plates are symmetrically arranged on the supporting steel plate 4. The spacing between the first vertical plate 1 and the second vertical plate 9 is determined according to the outer diameter of the head forging 12 to be shaped and the size of the large-tonnage hydraulic jack 8, thereby ensuring that the head forging 12 to be shaped and the hydraulic jack 8 can be placed between the two vertical plates; the functions of the first vertical plate 1 and the second vertical plate 9 are to bear the force generated by the jack, and can allow the force to act on the head forging 12, thereby deforming the long axis of the head forging 12.

[0080] In order to support the second vertical plate 9, the second head support assembly of the present invention also includes a plurality of second rib plates 10; the plurality of second rib plates 10 are arranged parallel to each other; the plurality of second rib plates 10 are arranged at one end of the second vertical plate 9 away from the second conformal steel plate 5, and one end of the second rib plate 10 is fixedly connected to the second vertical plate 9, and the bottom thereof is welded and fixed to the supporting steel plate 4. The second rib plate 10 is used to provide support for the second vertical plate 9 to ensure that the second vertical plate 9 does not deform under the action of the hydraulic jack 8.

[0081] Compared with the prior art, the present invention provides a plurality of second ribs 10 and fixes the second ribs 10 to the second vertical plate 9 by welding. When the head forging 12 is shaped, the second ribs 10 can provide support for the second vertical plate 9, thereby ensuring that the second vertical plate 9 provides stable support for the fixing assembly and the head forging 12.

[0082] In order to maintain the state of the head forging 12 after the shaping force is applied, the fixing assembly of the present invention also includes a first supporting steel plate 6 and a second supporting steel plate 7 arranged in parallel; after the force-applying assembly applies the shaping force to the head forging 12, the first supporting steel plate 6 and the second supporting steel plate 7 are arranged between the second conforming steel plate 5 and the second vertical plate 9; one end of the first supporting steel plate 6 and the second supporting steel plate 7 are welded to the second conforming steel plate 5, and the other end is against the second vertical plate 9, and the first supporting steel plate 6 and the second supporting steel plate 7 are used to fix the size of the head forging 12 after shaping.

[0083] Specifically, the first supporting steel plate 6 and the second supporting steel plate 7 of the present invention are two rectangular steel plates with the same structure. The first supporting steel plate 6 and the second supporting steel plate 7 are arranged in parallel, one end of both are welded to the second conformal steel plate 5, and the other end is against the second vertical plate 9; the hydraulic jack 8 is located in the gap formed by the first supporting steel plate 6 and the second supporting steel plate 7. After the first supporting steel plate 6 and the second supporting steel plate 7 are fixed, the hydraulic jack 8 is removed, and the first supporting steel plate 6 and the second supporting steel plate 7 are used to fix the size of the head forging 12 after correction.

[0084] Compared with the prior art, the present invention can support the head forging 12 by providing the first supporting steel plate 6 and the second supporting steel plate 7 so as to keep the size after being shaped.

[0085] It should be noted that after the head forging 12 reaches the required deformation amount, connecting blocks are welded between the first supporting steel plate 6, the second supporting steel plate 7 and the second vertical plate 9 respectively, that is, one end of the first supporting steel plate 6 and the second supporting steel plate 7 is welded to the second conformal steel plate 5, and the other end is fixedly connected to the second vertical plate 9 through a welded connecting block. The first supporting steel plate 6, the second supporting steel plate 7 and the connecting blocks welded thereto are jointly used to fix the size of the head forging 12 after correction.

[0086] In order to further ensure the deformation of the head forging 12, the fixing assembly of the present invention also includes a support block, which is arranged in the gap formed by the first support steel plate 6 and the second support steel plate 7, that is, the installation position before the hydraulic jack 8. One end of the support block is welded and fixed to the second conformal steel plate 5, and the other end is against the second vertical plate 9. The support block is used to prevent the first support steel plate 6 and the second support steel plate 7 from deforming during the subsequent stress relief heating process, so as to avoid affecting the stress relief process of the head forging 12.

[0087] It should be noted that the present invention can add blocks of different sizes between the second vertical plate 9 and the hydraulic jack 8 according to the diameter of the head forging 12, and change the sizes of the first conformal steel plate 3 and the second conformal steel plate 5, so as to realize the accurate correction of the head forgings 12 of different diameters. That is, the correction tool of the present invention is a universal tool, which can be used for the correction of the head forgings 12 of different diameters. For the head forgings 12 of smaller size, the stroke of the hydraulic jack 8 is not enough. In order to ensure effective correction, a block is added between the second vertical plate 9 and the hydraulic jack 8, and the block is a rectangular or cubic metal block.

[0088] It should be noted that the shape correction tool of the present invention also includes a level; Figure 3 As shown, the spirit level is placed on the supporting shim 11 at the center of the furnace bottom; the spirit level is used to detect whether the heights of all the supporting shims 11 are basically consistent. If not, find the highest one and use it as a reference to record the heights of the other shims that need to be filled in, and use thin steel plates to fill in the heights to form an equal height plane to ensure the horizontal placement of the supporting steel plate 4.

[0089] The present invention can change the height dimensions of the first support steel plate 6 , the second support steel plate 7 , the first conformal steel plate 3 and the second conformal steel plate 5 according to the actual deformation of the head forging 12 , so as to achieve accurate correction of different height ranges on the head forging 12 .

[0090] Furthermore, the present invention can change the shapes and sizes of the first conformal steel plate 3 and the second conformal steel plate 5 according to the actual shape and size of the head forging 12, so as to achieve precise correction of the head forging 12 of different diameters and shapes.

[0091] In summary, the shaping tooling of the head forging 12 of the present invention utilizes the hydraulic jack 8 as a force source to apply force to the long axis direction of the outer circle of the head forging 12, so that the head forging 12 undergoes elastic deformation in the radial direction, shortens the long axis, and lengthens the short axis, so as to achieve the purpose of shaping; when the deformation reaches a predetermined target value, a first supporting steel plate 6 and a second supporting steel plate 7 are arranged in the direction of the jack force to maintain the deformation, and then the hydraulic jack 8 is removed, the connecting block is welded, and finally the head forging 12 and the shaping tooling are put into the furnace as a whole for stress relief heat treatment, so that the head forging 12 is permanently deformed and the shaping is completed.

[0092] The process of performing shape correction using the shape correction tool of the present invention comprises the following steps:

[0093] Step 1: Before loading into the furnace, measure the size of the head forging 12, and mark the major axis and minor axis orientations of the head forging 12 on its outer surface;

[0094] Step 2, along the length direction of the supporting steel plate 4, weld the first vertical plate 1 and the first rib plate 2 at the designated position at one end of the supporting steel plate 4; weld the second vertical plate 9 and the second rib plate 10 at the designated position at the other end of the supporting steel plate 4; wherein the first vertical plate 1 and the second vertical plate 9 are symmetrically arranged on the supporting steel plate 4;

[0095] In the above step 2, the first rib plate 2 is located on the side of the first vertical plate 1 away from the head forging 12, and the first rib plate 2 is used to fix and support the first vertical plate 1; the second rib plate 10 is located on the side of the second vertical plate 9 away from the head forging 12; the second rib plate 10 is used to fix and support the second vertical plate 9; the first vertical plate 1 and the second vertical plate 9 are both used to withstand the shaping force generated by the hydraulic jack 8, and can allow the shaping force to act on the head forging 12, so that the head forging 12 is deformed along its long axis direction.

[0096] In the above step 2, the spacing between the first vertical plate 1 and the second vertical plate 9 is determined according to the outer diameter of the head forging 12 to be shaped and the size of the hydraulic jack 8 to ensure that the head forging 12 to be shaped and the hydraulic jack 8 can be placed between the two vertical plates.

[0097] Step 3: When loading the furnace, open the furnace door of the circular electric furnace, and install the supporting pad iron 11 and the supporting steel plate 4 on the working table of the circular electric furnace;

[0098] In the above step 3, the support pad 11 is arranged along the long axis direction of the head forging 12 on the workbench of the circular electric furnace, and the supporting steel plate 4 is horizontally placed on the support pad 11. Figure 3 As shown, the support pads 11 are placed along a straight line to facilitate supporting the support steel plate 4 placed horizontally above.

[0099] In the above step 3, when the support pad iron 11 is placed on the circular electric furnace (such as Figure 3 As shown), place the spirit level on the supporting shim 11 at the center of the furnace bottom; use the spirit level to check whether the heights of all the supporting shims 11 are basically consistent. If not, find the highest shim and use it as a reference to record the heights of the other shims that need to be filled in, and use thin steel plates to fill in the heights to form equal height planes.

[0100] Step 4, placing the head forging 12 on the supporting steel plate 4 in a calibrated position;

[0101] In the above step 4, the head forging 12 is hoisted by a crane and placed stably on the supporting steel plate 4, and the long axis of the head forging 12 is rotated to the alignment position. The supporting steel plate 4 is structured as follows: Figure 4 and Figure 5 shown.

[0102] In the above step 4, check and level the supporting parts of the head forging 12.

[0103] Step 5, placing the first conformable steel plate 3, the second conformable steel plate 5, the first support steel plate 6 and the second support steel plate 7 on the supporting steel plate 4, and welding one end of the first support steel plate 6 and the second support steel plate 7 to the second conformable steel plate 5;

[0104] In the above step 5, the first conformable steel plate 3 is placed between the first vertical plate 1 and the outer circle of the head forging 12, and the arc surface of the first conformable steel plate 3 contacts and conforms to the head forging 12; the second conformable steel plate 5 is placed in the gap between the first vertical plate 1 and the outer circle of the head forging 12, and the arc surface of the second conformable steel plate 5 contacts and conforms to the head forging 12; the first support steel plate 6 and the second support steel plate 7 are placed in parallel between the second conformable steel plate 5 and the second vertical plate 9; one end of the first support steel plate 6 and the second support steel plate 7 are welded to the second conformable steel plate 5, and the other end is against the second vertical plate 9.

[0105] In the above step 5, the functions of the first conformal steel plate 3 and the second conformal steel plate 5 are to evenly transmit the shaping force generated by the hydraulic jack 8 to the outer surface of the head forging 12 to avoid large local deformation of the head forging 12 resulting in the size not meeting the requirements; the first support steel plate 6 and the second support steel plate 7 are used to fix the size of the head forging 12 after shaping.

[0106] Step 6: Place the jack and calibrate the shape;

[0107] A hydraulic jack 8 is placed between the first supporting steel plate 6 and the second supporting steel plate 7 , and the hydraulic jack 8 applies force to the outer surface of the head forging 12 through the second conformal steel plate 5 to adjust the shape.

[0108] In the above step 6, the data required for shape adjustment is determined according to the size of the head forging 12 after deformation. Before shape adjustment, corresponding marks are made on the supporting steel plate 4. The shape adjustment is completed when the required deformation amount is reached.

[0109] The shape correction process is as follows: Step 61, the jack is first slowly pressurized to eliminate the assembly gap so that both the two conformable steel plates are in contact with the outer wall of the head;

[0110] Step 62, the jack increases the pressure to 10 MPa and maintains the pressure for 10 minutes, and detects the deformation of the major and minor axes of the head forging 12;

[0111] Step 63, the jack increases the pressure to 20 MPa and maintains the pressure for 10 minutes, and detects the deformation of the major and minor axes of the head forging 12;

[0112] Step 64, the jack increases the pressure to 30 MPa and maintains the pressure for 10 minutes, and detects the deformation of the major and minor axes of the head forging 12;

[0113] Step 65, gradually increase the pressure and maintain the pressure for 10 minutes;

[0114] Step 66, after the jack increases the pressure to 60 MPa and reaches the stroke required for the expected deformation, the pressurization is stopped and the pressure is maintained for 10 minutes to detect the actual deformation of the head forging 12.

[0115] Step 7: Before removing the jack, welding connecting blocks are performed between the first supporting steel plate 6 and the second supporting steel plate 7 and the vertical plate to fix the size of the head forging 12 after the shape adjustment;

[0116] In the above step 7, after the head forging 12 reaches the required deformation amount, connecting blocks are welded between the first supporting steel plate 6, the second supporting steel plate 7 and the second vertical plate 9, that is, one end of the first supporting steel plate 6 and the second supporting steel plate 7 is welded to the second conformal steel plate 5, and the other end is fixedly connected to the second vertical plate 9 through the welded connecting block. The first supporting steel plate 6, the second supporting steel plate 7 and the connecting block welded thereto are jointly used to fix the size of the head forging 12 after correction.

[0117] Step 8, unloading the hydraulic jack 8;

[0118] Remove the hydraulic jack 8 and set a support block at the position of the original hydraulic jack 8.

[0119] Step 9, performing stress relief heat treatment;

[0120] The head forging 12 is kept at a temperature of 250-300°C for 4 hours; then the temperature of the heat treatment furnace (i.e., the circular electric furnace) is raised to 510-530°C at a rate of ≤55°C / h and kept for 2 hours; then the temperature of the heat treatment furnace is raised to 570-590°C at a rate of ≤55°C / h and kept for 9 hours; finally, the temperature of the heat treatment furnace is lowered to 350°C at a rate of ≤55°C / h and air-cooled.

[0121] Step 10: After cooling to room temperature, remove the shape correction tooling;

[0122] Step 11: re-check the inner hole size of the head forging 12. After the shaped head forging 12 meets the requirements, the shaped head forging 12 is completed.

[0123] Compared with the prior art, after the head forging 12 is shaped by the shaping tool and the shaping process of the present invention, the size of the head forging 12 meets the size of the delivery drawing, and there is a 5mm processing allowance on one side, achieving an ideal shaping effect.

[0124] Example 1

[0125] This embodiment uses the above-mentioned shaping tool to accurately shape the deformed head forging 12.

[0126] Take a head forging 12 as an example. After deformation, the inner hole major axis size of the head forging 12 is Φ5332.8mm, the ellipse is 60mm, the thickness is 166mm, and the weight is 52t. The inner hole delivery size of the head forging 12 is Φ5334mm, and the target size of the inner hole major axis after correction is Φ5324mm, with a 5mm margin on one side.

[0127] The specific calibration process is as follows:

[0128] (3) Measure the size of the end cap forging 12. Select a position on the end cap forging 12 as 0°, measure the diameter of the end cap forging 12 at certain angles in the circumferential direction, record the position and diameter, and mark the outer circle of the end cap forging 12.

[0129] like Figure 1 , Figure 2 As shown, in this example, 5 angles are selected in the circumferential direction to measure the inner hole size of the head forging 12. The specific dimensions before correction are shown in Table 1 below:

[0130] Table 1 Dimensions of head forging 12 before correction

[0131]

[0132] From the inspection data, it can be seen that the size of the head forging 12 can meet the requirements of the delivery drawing, but the local margin is small, and there is a risk of lack of meat in the subsequent fine processing. In order to meet the fine processing size and have a 5mm margin on one side, it is necessary to correct the shape. After correction, the target value of the inner hole size is Φ5324mm.

[0133] (4) Mark the long axis and short axis orientations of the head forging 12 on the outer surface, place the head forging 12 with the large end facing downward, and turn the long axis orientation of the head forging 12 to Figure 3 The alignment orientation shown;

[0134] (5) Weld the first vertical plate 1, the first rib plate 2, the second vertical plate 9 and the second rib plate 10 to the supporting steel plate 4 as required; the two vertical plates are symmetrically arranged on the supporting steel plate 4, and the spacing between them is determined according to the outer diameter of the end cap forging 12 to be calibrated and the size of the jack, ensuring that the end cap forging 12 to be calibrated and the hydraulic jack 8 can be placed between the two vertical plates;

[0135] (6) On a round electric furnace, Figure 3 Place the support pad 11 as shown, and place the level on the support pad 11 at the center of the furnace bottom;

[0136] (7) Use a level to check whether the heights of all supporting shims 11 are basically consistent. If not, find the highest shim and use it as a reference to record the heights of the other shims that need to be filled up, and use thin steel plates to fill up the heights to form an equal height plane;

[0137] (8) Place the supporting steel plate 4 on the supporting pad 11, and check and level and pad each supporting part of the supporting steel plate 4;

[0138] (9) Use a crane to lift the head forging 12 and place it stably on the supporting steel plate 4;

[0139] (10) placing the first supporting steel plate 6, the second supporting steel plate 7, the first conformal steel plate 3 and the second conformal steel plate 5 on the supporting steel plate 4;

[0140] (11) A 500-ton hydraulic jack 8 is placed in the gap between the first supporting steel plate 6 and the second supporting steel plate 7 on the supporting steel plate 4, and the shape correction process is carried out:

[0141] The shape correction process is as follows: ① The jack is first pressurized slowly to eliminate the assembly gap and make the two conformal steel plates contact the outer wall of the head; ② The jack is pressurized to 10MPa and maintained for 10 minutes to detect the deformation of the long and short axes of the head forging 12; ③ The jack is pressurized to 20MPa and maintained for 10 minutes to detect the deformation of the long and short axes of the head forging 12; ④ The jack is pressurized to 30MPa and maintained for 10 minutes to detect the deformation of the long and short axes of the head forging 12. ⑤ Gradually increase the pressure and maintain the pressure for 10 minutes. ⑥ After the jack is pressurized to 60MPa and reaches the stroke required for the expected deformation, stop pressurizing, maintain the pressure for 10 minutes, and detect the actual deformation of the head forging 12.

[0142] (12) Welding a connecting block to one end of the first supporting steel plate 6 and the second supporting steel plate 7 adjacent to the second vertical plate 9 to fix the size of the head forging 12 after correction;

[0143] (13) Unload the jack. After removing the jack, place a support block at the original jack position to prevent deformation of the supporting steel plate during the subsequent stress relief heating process;

[0144] (14) Perform stress relief heat treatment. The method of stress relief heat treatment is as follows: Figure 6 As shown: the workpiece is kept at a temperature of 250-300℃ for 4 hours; then the temperature of the heat treatment furnace is raised to 510-530℃ at a rate of ≤55℃ / h and kept for 2 hours; then the temperature of the heat treatment furnace is raised to 570-590℃ at a rate of ≤55℃ / h and kept for 9 hours; finally, the temperature of the heat treatment furnace is lowered to 350℃ at a rate of ≤55℃ / h and air-cooled after being taken out of the furnace;

[0145] (15) After cooling to room temperature, remove the shaping tooling;

[0146] (16) Re-check the inner hole size of the head forging 12.

[0147] The inner hole dimensions of the head forging 12 after correction are shown in the following table:

[0148]

[0149] It can be seen from the inspection data that the dimensions in all directions meet the requirements of fine machining after correction, and the minimum machining allowance of the inner hole is 4mm.

[0150] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by any technician familiar with the technical field within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention.

Claims

1. A tool for correcting the shape of a head forging, characterized in that: It includes a supporting assembly, a first end cover supporting assembly, a second end cover supporting assembly, a fixing assembly and a force applying assembly; The support assembly is arranged along the long axis direction of the head forging, and the head forging is placed on the support assembly; The first head support assembly and the second head support assembly are located at both ends of the head forging in the long axis direction, and the bottom of the first head support assembly and the bottom of the second head support assembly are fixedly connected to the supporting assembly; the force-applying assembly and the fixing assembly are both arranged in the long axis direction of the head forging and located between the outer circle of the head forging and the second head support assembly, the force-applying assembly is used to apply a shaping force to the outer surface of the head forging, and the fixing assembly is used to maintain the head forging in a state after being shaped.

2. The shape correction tool for the head forging according to claim 1 is characterized in that: Also included is a round electric stove; The support assembly, the first end support assembly, the second end support assembly, the fixing assembly and the force application assembly are all arranged in the circular electric furnace; The circular electric furnace is used to perform heat treatment on the head forging that is subjected to the shaping force to eliminate stress.

3. The shape correction tool for the head forging according to claim 2 is characterized in that: Also included are a plurality of support shims; A plurality of support washers are arranged along the long axis direction of the head forging, and the support washers are used to support the support assembly to ensure its stability.

4. The shape correction tool for the head forging according to claim 3 is characterized in that: The support assembly comprises a support steel plate, and the support steel plate is a rectangular parallelepiped steel plate; The supporting steel plate is arranged on the supporting pad; the length of the supporting steel plate is greater than the major axis length of the head forging.

5. The shape correction tool for the head forging according to claim 4 is characterized in that: The first head support assembly includes a first vertical plate and a first conformal steel plate; The bottom surface of the first vertical plate is welded and fixed to the supporting steel plate; the first conformal steel plate is provided with an arcuate surface; the arcuate surface of the first conformal steel plate is conformal to the portion in contact with the head forging; when the head forging is calibrated, the first vertical plate provides supporting force to the head forging through the first conformal steel plate.

6. The shape correction tool for the head forging according to claim 5 is characterized in that: The first head support assembly further includes a plurality of first ribs; The plurality of first ribs are arranged parallel to each other; the plurality of first ribs are arranged at one end of the first vertical plate away from the first conformable steel plate and are fixedly connected to the vertical plate; The bottom of the first rib is welded and fixed to the supporting steel plate, and the first rib is used to provide support for the first vertical plate.

7. The shape correction tool for the head forging according to claim 6 is characterized in that: The fixing assembly includes a second conformal steel plate; Along the long axis direction of the head forging, the second conformal steel plate is located at the opposite end of the first conformal steel plate; the arc surface of the second conformal steel plate is conformal at the contact portion with the head forging; the force-applying component applies a conforming force to the outer surface of the head forging through the second conformal steel plate.

8. The shape correction tool for the head forging according to claim 7 is characterized in that: The second head support assembly includes a second vertical plate; The second vertical plate is a rectangular steel plate; the second vertical plate is welded to the supporting steel plate along the vertical direction.

9. The shape correction tool for the head forging according to claim 8, characterized in that: The second end cover support assembly further includes a plurality of second ribs; The plurality of second ribs are arranged parallel to each other; the plurality of second ribs are arranged at one end of the second vertical plate away from the second conformal steel plate, and one end of the second rib is fixedly connected to the second vertical plate; The bottom of the second rib plate is welded and fixed to the supporting steel plate, and the second rib plate is used to provide support for the second vertical plate.

10. A method for correcting the shape of a head forging, characterized in that: The shaping tool according to any one of claims 1 to 9 is used; the shaping method comprises the following steps: Step 1: Before loading into the furnace, measure the size of the head forging, and mark the major axis and minor axis orientation of the head forging on its outer surface; Step 2, welding the first end support assembly and the second end support assembly on the supporting steel plate; Step 3: When loading the furnace, open the furnace door and install the supporting pad iron and supporting steel plate on the working table of the circular electric furnace in sequence; Step 4, placing the end head forging on the supporting steel plate in a shaped orientation, wherein the end head forging is located between the first end head support assembly and the second end head support assembly; Step 5: Place the fixed components; The fixing assembly is located in the gap between the outer circle of the head forging and the second head supporting assembly; Step 6: Place the force-applying component, and the force-applying component calibrates the head forging through the fixing component; Step 7: Before removing the force-applying component, use the fixing component to fix the size of the head forging after the shape adjustment; Step 8: Uninstall the force-applying component; Remove the force-applying component and set a support block in its place; Step 9, performing stress relief heat treatment; Step 10: After cooling to room temperature, remove the shape correction tooling; Step 11: Re-check the inner hole size of the head forging. After the shaped head forging meets the requirements, the shaped head forging is completed.

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