Forging compaction method, application thereof and supporting roller

Abstract

The invention relates to a forging compaction method, application thereof and a support roller, belongs to the technical field of forging, and solves the problems of poor steel ingot core quality and high flaw detection rejection rate caused by the existing forging anvil arrangement mode. The forging compaction method comprises the steps that the first anvil is arranged in the middle of a steel ingot, and then the anvils are sequentially arranged from the middle to the two ends of the steel ingot. The first anvil is arranged in the middle of the steel ingot and corresponds to the center of the steel ingot, the maximum deformation amount can be concentrated on the part with the most serious defect in the middle of the steel ingot, the loose defect of the center of the steel ingot is fully compacted, the quality of the center of the steel ingot is improved, and the flaw detection rejection rate of products is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of forging, and in particular to a forging compaction method and an application thereof and a supporting roller. Background Art

[0002] The traditional KD compaction method generally places the anvils from the riser to the nozzle, from the nozzle to the riser, and alternately from the nozzle to the nozzle (for example, the first pass is to place the anvils from the nozzle to the riser, and the second pass is to place the anvils from the riser to the nozzle). We all know that after the solidification of the ingot, secondary shrinkage and looseness are inevitably left in the center of the ingot, which is a problem that must be solved in the subsequent forging compaction. The traditional anvil placement method generally starts from the nozzle or the riser. In the actual production process, this anvil placement method will result in some products failing the subsequent flaw detection and being scrapped due to the core defects that are not fully compacted. Summary of the invention

[0003] In view of the above analysis, the embodiment of the present invention aims to provide a forging compaction method and its application and support roller, so as to solve the problem that the existing forging anvil arrangement method leads to poor quality of the core of the steel ingot and a high defect detection rejection rate.

[0004] On the one hand, an embodiment of the present invention provides a forging and compacting method, which includes: arranging a first anvil in the middle of a steel ingot, and then sequentially placing anvils from the middle to both ends of the steel ingot.

[0005] Preferably, in odd-numbered passes, anvils are placed from one end of the ingot to the other end; in even-numbered passes, the first anvil is arranged in the middle of the ingot, and then anvils are placed from the middle position to both ends of the ingot.

[0006] Preferably, after the previous pass is completed, the steel ingot is turned 90° before the next pass is performed.

[0007] Preferably, the anvils are staggered between adjacent passes.

[0008] Preferably, in odd-numbered passes, the anvils are arranged from the riser end to the nozzle end of the ingot.

[0009] Preferably, in even-numbered passes, the first anvil is arranged in the middle of the ingot, and then the anvils are placed from the side of the first anvil close to the riser to the riser end of the ingot, and then the anvils are placed from the side of the first anvil close to the nozzle to the nozzle end of the ingot.

[0010] Preferably, the method is a KD forging method.

[0011] Preferably, the reduction in each pass is 20-25% of the height of the steel ingot.

[0012] In a second aspect, the present invention provides application of the above method in support roll forging production.

[0013] In a third aspect, the present invention provides a support roller, which is prepared by forging using the above method.

[0014] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0015] 1. The present invention arranges the first anvil in the middle of the steel ingot, corresponding to the core of the steel ingot, so that the maximum deformation can be concentrated at the position with the most serious defects in the middle of the steel ingot, so as to fully compact the loose defects in the core of the steel ingot, improve the quality of the core of the steel ingot, and reduce the scrap rate of the product.

[0016] 2. The present invention adopts a method of placing anvils differently in odd and even passes. The anvils are placed from one end of the ingot to the other end in odd passes, and the first anvil is placed in the middle of the ingot in even passes. Then, the anvils are placed from the middle to the two ends of the ingot respectively, which ensures that the anvils in adjacent passes are staggered. At the same time, the first anvil with the largest deformation in the even passes is placed in the middle of the ingot, so that the middle center of the ingot body produces sufficient deformation, which is more conducive to compacting and welding the defects in the center of the ingot.

[0017] 3. Compared with the existing anvil arrangement method, the forging and compacting anvil arrangement method of the present invention reduces the flaw detection scrap rate from 8% to less than 2%.

[0018] 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 description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] 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.

[0020] Figure 1 This is a schematic diagram of the traditional anvil arrangement method;

[0021] Figure 2 Schematic diagram of forging deformation before and after the first anvil is pressed down;

[0022] Figure 3 This is a diagram of the anvil arrangement method of the present invention;

[0023] Figure 4 This is a comparison diagram of the defect compaction effect at the middle position of the forging of Example 1 and Comparative Example 1. DETAILED DESCRIPTION

[0024] The preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of this application 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.

[0025] The traditional KD compaction method is to place the anvils from the riser to the nozzle in the first pass, turn the blank 90°, and place the anvils from the riser to the nozzle in the second pass. Figure 1 As shown; or, the first pass is to place the anvils from the sprue to the riser, and the blank is turned 90°, and the second pass is still to place the anvils from the sprue to the riser; or, the first pass is to place the anvils from the sprue to the riser, and the blank is turned 90°, and the second pass is still to place the anvils from the riser to the sprue, and the sprue and the riser are alternately placed. The first anvil of each pass in the above three traditional anvil placement methods is set at the sprue or the riser. In actual production, the inventor found that after the first anvil is pressed down, the hammer edge blank will be carried down with the pressing of the first anvil, such as Figure 2 As shown, the second anvil's pressing amount is significantly less than that of the first anvil, and the compaction effect of the subsequent anvils is significantly worse than that of the first anvil. The products produced by such forging often have a loose core that is not compacted, resulting in product scrapping.

[0026] Therefore, on the one hand, the present invention provides a forging and compacting method, which comprises: arranging a first anvil in the middle position of the steel ingot, and then sequentially placing anvils from the middle position to both ends of the steel ingot.

[0027] Compared with the prior art, the present invention arranges the first anvil that can cause the maximum deformation of the steel ingot in the middle position of the steel ingot, corresponding to the core of the steel ingot, so as to concentrate the maximum deformation at the part with the most serious defects in the middle of the steel ingot, so as to fully compact the loose defects in the core of the steel ingot, improve the quality of the core of the steel ingot, and reduce the scrap rate of the product.

[0028] In one embodiment, Figure 3 As shown, in odd-numbered passes, anvils are placed from one end of the ingot to the other end; in even-numbered passes, the first anvil is arranged in the middle position of the ingot, and then anvils are placed from the middle position to both ends of the ingot.

[0029] The present invention adopts a method of placing anvils differently in odd and even passes, where the anvils are placed from one end of the steel ingot to the other end in odd passes, and the first anvil in the even passes is placed in the middle of the steel ingot, and then the anvils are placed from the middle to the two ends of the steel ingot respectively, thereby ensuring that the anvils in adjacent passes are staggered, and at the same time, the first anvil with the largest deformation in the even passes is placed in the middle of the steel ingot, so that the middle center of the ingot body produces sufficient deformation, which is more conducive to compacting and welding the defects in the center of the steel ingot.

[0030] In the present invention, while the anvils are arranged differently in odd and even passes, the anvils are arranged staggered between adjacent passes. The staggered anvils between adjacent passes refer to the anvils of adjacent passes not being aligned, and the anvils in one pass correspond to the connection between two adjacent anvils in the adjacent pass. Since the compaction effect of the connection between adjacent anvils in the same pass is poor, the staggered anvil arrangement between adjacent passes can make up for the compaction effect of the connection between adjacent anvils in the same pass, further improving the compaction effect of the steel ingot.

[0031] Illustratively, in odd-numbered passes, the anvils are arranged from the riser end to the nozzle end of the steel ingot, or from the nozzle end to the riser end of the steel ingot.

[0032] Illustratively, in the even-numbered passes, the first anvil is arranged in the middle position of the ingot, and then the anvil is placed from the side of the first anvil close to the riser to the riser end of the ingot, and then the anvil is placed from the side of the first anvil close to the water nozzle to the water nozzle end of the ingot; alternatively, the first anvil is arranged in the middle position of the ingot, and then the anvil is placed from the side of the first anvil close to the water nozzle to the water nozzle end of the ingot, and then the anvil is placed from the side of the first anvil close to the riser to the riser end of the ingot.

[0033] It can be understood that the anvils of adjacent odd-numbered passes and even-numbered passes are staggered.

[0034] Since the exact position of the first anvil of the even-numbered passes has been determined and cannot be adjusted, in order to stagger the anvils between adjacent passes, the relative position of the first anvil of the odd-numbered passes and the end of the ingot can be adjusted to achieve staggered anvils between adjacent passes.

[0035] by Figure 3 For example, a steel ingot can complete one pass through 3 anvils, wherein in the odd-numbered passes, the anvils are arranged in sequence from the riser to the nozzle, including the first anvil, the second anvil and the third anvil arranged in sequence from the riser to the nozzle, such as Figure 3 As shown in (a); in the even-numbered passes, the first anvil is arranged in the middle of the ingot, and then the second anvil is arranged on the side of the first anvil close to the riser, and the third anvil is arranged on the side of the first anvil close to the nozzle, as shown in FIG. Figure 3 As shown in (b); at the same time, the staggered anvil arrangement between adjacent odd-numbered passes and even-numbered passes can be ensured by adjusting the relative position of the first anvil in the odd-numbered passes and the riser end of the ingot.

[0036] Exemplarily, the method further comprises: after the previous pass is completed, the steel ingot is flipped 90° before performing the next pass.

[0037] Exemplarily, the method is a KD forging method. The KD forging method is a high-temperature diffusion heating, upper and lower V-shaped wide anvils, and large reduction forging method developed on the basis of the WHF forging method (K and D are the first Chinese pinyin for wide and large). Its characteristics are: the steel ingot has sufficient plasticity under high temperature for a long time, and forging with upper and lower V-shaped wide anvils is conducive to forging porosity defects. Since the anvil arrangement method of the existing KD forging method is to set the first anvil of each pass at the water inlet or the riser, it is not conducive to the compaction of the loose position of the core of the steel ingot. Applying the anvil arrangement method of the present invention to the KD forging method can compact the loose position of the core of the steel ingot and improve the quality of the core of the steel ingot. At the same time, the staggered anvil arrangement between adjacent passes can further improve the compaction effect of the steel ingot.

[0038] Exemplarily, the length of the upper V-anvil and the lower V-anvil are both 3500-4000 mm, the width is both 1000-2000 mm, the height is both 1200-1800 mm, and the angle of the V-shaped groove is 120-150 degrees.

[0039] Exemplarily, the reduction amount of each pass is 20-25% of the height of the ingot billet, such as 21%, 22%, 23%, 24%, 25%, etc.

[0040] Since the edge of the anvil is usually arc-shaped, in order to improve the compaction connection between two adjacent anvils in the same pass, the two adjacent anvils in the same pass are partially overlapped.

[0041] In a second aspect, the present invention also provides an application of the above method in the production of forging support rollers. The method of the present invention is applied to forging support rollers to fully compact the loose defects in the center of the steel ingot, improve the quality of the center of the steel ingot, and thus improve the quality of the support rollers.

[0042] In a third aspect, the present invention further provides a support roller, which is prepared by forging using the method of the present invention.

[0043] When the support roller is forged by the existing anvil arrangement method, there is often a situation where the roller body has no bottom wave during flaw detection, and the flaw detection pass rate is low; the present invention arranges the first anvil in the middle of the ingot, and then arranges the anvils from the middle position to the two ends of the ingot in sequence, so that the first anvil that produces the maximum deformation of the ingot is arranged in the middle of the ingot, corresponding to the core of the ingot, and the maximum deformation can be concentrated in the part with the most serious defects in the middle of the ingot, so as to fully compact the loose defects in the core of the ingot, improve the quality of the core of the ingot, and reduce the product scrap rate. Compared with the support roller forged by the existing anvil arrangement method, the flaw detection scrap rate of the support roller of the present invention is reduced from 8% to 2%.

[0044] In a more preferred embodiment, an odd-numbered and even-numbered pass differential anvil placement is adopted, where the anvils are placed from one end of the ingot to the other end for the odd-numbered passes, and the first anvil for the even-numbered passes is placed in the middle of the ingot, and then the anvils are placed from the middle to the two ends of the ingot, respectively. This ensures that the anvils of adjacent passes are staggered, and at the same time, the first anvil with the largest deformation amount for the even-numbered passes is placed in the middle of the ingot, so that the middle center of the ingot body produces sufficient deformation, which is more conducive to compacting and welding the defects in the center of the ingot. The defect detection scrap rate of the support roller obtained by this embodiment can reach less than 2%. The present invention has no requirements on the material and size of the support roller.

[0045] The forging and compacting method and its application and the support roller of the present invention are further explained below through specific embodiments.

[0046] The ultrasonic flaw detection method for the forgings of the following examples and comparative examples is JB / T8467; the equipment model is HS-511; the acceptance standard is JB / T4120-2006, and the forgings are qualified if no record defects are found.

[0047] Example 1

[0048] This embodiment provides a support roller steel ingot forging and compacting method, comprising the following steps:

[0049] (1) Provide a steel ingot (81T steel ingot, made of Cr4 material, nozzle φ1776mm, riser φ2009mm, ingot length 2838mm), and prefabricate a hole defect (defect size φ50, length 900mm) in the center of the steel ingot;

[0050] (2) The steel ingot is placed between the upper V-anvil and the lower V-anvil. The length of the upper V-anvil and the lower V-anvil are 3500 mm, the width is 1400 mm, the height is 1200 mm, and the angle of the V-shaped groove is 120 degrees. The KD method is used for forging. After the previous pass is completed, the steel ingot is turned 90° before the next pass. The reduction in each pass is 23% of the height of the steel ingot.

[0051] Among them, in the odd-numbered passes, the first anvil, the second anvil and the third anvil are arranged in sequence from the riser end to the nozzle end of the ingot, and a total of 3 anvils are used to complete the anvil arrangement; in the even-numbered passes, the first anvil is arranged in the middle position of the ingot, and then the second anvil is arranged from the side of the first anvil close to the riser, and then the third anvil is arranged from the side of the first anvil close to the nozzle, and a total of 3 anvils are used to complete the anvil arrangement.

[0052] The anvils in adjacent passes are staggered by adjusting the relative position between the first anvil of the odd pass and the riser end of the ingot. The adjacent two anvils in the same pass are partially overlapped.

[0053] The compaction effect of the forging obtained in this embodiment is as follows: Figure 4 As shown, the ultrasonic flaw detection rejection rate is 1.5%.

[0054] Example 2

[0055] This embodiment provides a support roller steel ingot forging and compacting method, comprising the following steps:

[0056] (1) Provide a steel ingot (75T steel ingot, made of Cr3 material, nozzle φ1656mm, riser φ1832mm, ingot length 2637mm), and prefabricate a hole defect (defect size φ45, length 750mm) in the center of the steel ingot;

[0057] (2) The steel ingot is placed between the upper V-anvil and the lower V-anvil. The length of the upper V-anvil and the lower V-anvil are both 4000 mm, the width is 2000 mm, the height is 1800 mm, and the angle of the V-shaped groove is 150 degrees. The KD method is used for forging. After the previous pass is completed, the steel ingot is turned 90° before the next pass. The reduction in each pass is 20% of the height of the steel ingot.

[0058] Among them, in the odd-numbered passes, the first anvil, the second anvil and the third anvil are arranged in sequence from the water inlet end to the riser end of the ingot, and a total of 3 anvils are used to complete the anvil arrangement; in the even-numbered passes, the first anvil is arranged in the middle position of the ingot, and then the second anvil is arranged from the side of the first anvil close to the water inlet, and then the third anvil is arranged from the side of the first anvil close to the riser, and a total of 3 anvils are used to complete the anvil arrangement.

[0059] The anvils in adjacent passes are staggered by adjusting the relative position between the first anvil of the odd pass and the ingot nozzle end. The adjacent anvils in the same pass are partially overlapped.

[0060] The defective rate of forgings obtained in this embodiment is 1.8%.

[0061] Example 3

[0062] This embodiment provides a support roller steel ingot forging and compacting method, comprising the following steps:

[0063] (1) Provide a steel ingot (90T steel ingot, made of Cr5 material, nozzle φ1784mm, riser φ2561mm, ingot length 2983mm), and prefabricate a hole defect (defect size φ52, length 980mm) in the center of the steel ingot;

[0064] (2) The steel ingot is placed between the upper V-anvil and the lower V-anvil. The length of the upper V-anvil and the lower V-anvil are 3700 mm, the width is 1700 mm, the height is 1600 mm, and the angle of the V-shaped groove is 140 degrees. The KD method is used for forging. After the previous pass is completed, the steel ingot is turned 90° and the next pass is carried out. The reduction in each pass is 25% of the height of the steel ingot.

[0065] Among them, in the odd-numbered passes, the first anvil, the second anvil and the third anvil are arranged in sequence from the water inlet end to the riser end of the ingot, and a total of 3 anvils are used to complete the anvil arrangement; in the even-numbered passes, the first anvil is arranged in the middle position of the ingot, and then the second anvil is arranged from the side of the first anvil close to the riser, and then the third anvil is arranged from the side of the first anvil close to the water inlet, and a total of 3 anvils are used to complete the anvil arrangement.

[0066] The anvils in adjacent passes are staggered by adjusting the relative position between the first anvil of the odd pass and the ingot nozzle end. The adjacent anvils in the same pass are partially overlapped.

[0067] The defective rate of forgings obtained in this embodiment is 1.7%.

[0068] Example 4

[0069] This embodiment provides a support roller steel ingot forging and compacting method, comprising the following steps:

[0070] (1) providing a steel ingot identical to that in Example 1, and prefabricating a hole defect identical to that in Example 1 in the center of the steel ingot;

[0071] (2) The steel ingot is placed between the upper V-anvil and the lower V-anvil and forged using the KD method. After the previous pass is completed, the steel ingot is turned 90° and then the next pass is performed. The reduction in each pass is 23% of the height of the steel ingot.

[0072] The first anvil of each pass is arranged in the middle of the ingot, and then the second anvil is arranged from the side of the first anvil close to the riser, and the third anvil is arranged from the side of the first anvil close to the nozzle, that is, the anvil arrangement method of odd-numbered passes and even-numbered passes is the same, and there is no staggered anvil arrangement between adjacent passes. Two adjacent anvils in the same pass partially overlap.

[0073] The defective rate of forgings obtained in this embodiment is 2%.

[0074] Comparative Example 1

[0075] This embodiment provides a support roller steel ingot forging and compacting method, comprising the following steps:

[0076] (1) providing a steel ingot identical to that in Example 1, and prefabricating a hole defect identical to that in Example 1 in the center of the steel ingot;

[0077] (2) The steel ingot is placed between the upper V-anvil and the lower V-anvil and forged using the KD method. After the previous pass is completed, the steel ingot is turned 90° and then the next pass is performed. The reduction in each pass is 23% of the height of the steel ingot.

[0078] In each pass, the anvils are arranged from the riser end to the nozzle end of the ingot. The adjacent anvils in the same pass partially overlap.

[0079] The compaction effect of the forging obtained in this comparative example is as follows: Figure 4 As shown, the flaw detection scrap rate is 8%.

[0080] according to Figure 4 It can be seen that the equivalent strain value of the core of the forging (at 1000-1500mm) prepared by the forging and compaction method of the embodiment is greater than the equivalent strain value of the core of the forging prepared by the forging method of comparative example 1. It can be seen that compared with the existing anvil arrangement method, the anvil arrangement method of the forging and compaction method of the present invention can achieve a better defect compaction effect in the middle position of the billet. This is because the present invention arranges the first anvil that can cause the maximum deformation of the ingot in the middle position of the ingot, corresponding to the core of the ingot, and can concentrate the maximum deformation at the most serious defect position in the middle of the ingot, so as to fully compact the loose defects in the core of the ingot and improve the quality of the core of the ingot.

[0081] By comparing the results of Example 1 with those of Example 4, it can be seen that the compaction effect of the method of placing anvils in odd and even passes is better than the compaction effect of placing anvils in the middle of each pass. This is because the method of placing anvils in odd and even passes is adopted, the anvils are placed from one end of the ingot to the other end of the ingot in the odd passes, the first anvil of the even passes is arranged in the middle of the ingot, and then the anvils are placed from the middle to the two ends of the ingot respectively. The anvils between adjacent passes can be staggered by adjusting the relative position of the first anvil of the odd pass and the end of the ingot to compensate for the compaction effect of the connection between adjacent anvils in the same pass. At the same time, the first anvil with the largest deformation in the even pass is arranged in the middle of the ingot, so that the middle center of the ingot body produces sufficient deformation, which is more conducive to compacting the defects in the center of the welded ingot and improving the quality of the center of the ingot.

[0082] 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 forging and compacting method, characterized in that: The forging and compacting method comprises: arranging a first anvil at the middle position of the steel ingot, and then sequentially arranging anvils from the middle position to both ends of the steel ingot.

2. The method according to claim 1, characterized in that In odd-numbered passes, anvils are placed from one end of the ingot to the other end; in even-numbered passes, the first anvil is placed in the middle of the ingot, and then anvils are placed from the middle position to both ends of the ingot.

3. The method according to claim 2, characterized in that After the previous pass is completed, the ingot is turned 90° before the next pass.

4. The method according to claim 2, characterized in that: The anvils are staggered between adjacent passes.

5. The method according to claim 2, characterized in that: In odd-numbered passes, the anvils are placed from the riser end to the nozzle end of the ingot.

6. The method according to claim 2, characterized in that In the even-numbered passes, the first anvil is arranged in the middle of the ingot, and then the anvils are placed from the side of the first anvil close to the riser to the riser end of the ingot, and then from the side of the first anvil close to the nozzle to the nozzle end of the ingot.

7. The method according to claim 1, characterized in that The method is a KD forging method.

8. The method according to claim 7, characterized in that The reduction in each pass is 20-25% of the ingot height.

9. Application of the method according to any one of claims 1 to 8 in support roll forging production.

10. A support roller, characterized in that: The support roller is prepared by forging using the method described in any one of claims 1 to 8.

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