Method for compositely manufacturing aluminum alloy butt joint ring through additive forging

Abstract

The invention discloses a method for compositely manufacturing an aluminum alloy butt joint ring through additive forging, and belongs to the field of forging. The invention aims to solve the problems that the material utilization rate of the butt joint ring produced in the existing machining and welding mode is low, the overall bearing limit of a welding seam at the joint of a guide petal and a guide ring is reduced, and precise milling equipment is needed due to the complex shape of the guide petal. The method comprises: 1, forge piece shape design; 2, forging stock shape design; 3, forging and forming; and fourthly, the remaining butt joint ring guide rings are added. The method is used for compositely manufacturing the aluminum alloy butt joint ring through additive forging.

Description

Technical Field

[0001] The invention belongs to the field of forging. Background Art

[0002] Aluminum alloy is one of the important materials for achieving lightweight due to its advantages such as low density and high specific strength, and is widely used in the aerospace field. Additive manufacturing technology can form parts with complex shapes, achieve near-net forming, and improve material utilization. However, there are many defects inside additive parts, such as pores, microcrack structure and unevenness, but these defects can be eliminated through forging technology, while improving the comprehensive mechanical properties. The passive docking structure docking ring in the "heterogeneous isomorphic periphery" docking device of the space capsule can be divided into a guide flap and a guide ring. The docking ring is an important application of aluminum alloy in the aviation field.

[0003] At present, most guide flaps are manufactured by milling, and then the guide flaps and guide rings are connected by welding. This method of producing docking rings has low material utilization rate. The weld at the connection between the guide flaps and the guide rings reduces the overall load-bearing limit. At the same time, welding greatly reduces the three-dimensional spatial accuracy of the docking ring. In addition, additional ring rolling equipment is required to form the guide ring, and the material production cost is high. If the integral casting or additive manufacturing method is adopted, although it can improve the dimensional accuracy of the docking ring, realize integral forming, and greatly improve the material utilization rate, the defects caused by casting or additive manufacturing reduce the load-bearing limit and reduce safety. At the same time, due to the complex shape of the special-shaped thin wall of the docking ring, it is difficult to manufacture the casting sand mold and control the additive process. Summary of the invention

[0004] The present invention aims to solve the problems that the material utilization rate of the butt ring produced by the existing machining and welding methods is low, the weld at the connection between the guide flap and the guide ring reduces the overall load-bearing limit, and the complex shape of the guide flap requires precise milling processing equipment, and provides a method for additive forging composite manufacturing of aluminum alloy butt rings.

[0005] A method for additive forging composite manufacturing of an aluminum alloy butt ring is carried out according to the following steps:

[0006] 1. Forging shape design:

[0007] The docking ring part is composed of a guide ring and a guide petal, and three guide petals are evenly arranged on the circumference of the guide ring; the docking ring part is divided into a separate guide ring part and a guide petal and guide ring connection part; the guide petal and guide ring connection part forging is designed according to the structure of the guide petal and guide ring connection part;

[0008] The guide flap and guide ring connecting part forging is a left-right symmetrical structure composed of an arc-shaped web forging and a guide circular arc forging; edge bosses are arranged on the left and right edges and the upper edge of the arc-shaped web forging, the lower edge of the arc-shaped web forging is connected to the guide circular arc forging, two long vertical rib forgings and two short vertical rib forgings are symmetrically arranged on the arc-shaped web forging, one end of the two long vertical rib forgings is connected to the edge boss, and the other end is connected to the guide circular arc forging, and the short vertical rib forging is located on the inner side of the two long vertical rib forgings and connected to the guide circular arc forging;

[0009] Assume that the angle between the left and right edge bosses of the arc-shaped web forging is A. 1 , assuming that the angle between the arc web forging and the guide arc forging is A 2 , A 1 :A 2 =(1.90~2.10):1;

[0010] Assume the thickness of the curved web forging is T 1 , assuming that the width of the two long vertical rib forgings is T 2 , T 1 :T 2 =1:(1.12~1.25); Assume that the distance between the centers of the two long vertical rib forgings is D 1 , D 1 =250mm~260mm; Assume the thickness of the two long vertical rib forgings is H 1 , assuming the maximum height of the curved web forging is H 2 , H 1 :H 2 =1:(7.00~10.67);

[0011] Assume the thickness of the edge boss is T 3 , let the width of the edge boss be T 4 , T 3 :T 4 =1:(1.13~1.37);

[0012] Assume that the distance between the centers of the two short vertical rib forgings is D 2 , assuming that the width of the two short vertical rib forgings is T 5 , T 5 :D 2 =1:(10.77~13.64); Assume the bottom thickness of the two short vertical rib forgings is H 5 , H 5 =(0.7~0.9)H 1 ;

[0013] Assume that the inner radius of the guide arc forging is (R 1 ) min , assuming the outer radius of the guide arc forging is (R1 ) max , (R 1 ) min :(R 1 ) max =1:(1.20~1.25);

[0014] 2. Forging shape design:

[0015] Design the forging blank of the connecting part of the guide flap and the guide ring according to the forging of the connecting part of the guide flap and the guide ring;

[0016] The guide flap and guide ring connection part forging blank is a left-right symmetrical structure composed of an arc-shaped web forging blank and a guide circular arc forging blank. The lower edge of the arc-shaped web forging blank is connected to the guide circular arc forging blank. Two long vertical rib forging blanks are symmetrically arranged on the arc-shaped web forging blank. One end of the two long vertical rib forgings is connected to the edge, and the other end is connected to the guide circular arc forging blank.

[0017] Assume that the angle between the two sides of the arc-shaped web forging blank is A 3 , A 3 =(0.95~1.05)A 1 ; Assume that the angle between the arc web forging blank and the guide arc forging blank is A 4 , A 4 =(1.90~2.10)A 2 ;

[0018] Assume the thickness of the curved web forging blank is T 6 , T 6 =(1.1~1.5)T 1 ; Assume that the width of the two long vertical ribs is T 7 , T 7 =(0.9~1.2)T 2 ; Assume that the distance between the centers of the two long vertical ribs is D 3 , D 3 =250mm~260mm; Assume the thickness of the two long vertical ribs is H 3 , H 3 =(2.5~3.0)H 1 ; Assume that the maximum height of the arc-shaped web forging blank is H 4 , H 4 =(0.80~0.95)H 2 ;

[0019] Assume that the inner radius of the guide arc forging blank is (R 2 ) min , (R 2 ) min =(0.99~1.04)(R 1 ) min, assuming the outer radius of the guide arc forging is (R 2 ) max , (R 2 ) max =(0.99~1.03)(R 2 ) max ;

[0020] 3. Forging:

[0021] Spray lubricant on the forging blank of the connecting part of the guide flap and the guide ring and the surface of the forging die, then heat the forging blank of the connecting part of the guide flap and the guide ring and place it in the lower die for positioning, forge and shape until the closing height of the upper and lower dies is 0.9 mm to 1.1 mm, demold and air cool to room temperature, and sequentially perform pickling, deburring and polishing to obtain the forging of the connecting part of the guide flap and the guide ring;

[0022] 4. Additive remaining docking ring and guide ring:

[0023] The three guide petals are fixed to the guide ring connecting part forging, and the separate guide ring part of the docking ring part is manufactured by arc additive manufacturing, the rough surface is removed and cut, and finally the machining allowance is removed to obtain the docking ring part.

[0024] The beneficial effects of the present invention are:

[0025] The present invention proposes to forge an additive aluminum alloy billet to obtain the overall shape of the guide ring and the guide petal, and finally obtain the overall shape of the guide ring and the guide petal through simple machining and welding technology, thereby improving the bearing limit, forming efficiency and material utilization rate of the docking ring.

[0026] 1. Compared with the existing aluminum alloy butt ring forming process, the present invention fixes the forged part when adding the remaining butt ring guide ring, which can improve the three-dimensional space accuracy of the butt ring and achieve high-precision forming;

[0027] 2. Compared with the existing aluminum alloy butt ring forming process, the present invention forms a blank of a specific shape by adding materials, and then forms the guide flap in the butt ring by forging process, without using a large piece of forging blank for machining, thereby improving material utilization and saving blank cost;

[0028] 3. Compared with the existing aluminum alloy butt ring forming process, the present invention mass produces butt ring guide flaps by forging. The shape and size of the butt ring guide flaps are similar to the shape and size after machining. Only a small amount of machining is needed to form them later, which reduces machining time and improves production efficiency.

[0029] 4. Compared with the existing aluminum alloy butt ring forming process, the present invention integrally forges the butt ring guide flap and the guide ring. There is no need for welding between the butt ring guide flap and the guide ring. Instead, the weld is transferred to the guide ring, thereby improving the bearing limit of the butt ring.

[0030] The invention is used for a method for composite manufacturing of an aluminum alloy butt ring by additive forging. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a three-dimensional diagram of the forging of the connecting part of the guide flap and the guide ring in step 1 of the present invention, 1 is the edge boss, 2 is the arc-shaped web forging, 3 is the long vertical rib forging, 4 is the short vertical rib forging, and 5 is the guide arc forging;

[0032] Figure 2 It is a front view of the forging of the connecting portion of the guide flap and the guide ring in step 1 of the present invention;

[0033] Figure 3 It is a side view of the forging of the connecting portion of the guide flap and the guide ring in step 1 of the present invention;

[0034] Figure 4 It is a three-dimensional diagram of the forging blank of the connecting part of the guide flap and the guide ring in step 2 of the present invention, 6 is the arc-shaped web forging blank, 7 is the long vertical rib forging blank, and 8 is the guide arc forging blank;

[0035] Figure 5 It is a front view of the forging blank of the connecting part of the guide flap and the guide ring in step 2 of the present invention;

[0036] Figure 6 It is a side view of the forging blank of the connecting portion between the guide flap and the guide ring in step 2 of the present invention;

[0037] Figure 7 The upper die and lower mold surfaces of the forging die in step 3 of the present invention, (a) is the upper mold surface, and (b) is the lower mold surface;

[0038] Figure 8 The figure is a model diagram after the upper die and the lower die of the forging die in step 3 of the present invention are assembled, 9 is the flash, 10 is the cavity, and 11 is the jaws;

[0039] Fig. 9 Schematic diagram of the structure of the docking ring parts described in step 1 of the present invention, (a) is a top view, section A is the connecting part between the guide flap and the guide ring, and section B is the separate guide ring part; (b) is a bottom view;

[0040] Fig.10These are the finite element simulation results of forging and demolding in step three of Example 1, (a) is an intuitive picture of the forging in the lower die after simulated forming, (b) is an intuitive picture of the forging after simulated forming, (c) is the forming result of the forging between the upper die and the lower die after simulated forming, and (d) is the finite element simulation result of forging and the load change curve. DETAILED DESCRIPTION

[0041] The technical solution of the present invention is not limited to the specific implementation modes listed below, but also includes any combination of the specific implementation modes.

[0042] Specific implementation method 1, combined with Figures 1 to 9 Specific description: The method for additive forging composite manufacturing of aluminum alloy butt rings described in this embodiment is carried out according to the following steps:

[0043] 1. Forging shape design:

[0044] The docking ring part is composed of a guide ring and a guide petal, and three guide petals are evenly arranged on the circumference of the guide ring; the docking ring part is divided into a separate guide ring part and a guide petal and guide ring connection part; the guide petal and guide ring connection part forging is designed according to the structure of the guide petal and guide ring connection part;

[0045] The guide flap and guide ring connecting part forging is a left-right symmetrical structure composed of an arc-shaped web forging and a guide circular arc forging; edge bosses are arranged on the left and right edges and the upper edge of the arc-shaped web forging, the lower edge of the arc-shaped web forging is connected to the guide circular arc forging, two long vertical rib forgings and two short vertical rib forgings are symmetrically arranged on the arc-shaped web forging, one end of the two long vertical rib forgings is connected to the edge boss, and the other end is connected to the guide circular arc forging, and the short vertical rib forging is located on the inner side of the two long vertical rib forgings and connected to the guide circular arc forging;

[0046] Assume that the angle between the left and right edge bosses of the arc-shaped web forging is A. 1 , assuming that the angle between the arc web forging and the guide arc forging is A 2 , A 1 :A 2 =(1.90~2.10):1;

[0047] Assume the thickness of the curved web forging is T 1 , assuming that the width of the two long vertical rib forgings is T 2 , T 1 :T 2 =1:(1.12~1.25); Assume that the distance between the centers of the two long vertical rib forgings is D 1 , D 1 =250mm~260mm; Assume the thickness of the two long vertical rib forgings is H 1, assuming the maximum height of the curved web forging is H 2 , H 1 :H 2 =1:(7.00~10.67);

[0048] Assume the thickness of the edge boss is T 3 , let the width of the edge boss be T 4 , T 3 :T 4 =1:(1.13~1.37);

[0049] Assume that the distance between the centers of the two short vertical rib forgings is D 2 , assuming that the width of the two short vertical rib forgings is T 5 , T 5 :D 2 =1:(10.77~13.64); Assume the bottom thickness of the two short vertical rib forgings is H 5 , H 5 =(0.7~0.9)H 1 ;

[0050] Assume that the inner radius of the guide arc forging is (R 1 ) min , assuming the outer radius of the guide arc forging is (R 1 ) max , (R 1 ) min :(R 1 ) max =1:(1.20~1.25);

[0051] 2. Forging shape design:

[0052] Design the forging blank of the connecting part of the guide flap and the guide ring according to the forging of the connecting part of the guide flap and the guide ring;

[0053] The guide flap and guide ring connection part forging blank is a left-right symmetrical structure composed of an arc-shaped web forging blank and a guide circular arc forging blank. The lower edge of the arc-shaped web forging blank is connected to the guide circular arc forging blank. Two long vertical rib forging blanks are symmetrically arranged on the arc-shaped web forging blank. One end of the two long vertical rib forgings is connected to the edge, and the other end is connected to the guide circular arc forging blank.

[0054] Assume that the angle between the two sides of the arc-shaped web forging blank is A 3 , A 3 =(0.95~1.05)A 1 ; Assume that the angle between the arc web forging blank and the guide arc forging blank is A 4 , A 4 =(1.90~2.10)A 2 ;

[0055] Assume the thickness of the curved web forging blank is T 6 , T 6 =(1.1~1.5)T 1 ; Assume that the width of the two long vertical ribs is T 7 , T 7 =(0.9~1.2)T 2 ; Assume that the distance between the centers of the two long vertical ribs is D 3 , D 3 =250mm~260mm; Assume the thickness of the two long vertical ribs is H 3 , H 3 =(2.5~3.0)H 1 ; Assume that the maximum height of the arc-shaped web forging blank is H 4 , H 4 =(0.80~0.95)H 2 ;

[0056] Assume that the inner radius of the guide arc forging blank is (R 2 ) min , (R 2 ) min =(0.99~1.04)(R 1 ) min , assuming the outer radius of the guide arc forging is (R 2 ) max , (R 2 ) max =(0.99~1.03)(R 2 ) max ;

[0057] 3. Forging:

[0058] Spray lubricant on the forging blank of the connecting part of the guide flap and the guide ring and the surface of the forging die, then heat the forging blank of the connecting part of the guide flap and the guide ring and place it in the lower die for positioning, forge and shape until the closing height of the upper and lower dies is 0.9 mm to 1.1 mm, demold and air cool to room temperature, and sequentially perform pickling, deburring and polishing to obtain the forging of the connecting part of the guide flap and the guide ring;

[0059] 4. Additive remaining docking ring and guide ring:

[0060] The three guide petals are fixed to the guide ring connecting part forging, and the separate guide ring part of the docking ring part is manufactured by arc additive manufacturing, the rough surface is removed and cut, and finally the machining allowance is removed to obtain the docking ring part.

[0061] The beneficial effects of this embodiment are:

[0062] This embodiment proposes to forge the additive aluminum alloy billet to obtain the overall shape of the guide ring and the guide petal, and finally obtain the overall shape of the guide ring and the guide petal through simple machining and welding technology, thereby improving the bearing limit, forming efficiency and material utilization rate of the docking ring.

[0063] 1. Compared with the existing aluminum alloy butt ring forming process, when adding the remaining butt ring guide ring in this embodiment, the forged part is fixed, which can improve the three-dimensional space accuracy of the butt ring and achieve high-precision forming;

[0064] 2. Compared with the existing aluminum alloy butt ring forming process, this embodiment forms a blank of a specific shape by adding materials, and then forms the guide flap in the butt ring by a forging process. There is no need to use a large piece of forging blank for machining, which improves material utilization and saves blank cost;

[0065] 3. Compared with the existing aluminum alloy butt ring forming process, the present embodiment mass produces butt ring guide flaps by forging, and the shape and size of the butt ring guide flaps are similar to the shape and size after machining, and only a small amount of machining is needed to form them later, which reduces machining time and improves production efficiency;

[0066] 4. Compared with the existing aluminum alloy butt ring forming process, this embodiment performs integral forging of the butt ring guide flap and the guide ring. The butt ring guide flap and the guide ring do not need to be connected by welding. Instead, the weld is transferred to the guide ring, thereby improving the bearing limit of the butt ring.

[0067] Specific implementation method 2: This implementation method is different from specific implementation method 1 in that: in step 1, the machining allowance of the guide flap and guide ring connecting part processed by the forging piece is 5mm to 10mm; the forging blank of the guide flap and guide ring connecting part described in step 2 is processed by additive billet, and the additive billet is processed into the forging blank of the guide flap and guide ring connecting part. The addition allowance is 5mm to 10mm. The rest is the same as specific implementation method 1.

[0068] Specific implementation method 3: This implementation method is different from specific implementation methods 1 or 2 in that the cross-sections of the guide ring and the guide arc forging described in step 1 are both polygonal; the cross-section of the guide arc forging blank described in step 2 is polygonal. Other aspects are the same as specific implementation methods 1 or 2.

[0069] Specific embodiment 4: This embodiment is different from any one of the specific embodiments 1 to 3 in that: in step 1, the edges of the forgings at the connection between the guide flap and the guide ring are all chamfered, and the fillet radius at the connection between the edge boss and the arc-shaped web forging is the largest, and the fillet radius at the outer oblique edge of the edge boss is the smallest. The minimum fillet radius is (R 3 ) min , let the maximum fillet radius be (R3 ) max , (R 3 ) min :(R 3 ) max =1:(2~4); In step 2, the edges of the forging blank at the connection between the guide flap and the guide ring are all chamfered, and the fillet radius at the connection between the arc-shaped web forging blank and the long vertical rib forging is the largest, and the fillet radius at the outer oblique edge of the arc-shaped web forging blank is the smallest. The minimum fillet radius is (R 4 ) min , let the maximum fillet radius be (R 4 ) max , (R 4 ) min :(R 4 ) max =1:(2-4). The rest is the same as the first to third embodiments.

[0070] Specific embodiment 5: This embodiment differs from specific embodiments 1 to 4 in that the side surfaces of the guide flap and guide ring connection part forgings in step 1 that contact the lower die in step 3 are both provided with a draft angle of 7° to 10°. The rest is the same as specific embodiments 1 to 4.

[0071] Specific implementation method 6: This implementation method is different from specific implementation methods 1 to 5 in that: the forging blank of the guide flap and guide ring connection part described in step 2 and the raw material used for arc additive manufacturing in step 4 are both made of 7050 aluminum alloy; the volume of the forging blank of the guide flap and guide ring connection part described in step 2 is 1.25 to 1.35 times the volume of the forging of the guide flap and guide ring connection part in step 1. The rest is the same as specific implementation methods 1 to 5.

[0072] Specific embodiment 7: This embodiment is different from specific embodiments 1 to 6 in that the forging die described in step 3 includes an upper die and a lower die, and both the upper die and the lower die are bilaterally symmetrical and open structures. Others are the same as specific embodiments 1 to 6.

[0073] Specific embodiment 8: This embodiment is different from specific embodiments 1 to 7 in that: in step 3, the forging blank of the connecting part of the guide flap and the guide ring is heated to 440°C to 460°C, and is placed in the lower die for positioning, and forged at a pressing speed of 2.4mm / s to 2.6mm / s until the closing height of the upper and lower dies is 0.9mm to 1.1mm. The rest is the same as specific embodiments 1 to 7.

[0074] Specific embodiment 9: This embodiment differs from Specific embodiments 1 to 8 in that: in step 4, the separate guide ring part of the docking ring part is manufactured by arc additive manufacturing, and a processing allowance of 4mm to 6mm is left in the cross section, and the size after removing the rough surface is the same as the size of the guide arc forging. Others are the same as Specific embodiments 1 to 8.

[0075] Specific embodiment 10: This embodiment is different from specific embodiments 1 to 9 in that: the preparation method of the additive blank and the arc additive manufacturing method described in step 4 are both carried out according to the following steps: 7050 aluminum alloy wire is used as raw material, CMT+ADV mode is adopted, arc fuse additive manufacturing is carried out under the conditions of walking speed of 6mm / s~8mm / s, wire feeding speed of 6m / min~7m / min, current of 90A~100A, voltage of 11V~12V and wire feeding angle of 7°~10°. Others are the same as specific embodiments 1 to 9.

[0076] The following examples are used to verify the beneficial effects of the present invention:

[0077] Embodiment 1:

[0078] A method for additive forging composite manufacturing of an aluminum alloy butt ring is carried out according to the following steps:

[0079] 1. Forging shape design:

[0080] The docking ring part is composed of a guide ring and a guide petal, and three guide petals are evenly arranged on the circumference of the guide ring; the docking ring part is divided into a separate guide ring part and a guide petal and guide ring connection part; the guide petal and guide ring connection part forging is designed according to the structure of the guide petal and guide ring connection part;

[0081] The guide flap and guide ring connecting part forging is a left-right symmetrical structure composed of an arc-shaped web forging and a guide circular arc forging; edge bosses are arranged on the left and right edges and the upper edge of the arc-shaped web forging, the lower edge of the arc-shaped web forging is connected to the guide circular arc forging, two long vertical rib forgings and two short vertical rib forgings are symmetrically arranged on the arc-shaped web forging, one end of the two long vertical rib forgings is connected to the edge boss, and the other end is connected to the guide circular arc forging, and the short vertical rib forging is located on the inner side of the two long vertical rib forgings and connected to the guide circular arc forging;

[0082] Assume that the angle between the left and right edge bosses of the arc-shaped web forging is A. 1 , assuming that the angle between the arc web forging and the guide arc forging is A 2 , A 1 =90°, A 2 =45°;

[0083] Assume the thickness of the curved web forging is T1 , assuming that the width of the two long vertical rib forgings is T 2 , T 1 =19mm, T 2 =22mm; let the distance between the centers of the two long vertical rib forgings be D 1 , D 1 =255mm; Assume the thickness of the two long vertical rib forgings is H 1 , assuming the maximum height of the curved web forging is H 2 , H 1 =18mm, H 2 =150mm;

[0084] Assume the thickness of the edge boss is T 3 , let the width of the edge boss be T 4 , T 3 =12mm, T 4 =16mm;

[0085] Assume that the distance between the centers of the two short vertical rib forgings is D 2 , assuming that the width of the two short vertical rib forgings is T 5 , D 2 =145mm, T 5 =12mm; Assume the bottom thickness of the two short vertical rib forgings is H 5 , H 5 =15mm;

[0086] Assume that the inner radius of the guide arc forging is (R 1 ) min , assuming the outer radius of the guide arc forging is (R 1 ) max , (R 1 ) min =440mm, (R 1 ) max =540mm;

[0087] 2. Forging shape design:

[0088] Design the forging blank of the connecting part of the guide flap and the guide ring according to the forging of the connecting part of the guide flap and the guide ring;

[0089] The guide flap and guide ring connection part forging blank is a left-right symmetrical structure composed of an arc-shaped web forging blank and a guide circular arc forging blank. The lower edge of the arc-shaped web forging blank is connected to the guide circular arc forging blank. Two long vertical rib forging blanks are symmetrically arranged on the arc-shaped web forging blank. One end of the two long vertical rib forgings is connected to the edge, and the other end is connected to the guide circular arc forging blank.

[0090] Assume that the angle between the two sides of the arc-shaped web forging blank is A 3 , A3 =90°; let the included angle between the arc web forging blank and the guide arc forging blank be A 4 , A 4 =90°;

[0091] Assume the thickness of the curved web forging blank is T 6 , T 6 =25mm; Assume that the width of the two long vertical ribs is T 7 , T 7 =20mm; let the distance between the centers of the two long vertical ribs be D 3 , D 3 =250mm; Assume the thickness of the two long vertical ribs is H 3 , H 3 =45mm; Assume that the maximum height of the arc-shaped web forging blank is H 4 , H 4 =120mm;

[0092] Assume that the inner radius of the guide arc forging blank is (R 2 ) min , (R 2 ) min =445mm; Assume the outer radius of the guide arc forging is (R 2 ) max , (R 2 ) max =545mm;

[0093] 3. Forging:

[0094] Spray lubricant on the forging blank of the connecting part of the guide flap and the guide ring and the surface of the forging die, then heat the forging blank of the connecting part of the guide flap and the guide ring and place it in the lower die for positioning, forge and shape until the closing height of the upper and lower dies is 1.0 mm, demold and air cool to room temperature, and sequentially perform pickling, deburring and polishing to obtain the forging of the connecting part of the guide flap and the guide ring;

[0095] 4. Additive remaining docking ring and guide ring:

[0096] The three guide petals are fixed to the guide ring connecting part forging, and the separate guide ring part of the docking ring part is manufactured by arc additive manufacturing, the rough surface is removed and cut, and finally the machining allowance is removed to obtain the docking ring part.

[0097] In step one, the machining allowance of the guide flap and guide ring connecting part forged from the guide flap and guide ring connecting part is 5 mm; in step two, the guide flap and guide ring connecting part forging blank is machined from additive billet, and the additive billet is machined into the guide flap and guide ring connecting part forging blank with an allowance of 7 mm.

[0098] The cross-sections of the guide ring and the guide arc forging described in step one are both polygonal; the cross-section of the guide arc forging blank described in step two is polygonal.

[0099] In step 1, the edges of the forgings connecting the guide flap and the guide ring are all rounded, and the fillet radius at the connection between the edge boss and the arc-shaped web forging is the largest, and the fillet radius at the outer oblique edge of the edge boss is the smallest. The minimum fillet radius is (R 3 ) min , let the maximum fillet radius be (R 3 ) max , (R 3 ) min =4mm, (R 3 ) max =8mm; In step 2, the edges of the forging blanks at the connection between the guide flap and the guide ring are all chamfered, and the fillet radius at the connection between the arc-shaped web forging blank and the long vertical rib forging is the largest, and the fillet radius at the outer oblique edge of the arc-shaped web forging blank is the smallest. The minimum fillet radius is (R 4 ) min , let the maximum fillet radius be (R 4 ) max , (R 4 ) min =3mm, (R 4 ) max =7mm.

[0100] The side surfaces of the guide flap and guide ring connection part forging described in step one that contact the lower mold described in step three are both provided with a draft angle of 9°.

[0101] The materials of the forging blank of the guide flap and guide ring connecting part described in step 2 and the raw materials used for arc additive manufacturing in step 4 are both 7050 aluminum alloy; the volume of the forging blank of the guide flap and guide ring connecting part described in step 2 is 1.25 times the volume of the forging of the guide flap and guide ring connecting part in step 1.

[0102] The forging die described in step three includes an upper die and a lower die, and both the upper die and the lower die are bilaterally symmetrical structures and are open structures.

[0103] In step three, the forging blank of the connecting part of the guide flap and the guide ring is heated to 450°C, and is placed in the lower die for positioning, and forged at a pressing speed of 2.5 mm / s until the closing height of the upper and lower dies is 1.0 mm.

[0104] In step 4, the separate guide ring part of the docking ring part is manufactured by arc additive manufacturing, and a 5mm machining allowance is left in the cross section. After removing the rough surface, the size is the same as the guide arc forging size.

[0105] The preparation method of the additive blank and the arc additive manufacturing method described in step four are both carried out according to the following steps: using 7050 aluminum alloy wire as raw material, adopting CMT+ADV mode, arc fuse additive manufacturing is carried out under the conditions of walking speed of 7mm / s, wire feeding speed of 6.5m / min, current of 98A, voltage of 11.6V and wire feeding angle of 7°~10°.

[0106] Fig.10 The finite element simulation results of forging and demolding in step three of Example 1 are shown in Figures 1 and 2, (a) is a visual diagram of the forging in the lower die after simulated forming, (b) is a visual diagram of the forging after simulated forming, (c) is the forming result of the forging between the upper die and the lower die after simulated forming, and (d) is the finite element simulation result of forging and the load variation curve. It can be seen from the figure that after forging, the metal is completely filled in the cavity, the forging has a good shape, the metal of the jaws is well extruded through the flash, and it is suitable for taking out the forging. The maximum load after forging is about 15400t.

Claims

1. A method for additive forging composite manufacturing of aluminum alloy butt rings, characterized in that It is carried out according to the following steps:

1. Forging shape design: The docking ring part is composed of a guide ring and a guide petal, and three guide petals are evenly arranged around the guide ring; the docking ring part is divided into a separate guide ring part and a guide petal and guide ring connection part; the guide petal and guide ring connection part forging is designed according to the structure of the guide petal and guide ring connection part; The guide flap and guide ring connecting part forging is a left-right symmetrical structure composed of an arc-shaped web forging and a guide circular arc forging; edge bosses are arranged on the left and right edges and the upper edge of the arc-shaped web forging, the lower edge of the arc-shaped web forging is connected to the guide circular arc forging, two long vertical rib forgings and two short vertical rib forgings are symmetrically arranged on the arc-shaped web forging, one end of the two long vertical rib forgings is connected to the edge boss, and the other end is connected to the guide circular arc forging, and the short vertical rib forging is located on the inner side of the two long vertical rib forgings and connected to the guide circular arc forging; Assume that the included angle of the edge bosses on the left and right sides of the arc-shaped web forging is A1, and the included angle between the arc-shaped web forging and the guide arc forging is A2, A1:A2=(1.90-2.10):1; Assume that the thickness of the arc-shaped web forging is T1, and the width of the two long vertical rib forgings is T2, T1:T2=1:(1.12~1.25); Assume that the distance between the centers of the two long vertical rib forgings is D1, D1=250mm~260mm; Assume that the thickness of the two long vertical rib forgings is H1, and the maximum height of the arc-shaped web forging is H2, H1:H2=1:(7.00~10.67); Assume that the thickness of the edge boss is T3, and the width of the edge boss is T4, T3:T4=1:(1.13-1.37); Assume that the distance between the centers of the two short vertical rib forgings is D2, and the widths of the two short vertical rib forgings are both T5, T5:D2=1:(10.77~13.64); Assume that the bottom thickness of the two short vertical rib forgings is H5, H5=(0.7~0.9)H1; Assume the inner radius of the guide arc forging is (R1) min , assuming the outer radius of the guide arc forging is (R1) max , (R1) min :(R1) max =1:(1.20~1.25); 2. Forging shape design: Design the forging blank of the connecting part of the guide flap and the guide ring according to the forging of the connecting part of the guide flap and the guide ring; The guide flap and guide ring connection part forging blank is a left-right symmetrical structure composed of an arc-shaped web forging blank and a guide circular arc forging blank. The lower edge of the arc-shaped web forging blank is connected to the guide circular arc forging blank. Two long vertical rib forging blanks are symmetrically arranged on the arc-shaped web forging blank. One end of the two long vertical rib forgings is connected to the edge, and the other end is connected to the guide circular arc forging blank. The angle between the edges of the two sides of the arc-shaped web forging blank is set to A3, A3 = (0.95 ~ 1.05) A1; the angle between the arc-shaped web forging blank and the guide circular arc forging blank is set to A4, A4 = (1.90 ~ 2.10) A2; Assume that the thickness of the arc-shaped web forging blank is T6, T6 = (1.1 ~ 1.5) T1; Assume that the width of the two long vertical ribs forging blank is T7, T7 = (0.9 ~ 1.2) T2; Assume that the distance between the centers of the two long vertical ribs forging blank is D3, D3 = 250mm ~ 260mm; Assume that the thickness of the two long vertical ribs forging blank is H3, H3 = (2.5 ~ 3.0) H1; Assume that the maximum height of the arc-shaped web forging blank is H4, H4 = (0.80 ~ 0.95) H2; Assume the inner radius of the guide arc forging blank is (R2) min , (R2) min =(0.99~1.04)(R1) min , assuming the outer radius of the guide arc forging is (R2) max , (R2) max =(0.99~1.03)(R2) max ; 3. Forging: Spray lubricant on the forging blank of the connecting part of the guide flap and the guide ring and the surface of the forging die, then heat the forging blank of the connecting part of the guide flap and the guide ring and place it in the lower die for positioning, forge and shape until the closing height of the upper and lower dies is 0.9 mm to 1.1 mm, demold and air cool to room temperature, and sequentially perform pickling, deburring and polishing to obtain the forging of the connecting part of the guide flap and the guide ring; 4. Additive remaining docking ring and guide ring: The three guide petals are fixed to the guide ring connecting part forging, and the separate guide ring part of the docking ring part is manufactured by arc additive manufacturing, the rough surface is removed and cut, and finally the machining allowance is removed to obtain the docking ring part.

2. The method for manufacturing an aluminum alloy butt ring by additive forging according to claim 1, characterized in that In step one, the machining allowance of the guide flap and guide ring connecting part processed by the forging of the guide flap and guide ring connecting part is 5mm to 10mm; the guide flap and guide ring connecting part forging blank described in step two is processed by additive billet, and the additive billet is processed into the guide flap and guide ring connecting part forging blank with an additive allowance of 5mm to 10mm.

3. The method for manufacturing an aluminum alloy butt ring by additive forging according to claim 1, characterized in that The cross-sections of the guide ring and the guide arc forging described in step one are both polygonal; the cross-section of the guide arc forging blank described in step two is polygonal.

4. The method for manufacturing an aluminum alloy butt ring by additive forging according to claim 1, characterized in that In step 1, the edges of the forgings connecting the guide flap and the guide ring are chamfered, and the fillet radius at the connection between the edge boss and the arc-shaped web forging is the largest, and the fillet radius at the outer oblique edge of the edge boss is the smallest. The minimum fillet radius is (R3) min , let the maximum fillet radius be (R3) max , (R3) min :(R3) max =1:(2~4); In step 2, the edges of the forging blank at the connection between the guide flap and the guide ring are all chamfered, and the fillet radius at the connection between the arc-shaped web forging blank and the long vertical rib forging is the largest, and the fillet radius at the outer oblique edge of the arc-shaped web forging blank is the smallest. The minimum fillet radius is (R4) min , let the maximum fillet radius be (R4) max , (R4) min :(R4) max =1:(2~4).

5. The method for manufacturing an aluminum alloy butt ring by additive forging composite according to claim 1, characterized in that The side surfaces of the guide flap and guide ring connection part forging described in step one that contact the lower mold described in step three are both provided with a draft angle of 7° to 10°.

6. The method for manufacturing an aluminum alloy butt ring by additive forging composite according to claim 1, characterized in that The materials of the forging blank of the guide flap and guide ring connecting part described in step 2 and the raw materials used for arc additive manufacturing in step 4 are both 7050 aluminum alloy; the volume of the forging blank of the guide flap and guide ring connecting part described in step 2 is 1.25 times to 1.35 times the volume of the forging of the guide flap and guide ring connecting part in step 1.

7. The method for manufacturing an aluminum alloy butt ring by additive forging composite according to claim 1, characterized in that The forging die described in step three includes an upper die and a lower die, and both the upper die and the lower die are bilaterally symmetrical structures and are open structures.

8. The method for manufacturing an aluminum alloy butt ring by additive forging composite according to claim 1, characterized in that In step three, the forging blank of the connecting part of the guide flap and the guide ring is heated to 440°C to 460°C, and is placed in the lower die for positioning, and forged at a pressing speed of 2.4mm / s to 2.6mm / s until the closing height of the upper and lower dies is 0.9mm to 1.1mm.

9. The method for manufacturing an aluminum alloy butt ring by additive forging composite according to claim 1, characterized in that In step 4, the separate guide ring part of the docking ring part is manufactured by arc additive manufacturing, and a processing allowance of 4mm to 6mm is left in the cross section. After removing the rough surface, the size is the same as the size of the guide arc forging.

10. The method for manufacturing an aluminum alloy butt ring by additive forging composite according to claim 2 or 9, characterized in that The preparation method of the additive blank and the arc additive manufacturing method described in step four are both carried out according to the following steps: using 7050 aluminum alloy wire as raw material, adopting CMT+ADV mode, and performing arc fuse additive manufacturing under the conditions of a walking speed of 6mm / s~8mm / s, a wire feeding speed of 6m / min~7m / min, a current of 90A~100A, a voltage of 11V~12V and a wire feeding angle of 7°~10°.

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