A method of additively forged hybrid manufacturing of an aluminum alloy butt ring

Abstract

The application relates to a method for additively forging and composite manufacturing of an aluminum alloy butt joint ring, and belongs to the field of forging. The application aims to solve the problems of low material utilization rate of the existing machining and welding method for producing the butt joint ring, the welding seam at the connecting position of the guide petals and the guide ring reducing the overall bearing limit, and the problem of needing precise milling machining equipment due to the complex shape of the guide petals. The method comprises the following steps: one, forging shape design; two, forging blank shape design; three, forging forming; and four, additively remaining butt joint ring guide ring. The application is used for additively forging and composite manufacturing of the aluminum alloy butt joint ring.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of forging. BACKGROUND

[0002] Aluminum alloy is one of the important materials for lightweight due to its low density and high specific strength, and is widely used in the field of aerospace. Additive manufacturing technology can form complex shape parts, realize near-net shaping, and improve material utilization. However, there are many defects in the additive parts, such as pores, micro-cracks, and unevenness, but these defects can be eliminated through forging process, and the comprehensive mechanical properties can be improved. The passive docking structure of the "heterogeneous periphery" docking device of the space cabin body can be divided into a guide petal and a guide ring. The docking ring is an important application of aluminum alloy in the field of aviation.

[0003] Most of the current guide petals are manufactured by milling, and then the guide petals and guide rings are connected by welding. This way of producing docking rings has low material utilization, and the weld at the connection between the guide petals and the guide rings reduces the overall load limit. At the same time, welding greatly reduces the three-dimensional spatial precision of the docking ring. And it needs additional ring rolling equipment to form the guide ring, which has high material production cost. If the whole casting or additive manufacturing method is used, although it can improve the dimensional accuracy of the docking ring, realize the whole forming, and greatly improve the material utilization, the defects caused by casting or additive manufacturing reduce the load limit, which reduces the safety. At the same time, due to the complex shape of the docking ring, it is difficult to manufacture the casting sand mold and control the additive manufacturing process. SUMMARY

[0004] The present application solves the problems of low material utilization of the existing machining and welding method for producing docking rings, the weld at the connection between the guide petals and the guide rings reduces the overall load limit, and the complex shape of the guide petals requires precise milling equipment, and provides a method for additive forging composite manufacturing of aluminum alloy docking rings.

[0005] A method for additive forging composite manufacturing of aluminum alloy docking rings, which is carried out according to the following steps:

[0006] I. Design of the shape of the forging

[0007] The docking ring part is composed of a guide ring and a guide petal, and the guide ring is circumferentially arranged with three guide petals; the docking ring part is divided into a separate guide ring part, a guide petal and a guide ring connecting part; the guide petal and the guide ring connecting part forging is designed according to the structure of the guide petal and the guide ring connecting part;

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

[0009] The included angle of the left and right side edge bosses of the arc web forging is A1, and the included angle of the arc web forging and the guiding circular arc forging is A2, and A1:A2=(1.90-2.10):1;

[0010] The thickness of the arc web forging is T1, the width of the two long vertical rib forgings is T2, and T1:T2=1:(1.12-1.25); the distance between the centers of the two long vertical rib forgings is D1, and D1=250mm-260mm; the thickness of the two long vertical rib forgings is H1, and the maximum height of the arc web forging is H2, and H1:H2=1:(7.00-10.67);

[0011] The thickness of the edge boss is T3, and the width of the edge boss is T4, and T3:T4=1:(1.13-1.37);

[0012] The distance between the centers of the two short vertical rib forgings is D2, the width of the two short vertical rib forgings is T5, and T5:D2=1:(10.77-13.64); the bottom thickness of the two short vertical rib forgings is H5, and H5=(0.7-0.9)H1;

[0013] The inner circle radius of the guiding circular arc forging is (R1) min , the outer circle radius of the guiding circular arc forging is (R1) max , (R1) min :(R1) max =1:(1.20-1.25);

[0014] II. Shape design of the forging blank

[0015] The guiding vane and guiding ring connecting part forging blank is designed according to the guiding vane and guiding ring connecting part forging;

[0016] The guiding vane and guiding ring connecting part forging blank is a left-right symmetrical structure composed of an arc web forging and a guiding circular arc forging, the lower edge of the arc web forging is connected with the guiding circular arc forging, two long vertical rib forgings are symmetrically arranged on the upper edge of the arc web forging, and one end of the two long vertical rib forgings is connected with the edge, and the other end is connected with the guiding circular arc forging;

[0017] Let the included angle between the two edges of the arc-shaped web plate forging blank be A3, A3 = (0.95~1.05)A1; let the included angle between the arc-shaped web plate forging blank and the guide arc forging blank be A4, A4 = (1.90~2.10)A2;

[0018] Let the thickness of the arc-shaped web forging blank be T6, T6 = (1.1~1.5)T1; let the width of the two long vertical rib forging blanks be T7, T7 = (0.9~1.2)T2; let the distance between the centers of the two long vertical rib forging blanks be D3, D3 = 250mm~260mm; let the thickness of the two long vertical rib forging blanks be H3, H3 = (2.5~3.0)H1; let the maximum height of the arc-shaped web forging blank be H4, H4 = (0.80~0.95)H2;

[0019] Let the inner radius of the guide arc forging blank be (R2). min (R2) min =(0.99~1.04)(R1) min Let the outer radius of the guide arc forging be (R2). max (R2) max =(0.99~1.03)(R2) max ;

[0020] III. Forging and Shaping:

[0021] Lubricant is sprayed onto the surface of the forging blank and the forging die for the part connecting the guide flap and the guide ring. Then, the forging blank for the part connecting the guide flap and the guide ring is heated and placed into the lower die for positioning. The forging is carried out until the closing height of the upper and lower dies is 0.9mm to 1.1mm. The blank is demolded and air-cooled to room temperature. Pickling, flash removal and polishing are performed in sequence to obtain the forging part connecting the guide flap and the guide ring.

[0022] IV. Additive manufacturing remaining docking ring guide ring:

[0023] The three guide flaps are fixed to the forging of the guide ring connection part. The individual guide ring part of the docking ring part is manufactured by arc additive manufacturing. The rough surface is removed and cut. Finally, the machining allowance is removed to obtain the docking ring part.

[0024] The beneficial effects of this invention are:

[0025] This invention proposes to forge additive aluminum alloy billets to obtain the overall shape of guide rings and guide flaps, and finally obtain the overall shape of guide rings and guide flaps through simple machining and welding techniques, thereby improving the bearing limit, forming efficiency and material utilization of the mating ring.

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

[0027] 2、Compared with the existing aluminum alloy butt joint ring forming process, the application forms the guide petals in the butt joint ring through additive specific shape blank, and does not need to use large forging blank for machining, improves the material utilization rate, and saves the blank cost;

[0028] 3、Compared with the existing aluminum alloy butt joint ring forming process, the application produces the guide petals of the butt joint ring in batches through forging, the shape and size of the guide petals of the butt joint ring are similar to the shape and size after machining, and only a small amount of machining is needed for subsequent forming, the machining time is reduced, and the production efficiency is improved;

[0029] 4、Compared with the existing aluminum alloy butt joint ring forming process, the application integrally forges the guide petals of the butt joint ring and the guide ring, and the guide petals of the butt joint ring and the guide ring do not need to be connected through welding, but the welding seam is transferred to the guide ring, and the load limit of the butt joint ring is improved.

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

[0031] Figure 1 It is a perspective view of the forging of the connecting part of the guide petals and the guide ring in step one of the application, 1 is an edge boss, 2 is an arc web forging, 3 is a long vertical rib forging, 4 is a short vertical rib forging, and 5 is a guide circular arc forging;

[0032] Figure 2 It is a front view of the forging of the connecting part of the guide petals and the guide ring in step one of the application;

[0033] Figure 3 It is a side view of the forging of the connecting part of the guide petals and the guide ring in step one of the application;

[0034] Figure 4 It is a perspective view of the forging blank of the connecting part of the guide petals and the guide ring in step two of the application, 6 is an arc web forging blank, 7 is a long vertical rib forging blank, and 8 is a guide circular arc forging blank;

[0035] Figure 5 It is a front view of the forging blank of the connecting part of the guide petals and the guide ring in step two of the application;

[0036] Figure 6 It is a side view of the forging blank of the connecting part of the guide petals and the guide ring in step two of the application;

[0037] Figure 7 It is the upper die surface and the lower die surface of the forging die in step three of the application, (a) is the upper die surface, and (b) is the lower die surface;

[0038] Figure 8Figure 9 is the upper die and lower die assembly model of the forging die in step three of the present application, 9 is the flash, 10 is the cavity, and 11 is the jaw;

[0039] Figure 9 Figure 1 is a structural schematic diagram of the butt joint ring part in step one of the present application, (a) is a top view, segment A is the connecting part of the guide petals and the guide ring, and segment B is a separate guide ring part; (b) is a bottom view;

[0040] Figure 10 Figure 3 is the finite element simulation result of the forging forming and demolding in step three of the embodiment, (a) is a direct view of the forged piece in the lower die after simulation forming, (b) is a direct view of the forged piece after simulation forming, (c) is the forming result of the intermediate forged piece in the upper die and the lower die after simulation forming, and (d) is the finite element simulation result of the forging forming and the load change curve. DETAILED DESCRIPTION

[0041] The technical scheme of the present application is not limited to the following specific embodiments, but also includes any combination between the specific embodiments.

[0042] Specific embodiment one, in combination with Figures 1 to 9 Specific description: the method for additive forging composite manufacturing of the aluminum alloy butt joint ring in the embodiment is performed according to the following steps:

[0043] I. Design of the shape of the forged piece:

[0044] The butt joint ring part is composed of a guide ring and guide petals, and three guide petals are arranged in the circumferential direction of the guide ring; the butt joint ring part is divided into a separate guide ring part and a guide petal and guide ring connecting part; the guide petal and guide ring connecting part forged piece is designed according to the structure of the guide petal and guide ring connecting part;

[0045] The guide petal and guide ring connecting part forged piece is a left-right symmetrical structure composed of an arc web forged piece and a guide circular arc forged piece; the left and right side edges and the upper edge of the arc web forged piece are each provided with an edge boss, the lower edge of the arc web forged piece is connected with the guide circular arc forged piece, two long vertical rib forged pieces and two short vertical rib forged pieces are arranged in the arc web forged piece in a left-right symmetrical manner, one end of the two long vertical rib forged pieces is connected with the edge boss, and the other end is connected with the guide circular arc forged piece, and the short vertical rib forged pieces are located inside the two long vertical rib forged pieces and connected with the guide circular arc forged piece;

[0046] The included angle of the edge bosses of the left and right side edges of the arc web forged piece is A1, the included angle of the arc web forged piece and the guide circular arc forged piece is A2, and A1:A2=(1.90-2.10):1;

[0047] The thickness of the arc-shaped web is T1, the width of the two long vertical ribs is T2, and T1:T2=1:(1.12-1.25); the distance between the centers of the two long vertical ribs is D1, and D1=250mm-260mm; the thickness of the two long vertical ribs is H1, and the maximum height of the arc-shaped web is H2, and H1:H2=1:(7.00-10.67);

[0048] The thickness of the edge boss is T3, and the width of the edge boss is T4, and T3:T4=1:(1.13-1.37);

[0049] The distance between the centers of the two short vertical ribs is D2, the width of the two short vertical ribs is T5, and T5:D2=1:(10.77-13.64); the bottom thickness of the two short vertical ribs is H5, and H5=(0.7-0.9)H1;

[0050] The inner circle radius of the guide circular arc is (R1) min , the outer circle radius of the guide circular arc is (R1) max , (R1) min :(R1) max =1:(1.20-1.25);

[0051] II. Shape design of the forging blank:

[0052] The guide lobe and guide ring connecting part forging blank is designed according to the guide lobe and guide ring connecting part forging;

[0053] The guide lobe and guide ring connecting 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 with the guide circular arc forging blank, two long vertical rib forging blanks are symmetrically arranged on the upper and lower edges of the arc-shaped web forging blank, one end of the two long vertical rib forging blanks is connected with the edge, and the other end is connected with the guide circular arc forging blank;

[0054] The included angle of the two sides of the arc-shaped web forging blank is A3, and A3=(0.95-1.05)A1; the included angle of the arc-shaped web forging blank and the guide circular arc forging blank is A4, and A4=(1.90-2.10)A2;

[0055] The thickness of the arc-shaped web forging blank is T6, T6=(1.1-1.5)T1; the width of the two long vertical rib forging blanks is T7, T7=(0.9-1.2)T2; the distance between the centers of the two long vertical rib forging blanks is D3, D3=250mm-260mm; the thickness of the two long vertical rib forging blanks is H3, H3=(2.5-3.0)H1; the maximum height of the arc-shaped web forging blank is H4, H4=(0.80-0.95)H2;

[0056] Suppose the inner circle radius of the guide arc forging blank is (R2) min Suppose the inner circle radius of the guide arc forging blank is (R2) min = (0.99-1.04) (R1) min Suppose the outer circle radius of the guide arc forging blank is (R2) max Suppose the outer circle radius of the guide arc forging blank is (R2) max = (0.99-1.03) (R2) max ;

[0057] III. Forging forming:

[0058] The guide petal and guide ring connecting portion forging blank and the surface of the forging die are sprayed with lubricant, then the guide petal and guide ring connecting portion forging blank is heated and positioned in the lower die, and is forged to form until the closing height of the upper and lower dies is 0.9mm-1.1mm, and is demolded and air cooled to room temperature, and is sequentially subjected to pickling, deburring and polishing to obtain the guide petal and guide ring connecting portion forging;

[0059] IV. Additive remaining butt joint ring guide ring:

[0060] The three guide petal and guide ring connecting portion forgings are fixed, the single guide ring portion of the butt joint ring part is manufactured by electric arc additive manufacturing, the rough surface is removed and cut, and finally the machining allowance is removed to obtain the butt joint ring part.

[0061] The beneficial effects of the embodiment are:

[0062] The embodiment proposes to forge the additive aluminum alloy blank to obtain the overall shape of the guide ring and the guide petal, and finally obtains the overall shape of the guide ring and the guide petal through simple machining and welding technology, improves the bearing limit of the butt joint ring, forming efficiency and material utilization rate.

[0063] 1. Compared with the existing aluminum alloy butt joint ring forming process, the embodiment fixes the part of the forging when the additive remaining butt joint ring guide ring is formed, which can improve the three-dimensional spatial precision of the butt joint ring and realize high-precision forming;

[0064] 2. Compared with the existing aluminum alloy butt joint ring forming process, the embodiment forms the guide petal in the butt joint ring by additive manufacturing of a specific shaped blank and then forging, without using large forgings for machining, thereby improving material utilization and saving blank cost;

[0065] 3. Compared with the existing aluminum alloy butt joint ring forming process, the embodiment produces the guide petal of the butt joint ring in batches by forging, and the shape and size of the guide petal of the butt joint ring are similar to those after machining, so that only a small amount of machining is required for subsequent forming, reducing machining time and improving production efficiency;

[0066] 4. Compared with the existing aluminum alloy butt joint ring forming process, the embodiment is characterized in that the guide petals and the guide ring are integrally forged, the guide petals and the guide ring are not connected by welding, and the welding seam is transferred to the guide ring, thereby improving the load limit of the butt joint ring.

[0067] Specific implementation two: the difference between the embodiment and the specific implementation one is that the machining allowance of the guide petal and the guide ring connecting part of the guide petal and the guide ring connecting part forging in step one is 5mm-10mm; the guide petal and the guide ring connecting part forging blank is processed from the additive blank, and the additive blank is processed into the guide petal and the guide ring connecting part forging blank with an allowance of 5mm-10mm. The others are the same as the specific implementation one.

[0068] Specific implementation three: the difference between the embodiment and the specific implementation one or two is that the cross section of the guide ring and the guide arc forging in step one is polygonal; the cross section of the guide arc forging blank in step two is polygonal. The others are the same as the specific implementation one or two.

[0069] Specific implementation four: the difference between the embodiment and the specific implementation one to three is that the edges of the guide petal and the guide ring connecting part forging are chamfered in step one, and the maximum chamfer radius is at the connection between the edge boss and the arc web forging, the minimum chamfer radius is at the outer inclined edge of the arc web forging, the minimum chamfer radius is (R3) min , the maximum chamfer radius is (R3) max , (R3) min :(R3) max =1:(2-4); the edges of the guide petal and the guide ring connecting part forging blank are chamfered in step two, and the maximum chamfer radius is at the connection between the arc web forging blank and the long vertical rib forging, the minimum chamfer radius is at the outer inclined edge of the arc web forging blank, the minimum chamfer radius is (R4) min , the maximum chamfer radius is (R4) max , (R4) min :(R4) max =1:(2-4). The others are the same as the specific implementation one to three.

[0070] Specific implementation five: the difference between the embodiment and the specific implementation one to four is that the side surface of the guide petal and the guide ring connecting part forging in step one and the lower die in step three are provided with a 7°-10° draft angle. The others are the same as the specific implementation one to four.

[0071] Sixth embodiment: different from one of the first to fifth embodiments is that the material of the guiding vane and the guiding ring connecting part forging blank in step two and the material of the raw material used in the electric arc additive manufacturing in step four are both 7050 aluminum alloy; the volume of the guiding vane and the guiding ring connecting part forging blank in step two is 1.25 to 1.35 times the volume of the guiding vane and the guiding ring connecting part forging in step one. The others are the same as the first to fifth embodiments.

[0072] Seventh embodiment: different from one of the first to sixth embodiments is that the forging die in step three includes an upper die and a lower die, and both the upper die and the lower die are left-right symmetrical structures and are open structures. The others are the same as the first to sixth embodiments.

[0073] Eighth embodiment: different from one of the first to seventh embodiments is that the guiding vane and the guiding ring connecting part forging blank in step three is heated to 440 to 460℃ and is positioned in the lower die, and is forged to form at a pressing speed of 2.4 to 2.6 mm / s until the closing height of the upper and lower dies is 0.9 to 1.1 mm. The others are the same as the first to seventh embodiments.

[0074] Ninth embodiment: different from one of the first to eighth embodiments is that the single guiding ring part of the butt joint ring part is manufactured by electric arc additive manufacturing in step four, and a machining allowance of 4 to 6 mm is left in the cross section, and after the rough surface is removed, the size is the same as that of the guiding circular arc forging. The others are the same as the first to eighth embodiments.

[0075] Tenth embodiment: different from one of the first to ninth embodiments is that the additive blank preparation method and the electric arc additive manufacturing method in step four are both performed according to the following steps: taking 7050 aluminum alloy wire as the raw material, adopting CMT+ADV mode, and performing electric arc wire melting additive manufacturing under the conditions of a walking speed of 6 to 8 mm / s, a wire feeding speed of 6 to 7 m / min, a current of 90 to 100 A, a voltage of 11 to 12 V, and a wire feeding angle of 7 to 10°. The others are the same as the first to ninth embodiments.

[0076] The beneficial effects of the present application are verified by the following examples:

[0077] Example one:

[0078] A method for additive forging composite manufacturing of an aluminum alloy butt joint ring, which is performed according to the following steps:

[0079] I. Forging shape design:

[0080] The butt joint ring part is composed of a guide ring and guide petals, and the guide ring is circumferentially and evenly provided with three guide petals; the butt joint ring part is divided into a single guide ring part, a guide petal and guide ring connecting part; the guide petal and guide ring connecting part forging is designed according to the structure of the guide petal and guide ring connecting part;

[0081] The guide petal and guide ring connecting part forging is a left-right symmetrical structure composed of an arc web forging and a guide circular arc forging; the left and right side edges and the upper edge of the arc web forging are provided with edge bosses, the lower edge of the arc web forging is connected with the guide circular arc forging, the arc web forging is provided with two long vertical rib forgings and two short vertical rib forgings in a left-right symmetrical manner, one end of the two long vertical rib forgings is connected with the edge boss, and the other end is connected with the guide circular arc forging, and the short vertical rib forging is located inside the two long vertical rib forgings and connected with the guide circular arc forging;

[0082] The included angle of the left and right side edge bosses of the arc web forging is A1, and the included angle of the arc web forging and the guide circular arc forging is A2, A1 = 90°, and A2 = 45°;

[0083] The thickness of the arc web forging is T1, the width of the two long vertical rib forgings is T2, T1 = 19 mm, and T2 = 22 mm; the distance between the centers of the two long vertical rib forgings is D1, D1 = 255 mm; the thickness of the two long vertical rib forgings is H1, and the maximum height of the arc web forging is H2, H1 = 18 mm, and H2 = 150 mm;

[0084] The thickness of the edge boss is T3, and the width of the edge boss is T4, T3 = 12 mm, and T4 = 16 mm;

[0085] The distance between the centers of the two short vertical rib forgings is D2, the width of the two short vertical rib forgings is T5, D2 = 145 mm, and T5 = 12 mm; the bottom thickness of the two short vertical rib forgings is H5, H5 = 15 mm;

[0086] The inner circle radius of the guide circular arc forging is (R1) min , the outer circle radius of the guide circular arc forging is (R1) max , (R1) min = 440 mm, and (R1) max = 540 mm;

[0087] II. Forging blank shape design:

[0088] The guide petal and guide ring connecting part forging is designed according to the structure of the guide petal and guide ring connecting part forging;

[0089] The guiding petal and guiding ring connecting part forging blank is composed of an arc-shaped web forging blank and a guiding circular arc forging blank in a left-right symmetrical structure, the lower edge of the arc-shaped web forging blank is connected with the guiding circular arc forging blank, two long vertical rib forging blanks are symmetrically arranged on the upper and lower edges of the arc-shaped web forging blank, one end of the two long vertical rib forging blanks is connected with the edge, and the other end is connected with the guiding circular arc forging blank;

[0090] The angle between the two side edges of the arc-shaped web forging blank is A3, A3 = 90°, and the angle between the arc-shaped web forging blank and the guiding circular arc forging blank is A4, A4 = 90°.

[0091] The thickness of the arc-shaped web forging blank is T6, T6 = 25 mm, the width of the two long vertical rib forging blanks is T7, T7 = 20 mm, the distance between the centers of the two long vertical rib forging blanks is D3, D3 = 250 mm, the thickness of the two long vertical rib forging blanks is H3, H3 = 45 mm, and the maximum height of the arc-shaped web forging blank is H4, H4 = 120 mm.

[0092] The inner circle radius of the guiding circular arc forging blank is (R2) min , (R2) min = 445 mm, and the outer circle radius of the guiding circular arc forging blank is (R2) max , (R2) max = 545 mm.

[0093] Three, forging forming:

[0094] The guiding petal and guiding ring connecting part forging blank and the surface of the forging die are sprayed with lubricant, then the guiding petal and guiding ring connecting part forging blank is heated and positioned in the lower die, and is forged to form until the closing height of the upper and lower dies is 1.0 mm, and is demolded and air cooled to room temperature, and is sequentially subjected to pickling, deburring and polishing to obtain the guiding petal and guiding ring connecting part forging.

[0095] Four, additive remaining butt joint ring guiding ring:

[0096] Three guiding petal and guiding ring connecting part forgings are fixed, the single guiding ring part of the butt joint ring part is manufactured by electric arc additive manufacturing, the rough surface is removed and cut, and finally the machining allowance is removed to obtain the butt joint ring part.

[0097] The machining allowance of the guiding petal and guiding ring connecting part in step one is 5 mm; the guiding petal and guiding ring connecting part forging blank in step two is machined from additive blank, and the additive blank has a machining allowance of 7 mm when machined into the guiding petal and guiding ring connecting part forging blank.

[0098] The cross section of the guiding ring and the guiding circular arc forging in step one is polygonal; the cross section of the guiding circular arc forging blank in step two is polygonal.

[0099] The edge of the guide vane and guide ring connecting part forging in step one is chamfered, and the maximum chamfer radius is at the connection between the edge boss and the arc web forging, and the minimum chamfer radius is at the inclined edge outside the arc web, wherein the minimum chamfer radius is (R3) min , the maximum chamfer radius is (R3) max , (R3) min = 4mm, and (R3) max = 8mm. The edge of the guide vane and guide ring connecting part forging blank in step two is chamfered, and the maximum chamfer radius is at the connection between the arc web blank and the long vertical rib forging, and the minimum chamfer radius is at the inclined edge outside the arc web blank, wherein the minimum chamfer radius is (R4) min , the maximum chamfer radius is (R4) max , (R4) min = 3mm, and (R4) max = 7mm.

[0100] The side surface of the guide vane and guide ring connecting part forging in step one and the lower die in step three are provided with a 9° draft angle.

[0101] The material of the guide vane and guide ring connecting part forging blank in step two and the raw material for the electric arc additive manufacturing in step four is 7050 aluminum alloy; the volume of the guide vane and guide ring connecting part forging blank in step two is 1.25 times the volume of the guide vane and guide ring connecting part forging in step one.

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

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

[0104] In step four, the single guide ring part of the joint ring part is manufactured by electric arc additive manufacturing, and a 5mm machining allowance is left in the cross section, and after the rough surface is removed, the size is the same as that of the guide arc forging.

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

[0106] Figure 10For the finite element simulation results of forging forming and demolding in step three of the embodiment, (a) is a direct view of the forged piece in the lower die after simulation forming, (b) is a direct view of the forged piece after simulation forming, (c) is the forming result of the intermediate forged piece in the upper die and the lower die after simulation forming, and (d) is the forging forming finite element simulation result and the load change curve; as shown in the figure, the metal is completely filled in the cavity after forging, the shape of the forged piece is good, the metal in the jaw is well extruded by the flash, the forged piece is suitable to be taken out, and the maximum load after forging forming is about 15400t.

Claims

1. A method of additively forged hybrid manufactured aluminum alloy butt ring, characterized by It is carried out according to the following steps: I. Forging shape design: The butt joint ring part is composed of a guide ring and guide petals, and the guide ring is uniformly arranged with three guide petals in the circumferential direction; the butt joint ring part is divided into a single guide ring part, a guide petal and guide ring connecting part; the guide petal and guide ring connecting part forging is designed according to the structure of the guide petal and guide ring connecting part; The guide petal and guide ring connecting part forging is a left-right symmetrical structure composed of an arc web forging and a guide circular arc forging; the left and right side edges and the upper edge of the arc web forging are provided with edge bosses, the lower edge of the arc web forging is connected with the guide circular arc forging, the arc web forging is provided with two long vertical rib forgings and two short vertical rib forgings on the left and right sides, one end of the two long vertical rib forgings is connected with the edge boss, and the other end is connected with the guide circular arc forging, and the short vertical rib forging is located inside the two long vertical rib forgings and connected with the guide circular arc forging; The included angle of the left and right side edge bosses of the arc web forging is A1, the included angle of the arc web forging and the guide circular arc forging is A2, and A1:A2=(1.90~2.10):1; The thickness of the arc web forging is T1, the width of the two long vertical rib forgings is T2, T1:T2=1:(1.12~1.25), the distance between the centers of the two long vertical rib forgings is D1, D1=250mm~260mm, the thickness of the two long vertical rib forgings is H1, and the maximum height of the arc web forging is H2, H1:H2=1:(7.00~10.67); The thickness of the edge boss is T3, the width of the edge boss is T4, T3:T4=1:(1.13~1.37); The distance between the centers of the two short vertical rib forgings is D2, the width of the two short vertical rib forgings is T5, T5:D2=1:(10.77~13.64), the bottom thickness of the two short vertical rib forgings is H5, and H5=(0.7~0.9)H1; Let the inner circle radius of the guide circular arc forging be (R1) min Let the outer circle radius of the guide circular arc forging be (R1) max (R1) min (R1) max =1:(1.20~1.25) II. Forging blank shape design: The guide petal and guide ring connecting part forging blank is designed according to the guide petal and guide ring connecting part forging; The guide petal and guide ring connecting part forging blank is a left-right symmetrical structure composed of an arc web forging blank and a guide circular arc forging blank, the lower edge of the arc web forging blank is connected with the guide circular arc forging blank, and the arc web forging blank is provided with two long vertical rib forgings on the left and right sides, one end of the two long vertical rib forgings is connected with the edge, and the other end is connected with the guide circular arc forging blank; The included angle of the two side edges of the arc web forging blank is A3, A3=(0.95~1.05)A1; the included angle of the arc web forging blank and the guide circular arc forging blank is A4, A4=(1.90~2.10)A2; The thickness of the arc-shaped web forging blank is T6, T6=(1.1~1.5)T1; the width of the two long vertical ribs forging blanks is T7, T7=(0.9~1.2)T2; the distance between the centers of the two long vertical ribs forging blanks is D3, D3=250mm~260mm; the thickness of the two long vertical ribs forging blanks is H3, H3=(2.5~3.0)H1; and the maximum height of the arc-shaped web forging blank is H4, H4=(0.80~0.95)H2; The inner circle radius of the guiding circular arc forging blank is (R2) min , (R2) min = (0.99~1.04)(R1) min The outer circle radius of the guiding circular arc forging blank is (R2) max , (R2) max = (0.99~1.03)(R2) max The guiding petal and the connecting part of the guiding ring are processed from additive blank. III. Forging forming: The guiding lobe and guiding ring connecting portion forging blank and the surface of the forging die are sprayed with lubricant, then the guiding lobe and guiding ring connecting portion forging blank is heated and positioned in the lower die, and is forged until the height of the closed die is 0.9mm~1.1mm, and is demoulded and air-cooled to room temperature, and is sequentially subjected to pickling, deburring and polishing to obtain the guiding lobe and guiding ring connecting portion forging. IV. Additive remaining butt joint ring guiding ring: Three guiding lobe and guiding ring connecting portion forgings are fixed, and the single guiding ring portion of the butt joint ring part is manufactured by electric arc additive manufacturing, the rough surface is removed and cut, and finally the machining allowance is removed to obtain the butt joint ring part.

2. The method of additively forging a composite manufactured aluminum alloy butt ring of claim 1, wherein The machining allowance of the guiding lobe and guiding ring connecting portion in step one is 5mm~10mm; and the additive blank in step two is machined into the guiding lobe and guiding ring connecting portion forging blank with an allowance of 5mm~10mm.

3. The method of claim 1, wherein The cross section of the guiding ring and guiding arc forging in step one is polygonal; and the cross section of the guiding arc forging blank in step two is polygonal.

4. The method of additively forging a composite manufactured aluminum alloy butt ring of claim 1, wherein The edge of the forging of the connecting part of the guide vane and the guide ring is chamfered in step one, and the maximum chamfer radius is at the connecting part of the edge boss and the arc web forging, and the minimum chamfer radius is at the outer inclined edge of the edge boss, the minimum chamfer radius is (R3) min , the maximum chamfer radius is (R3) max , (R3) min :(R3) max =1:(2~4); the edge of the forging of the connecting part of the guide vane and the guide ring is chamfered in step two, and the maximum chamfer radius is at the connecting part of the arc web forging and the long vertical rib forging, and the minimum chamfer radius is at the outer inclined edge of the arc web forging, the minimum chamfer radius is (R4) min , the maximum chamfer radius is (R4) max , (R4) min :(R4) max =1:(2~4).

5. The method of additively forging a composite manufactured aluminum alloy butt ring of claim 1, wherein The side surface of the guiding lobe and guiding ring connecting portion forging in step one and the side surface of the lower die in step three are both provided with a draw draft of 7°~10°.

6. The method of additively forging a composite manufactured aluminum alloy butt ring of claim 1, wherein The material of the guiding lobe and guiding ring connecting portion forging blank in step two and the material of the raw material used in the electric arc additive manufacturing in step four are both 7050 aluminum alloy; and the volume of the guiding lobe and guiding ring connecting portion forging blank in step two is 1.25 times~1.35 times the volume of the guiding lobe and guiding ring connecting portion forging in step one.

7. The method of additively forging a composite manufactured aluminum alloy butt ring of claim 1, wherein The forging die in step three includes an upper die and a lower die, and the upper die and the lower die are both left-right symmetrical structures and are open structures.

8. The method of additively forging a composite manufactured aluminum alloy butt ring of claim 1, wherein In step three, the guiding lobe and guiding ring connecting portion forging blank is heated to 440℃~460℃ and positioned in the lower die, and is forged at a pressing speed of 2.4mm / s~2.6mm / s until the height of the closed die is 0.9mm~1.1mm.

9. The method of additively forging a composite manufactured aluminum alloy butt ring of claim 1, wherein In step four, the single guiding ring portion of the butt joint ring part is manufactured by electric arc additive manufacturing, and a machining allowance of 4mm~6mm is left in the cross section, and the size is the same as that of the guiding arc forging after the rough surface is removed.

10. A method of additively forging a composite manufactured aluminum alloy butt ring according to claim 2 or 9, characterized in that The preparation method of the additive material and the electric arc additive manufacturing method in step four are carried out according to the following steps: taking 7050 aluminum alloy wire as raw material, adopting CMT+ADV mode, and 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°, electric arc fusion wire additive manufacturing is carried out.

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