Efficient forging process for output shaft shared by ship accessories and mining machinery

Abstract

The invention relates to the field of forging processes, and discloses an efficient forging process for an output shaft shared by ship accessories and mining machinery, which comprises the following steps of: 1, simulating the stress condition of a mold by adopting finite element analysis through mold design and optimization, ensuring uniform stress of the mold, and avoiding mold wear and material segregation; secondly, the forging force and the deformation rate are precisely controlled through a numerical control forging machine tool, so that stable control over the forming precision of the forge piece is achieved; thirdly, a composite forging process is adopted, wherein the composite forging process comprises a pre-forging process and a precision forging process; 4, optimizing a heat treatment process; and 5, monitoring temperature, stress and deformation data in real time in cooperation with an intelligent temperature control and monitoring system. The forging force and the deformation rate are precisely controlled through the numerical control forging machine tool, the high consistency of the shape and the size of the forge piece in the forging process is guaranteed, error accumulation in the forging process is avoided, and the forming precision of the forge piece is improved.

Description

Technical Field

[0001] The invention relates to the technical field of forging technology, and in particular to a high-efficiency forging technology for a common output shaft of ship accessories and mining machinery. Background Art

[0002] Heavy equipment such as ship parts and mining machinery are subject to large mechanical loads during long-term operation, so their core components are required to have high mechanical properties and long service life. As an important component connecting the power source and the working device, the manufacturing process of the output shaft directly affects the performance and reliability of the product. In the existing manufacturing process, traditional forging processes usually rely on manual control and experience accumulation. The mechanical control accuracy and mold design in the forging process are often unsatisfactory, resulting in poor product consistency, short mold service life, and high cost.

[0003] At present, the output shafts of ship parts and mining machinery mostly adopt traditional forging processes, mainly including free forging and die forging processes. Although these processes can produce qualified forgings, due to the lack of precision control, there are often problems such as dimensional deviation and uneven internal structure of forgings. Especially in the forging process, due to uneven force and deformation rate, forgings often have defects such as cracks and material segregation. The design and use of traditional molds also have certain limitations. The molds have poor durability, wear quickly, and need to be replaced frequently, which increases production costs.

[0004] In the existing technology, problems such as shape and size control in the forging process, uneven die force, and insufficient material performance have not been effectively solved. In addition, insufficient control of cooling rate and tempering parameters in traditional heat treatment processes often leads to the inability to achieve an optimal balance between the hardness and toughness of the forgings, affecting the comprehensive performance of the forgings. Summary of the invention

[0005] In view of the shortcomings of the prior art, the present invention provides an efficient forging process for common output shafts of ship accessories and mining machinery, which solves the problem that insufficient control of cooling rate and tempering parameters in traditional heat treatment processes often leads to the inability to achieve an optimal balance between the hardness and toughness of forgings, affecting the comprehensive performance of the forgings.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: A high-efficiency forging process for a common output shaft for ship accessories and mining machinery, comprising the following steps:

[0007] Step 1: Through mold design and optimization, finite element analysis is used to simulate the force of the mold to ensure uniform force on the mold and avoid mold wear and material segregation;

[0008] Step 2: Use CNC forging machine tools to precisely control the forging force and deformation rate to achieve stable control of forging forming accuracy;

[0009] Step 3: Use a composite forging process, including a pre-forging process and a fine forging process, where:

[0010] The pre-forging process controls the heating temperature and heating rate through a thermodynamic model;

[0011] The precision forging process optimizes pressure and deformation rate through rheological stress model;

[0012] Step 4: Optimize the heat treatment process, including austempering and tempering processes, and use heat conduction simulation to adjust the cooling rate and tempering parameters in real time to ensure the balance between hardness and toughness of the forgings;

[0013] Step 5: Cooperate with the intelligent temperature control and monitoring system to monitor the temperature, stress and deformation data in real time, and automatically optimize various parameters in the forging process through machine learning algorithms.

[0014] Preferably, the steps of mold design and optimization include:

[0015] Finite element analysis is used to simulate the stress conditions of the mold to ensure that the strength of the mold is evenly distributed;

[0016] Optimize mold material and structure design based on simulation results to ensure the service life and stability of the mold.

[0017] Preferably, the CNC forging machine tool precision control step includes:

[0018] Through the real-time feedback control system, the pressure and deformation rate of the forging machine are accurately adjusted to ensure the dimensional accuracy of the forgings;

[0019] Sensors are used to collect temperature, pressure and deformation data in real time and automatically adjust forging parameters.

[0020] Preferably, the pre-forging step in the composite forging process includes:

[0021] Control the heating temperature and heating rate to ensure uniform heating of the forgings, and use a temperature control system to avoid local overheating;

[0022] During the pre-forging process, the forging pressure and deformation rate are precisely controlled to ensure uniform forming of the blank.

[0023] Preferably, the precision forging step in the composite forging process includes:

[0024] Adopt rheological stress model to optimize pressure and deformation rate during precision forging to ensure the final forming accuracy of forgings;

[0025] During the precision forging process, the pressure and deformation rate are finely adjusted to ensure uniform material flow and avoid internal stress accumulation.

[0026] Preferably, the isothermal quenching step in the heat treatment process includes:

[0027] By real-time monitoring of the cooling rate and adjusting the flow rate of the cooling medium, the temperature of the forging surface and inside can be evenly distributed to avoid cracks caused by uneven cooling.

[0028] Preferably, the tempering step in the heat treatment process includes:

[0029] Control the tempering temperature and tempering time to accurately adjust the hardness and toughness of the forgings to achieve the best mechanical properties;

[0030] Adjust the temperature during tempering to ensure uniform tempering and avoid increased brittleness.

[0031] Preferably, the temperature control and monitoring system includes:

[0032] High-precision temperature sensors are used to monitor the temperature of the die and forgings in real time, and automatically adjust the heating and cooling process through the temperature control system;

[0033] Stress sensors are used to monitor the stress state of forgings in real time and adjust the pressure and deformation rate during the forging process according to the stress data.

[0034] Preferably, the data analysis and optimization step comprises:

[0035] By collecting data such as temperature, stress, deformation rate, etc. generated during the forging process, the relationship between various parameters and forging quality is analyzed;

[0036] Based on the data analysis results, various parameters in the forging process are automatically adjusted to optimize temperature, pressure and deformation rate to improve forging efficiency.

[0037] Preferably, in the efficient forging process, the calculation formula includes:

[0038] Pre-forging heating temperature control formula:

[0039]

[0040] Where T is the heating temperature, T 0 is the initial temperature, T f is the target temperature, t is the heating time, and τ is the heating rate constant;

[0041] Optimization formula of precision forging pressure and deformation rate:

[0042]

[0043] Among them, σ is the rheological stress of the material, K is the rheological constant, d is the current deformation size, and d 0is the initial size, and n is the stress exponent.

[0044] The present invention provides an efficient forging process for a common output shaft for ship accessories and mining machinery. It has the following beneficial effects:

[0045] 1. The present invention uses a CNC forging machine to precisely control the forging force and deformation rate, thereby ensuring the high consistency of the shape and size of the forging during the forging process, avoiding the accumulation of errors during the forging process, and improving the forming accuracy of the forging. This control method effectively reduces forging defects and improves the consistency and reliability of the product.

[0046] 2. The present invention optimizes the mold design by performing finite element analysis on the mold stress conditions, thereby ensuring the uniformity of the mold stress during the forging process, effectively avoiding premature wear of the mold and material segregation, thereby increasing the mold service life and reducing the mold replacement frequency and maintenance cost.

[0047] 3. The present invention adopts a composite forging process, including a pre-forging process and a fine forging process. By applying a thermodynamic model and a rheological stress model, the heating temperature, heating rate, deformation rate and forging pressure are strictly controlled, so that the internal structure of the forging is more uniform, and the mechanical properties of the material are significantly improved, especially in terms of fatigue resistance and impact resistance.

[0048] 4. In the heat treatment stage, the present invention adopts the optimized process of isothermal quenching and tempering, and adjusts the cooling rate and tempering parameters through heat conduction simulation to effectively balance the hardness and toughness of the forging. By accurately controlling the heat treatment process, the wear resistance and corrosion resistance of the forging are improved, while the deformation and cracking problems of the forging caused by uneven temperature are reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 The figure is a flow chart of the method of the present invention. DETAILED DESCRIPTION

[0050] The following will be combined with the drawings in the specification of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0051] Please see attached Figure 1 The embodiment of the present invention provides an efficient forging process for a common output shaft of ship accessories and mining machinery, comprising the following steps:

[0052] Step 1: Through mold design and optimization, finite element analysis is used to simulate the force of the mold to ensure uniform force on the mold and avoid mold wear and material segregation;

[0053] Step 2: Use CNC forging machine tools to precisely control the forging force and deformation rate to achieve stable control of forging forming accuracy;

[0054] Step 3: Use a composite forging process, including a pre-forging process and a fine forging process, where:

[0055] The pre-forging process controls the heating temperature and heating rate through a thermodynamic model;

[0056] The precision forging process optimizes pressure and deformation rate through rheological stress model;

[0057] Step 4: Optimize the heat treatment process, including austempering and tempering processes, and use heat conduction simulation to adjust the cooling rate and tempering parameters in real time to ensure the balance between hardness and toughness of the forgings;

[0058] Step 5: Cooperate with the intelligent temperature control and monitoring system to monitor the temperature, stress and deformation data in real time, and automatically optimize various parameters in the forging process through machine learning algorithms.

[0059] The steps of mold design and optimization include:

[0060] Finite element analysis is used to simulate the stress conditions of the mold to ensure that the strength of the mold is evenly distributed;

[0061] Optimize mold material and structure design based on simulation results to ensure the service life and stability of the mold.

[0062] The precision control steps of CNC forging machine tools include:

[0063] Through the real-time feedback control system, the pressure and deformation rate of the forging machine are accurately adjusted to ensure the dimensional accuracy of the forgings;

[0064] Sensors are used to collect temperature, pressure and deformation data in real time and automatically adjust forging parameters.

[0065] The pre-forging steps in the composite forging process include:

[0066] Control the heating temperature and heating rate to ensure uniform heating of the forgings, and use a temperature control system to avoid local overheating;

[0067] During the pre-forging process, the forging pressure and deformation rate are precisely controlled to ensure uniform forming of the blank.

[0068] The precision forging steps in the composite forging process include:

[0069] Adopt rheological stress model to optimize pressure and deformation rate during precision forging to ensure the final forming accuracy of forgings;

[0070] During the precision forging process, the pressure and deformation rate are finely adjusted to ensure uniform material flow and avoid internal stress accumulation.

[0071] The austempering step in the heat treatment process includes:

[0072] By real-time monitoring of the cooling rate and adjusting the flow rate of the cooling medium, the temperature of the forging surface and inside can be evenly distributed to avoid cracks caused by uneven cooling.

[0073] The tempering step in the heat treatment process includes:

[0074] Control the tempering temperature and tempering time to accurately adjust the hardness and toughness of the forgings to achieve the best mechanical properties;

[0075] Adjust the temperature during tempering to ensure uniform tempering and avoid increased brittleness.

[0076] The temperature control and monitoring system includes:

[0077] High-precision temperature sensors are used to monitor the temperature of the die and forgings in real time, and automatically adjust the heating and cooling process through the temperature control system;

[0078] Stress sensors are used to monitor the stress state of forgings in real time and adjust the pressure and deformation rate during the forging process according to the stress data.

[0079] The data analysis optimization steps include:

[0080] By collecting data such as temperature, stress, deformation rate, etc. generated during the forging process, the relationship between various parameters and forging quality is analyzed;

[0081] Based on the data analysis results, various parameters in the forging process are automatically adjusted to optimize temperature, pressure and deformation rate to improve forging efficiency.

[0082] An efficient forging process, where the calculation formula includes:

[0083] Pre-forging heating temperature control formula:

[0084]

[0085] Where T is the heating temperature, T 0 is the initial temperature, T f is the target temperature, t is the heating time, and τ is the heating rate constant;

[0086] Optimization formula of precision forging pressure and deformation rate:

[0087]

[0088] Among them, σ is the rheological stress of the material, K is the rheological constant, d is the current deformation size, and d 0 is the initial size, and n is the stress exponent.

[0089] In one embodiment, step 1: mold design and optimization

[0090] Mould selection and design

[0091] According to the size and shape of the output shaft, the mold is selected first. The mold material is high-strength alloy steel, which has good high temperature resistance and wear resistance. In the design stage, the preliminary design is carried out through CAD software to form a three-dimensional model of the mold. Subsequently, the stress condition of the mold is simulated and analyzed using finite element analysis software (such as ANSYS), the areas where stress concentration may occur are identified, and the mold thickness and material distribution are adjusted to optimize the mold to ensure uniform stress on the mold.

[0092] Die force simulation and optimization

[0093] Finite element analysis is used to perform die strength analysis under various simulated loading conditions. Specifically, the material flow, heat distribution and other data of the die during the forging process are input, and the stress conditions of the die under different temperatures and pressures are predicted through simulation calculations. The simulation results show that there is an area in the middle of the die that is subjected to excessive stress, and a thickening design is required. By adjusting the wall thickness of the die and adding cooling channels, the die can withstand greater pressure and dissipate heat evenly, avoiding common die wear and material segregation problems.

[0094] Step 2: Precision control of CNC forging machine

[0095] Forging Equipment Preparation and Calibration

[0096] The use of CNC forging machines for precision forging ensures that the forging force and deformation rate can be accurately controlled throughout the forging process. First, a comprehensive inspection of the machine tool is carried out to ensure the normal operation of the CNC system, hydraulic system and transmission system. The machine tool is calibrated using laser measuring instruments to ensure the displacement accuracy during the forging process.

[0097] Real-time adjustment of forging force and deformation rate

[0098] Real-time feedback control technology is used to monitor the deformation process of forgings through precision sensors, and the pressure and speed applied to the forgings are adjusted in real time. Specifically, the pressure sensors are used to monitor the pressure on the forgings in real time, and the pressure and deformation rate are adjusted through the CNC system to keep the stress changes of the forgings in each stage within the optimal range. Through this process, the high precision of forging forming is guaranteed.

[0099] Step 3: Application of composite forging process

[0100] Pre-forging process

[0101] Thermodynamic models are used to control the heating temperature and heating rate. First, the forging is heated to an appropriate temperature range (approximately 850-1000°C), and a thermocouple is used to monitor the temperature change during the heating process in real time. The heating rate is adjusted according to the material of the forging to avoid excessive thermal stress during the heating process. The uniform temperature distribution design in the furnace makes the temperature uniform during the heating process of the forging, avoids the occurrence of overheating or cold spots, and reduces the defects on the surface and inside of the forging.

[0102] Precision forging process

[0103] After pre-forging, the final forging process begins. During final forging, the rheological stress model is used to optimize the applied pressure and deformation rate. The rheological stress model can predict the optimal pressure and deformation rate based on the material properties, temperature and deformation state of the forging, thereby ensuring uniform deformation of the forging and avoiding local excessive deformation or uneven material flow. By adjusting the pressure and temperature field of the die and controlling the organizational structure of the forging, the mechanical properties of the forging are made more uniform.

[0104] Step 4: Heat treatment process

[0105] Isothermal quenching process

[0106] In order to improve the hardness of forgings, an isothermal quenching process is implemented. After fine forging, the forgings enter the quenching furnace for heating, and the temperature is controlled between 850-900℃. At this temperature, the forgings are quickly heated to the austenitized state, and then immediately transferred to a water-cooled or oil-cooled medium for quenching. In order to control the cooling rate, a heat conduction simulation system is used to adjust the flow rate and temperature of the cooling medium to ensure uniform cooling inside and on the surface of the forgings, thereby avoiding internal stress or crack problems caused by uneven cooling.

[0107] Tempering process

[0108] After quenching, tempering treatment is carried out to eliminate internal stress and optimize the toughness of the forgings. The tempering temperature is controlled between 500-600℃. Through the precise control of temperature and time, the hardness and toughness of the forgings are achieved in an ideal balance. During the tempering process, the temperature and time in the tempering furnace are automatically adjusted by the temperature control system to achieve the best tempering effect.

[0109] Step 5: Application of intelligent temperature control and monitoring system

[0110] Temperature control system settings

[0111] During the entire forging process, an intelligent temperature control system is equipped to monitor the temperature of the forgings in real time. In each stage of pre-forging, fine forging, heat treatment, etc., high-precision temperature sensors continuously collect temperature data on the surface and inside of the forgings. The temperature control system automatically adjusts the temperature and flow of the heating furnace and cooling equipment to ensure that the temperature changes remain within the optimal range and prevent forming defects caused by temperature fluctuations.

[0112] Stress and deformation monitoring

[0113] Stress sensors and displacement sensors are used to monitor the stress distribution and deformation state of forgings in real time during the entire forging process. The system automatically adjusts the forging pressure and deformation rate through data feedback to ensure that the deformation process of the forgings meets expectations and avoids excessive internal stress or uneven deformation.

[0114] Machine Learning Optimization

[0115] By collecting a large amount of data from the forging process, using machine learning algorithms to analyze historical data, and optimizing various parameters in the forging process through models, including optimizing parameters such as heating temperature, deformation rate, and cooling rate, automatically adjusting various control parameters in the production process, and improving the stability of the forging process and the quality of the finished product.

[0116] Embodiment 2:

[0117] Improvement steps: Optimize cooling rate control in heat treatment process

[0118] In Example 1, we further improved the performance of the forgings by optimizing the cooling process in the heat treatment process. The specific improvement is to introduce a real-time cooling rate control system, that is, in the traditional heat treatment process, by controlling the liquid flow rate of the cooling tank, the temperature of the cooling medium and other parameters, to achieve precise control of the cooling rate. This system combines the intelligent temperature control and monitoring system of the present invention, and dynamically optimizes the cooling process through real-time monitoring data and machine learning algorithms to ensure the best balance between the hardness and toughness of the forgings.

[0119] Improved specific implementation method:

[0120] Implementation of cooling rate control system:

[0121] During the cooling stage of the heat treatment process, an intelligent temperature control device is equipped to predict the cooling speed and time through heat conduction simulation.

[0122] The flow rate control device of the cooling liquid (such as water or oil) is used to adjust the liquid flow rate and the cooling medium temperature in real time.

[0123] Temperature sensors are placed on the surface and inside of the forging to ensure that the temperature difference during cooling does not exceed the preset threshold.

[0124] The cooling tank works in conjunction with the cooling system and uses an automatic adjustment device to ensure that the cooling rate of each batch of products is within the set range.

[0125] Effect of cooling rate control on heat treatment effect:

[0126] Optimizing the cooling rate helps to improve the hardness, toughness and flatness of the material and reduce the incidence of surface cracks on forgings.

[0127] This improvement can achieve a more accurate hardness distribution, especially the hardness and toughness of the thick-walled parts of the forgings, further improving the service life of the product.

[0128]

[0129] Table 1

[0130] Hardness (HB): Use a Brinell hardness tester to measure the hardness of the forging surface.

[0131] Toughness (J / cm 2 ): The impact toughness of the sample was measured by impact test.

[0132] Surface roughness (Ra, μm): Use a surface roughness meter to measure the Ra value of the forging surface.

[0133] Cooling rate (℃ / s): The rate of temperature change of the coolant during the cooling process.

[0134] Crack incidence (%): The surface of the forging after cooling was microscopically analyzed and the proportion of cracks occurred was recorded.

[0135] Production cycle (one hour): the total production time including preheating, forging, heat treatment, etc.

[0136] Comparative analysis:

[0137] Hardness and toughness: The improved process increases the hardness of the forging from 200HB to 240HB and the toughness from 12J / cm 2 Increased to 15J / cm 2 , indicating that optimized cooling rate control significantly improves the mechanical properties of forgings, especially in terms of the balance between hardness and toughness.

[0138] Surface roughness: The surface roughness of forgings produced by traditional processes is relatively high (4.2 μm), while the improved process reduces the surface roughness to 2.1 μm by precisely controlling the cooling rate, significantly improving the surface quality.

[0139] Crack incidence: In the traditional process, the crack incidence is 5% due to uneven cooling, while the improved process greatly reduces the crack incidence to only 1% by optimizing the cooling process.

[0140] Production cycle: By optimizing the cooling rate, the production cycle was shortened from 10 hours to 8 hours, which improved production efficiency and reduced manufacturing costs.

[0141] Embodiment three:

[0142] On the basis of Example 1, we further improved the die design and optimization steps, and used a more accurate finite element analysis simulation method to dynamically optimize the die stress conditions, so as to reduce die wear and improve the dimensional accuracy and surface quality of the forgings.

[0143] Improved specific implementation method:

[0144] High-precision finite element analysis:

[0145] An improved version of the finite element analysis software is used to conduct a detailed analysis of the stress conditions of the mold and forgings through 3D modeling and simulation to ensure uniform stress on the mold and avoid local overload.

[0146] By using more accurate friction models and temperature distribution analysis, we optimize the design of the mold for high temperature and high pressure conditions to reduce damage to the mold due to high temperature fatigue.

[0147] Mould material and surface treatment:

[0148] Use mold materials with high wear resistance and high thermal conductivity, and use surface hardening treatment technology (such as nitriding and carburizing) to enhance the wear resistance of the mold surface and extend the service life of the mold.

[0149] Multi-objective optimization of mold design:

[0150] In mold design, a multi-objective optimization algorithm (for example, based on genetic algorithm, particle swarm algorithm, etc.) is used to comprehensively consider factors such as mold manufacturing cost, service life, force uniformity, etc., to design a more efficient mold structure.

[0151]

[0152]

[0153] Table 2

[0154] illustrate:

[0155] Dimensional accuracy (mm): The dimensional tolerance of forgings is measured using a three-coordinate measuring machine.

[0156] Die wear (mm 2 ): The area of ​​mold wear is obtained by measuring the mold surface.

[0157] Surface finish (Ra, μm): Surface roughness tester measures the surface finish of forgings.

[0158] Forging process time (hours): the total time from die heating to forging completion.

[0159] Production cycle (hours): the total time from raw material preparation to forging completion.

[0160] analyze:

[0161] Dimensional accuracy: After optimizing the die design through high-precision finite element analysis, the dimensional accuracy of the forgings was improved from ±0.5mm to ±0.2mm.

[0162] Mold wear: The optimized mold wear is significantly reduced, and the wear area is reduced from 5mm 2 Reduced to 1mm 2 , greatly extending the service life of the mold.

[0163] Surface finish: The surface finish of the forgings is improved, and the Ra value is reduced from 3.5μm to 2.0μm, which significantly improves the surface quality.

[0164] Production cycle: Since the optimized mold design reduces the frequency of wear and maintenance, the overall production cycle is shortened and the forging production efficiency is improved.

[0165] Summary: By further optimizing the die design and using more accurate finite element analysis simulation, we have significantly improved the dimensional accuracy and surface quality of the forgings, reduced die wear, and improved production efficiency. This improvement further enhances the application value of the invention, especially in improving production efficiency and reducing die maintenance costs.

[0166] Embodiment 4:

[0167] On the basis of Example 1, we further optimized the precision forging process in the composite forging process, combined the rheological stress model with the intelligent control system, and achieved the optimal regulation of pressure and deformation rate to further improve the material properties and shape accuracy of the forgings.

[0168] Improved specific implementation method:

[0169] Rheological stress model optimization:

[0170] Advanced flow stress models (such as those based on strain hardening, strain rate, and temperature) are used to optimize the pressure and deformation rate during forging.

[0171] The model calculates stress and strain at different stages in real time, thereby accurately controlling the deformation behavior of the forging, avoiding excessive deformation or stress concentration, and ensuring the uniformity of the forging.

[0172] Intelligent forging process control:

[0173] An artificial intelligence-based optimization algorithm is introduced to monitor the deformation state, temperature and pressure of forgings through real-time sensors, and dynamically adjust the pressure and speed of the forging machine to ensure that the optimal forming state is maintained throughout the forging process.

[0174] Historical production data is learned through machine learning models to provide adaptive optimization control solutions for different types of forgings.

[0175]

[0176] Table 3

[0177] Tensile Strength (MPa): The tensile strength of a forging is measured by a tensile test.

[0178] Elongation (%): Measures the extent to which a forging extends in a tensile test, reflecting its toughness.

[0179] Forging accuracy (mm): dimensional tolerance of forgings.

[0180] Forming temperature (℃): Material temperature during forging process.

[0181] Material utilization rate (%): calculated by the ratio of the actual weight of the forging to the weight of the raw material.

[0182] Forging process time (hours): the total time to complete the forging.

[0183] analyze:

[0184] Tensile strength: After optimizing the rheological stress model to control the pressure and deformation rate during the forging process, the tensile strength of the forging was increased from 650MPa to 750MPa, showing higher mechanical properties.

[0185] Elongation: The elongation of the forging increased from 12% to 18%, indicating that the ductility and toughness of the material have been significantly improved.

[0186] Forging accuracy: Due to more precise control of deformation rate and pressure, the dimensional accuracy of forgings is improved from ±0.5mm to ±0.2mm.

[0187] Material utilization rate: The material utilization rate increased from 85% to 92%, significantly reducing material waste.

[0188] Forging process time: Although the performance of forgings has been improved, the forging process has been optimized through an intelligent control system, shortening the forging time from 6 hours to 5 hours.

[0189] Through the improvement of Example 2, Example 3 and Example 4, it can be seen that the optimization of the present invention in terms of die design, cooling rate, rheological stress optimization and intelligent control not only significantly improves the performance of forgings (such as hardness, toughness, strength, elongation, etc.), but also greatly improves production efficiency and material utilization. Each improvement provides technical support for realizing efficient forging technology and further verifies the innovation and practicality of the present invention.

[0190] Comparative Example 1:

[0191] Purpose:

[0192] Comparing the traditional forging process with the high-efficiency forging process proposed in the present invention, the differences in the forming accuracy, hardness, toughness and production efficiency of the forgings are observed.

[0193] Experimental conditions:

[0194] Forging material: high strength alloy steel (such as 42CrMo);

[0195] Forging shape: Ship accessories and mining machinery share output shafts;

[0196] Forging equipment: CNC forging machine tools;

[0197] Heat treatment method: isothermal quenching and tempering;

[0198] Mold material: high strength alloy steel;

[0199] Temperature control: intelligent temperature control system and traditional temperature control system.

[0200] project Traditional crafts Process of the present invention Forging Dimension Error ±0.5mm ±0.1mm Surface roughness Ra3.0μm Ra1.5μm Forming accuracy 85％ 95％

[0201] Table 4

[0202] Result analysis:

[0203] The present invention significantly improves the forming accuracy of forgings by optimizing the force of precision CNC forging machines and dies. In the traditional process, the forging pressure and deformation rate are not accurately controlled, resulting in large dimensional errors and high surface roughness of forgings. However, the present invention successfully controls the dimensional error within ±0.1mm through intelligent control systems and finite element analysis, and improves the forming accuracy by 10%.

[0204] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An efficient forging process for common output shafts for ship accessories and mining machinery, characterized in that: The following steps are involved: Step 1: Through mold design and optimization, finite element analysis is used to simulate the force of the mold to ensure uniform force on the mold and avoid mold wear and material segregation; Step 2: Use CNC forging machine tools to precisely control the forging force and deformation rate to achieve stable control of forging forming accuracy; Step 3: Use a composite forging process, including a pre-forging process and a fine forging process, where: The pre-forging process controls the heating temperature and heating rate through a thermodynamic model; The precision forging process optimizes pressure and deformation rate through rheological stress model; Step 4: Optimize the heat treatment process, including austempering and tempering processes, and use heat conduction simulation to adjust the cooling rate and tempering parameters in real time to ensure the balance between hardness and toughness of the forgings; Step 5: Cooperate with the intelligent temperature control and monitoring system to monitor the temperature, stress and deformation data in real time, and automatically optimize various parameters in the forging process through machine learning algorithms.

2. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1 is characterized in that: The steps of mold design and optimization include: Finite element analysis is used to simulate the stress conditions of the mold to ensure that the strength of the mold is evenly distributed; Optimize mold material and structure design based on simulation results to ensure the service life and stability of the mold.

3. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1 is characterized in that: The CNC forging machine tool precision control steps include: Through the real-time feedback control system, the pressure and deformation rate of the forging machine are accurately adjusted to ensure the dimensional accuracy of the forgings; Sensors are used to collect temperature, pressure and deformation data in real time and automatically adjust forging parameters.

4. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1 is characterized in that: The pre-forging step in the composite forging process includes: Control the heating temperature and heating rate to ensure uniform heating of the forgings, and use a temperature control system to avoid local overheating; During the pre-forging process, the forging pressure and deformation rate are precisely controlled to ensure uniform forming of the blank.

5. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1, characterized in that: The precision forging step in the composite forging process includes: Adopt rheological stress model to optimize pressure and deformation rate during precision forging to ensure the final forming accuracy of forgings; During the precision forging process, the pressure and deformation rate are finely adjusted to ensure uniform material flow and avoid internal stress accumulation.

6. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1, characterized in that: The isothermal quenching step in the heat treatment process includes: By real-time monitoring of the cooling rate and adjusting the flow rate of the cooling medium, the temperature of the forging surface and inside can be evenly distributed to avoid cracks caused by uneven cooling.

7. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1, characterized in that: The tempering step in the heat treatment process includes: Control the tempering temperature and tempering time to accurately adjust the hardness and toughness of the forgings to achieve the best mechanical properties; Adjust the temperature during tempering to ensure uniform tempering and avoid increased brittleness.

8. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1 is characterized in that: The temperature control and monitoring system comprises: High-precision temperature sensors are used to monitor the temperature of the die and forgings in real time, and automatically adjust the heating and cooling process through the temperature control system; Stress sensors are used to monitor the stress state of forgings in real time and adjust the pressure and deformation rate during the forging process according to the stress data.

9. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1, characterized in that: The data analysis and optimization step comprises: By collecting data such as temperature, stress, deformation rate, etc. generated during the forging process, the relationship between various parameters and forging quality is analyzed; Based on the data analysis results, various parameters in the forging process are automatically adjusted to optimize temperature, pressure and deformation rate to improve forging efficiency.

10. The high-efficiency forging process for a common output shaft for ship accessories and mining machinery according to claim 1, characterized in that: The high-efficiency forging process described above, wherein the calculation formula include: Pre-forging heating temperature control formula: Where T is the heating temperature, T0 is the initial temperature, T f is the target temperature, t is the heating time, and τ is the heating rate constant; Optimization formula of precision forging pressure and deformation rate: Among them, σ is the rheological stress of the material, K is the rheological constant, d is the current deformation size, d0 is the initial size, and n is the stress exponent.

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