A forging method for concave-shaped plate parts

Abstract

This invention belongs to the field of plate forging, specifically relating to a forging method for a U-shaped plate. It includes the design of a flat forging blank, the design of a flat forging die, and the determination of the blanking dimensions, so that a forging conforming to the dimensions required by the drawing can be obtained during final forging.

Description

Technical Field

[0001] This invention belongs to the field of plate forging, and specifically relates to a forging method for a U-shaped plate. Background Technology

[0002] Currently, forgings of this type, characterized by large ends and a thin web in the middle, are typically formed by directly forging larger blanks or using a combination of free forging and die forging due to their shape constraints. Both of these methods result in low material utilization and poor deformation matching during hot working. Free forging produces billets with significant forging defects, poor dimensional consistency, unstable microstructure, and high production costs. Therefore, a new process solution needs to be developed to address these pain points. Summary of the Invention

[0003] Purpose of the invention: To provide a forging method for concave plate-like parts, solving the problems of low material utilization, poor matching of deformation in hot working processes, large forging defects, and high production costs caused by existing technologies.

[0004] Technical solution:

[0005] A forging method for a U-shaped plate-like part includes:

[0006] Step 1: Determine the shape and size of the flat forging blank: Draw a 3D model based on the forging drawing, and cut the cross-sections at both ends and the middle web. Multiply the cross-sectional area by the flash coefficient to calculate the cross-sectional area of ​​the corresponding part of the blank. In order to evenly distribute the deformation, the cross-section of the blank corresponding to the web is designed as an ellipse, and the two ends are designed as circles. The length and transition radius of the web and the two ends are determined according to the final forging drawing.

[0007] Step 2: Perform Deform simulation to verify the shape and dimensions of the flat forging blank;

[0008] Step 3: Adjust the rough shape dimensions based on the simulation results of Step 2 until the overall deformation is within the range of 40% to 70% and there are no defects.

[0009] Step 4: Based on the rough shape dimensions determined in Step 3, multiply by the thermal coefficient to make a flat forging die. The flat forging die includes an upper die, a lower die, and left and right punches. The left and right punches have a pre-reserved fit clearance with the upper and lower die cavities.

[0010] Step 5: Based on the rough shape dimensions determined in Step 3, draw a 3D digital model, determine the volume of the rough shape, and determine the diameter of the bar stock based on the area of ​​the central ellipse of the rough shape, so that the area of ​​the central ellipse of the rough shape and the cross-sectional area of ​​the bar stock are consistent, and convert the required bar stock length into equal volume.

[0011] Step 6: Cut the alloy bar to the required length and chamfer the end face, spray with high-temperature glass lubricant, heat to the required initial forging temperature and hold for a period of time, put the alloy bar into the flat forging die, forge it into shape, and forge it to the dimensions and specifications of the rough shape.

[0012] Step 7: After cleaning, grinding and removing defects from the rough shape produced in Step 6, spray high-temperature glass lubricant and protectant, heat to the required initial forging temperature of the material and hold for a period of time, then place it into the final forging mold cavity for forging and shaping.

[0013] Step 8: Perform heat treatment and physical and chemical testing on the forgings according to relevant requirements.

[0014] Preferably, in step 1, forging flash is generated on both sides of the web portion, with a flash coefficient of 1.1 to 1.15, and forging flash is generated on the three sides of both ends, with a flash coefficient of 1.2 to 1.3.

[0015] Preferably, in step 1, the rough shape length of the web portion is consistent with the web length of the forging, and the rough shape length of both ends is 5-10mm shorter than that of the forging, while ensuring that the rough shape meets the requirements of filling the cavity during forging and having a reasonable deformation distribution.

[0016] Preferably, in step 4, the thermal coefficient is 1.008 to 1.010, and the single-sided fitting clearance between the left and right punches and the upper and lower dies is 0.4 mm to 0.5 mm, wherein the single-sided fitting clearance is taken from the punch.

[0017] Preferably, in step 6, the end face chamfer of the alloy rod is 2mm × 45°.

[0018] Preferably, in steps 6 and 7, the application of a high-temperature glass lubricant and protective agent specifically involves:

[0019] In the heat preservation box, set the temperature to 150℃~200℃, place the bar stock in the heat preservation box and keep it at that temperature for 60min~120min, then take it out and spray glass lubricant on the surface of the billet. The spray thickness of the glass lubricant is 0.06mm~0.10mm on one side.

[0020] Preferably, in steps 6 and 7, the forging heating and holding time is calculated as 0.9 min / mm to 1.1 min / mm, and the initial forging temperature is selected in the range of 930℃ to 960℃.

[0021] Preferably, in steps 6 and 7, a high-temperature glass lubricant is sprayed before each forging.

[0022] Beneficial effects:

[0023] (1) Flat forging billet, the rough shape size is controlled by the mold, which solves the problems of low utilization rate of forging materials, poor matching of deformation in hot working process, large forging defects and high production cost from the root.

[0024] (2) The bar stock is formed in the flat forging die, and the produced rough shape has complete streamline, good consistency in shape and size, and stable and reliable quality. Attached Figure Description

[0025] To more clearly illustrate the technical solutions implemented in this invention, the accompanying drawings used in the embodiments of this invention will be briefly explained below. Obviously, the drawings described below are merely some embodiments of this invention. Those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0026] Figure 1 Schematic diagram of forging, in which, Figure 1 (a) Front view Figure 1 (b) is a top view. Figure 1 (c) is a sectional view;

[0027] Figure 2 A schematic diagram of the undeveloped terrain, in which, Figure 2 (a) Front view Figure 2 (b) is a top view. Figure 2 (c) is a sectional view;

[0028] Figure 3 A schematic diagram of a flat forging die, in which ① is the upper die, ② is the lower die, and ③ is the left and right punches;

[0029] Figure 4 A schematic diagram of matching the rough shape with the forging, where the double-dotted line represents the outline of the rough shape;

[0030] Figure 5 Simulation results;

[0031] Figure 6 Low magnification of forgings;

[0032] Figure 7 Microstructure of forgings. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] The features of various aspects of the embodiments of the present invention will now be described in detail. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention can also be practiced without these specific details. The following description of the embodiments is merely intended to provide a better understanding of the invention by illustrating examples. The invention is not limited to any specific setups and methods provided below, but covers all improvements, substitutions, etc., to product structures and methods without departing from the spirit of the invention.

[0035] In the various accompanying drawings and the following description, well-known structures and techniques are not shown in order to avoid unnecessarily obscuring the invention.

[0036] like Figure 1-7 A forging method for a U-shaped plate-like part includes the design of a flat forging blank, the design of a flat forging die, and the determination of the blanking dimensions, so that a forging conforming to the dimensions required by the drawing can be obtained during final forging. Specifically, it includes:

[0037] Step 1: Determine the shape and size of the flat forging blank: Draw a 3D model based on the forging drawing, and cut the cross-sections at both ends and the middle web. Multiply the cross-sectional area by the flash coefficient to calculate the cross-sectional area of ​​the corresponding part of the blank. In order to evenly distribute the deformation, the cross-section of the blank corresponding to the web is designed as an ellipse, and the two ends are designed as circles. The length and transition radius of the web and the two ends are determined according to the final forging drawing.

[0038] Preferably, in step 1, forging flash is generated on both sides of the web portion, with a flash coefficient of 1.1 to 1.15, and forging flash is generated on the three sides of both ends, with a flash coefficient of 1.2 to 1.3.

[0039] Preferably, in step 1, the rough shape length of the web portion is consistent with the web length of the forging, and the rough shape length of both ends is 5-10mm shorter than that of the forging, while ensuring that the rough shape meets the requirements of filling the cavity during forging and having a reasonable deformation distribution.

[0040] Step 2: Perform Deform simulation to verify the shape and dimensions of the flat forging blank;

[0041] Step 3: Adjust the rough shape dimensions based on the simulation results of Step 2 until the overall deformation is within the range of 40% to 70% and there are no defects.

[0042] Step 4: Based on the rough shape dimensions determined in Step 3, multiply by the thermal coefficient to make a flat forging die. The flat forging die includes an upper die, a lower die, and left and right punches. The left and right punches have a pre-reserved fit clearance with the upper and lower die cavities.

[0043] Preferably, in step 4, the thermal coefficient is 1.008 to 1.010, and the single-sided fitting clearance between the left and right punches and the upper and lower dies is 0.4 mm to 0.5 mm, wherein the single-sided fitting clearance is taken from the punch.

[0044] Step 5: Based on the rough shape dimensions determined in Step 3, draw a 3D digital model, determine the volume of the rough shape, and determine the diameter of the bar stock based on the area of ​​the central ellipse of the rough shape, so that the area of ​​the central ellipse of the rough shape and the cross-sectional area of ​​the bar stock are consistent, and convert the required bar stock length into equal volume.

[0045] Step 6: Cut the alloy bar to the required length and chamfer the end face, spray with high-temperature glass lubricant, heat to the required initial forging temperature and hold for a period of time, put the alloy bar into the flat forging die, forge it into shape, and forge it to the dimensions and specifications of the rough shape.

[0046] Preferably, in step 6, the end face chamfer of the alloy rod is 2mm × 45°.

[0047] Step 7: After cleaning, grinding and removing defects from the rough shape produced in Step 6, spray high-temperature glass lubricant and protectant, heat to the required initial forging temperature of the material and hold for a period of time, then place it into the final forging mold cavity for forging and shaping.

[0048] Preferably, in steps 6 and 7, the application of a high-temperature glass lubricant and protective agent specifically involves:

[0049] In the heat preservation box, set the temperature to 150℃~200℃, place the bar stock in the heat preservation box and keep it at that temperature for 60min~120min, then take it out and spray glass lubricant on the surface of the billet. The spray thickness of the glass lubricant is 0.06mm~0.10mm on one side.

[0050] Preferably, in steps 6 and 7, the forging heating and holding time is calculated as 0.9 min / mm to 1.1 min / mm, and the initial forging temperature is selected in the range of 930℃ to 960℃.

[0051] Preferably, in steps 6 and 7, a high-temperature glass lubricant is sprayed before each forging.

[0052] It can solve the problems of unstable billet size and microstructure in traditional free forging and poor deformation matching in various hot working processes. It includes blanking, closed flat forging, and final forging.

[0053] Step 8: Perform heat treatment and physical and chemical testing on the forgings according to relevant requirements.

[0054] Example:

[0055] A certain TC4 alloy concave plate-like part is produced by die forging using the method of this invention.

[0056] Step 1: Design of the flat forging blank, based on the forging drawing finally delivered to the customer ( Figure 1 Draw a 3D model, then extract the cross-sectional areas of the two ends I and III, and the cross-sectional area of ​​the middle web II. Based on the cross-sectional areas at the corresponding positions, multiply the cross-sectional areas of the two ends I and III by a flash factor of 1.25, and multiply the cross-sectional area of ​​the middle web II by a flash factor of 1.1, to calculate the actual values ​​of Φ1, Φ2, and the major axis b and minor axis a of the ellipse for the corresponding parts of the rough shape. Add constraints to the calculation of the minor axis a of the ellipse at the middle position of the rough shape. The value is controlled between 0.5 and 0.8. The rough shape length of the web portion is consistent with the web length of the forging, and the rough shape length at both ends is 6.5mm shorter than that of the forging. Figure 4 ;

[0057] Step 2: Based on the rough shape dimensions determined in Step 1, draw a 3D digital model. Combine the Deform simulation results to further refine the rough shape dimensions and ensure the overall deformation amount ( Figure 5 The actual deformation was 50% to 70%, and the rationality of the rough shape dimensions and transition fillets was further verified.

[0058] Step 3: Refine the rough shape dimensions based on the simulation results from Step 2 (see attached) Figure 2 );

[0059] Step 4: Based on the rough shape dimensions determined in Step 3, scale up all dimensions proportionally by a factor of 1.008 to create the flat forging die cavity; for example... Figure 3 It includes an upper mold, a lower mold, and left and right punches. The left and right punches are reserved with a fitting clearance of 0.4mm on each side of the upper and lower mold cavities.

[0060] Step 5: Determine the blanking specifications. Based on the rough shape dimensions determined in Step 3, draw a 3D digital model to determine the volume of the rough shape. Based on the area of ​​the ellipse in the middle of the rough shape, determine the diameter of the bar stock to be Φ55, so that the cross-sectional area of ​​the rough shape and the bar stock are consistent. The required bar stock length is 488 when converted to equal volume.

[0061] Step 6: Cut the alloy bar to the required length and chamfer the end face by 2mm×45°, spray with high temperature glass lubricant, heat to the required initial forging temperature of 960℃ and hold for 55 minutes, put the alloy bar into the flat forging die and forge it into the desired shape.

[0062] Step 7: After cleaning, grinding and removing defects from the rough shape produced in Step 6, spray high-temperature glass lubricant and protectant, heat to the required initial forging temperature of 960℃ and hold for 45 minutes, place the rough shape into the final forging die and forge to the dimensions required by the drawing.

[0063] Step 8: Perform heat treatment and physical and chemical testing on the forgings according to relevant requirements, such as... Figure 6 and Figure 7 .

[0064] Using the design and forging process of this invention, a certain TC4 alloy concave plate-like part was produced. After physical and chemical testing and dissection, the longitudinal section of the forging showed uniform microstructure at low magnification, which met the microstructure requirements of relevant standards for TC4 alloy forgings.

Claims

1. A forging method for a U-shaped plate-like part, characterized in that, include: Step 1: Determine the shape and size of the flat forging blank: Draw a 3D model based on the forging drawing, and cut the cross-sections at both ends and the middle web. Multiply the cross-sectional area by the flash coefficient to calculate the cross-sectional area of ​​the corresponding part of the blank. To evenly distribute the deformation, the blank cross-section of the web part is designed as an ellipse, and the two ends are designed as circles. The length and transition radius of the web and the two ends are determined according to the final forging drawing. The blank length of the web part is consistent with the web length of the forging. The blank length of the two ends is 5-10mm shorter than the forging. At the same time, it is ensured that the blank fills the cavity during forging and has a reasonable deformation distribution. Step 2: Perform Deform simulation to verify the shape and dimensions of the flat forging blank; Step 3: Adjust the rough shape dimensions based on the simulation results of Step 2 until the overall deformation is within the range of 40% to 70% and there are no defects. Step 4: Based on the rough shape dimensions determined in Step 3, multiply by the thermal coefficient to make a flat forging die. The flat forging die includes an upper die, a lower die, and left and right punches. The left and right punches have a pre-reserved fit clearance with the upper and lower die cavities. Step 5: Based on the rough shape dimensions determined in Step 3, draw a 3D digital model, determine the volume of the rough shape, and determine the diameter of the bar stock based on the area of ​​the central ellipse of the rough shape, so that the area of ​​the central ellipse of the rough shape and the cross-sectional area of ​​the bar stock are consistent, and convert the required bar stock length into equal volume. Step 6: Cut the alloy bar to the required length and chamfer the end face, spray with high-temperature glass lubricant, heat to the required initial forging temperature and hold for a period of time, put the alloy bar into the flat forging die, forge it into shape, and forge it to the dimensions and specifications of the rough shape. Step 7: After cleaning, grinding and removing defects from the rough shape produced in Step 6, spray high-temperature glass lubricant and protectant, heat to the required initial forging temperature of the material and hold for a period of time, then place it into the final forging mold cavity for forging and shaping. Step 8: Perform heat treatment and physical and chemical testing on the forgings according to relevant requirements.

2. The method according to claim 1, characterized in that, In step 1, forging flash is generated on both sides of the web, with a flash coefficient of 1.1 to 1.

15. Forging flash is generated on the three sides of both ends, with a flash coefficient of 1.2 to 1.

3.

3. The method according to claim 1, characterized in that, In step 4, the thermal coefficient is 1.008 to 1.010, and the single-sided fitting clearance between the left and right punches and the upper and lower dies is 0.4 mm to 0.5 mm, wherein the single-sided fitting clearance is taken from the punch.

4. The method according to claim 1, characterized in that, In step 6, the end face of the alloy rod is chamfered to 2mm × 45°.

5. The method according to claim 1, characterized in that, In steps 6 and 7, a high-temperature glass lubricant and protective agent is sprayed, specifically as follows: In the heat preservation box, set the temperature to 150℃~200℃, place the bar stock in the heat preservation box and keep it at that temperature for 60min~120min, then take it out and spray glass lubricant on the surface of the billet. The spray thickness of the glass lubricant is 0.06mm~0.10mm on one side.

6. The method according to claim 1, characterized in that, In steps 6 and 7, the forging heating and holding time is calculated as 0.9 min / mm to 1.1 min / mm, and the initial forging temperature is selected in the range of 930℃ to 960℃.

7. The method according to claim 1, characterized in that, In steps 6 and 7, a high-temperature glass lubricant is sprayed before each forging.

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