Casting and forging combined upsetting leakage disc and assembling method thereof

Abstract

The invention relates to a casting and forging combined type upsetting leakage plate and an assembly method thereof, belongs to the technical field of forging and upsetting forming equipment, and solves the problems that an upsetting leakage plate in the prior art is poor in mechanical property and wear resistance, easy to deform and crack and short in service life. A casting and forging combined type upsetting leakage disc comprises a leakage disc base and a bushing, the leakage disc base comprises a base a and a base b, the outer diameter of the base a is larger than that of the base b, and the base a and the base b are in transition connection through a first fillet; the base a is provided with a central through hole a and comprises an upper inverted cone section, a middle cylindrical section and a lower inverted cone section, so that a stepped transition structure is formed; a central through hole b is formed in the base b, is in an inverted cone shape and is coaxially and smoothly connected with an inverted cone section at the lower part of the central through hole a; the base a and the base b are integrated castings; and the bushing is a forge piece, is embedded in the middle cylindrical section of the base a, and is provided with a central through hole c. And the mechanical property and the service life of the upsetting leakage disc are improved.

Description

Technical Field

[0001] The invention relates to the technical field of forging upsetting forming equipment, in particular to a casting and forging combined upsetting drain plate and an assembly method thereof. Background Art

[0002] Upsetting is a deformation method with a high popularity in forgings. It can increase the cross-section of the billet while reducing its height. On the one hand, it provides dimensional conditions for the subsequent drawing process and increases the degree of drawing deformation. It is a preparatory process for the subsequent drawing process. On the other hand, it can crush the original cast coarse grains, thereby refining the grains and improving the mechanical properties of the forgings.

[0003] At present, the upsetting disks used in the forging industry are generally integrated castings. Due to the limitations of their usage scenarios, during upsetting, the contact surface temperature of the upsetting disk and the blank is high, the yield strength of the upsetting disk is reduced, and its mechanical properties and wear resistance are difficult to guarantee. After a certain number of years of use, the upsetting disk is prone to deformation and cracking (cracks extend from the inner wall to the outer wall), and the inner wall is subject to varying degrees of wear, which affects the dimensional accuracy of the forgings and production efficiency in the actual production process. Summary of the invention

[0004] In view of the above analysis, an embodiment of the present invention aims to provide a cast-forged combined upsetting leaking plate and an assembly method thereof, so as to solve at least one of the problems of the existing upsetting leaking plate, such as poor mechanical properties, poor wear resistance, easy deformation and cracking, and short service life.

[0005] On the one hand, an embodiment of the present invention provides a cast and forged combined upsetting leak plate, comprising a leak plate base 1 and a sleeve 2, wherein the leak plate base 1 comprises a base a 101 and a base b 102, wherein the outer diameter of the base a is greater than the outer diameter of the base b, and the two are transitionally connected via a first fillet 7; the base a is provided with a central through hole a, comprising an upper inverted cone section, an intermediate cylindrical section and a lower inverted cone section, forming a stepped transition structure; the base b is provided with a central through hole b, which is inverted cone shape, coaxial with the lower inverted cone section of the central through hole a and smoothly connected;

[0006] The base a 101 and the base b 102 are integral castings; the insert 2 is a forging, embedded in the middle cylindrical section of the base a 101, and provided with a central through hole c.

[0007] Preferably, the upper inverted cone section and the lower inverted cone section of the central through hole a have different cone angles; the inverted cone angle of the central through hole b is the same as the taper of the lower inverted cone section of the central through hole a, and the size is continuous;

[0008] The central through hole c includes an upper cone portion and a lower cone portion. The upper cone portion is an inverted cone, which has the same cone angle as the upper inverted cone section of the central through hole a and is smoothly connected to form an upper cone surface 4; the lower cone portion is an inverted cone, which has the same cone angle as the central through hole b and is smoothly connected to form a lower cone surface 5; the upper cone surface 4 and the lower cone surface 5 are transitioned through a second fillet 8.

[0009] Furthermore, the diameter of the center plane of the transition zone between the upper conical surface and the lower conical surface is in is the inner diameter of the lower end surface of the central through hole b of the base b; the height H1 between the central surface 9 of the transition zone between the upper conical surface 4 and the lower conical surface 5 and the upper end surface of the base a satisfies:

[0010]

[0011] It should be noted that the inner diameter of the middle cylindrical section of the drain pan base a is / 2, where It is the inner diameter of the upper end surface of the upper inverted cone section of the central through hole a; the total height H0 of the leakage disk base satisfies: H0≥L0+200mm, where L0 is the jaw length of the blank, and the units of H0 and L0 are mm; the heights of the base a and the base b are H2 and H3 respectively, and H2=H3.

[0012] Furthermore, the annular surface surrounding the base determined by the line connecting the center points of the arc of the first fillet 7 is set as the pre-fracture surface P1 of the drain disc base, and the height H5 of the lower inverted cone section of the drain disc base a satisfies the following formula:

[0013]

[0014] T is the pressure on the drain plate during upsetting, in t;

[0015] is the inner diameter of the middle cylindrical section of the drain pan base a, in mm;

[0016] θ is the angle between the pre-fracture surface P1 and the vertical ground direction, which is 45° to 60°;

[0017] δ is the yield strength of the selected drain pan base material at the service temperature, in MPa.

[0018] Preferably, the wall thickness B2 of the drain disc base b satisfies: 1.5B1≥B2>B1, wherein B1 is the wall thickness of the insert.

[0019] Furthermore, the drain pan base 1 is provided with a lifting lug 3, which is a casting and is integrally formed with the drain pan base 1, and there are four of them in total, which are symmetrically distributed, and the spacing B0 on ​​the same side of the lifting lugs satisfies: is the outer diameter of the upper end surface of the base a; the shaft diameter of the ear clamp is

[0020] On the other hand, an embodiment of the present invention further provides an assembly method for a cast and forged combined upsetting leak plate, wherein the combined upsetting leak plate is assembled, the leak plate base (1) is heated to a hot-loading temperature and is kept warm before being taken out of the furnace, the time Y required for heating the leak plate base (1) from a cold state to the hot-loading temperature is calculated based on a heating time of 15 minutes per 10 mm of wall thickness; the cold sleeve is placed in the middle cylindrical section of the base a, and allowed to stand and air-cool, thereby completing the assembly.

[0021] Furthermore, the heat-loading temperature calculation method is as follows:

[0022] △1=Φ2 / 25×0.04;

[0023] △2=k△1;

[0024] X = △2 / (Φ2*γ);

[0025] X is the hot-loading temperature, °C;

[0026] is the inner diameter of the middle cylindrical section of the drain pan base a, mm;

[0027] is the outer diameter of the sleeve, mm;

[0028] △1 is and The interference between them, mm;

[0029] △2 is the inner diameter expansion of the drain pan base a before and after heating, mm;

[0030] γ is the linear expansion coefficient corresponding to the base material;

[0031] k is the thermal installation coefficient, which ranges from 2 to 2.5.

[0032] Preferably, the heat preservation time Z at the hot charging temperature is calculated based on 8 minutes of heating time for every 10 mm of wall thickness.

[0033] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0034] 1. The upsetting drain disc of the present invention is designed as a cast and forged combined drain disc. The sleeve part of the drain disc that needs to withstand high loads is designed as a forging to improve wear resistance, yield strength and other performance properties. The drain disc base and the lifting lug are designed as castings. Under the premise of ensuring the reliability of the upsetting drain disc, the service life of the attachment is extended and the manufacturing cost is reduced. In the subsequent use process, the cost of using the attachment is reduced to meet the production needs.

[0035] 2. The upsetting leak disk provided by the present invention adopts a conical surface design at multiple locations on the inner side wall, making full use of the cone angle design of the inner wall of the upsetting leak disk to optimize the forming forging. First, the central through hole a of the leak disk base a, that is, the transition area between the upper end surface of the upper inverted cone section and the through hole is designed with a certain taper, so that after the leak disk is used for upsetting in actual production, the transition area between the forging blank and the pliers handle will form a taper corresponding to the upsetting leak disk, which can effectively strengthen the pliers handle and prevent the root of the pliers handle from being dented during subsequent pulling; second, the central through hole b of the base b is continuous in size with the lower inverted cone section of the central through hole a, and a certain taper is designed with the axis, which is conducive to reducing the radial expansion force on the upsetting leak disk caused by the expansion of the radial size of the jaws during the deformation process, reducing the load on the inner wall of the upsetting leak disk, preventing the pliers handle and the leak disk from locking after upsetting, and effectively extending the service life of the upsetting leak disk.

[0036] 3. The cast and forged combined upsetting drain pan provided by the present invention optimizes the dimensions of the drain pan base according to the materials selected for the drain pan base and the insert sleeve, thereby ensuring the reliability of the drain pan and reducing the manufacturing cost.

[0037] 4. The cast and forged combined upset drain pan provided by the present invention, the drain pan base and the insert sleeve are assembled by heat-fitting, and the assembly method is scientific and simple, which can ensure that the integrity of the cast and forged combined drain pan after assembly is not inferior to that of the traditional integrated upset drain pan. On the one hand, the drain pan base is heated to the heat-fitting temperature, while the insert sleeve remains cold. This temperature difference helps to control the thermal expansion of the overall structure, thereby reducing deformation after assembly; on the other hand, heat-fitting can improve the fit of the mating surface, because thermal expansion can temporarily increase the size of the base a, making it easier to fit with the cold insert sleeve, thereby improving assembly accuracy, extending the service life of the product, and reducing maintenance costs.

[0038] In the present invention, the above-mentioned technical solutions can also be combined with each other to achieve more preferred combination solutions. Other features and advantages of the present invention will be described in the subsequent description, and some advantages can become obvious from the description, or can be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained through the contents particularly pointed out in the description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The drawings are only for the purpose of illustrating particular embodiments and are not to be considered limiting of the present invention. Like reference symbols denote like components throughout the drawings.

[0040] Figure 1 The invention discloses a cast and forged combined upsetting drain pan;

[0041] Figure 2 This is a load cloud diagram of the upset leaking disc of the present invention;

[0042] Figure 3 This is a schematic diagram of the sleeve structure of the present invention;

[0043] Figure 4 This is a schematic diagram of the structure of the drain pan base of the present invention;

[0044] Figure 5 Schematic diagram of the drain pan base and the inlay after assembly of the present invention;

[0045] Figure 6 This is a distribution diagram of the lifting lugs of the present invention;

[0046] Figure 7 Schematic diagram of thermal installation of the present invention;

[0047] Figure 8 It is the hot charging curve of the present invention;

[0048] Fig. 9 This is the hot charging curve of Example 1 of the present invention.

[0049] Reference numerals:

[0050] 1- drain pan base; 101- base a; 102- base b; 2- sleeve; 3- ear; 4- upper cone surface; 5- lower cone surface; 6- chamfer; 7- first fillet; 8- second fillet; 9- center plane of transition zone between upper cone surface and lower cone surface;

[0051] H0-total height of the drain pan base; H1-height between the center plane of the transition zone between the upper cone and the lower cone and the upper end surface of the base a; H2-height of the base a; H3-height of the base b; H4-height of the insert; H5-height of the middle cylindrical section of the drain pan base a;

[0052] B0-spacing between the lifting ears on the same side; B1-wall thickness of the insert; B2-wall thickness of the drain pan base b;

[0053] -Inner diameter of the upper end surface of the upper inverted cone section of the central through hole a; - outer diameter of the sleeve; -Inner diameter of the middle cylindrical section of the drain pan base a; -The diameter of the center plane of the transition zone between the upper cone and the lower cone; -Inner diameter of the lower end surface of the central through hole b of the base b; - The outer diameter of the lower end surface of the central through hole b of the base b; -Outer diameter of the upper end surface of base a; -Shaft diameter of the lifting lug and snap ring; -The diameter of the smooth connection between the lower cone of the sleeve and the central through hole b. DETAILED DESCRIPTION

[0054] The preferred embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not used to limit the scope of the present invention.

[0055] At present, the upsetting drain plates used in the forging industry are generally integrated castings. Due to the limitations of their usage scenarios, when designing a cast-forged combined upsetting drain plate, if the design is only based on experience and the size of the integrated upsetting drain plate, it is difficult to meet the usage requirements.

[0056] On the one hand, a specific embodiment of the present invention discloses a cast and forged combined upsetting drain plate, such as Figure 1 As shown, it includes a drain pan base 1 and a sleeve 2, the drain pan base 1 includes a base a101 and a base b102, the outer diameter of the base a is larger than the outer diameter of the base b, and the two are transitionally connected through a first fillet 7; the base a is provided with a central through hole a, including an upper inverted cone section, a middle cylindrical section and a lower inverted cone section, forming a step-type transition structure; the base b is provided with a central through hole b, which is inverted cone shape, coaxial with the lower inverted cone section of the central through hole a and smoothly connected;

[0057] The base a 101 and the base b 02 are integral castings; the insert 2 is a forging, embedded in the middle cylindrical section of the base a 101, and provided with a central through hole c.

[0058] like Figure 2 As shown in the figure, through numerical simulation analysis, the inner wall side of the leakage disk serves as the direct contact surface during upsetting and bears a large load, especially the inner wall side of the leakage disk. Designing the sleeve part as a forging can improve its performance, including wear resistance and yield strength. The leakage disk base and the ear are designed as castings to ensure the reliability of the leakage disk while reducing costs.

[0059] Furthermore, the upper inverted cone section and the lower inverted cone section of the central through hole a have different cone angles; the inverted cone angle of the central through hole b is the same as that of the lower inverted cone section of the central through hole a, and the size is continuous.

[0060] Specifically, Figure 4 , Figure 5 As shown, the central through hole c includes an upper cone portion and a lower cone portion, the upper cone portion is an inverted cone, which has the same cone angle as the upper inverted cone section of the central through hole a and is smoothly connected to form an upper cone surface 4; the lower cone portion is an inverted cone, which has the same cone angle as the central through hole b and is smoothly connected to form a lower cone surface 5; the upper cone surface 4 and the lower cone surface 5 are transitioned through a second fillet 8, and the center surface 9 of the transition zone between the upper cone surface and the lower cone surface has a diameter of in It is the inner diameter of the lower end surface of the central through hole b of the base b, and its value is selected based on the actual forging jaw diameter.

[0061] Preferably, the upper conical surface formed by the drain disc base a and the insert sleeve is used to ensure that the jaws and the shaft body form a transition zone when the blank is upsetting, which can effectively prevent the jaws from being folded in the subsequent drawing process. The lower conical surface formed by the drain disc base b and the insert sleeve is conducive to the rapid assembly of the forging pliers and the drain disc and the rapid withdrawal of the forging after the subsequent upsetting (anti-locking), and on the other hand, it is conducive to reducing the radial tensile stress on the upsetting drain disc caused by the radial expansion of the jaws during the deformation process, reducing the load on the inner wall of the upsetting drain disc, and extending the service life of the upsetting drain disc.

[0062] Specifically, Figure 3 As shown, the assembly surface between the lower outer circle of the insert sleeve and the base a is provided with a chamfer 6 to facilitate assembly. The angle range of the chamfer is Where B1 is the wall thickness of the sleeve.

[0063] For example, the inner diameter of the middle cylindrical section of the drain pan base a is in is the inner diameter of the upper end surface of the upper inverted cone section of the center through hole a, Larger than the shaft diameter of the blank before upsetting.

[0064] Furthermore, the total height H0 of the drain pan base satisfies: H0≥L0+200mm, wherein L0 is the jaw length of the blank, and the units of H0 and L0 are mm; the heights of the base a and the base b are H2 and H3 respectively, and H2=H3.

[0065] Preferably, the height H1 between the center plane 9 of the transition zone between the upper conical surface and the lower conical surface and the upper end surface of the base a satisfies:

[0066] It should be noted that the pre-fracture surface P1 of the drain disc base is an annular surface surrounding the base determined by a line connecting the center points of the first fillet arc.

[0067] Preferably, the height H5 of the lower inverted cone section of the drain pan base a satisfies the following formula:

[0068]

[0069] T is the pressure on the drain plate during upsetting, in t;

[0070] is the inner diameter of the middle cylindrical section of the drain pan base a, in mm;

[0071] θ is the angle between the pre-fracture surface P1 and the vertical ground direction;

[0072] δ is the yield strength of the selected drain pan base material at the service temperature, in MPa.

[0073] Specifically, the pressure borne by the drain plate during upsetting is the sum of the press pressure and the deadweight of the blank. The angle θ between the pre-fracture surface P1 and the vertical ground direction is 45° to 60°.

[0074] like Figure 3 , Figure 5 As shown, the sleeve wall thickness B1 is and The difference between is the outer diameter of the sleeve, is the diameter of the smooth connection between the lower cone of the sleeve and the central through hole b; the lower cone surface 5 Therefore, by determining the diameter and height, B1 can be calculated.

[0075] The existing traditional integrated upset leak plate design usually sets the size of the fracture-prone area as large as possible based on experience to ensure that the use requirements are met. This design idea lacks certain scientific basis and does not consider the manufacturing cost. The size calculated by the formula in the present invention is the minimum necessary value, and the lower limit of the design parameter is clearly set. This is not only based on scientific principles, but also can reasonably reduce the manufacturing cost and achieve cost-effectiveness optimization.

[0076] According to the principle of lightweight design, the smaller the H5 value, the better, that is, the larger the θ value, the better. However, the smaller the H5, the larger the sleeve height H4 will be. Figure 4 , Figure 5 As shown, H4 = H2-H5-(1 / 2*H1). As the cost of forgings is much greater than that of castings, taking lightweight and manufacturing costs into consideration, θ is 45-60°. According to the stress analysis, the pre-fracture surface is the weakest area of ​​the entire drain pan base. The yield strength at the pre-fracture surface is improved through the complementary combination of material and pre-fracture surface size.

[0077] In a possible design, the drain pan base is made of ZG25, the yield strength δ is 230MPa at 20℃, the yield strength δ is about 100Mpa at 550℃, and the outer diameter of the sleeve is It is 2000mm, the maximum pressure T during upsetting is 14000t, θ is 45°, H5 in the leak plate base should be greater than or equal to 109.2mm, and H5 is rounded to 150mm.

[0078] Exemplarily, the wall thickness B2 of the drain disk base b satisfies: 1.5B1≥B2>B1, where B1 is the wall thickness of the insert.

[0079] Specifically, the height H4 of the insert sleeve matches the wall thickness B1 of the insert sleeve and the size of the middle cylindrical section of the base a.

[0080] Preferably, if Figure 6As shown, the drain pan base 1 is provided with a lifting ear 3, which is a casting and is integrally formed with the drain pan base. There are four of them in total and they are symmetrically distributed. The spacing B0 on ​​the same side of the lifting ears satisfies: It is the outer diameter of the upper end surface of base a.

[0081] Furthermore, the shaft diameter of the lifting lug clamp is

[0082] Preferably, if Figure 7 As shown, the drain plate base a and the insert sleeve are assembled by heat-fitting. and The size is an interference fit, that is, the outer diameter of the sleeve Slightly larger than the inner diameter of the middle cylindrical section of the base a

[0083] On the other hand, a specific embodiment of the present invention, as Figure 8 As shown, a method for assembling a cast and forged combined upsetting drain pan is disclosed, wherein the drain pan base 1 is heated to a hot-loading temperature and then taken out of the furnace after being kept warm. The time Y required for heating the drain pan base (1) from a cold state to the hot-loading temperature is calculated based on a heating time of 15 minutes per 10 mm wall thickness. The cold insert is placed in the middle cylindrical section of the base a, and allowed to stand and air-cool to complete the assembly.

[0084] On the one hand, the drain plate base is heated to the hot-loading temperature, while the insert sleeve remains cold. This temperature difference helps to control the thermal expansion of the overall structure, thereby reducing deformation after assembly. On the other hand, hot-loading can improve the fit of the mating surfaces because thermal expansion can temporarily increase the size of the base a, making it easier to fit with the cold insert sleeve, thereby improving assembly accuracy, extending the service life of the product, and reducing maintenance costs.

[0085] It should be noted that a temporary lifting lug is welded on the inner wall of the sleeve before assembly, and the temporary lifting lug is removed after assembly.

[0086] Furthermore, the heat-loading temperature calculation method is as follows:

[0087] △1=Φ2 / 25×0.04;

[0088] △2=k△1;

[0089] X = △2 / (Φ2*γ);

[0090] X is the hot-loading temperature, °C;

[0091] is the outer diameter of the sleeve, mm;

[0092] is the inner diameter of the middle cylindrical section of the drain pan base a, mm;

[0093] △1 is and The interference between them, mm;

[0094] △2 is the inner diameter expansion of the drain pan base a before and after heating, mm;

[0095] γ is the thermal expansion coefficient of the drain pan base material within the phase change temperature range;

[0096] k is the thermal installation coefficient, which ranges from 2 to 2.5.

[0097] Preferably, the heat-fitting temperature X should be below the phase transition temperature of the corresponding material. The inner diameter expansion amount Δ2 should be as large as possible to facilitate heat-fitting.

[0098] It should be noted that the temperature during hot charging is controlled within the range of X to X+50°C.

[0099] Furthermore, the time Y required to heat up to the hot-loading temperature is calculated based on 20 minutes of heating time for every 10 mm of wall thickness, and the calculated result is rounded up.

[0100] Preferably, the holding time Z at the hot charging temperature is calculated based on 8 minutes of heating time for every 10 mm of wall thickness, and the calculation result is rounded up.

[0101] It should be noted that, unlike the hot-loading temperature of ordinary bearings, the accessories used for large forgings (such as upsetting leaking discs) have two key indicators due to their large heating area: heating rate and holding time. The two determine the deformation uniformity of the hot-loading parts to a certain extent, thereby affecting the hot-loading efficiency. If the temperature is uneven during hot-loading, the hot-loading parts are prone to internal stress, affecting the mechanical properties of the hot-loading parts. Furthermore, the present invention further optimizes the hot-loading temperature. On the one hand, a hot-loading coefficient k is set, which further limits the expansion amount, ensuring that during the hot-loading process, the fit between the parts can achieve the purpose of tight assembly, and can avoid excessive assembly stress or part damage caused by excessive expansion, further improving the assembly efficiency; on the other hand, with the hot-loading temperature X as the reference, the temperature range of X to X+50°C during hot-loading is clarified, which effectively avoids irreversible deformation of the accessories caused by excessive hot-loading temperature, and can reduce energy consumption, thereby reducing manufacturing costs.

[0102] In summary, the upset leak disk of the present invention is designed as a cast-forged combined leak disk, and the sleeve part of the leak disk that needs to withstand high loads is designed as a forging to improve wear resistance, yield strength and other performance properties, and the leak disk base and the lifting lug are designed as castings. Under the premise of ensuring the reliability of the upset leak disk, the service life of the attachment is extended, the manufacturing cost is reduced, and then in the subsequent use process, the cost of using the attachment is reduced to meet production needs; the present invention adopts a conical surface design at multiple locations on the inner wall of the leak disk, and makes full use of the inner wall cone angle to optimize the forming of the forging. First, the central through hole a of the base a, that is, the upper end surface of the upper inverted cone section and the through hole A certain taper is designed in the transition area, so that after the leak disk is upset in actual production, the transition area between the forging blank and the pliers handle will form a taper corresponding to the upset leak disk, which can effectively strengthen the pliers handle and prevent the root of the pliers handle from being folded during subsequent pulling; secondly, the central through hole b of the base b and the lower inverted cone section of the central through hole a are continuous in size, and a certain taper is designed with the axis, which is beneficial to reduce the radial expansion force on the upset leak disk caused by the radial expansion of the jaws during the deformation process, reduce the load on the inner wall of the upset leak disk, prevent the pliers handle and the leak disk from being locked after upsetting, and effectively extend the service life of the upset leak disk.

[0103] In addition, the dimensions of the leak pan base are optimized based on the materials selected for the leak pan base and the sleeve, which ensures the reliability of the leak pan while further reducing manufacturing costs.

[0104] The drain pan base and the insert sleeve of the present invention are assembled by heat-fitting, which further optimizes the heat-fitting curve while ensuring assembly efficiency and use reliability, improves assembly accuracy, prolongs the service life of the product, and reduces maintenance costs.

[0105] The cast and forged combined upsetting drain plate and the assembly method of the present invention are described below in conjunction with specific embodiments.

[0106] Example 1

[0107] This embodiment provides a cast and forged combined upsetting drain plate and an assembly method, such as Figure 1 , Figure 7 shown.

[0108] A forging combined upsetting plate is designed to withstand a maximum pressure of 16000t during upsetting. The jaw diameter of the forging in service is 1500mm, and the jaw length is L=1700mm.

[0109] According to the forging jaw diameter, determine the inner diameter of the lower end surface of the center through hole b of the base b. H0=2000mm; then H2=H3=1000mm, Drain plate outer diameter Inner diameter of the middle cylindrical section of the drain pan base a

[0110] The drain pan base is made of ZG25 material, and its yield strength is 230MPa at 20℃. It is affected by heat transfer during upsetting, and the service temperature is 550℃, at which time its yield strength is about 100Mpa.

[0111] The insert is made of 35CrMo material, and its yield strength at 550°C is as high as 800Mpa.

[0112] θ is 45°, T is 16000t, The diameter is 2400mm, and the yield strength δ of the drain pan base material at the service temperature is 100Mpa;

[0113] By formula Therefore, H5 in the drain pan base should be greater than or equal to 104mm, and H5 is rounded to 150mm.

[0114] By formula The height of the upper cone formed by the drain plate base and the sleeve is H1 = 160 ~ 320, with the middle value of 300mm.

[0115] According to the formula, the specifications of the drain plate lifting ears are: 1800mm≥B0≥1200mm,

[0116] The assembly method is as follows:

[0117] According to the formula △1=Φ2 / 25×0.04, the interference △1 is about 4mm, the wall thickness of the drain pan base a is 700mm, the inner diameter expansion of the drain pan base a is 10mm during the proposed hot installation, and the thermal expansion coefficient γ of the ZG25 material within the phase change temperature range is 0.00001. The manufacturing and assembly process of the drain pan base and the insert is as follows:

[0118] Step 1: The drain pan base is manufactured by casting and processed to the assembly size. The inner diameter expansion of the drain pan base a is △2=(2~2.5)△1=8~10mm.

[0119] Bushing size: H4 = H2-H5-(1 / 2*H1) = 700mm; B1 is 70mm (rounded off),

[0120] Step 2: The insert is manufactured in the form of a forging. The manufacturing process is as follows:

[0121] Ingots - upsetting, punching - hole expansion to produce finished products - heat treatment after forging - rough machining - performance heat treatment - fine machining to assembly size.

[0122] Step 3: Press Fig. 9 The hot charging curve heats the drain plate base. Before hot charging, a temporary lifting lug is welded on the inner wall of the sleeve, and the sleeve is placed in a cold state. After the lower upsetting plate is taken out of the furnace, the sleeve is pressed Figure 7 The schematic diagram is placed on the bottom of the drain pan, left to cool in air, and the temporary lifting lugs are removed after assembly.

[0123] Step 4: Insert the forging blank jaws into the inner wall of the upsetting drain plate to ensure that the axis of the forging blank coincides with the axis of the upsetting drain plate.

[0124] After assembly, the cast and forged combined upsetting leaking plate was subjected to an upsetting test. The test parameters were as follows: the digital display pressure value of the press was 16180t, and the pressure holding test was carried out at this pressure value according to the average upsetting time. After the test, the upsetting leaking plate had no deformation or cracking.

[0125] Comparative Example 1

[0126] This embodiment provides a cast-forged combined upsetting drain plate and an assembly method.

[0127] The design load and size are the same as those in Example 1, except that the drain pan base and the insert sleeve are both in a cold state during assembly. Since there is a certain interference between the outer diameter of the insert sleeve and the assembly surface of the drain pan base, the insert sleeve cannot be embedded in the drain pan base, and the assembly fails.

[0128] Comparative Example 2

[0129] This embodiment provides a cast-forged combined upsetting drain plate and an assembly method.

[0130] The design load and dimensions are the same as those in Example 1, except that the heating temperature of the drain pan base during assembly is relatively low, 150° C. It can be deduced by the formula that the expansion of the drain pan base a is about 3.6 mm at 150° C., while the interference △1 corresponding to the nominal diameter of the assembly surface of the drain pan base and the insert sleeve is about 4 mm. There is still interference during hot assembly, and the insert sleeve cannot be embedded in the drain pan base, resulting in assembly failure.

[0131] Comparative Example 3

[0132] This embodiment provides a cast-forged combined upsetting drain plate and an assembly method.

[0133] The design load is the same as that of Example 1, and the main dimensions of the combined leakage plate are the same as those of Example 1. The difference is The drain plate base b and the insert sleeve form a vertical surface instead of a lower conical surface. The assembly method is the same as that of the first embodiment.

[0134] After assembly, the cast and forged combined upsetting leak plate is subjected to an upsetting test. After being upset to the process size, the blank and the upsetting leak plate cannot be separated, i.e., "locking" occurs. This is because the radial dimension of the root of the blank jaws increases during upsetting, and a radial expansion force is generated between the root of the blank jaws and the inner wall of the upsetting leak plate, resulting in a "locking" phenomenon.

[0135] The size and internal surface design of the cast and forged combined leakage disc provided in Example 1 meet the requirements of the present invention, and the hot loading curve provided in the present invention is used for assembly. After the upsetting test, the upsetting leakage disc has no deformation or cracking; in Example 1, since the leakage disc base and the sleeve are both in a cold state during assembly, and compared with Example 1, the preheating temperature of the leakage disc base in Example 2 is lower and does not meet the hot loading curve of the present invention, both result in the inability to embed the sleeve into the leakage disc base and the assembly fails; compared with Example 1, since the matching surface between the leakage disc base b and the sleeve is not designed with a conical surface, the cast and forged combined upsetting leakage disc is subjected to an upsetting test after assembly. After upsetting to the process size, the blank and the upsetting leakage disc cannot be separated, and a locking phenomenon occurs.

[0136] In summary, the upset leak disc of the present invention is designed as a cast-forged combined leak disc, and the sleeve part of the leak disc that needs to bear high loads is designed as a forging to improve wear resistance, yield strength and other performance properties, and the leak disc base and lifting lugs are designed as castings. Under the premise of ensuring the reliability of the upset leak disc, the service life of the accessories is extended and the manufacturing cost is reduced, and then in the subsequent use process, the cost of using the accessories is reduced to meet production needs; the present invention adopts a conical surface design at multiple locations on the inner wall of the leak disc, and makes full use of the inner wall cone angle to optimize the forming forgings, effectively reducing the load on the inner wall of the leak disc, and preventing the clamp handle and the leak disc from locking after upsetting, thereby significantly extending the service life of the upset leak disc; in addition, according to the selected materials of the leak disc base and the sleeve, the various dimensions of the leak disc base are optimized to ensure the reliability of the leak disc while further reducing the manufacturing cost. The leak disc base and the sleeve of the present invention are assembled by hot-fitting, and the hot-fitting curve is optimized, which improves the assembly accuracy, extends the service life of the product, and reduces maintenance costs.

[0137] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by any technician familiar with the technical field within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention.

Claims

1. A cast and forged combined upsetting drain plate, characterized in that: The invention comprises a drain pan base (1) and a sleeve (2), wherein the drain pan base (1) comprises a base a (101) and a base b (102), wherein the outer diameter of the base a is larger than the outer diameter of the base b, and the two are transitionally connected via a first fillet (7); the base a (101) is provided with a central through hole a, comprising an upper inverted cone section, a middle cylindrical section and a lower inverted cone section, forming a step-type transition structure; the base b is provided with a central through hole b, which is in an inverted cone shape and is coaxial with and smoothly connected to the lower inverted cone section of the central through hole a; The base a (101) and the base b (102) are integral castings; the insert (2) is a forging, embedded in the middle cylindrical section of the base a (101), and provided with a central through hole c.

2. The upset drain disc according to claim 1, characterized in that: The upper inverted cone section and the lower inverted cone section of the central through hole a have different cone angles; the inverted cone angle of the central through hole b is the same as the taper of the lower inverted cone section of the central through hole a, and the size is continuous; The central through hole c comprises an upper sleeve cone portion and a lower sleeve cone portion, the upper sleeve cone portion is an inverted cone, has the same cone angle as the upper inverted cone section of the central through hole a and is smoothly connected to form an upper cone surface (4); the lower sleeve cone portion is an inverted cone, has the same cone angle as the central through hole b and is smoothly connected to form a lower cone surface (5); the upper cone surface (4) and the lower cone surface (5) are transitioned through a second fillet (8).

3. The upset drain disc according to claim 2, characterized in that: The diameter of the center surface (9) of the transition zone between the upper conical surface (4) and the lower conical surface (5) is in is the inner diameter of the lower end surface of the central through hole b of the base b; the height H1 between the central surface (9) of the transition zone between the upper conical surface and the lower conical surface and the upper end surface of the base a satisfies:

4. The upset drain disc according to claim 1, characterized in that: The inner diameter of the middle cylindrical section of the drain pan base a is in It is the inner diameter of the upper end surface of the upper inverted cone section of the central through hole a; the total height H0 of the leakage disk base satisfies: H0≥L0+200mm, where L0 is the jaw length of the blank, and the units of H0 and L0 are mm; the heights of the base a and the base b are H2 and H3 respectively, and H2=H3.

5. The upset drain disc according to claim 1, characterized in that: The annular surface surrounding the base determined by the line connecting the center points of the first fillet arc is set as the pre-fracture surface P1 of the drain disc base, and the height H5 of the lower inverted cone section of the drain disc base a satisfies the following formula: T is the pressure on the drain plate during upsetting, in t; is the inner diameter of the middle cylindrical section of the drain pan base a, in mm; θ is the angle between the pre-fracture surface P1 and the vertical ground direction, which is 45° to 60°; δ is the yield strength of the selected drain pan base material at the service temperature, in MPa.

6. The upset drain disc according to claim 1, characterized in that: The wall thickness B2 of the drain pan base b satisfies: 1.5B1≥B2>B1, where B1 is the wall thickness of the sleeve.

7. The upset drain disc according to claim 1, characterized in that: The drain pan base (1) is provided with a lifting lug (3), which is a casting and is integrally formed with the drain pan base. There are four lifting lugs in total and they are symmetrically distributed. The spacing B0 on ​​the same side of the lifting lugs satisfies: is the outer diameter of the upper end surface of the base a; the shaft diameter of the ear clamp is 8. A method for assembling a cast and forged combined upsetting drain plate, characterized in that: The combined upsetting leak pan described in any one of claims 1 to 7 is assembled, the leak pan base (1) is heated to the hot loading temperature and kept warm before being taken out of the furnace, the time Y required for heating the leak pan base (1) from a cold state to the hot loading temperature is calculated as 15 minutes of heating time for every 10 mm of wall thickness; the cold sleeve is placed in the middle cylindrical section of the base a, left to cool in air, and the assembly is completed.

9. The assembly method according to claim 8, characterized in that: The thermal charging temperature calculation method is as follows: △1=Φ2 / 25×0.04; △2＝k△1； X = △2 / (Φ2*γ); X is the hot-loading temperature, °C; is the inner diameter of the middle cylindrical section of the drain pan base a, mm; is the outer diameter of the sleeve, mm; △1 is and The interference between them, mm; △2 is the inner diameter expansion of the drain pan base a before and after heating, mm; γ is the linear expansion coefficient corresponding to the base material; k is the thermal installation coefficient, which ranges from 2 to 2.

5.

10. The assembly method according to claim 8, characterized in that: The holding time Z at the hot charging temperature is calculated based on 8 minutes of heating time for every 10 mm of wall thickness.

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