Die forging manufacturing method and forging die

Abstract

The invention provides a die forging manufacturing method and a forging die, and the die forging manufacturing method comprises the following steps: S1, selecting a blank; s2, a forging die is designed according to the product shape, the forging die comprises a plurality of product cavities, a wad cavity and a flash cavity, every two adjacent product cavities are communicated through the wad cavity, the flash cavity is communicated with the product cavities, the product cavities are used for forming forged parts, the wad cavity is used for containing wad, and the flash cavity is used for containing flash; s3, the blank is forged through the forging die so that a forged blank can be formed, the forged blank comprises a plurality of forging pieces, connecting pieces and flashes, every two adjacent forging pieces in the multiple forging pieces are connected through the connecting pieces, and the flashes are connected with the edges of the multiple forging pieces; and S4, connecting skins and flashes on the forging parts are removed so that the multiple forging parts can be separated. Therefore, the die forging manufacturing method has the advantage of improving the product forging efficiency and quality.

Description

Technical Field

[0001] The invention relates to the technical field of die forging technology, and in particular to a die forging manufacturing method and a forging die. Background Art

[0002] In the related art, aluminum forgings are made of multiple pieces in one mold, usually by opening two or more cavities on one model, and using two or more billets to be placed in each cavity for forging at the same time. This is mainly to solve the problem of large height difference of the parting line of a single forging, excessive forging misalignment force, serious product misalignment and scrapping, or low mold life, by symmetrically arranging multiple cavities to offset the forging misalignment force. However, it has the disadvantages of non-uniform positioning of billets during forging, because multiple billets are required to be placed in different cavities for forging at the same time, the time from the billets being taken out of the furnace to forging is inconsistent, and the initial forging temperature is also inconsistent, resulting in extremely unstable product quality, low production efficiency, and not conducive to the realization of forging automation. Summary of the invention

[0003] The present invention aims to solve one of the technical problems in the related art at least to a certain extent. To this end, an embodiment of the present invention provides a die forging manufacturing method and a forging die.

[0004] The die forging manufacturing method according to the embodiment of the present invention comprises the following steps:

[0005] S1, select the blank;

[0006] S2. Design a forging die according to the product shape, wherein the forging die includes a plurality of product cavities, a skin-jointing cavity and a flash cavity, wherein two adjacent product cavities are connected through the skin-jointing cavity, and the flash cavity is connected with a plurality of product cavities, wherein the product cavity is used to form a forged part, the skin-jointing cavity is used to accommodate the skin-jointing cavity, and the flash cavity is used to accommodate the flash;

[0007] S3, forging the blank using the forging die to form a forging blank, wherein the forging blank comprises a plurality of forgings, a joint skin and a flash, wherein two adjacent ones of the plurality of forgings are connected by a joint skin, and the flash is connected to the edges of the plurality of forgings;

[0008] S4. Removing the skin and flash on the forgings so as to separate the plurality of forgings.

[0009] Therefore, the die forging manufacturing method according to the embodiment of the present invention has the advantages of improving the forging efficiency and quality of the product.

[0010] In some embodiments, in step S1,

[0011] The billet is at least one of a cast rod, an extruded rod, a profile and a plate;

[0012] The blank is preformed, and the preforming step includes at least one of upsetting, roll forging, wedge cross rolling and bending.

[0013] In some embodiments, in step S1,

[0014] When the blank is a bar, the bar is chamfered, and the radius of the chamfer is greater than or equal to 2 mm;

[0015] The relationship between the diameter of the bar and the maximum cross-section of the forging satisfies the formula:

[0016]

[0017] Wherein, D is the diameter of the bar, S is the area of ​​the maximum cross section of the forging, and 0.8≤k≤1.2.

[0018] In some embodiments, the forging die includes at least one product cavity group, and each of the product cavity groups includes two product cavities;

[0019] The two product cavities of each product cavity group are point symmetrical so that the two forgings formed by the two product cavities of each product cavity group are point symmetrical on the forging blank;

[0020] Alternatively, the two product cavities of each product cavity group are symmetrical so that the two forgings formed by the two product cavities of each product cavity group are symmetrical on the forging blank;

[0021] Alternatively, the two product cavities of each product cavity group are translationally symmetrical so that the two forgings formed by the two product cavities of each product cavity group are translationally symmetrical on the forging blank;

[0022] Alternatively, the axes of the two product cavities of each product cavity group are rotationally symmetric so that the two forgings formed by the two product cavities of each product cavity group are rotationally symmetric on the axes of the forging blank.

[0023] In some embodiments, in the step S2, the forging die includes a pre-forging die and a final forging die, and both the pre-forging die and the final forging die have the product cavity, the skin cavity and the flash cavity;

[0024] In the step S3, the pre-forging die is used to pre-forge the blank to form a plurality of pre-forgings, wherein two adjacent pre-forgings are connected by a joint, and the final forging die is used to forge the pre-forgings to form a plurality of forgings.

[0025] In some embodiments, in step S3,

[0026] The pre-forging die pre-forges the blank to form the pre-forging, and the final forging die forges the pre-forging to form the final forging, and the mass ratio of the pre-forging to the final forging is (1-1.4):1;

[0027] The final forging die comprises a material storage cavity, and the material storage cavity is communicated with the skin connection cavity.

[0028] In some embodiments, the distance between two adjacent product cavities is greater than or equal to 10 mm so that the width of the skin between the two forgings on the forging blank is greater than or equal to 10 mm.

[0029] In some embodiments, in step S4,

[0030] A first portion of the skin on the forged part is removed by a trimming and punching die, and then a second portion of the skin on the forged part is removed by machining, wherein the width of the first portion of the skin is greater than or equal to 20 mm, and the width of the second portion of the skin is greater than or equal to 10 mm.

[0031] The die forging manufacturing method of the embodiment of the present invention further includes step S5, in which the forging is heat treated.

[0032] The present invention also proposes a forging die suitable for the above-mentioned die forging manufacturing method, wherein the forging die includes multiple product cavities, skin cavities and flash cavities, two adjacent product cavities are connected through the skin-connecting cavity, the flash cavity is connected with multiple product cavities, the product cavity is used to form a forging, the skin-connecting cavity is used to accommodate the skin, and the flash cavity is used to accommodate the flash. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 Schematic diagram of a forging with a portion of skin removed according to an embodiment of the present invention.

[0034] Figure 2 It is a schematic diagram of the forging process of the die forging manufacturing method according to an embodiment of the present invention.

[0035] Figure 3 Schematic diagram of a forging blank with skin according to an embodiment of the present invention.

[0036] Figure 4 Schematic diagram of a forging blank with skin according to an embodiment of the present invention. DETAILED DESCRIPTION

[0037] Embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to be used to explain the present invention, but should not be understood as limiting the present invention.

[0038] The die forging manufacturing method according to the embodiment of the present invention is described below with reference to the accompanying drawings. The present invention also proposes a forging die suitable for the die forging manufacturing method according to the embodiment of the present invention. The die forging manufacturing method according to the embodiment of the present invention is specifically described below in combination with the forging die according to the embodiment of the present invention.

[0039] like Figures 1 to 4 As shown, the die forging manufacturing method according to an embodiment of the present invention comprises the following steps:

[0040] S1. Select a blank. Specifically, in step S1, the blank is at least one of a cast rod, an extruded rod, a profile, and a plate. Blanks of different shapes can be suitable for different products. For example, the blank is made of aluminum. When the blank is a bar, the bar is chamfered, and the radius of the chamfer is greater than or equal to 2 mm.

[0041] In some embodiments, the relationship between the diameter of the bar and the maximum cross-section of the forging satisfies the formula:

[0042]

[0043] Where D is the diameter of the bar, S is the area of ​​the maximum cross section of the forged part, and 0.8≤k≤1.2. When this formula is met, the material utilization rate of the bar can be improved.

[0044] In some embodiments, in step S1, the blank is preformed, and the preforming step includes at least one of upsetting, roll forging, wedge cross rolling and bending. Specifically, a raw material of a suitable shape is selected according to the blank, and the blank is preformed to improve material utilization.

[0045] S2. Design a forging die according to the shape of the product. The forging die includes a plurality of product cavities, a skin-jointing cavity and a flash cavity. Two adjacent product cavities are connected through a skin-jointing cavity. The flash cavity is connected to a plurality of product cavities so that each product cavity is connected to the flash cavity. The product cavity is used to form a forging, the skin-jointing cavity is used to accommodate the skin, and the flash cavity is used to accommodate the flash. The forging die includes a plurality of product cavities, so that a plurality of forgings can be formed by one die. When the forging die forges the blank, the excess material can be made into skin-jointing and flash so that the product can be completely formed. For example, the skin-jointing cavity is located between the two product cavities in the horizontal direction, and the flash cavity is located on the outside of the product cavity in the horizontal direction.

[0046] S3. Forging the blank with a forging die to form a forging blank, wherein the forging blank includes a plurality of forgings, a skin and a flash, wherein two adjacent forgings are connected by the skin, and the flash is connected to the edges of the plurality of forgings. Specifically, the forging blank is a whole, and the plurality of forgings are connected by the skin, thereby improving the consistency of the plurality of forgings.

[0047] The forging die includes at least one product cavity group, and each product cavity group includes two product cavities. Specifically, the two product cavities of each product cavity group are connected through a connecting cavity, and the two forgings formed by the two product cavities of each product cavity group are connected through the connecting cavity. Thus, the forging efficiency of the forging die can be improved. The two product cavities of each product cavity group can be symmetrically arranged or arranged in parallel, so as to improve the consistency of the product and save space. For example, the forging die includes two product cavities.

[0048] In some embodiments, the two product cavities of each product cavity group are point symmetrical, so that the two forgings formed by the two product cavities of each product cavity group are point symmetrical on the forging blank. The two product cavities of each product cavity group are point symmetrical, that is, one product cavity can overlap with another product cavity after rotating a certain angle (for example, 90°, 120° or 180°) around a certain point. The two forgings are point symmetrical on the forging blank, that is, one forging can overlap with another forging after rotating a certain angle (for example, 90°, 120° or 180°) around a certain point. For products with more complex structures, the two product cavities are arranged point symmetrically, so that the two forgings can be staggered, that is, one forging can extend into another forging to save space.

[0049] In some embodiments, the two product cavities of each product cavity group are symmetrical in surface, so that the two forgings formed by the two product cavities of each product cavity group are symmetrical on the forging blank. The two product cavities of each product cavity group are symmetrical in surface, that is, the two product cavities of each product cavity group are arranged in mirror symmetry. The two forgings are symmetrical on the forging blank, that is, the two forgings are arranged in mirror symmetry.

[0050] In some embodiments, the two product cavities of each product cavity group are translationally symmetrical, so that the two forgings formed by the two product cavities of each product cavity group are translationally symmetrical on the forging blank. The two product cavities of each product cavity group are translationally symmetrical, that is, one product cavity of each product cavity group (in the horizontal direction) overlaps with the other product cavity after a certain distance and parallel movement. The two forgings are translationally symmetrical on the forging blank, that is, one forging (in the horizontal direction) overlaps with the other forging after a certain distance and parallel movement.

[0051] In some embodiments, the two product cavities of each product cavity group are rotationally symmetrical about the axis, so that the two forgings formed by the two product cavities of each product cavity group are rotationally symmetrical about the axis on the forging blank. The two product cavities of each product cavity group are rotationally symmetrical about the axis, that is, one product cavity of each product cavity group can overlap with another product cavity after rotating about the axis (and translating a certain distance). The two forgings are rotationally symmetrical about the axis on the forging blank, that is, one forging can overlap with another forging after rotating about the axis (and translating a certain distance). For example, one forging can overlap with another forging after rotating 180° about the axis.

[0052] In some embodiments, in step S2, the forging die includes a pre-forging die and a final forging die, and both the pre-forging die and the final forging die have a product cavity, a skin cavity and a flash cavity. In step S3, the blank is pre-forged using the pre-forging die to form a plurality of pre-forgings, and two adjacent pre-forgings in the plurality of pre-forgings are connected by skins, and the pre-forgings are forged using the final forging die to form a plurality of forgings, and two adjacent pre-forgings in the plurality of forgings (final forgings) are connected by skins.

[0053] In some embodiments, in step S3, the pre-forging die pre-forges the blank to form a pre-forging, and the final forging die forges the pre-forging to form a final forging, and the final forging is a qualified forging. The mass ratio of the pre-forging to the final forging is (1-1.4):1. By controlling the mass ratio of the pre-forging to the final forging, the product can be completely formed. For example, the mass ratio of the pre-forging to the final forging is 1.2:1.

[0054] In some embodiments, the final forging die includes a material storage cavity, which is connected to the skin-joining cavity. Specifically, the skin-joining cavity (in the horizontal direction) is located in the middle of the material storage cavity, so that during final forging, the material storage cavity can provide a space for excess material to escape, and the side of the skin-joining cavity can be made thinner. For example, the trimming and punching die, the pre-forging die, and the final forging die all have a material storage cavity.

[0055] S4. Remove the skin and flash on the forgings to separate multiple forgings. Specifically, the trimming and punching process can be performed by a trimming and punching die to separate multiple forgings, or part of the forging skin can be retained, and the remaining skin can be separated by machining later. The trimming and punching die includes a trimming die and a punching die. The distance between two adjacent product cavities is greater than or equal to 10 mm so that the width of the skin between the two forgings on the forging blank is greater than or equal to 10 mm. In this way, it is easy to remove the skin on the forging. The width direction of the skin is consistent with the direction in which the two forgings are arranged side by side.

[0056] In some embodiments, in step S4, a trimming punching die is used to remove the first part of the skin on the forging, and then the second part of the skin on the forging is removed by machining, the width of the first part of the skin is greater than or equal to 20 mm, and the width of the second part of the skin is greater than or equal to 10 mm. The width of the first part of the skin is greater than or equal to the width of the second part of the skin. In other words, the wider part of the skin (the first part) can be removed by a trimming punching die first. For the narrower part (the second part), the skin can be removed by at least one of machining, milling, grinding, and drilling. For example, Figure 1 As shown, after the first part of the skin on the forging is removed by a trimming punching die, the ends of the two forgings are connected by the second part of the skin.

[0057] The die forging manufacturing method according to the embodiment of the present invention further includes step S5, in which the forging is heat treated. Specifically, the separated forging is heat treated online or offline to ensure the required performance index of the forging. For example, when the forging is heat treated offline, the solution temperature is greater than or equal to 500°C and less than or equal to 560°C.

[0058] like Figures 1 to 3 As shown, in a specific embodiment, the following steps are specifically included:

[0059] The raw material of the blank is selected as a bar material with a suitable shape, and the bar material is sawn into a blank material of a required length by a circular saw; the blank material is chamfered by a chamfering machine; the chamfered blank material is heated by a heating furnace to reach the pre-forging starting temperature.

[0060] In the forging step, the pre-forging die is designed according to the material fluidity to avoid defects such as folding in the key areas of the forging. The billet, which has been heated to the initial forging temperature, is taken out of the furnace and placed in the pre-forging die cavity for positioning, and the pre-forging is completed by the main forging press. Based on the shape of the forging, it is reasonably arranged into one die and two pieces, and the final forging cavity is optimized. The pre-forged billet is moved from the pre-forging station to the final forging cavity, and the final forging is completed by the main forging press. The final forging is as follows Figure 3 As shown, the first forging and the second forging are inserted into the inner side of each other to save space. The first forging and the second forging are connected by a connecting skin, and the connecting skin between the first forging and the second forging is provided with a material storage portion entering the material storage cavity.

[0061] Remove the flash by trimming and punching, and keep part of the forging skin (such as Figure 1 The forgings are then separated by machining. The separated forgings are heat treated to ensure the required performance indicators of the forgings. Figure 2As shown, a pre-forging is formed from a bar stock, and a final forging is formed from the pre-forging. A portion of the skin is removed from the final forging, and then the flash is removed, and then the final skin is removed.

[0062] like Figure 4 As shown, in a specific embodiment, a two-piece forged aluminum control arm is provided, which specifically includes the following steps:

[0063] According to the pre-forging blank, the raw material of suitable shape is selected as the bar material, and the bar material is cut into the blank of required length by a circular saw. The blank is chamfered by a chamfering machine, and the chamfered blank is heated to the pre-forging starting temperature by a heating furnace.

[0064] In the forging step, the pre-forging die is designed according to the material fluidity to avoid defects such as folding in the key areas of the forging. The billet that has been heated to the initial forging temperature is taken out of the furnace and placed in the pre-forging die cavity for positioning, and the pre-forging is completed by the main forging press. Based on the shape of the forging, it is reasonably arranged into one die and two pieces, and the final forging cavity is optimized. The pre-forged billet is moved from the pre-forging station to the final forging cavity, and the final forging is completed by the main forging press. After the final forging, there is a skin between the two forgings, and the skin is provided with a storage part that enters the storage cavity.

[0065] Punching is used to remove the skin, trimming is used to remove the flash and separate the forgings. The separated forgings are heat treated to ensure the required performance indicators of the forgings.

[0066] According to the die forging manufacturing method of the embodiment of the present invention, the product cavity is optimized so that the forgings formed by the product cavity are connected by a continuous skin, thereby solving the problem of a single forging being scrapped or having a short die life due to excessive misalignment of the die force. Multiple forgings can be separated by simultaneous trimming, punching or machining to obtain multiple forged parts with consistent performance and shape. And only one billet is used to form multiple forgings at the same time, to achieve a unified starting forging temperature for multiple forgings, to reduce the technical problem of uneven performance of forgings in different product cavities, and to solve the problem of low effect of placing multiple forgings and difficulty in realizing automated production, thereby improving the efficiency and quality of forging.

[0067] Therefore, the die forging manufacturing method according to the embodiment of the present invention has the advantages of improving the forging efficiency and quality of the product.

[0068] In the description of the present invention, it is to be understood that the terms “center”, “longitudinal”, “lateral”, “length”, “width”, “thickness”, “up”, “down”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential”, etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0069] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0070] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection, an electrical connection, or communication with each other; it can be a direct connection, or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0071] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being "above", "above" or "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below", "below" or "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0072] In the present invention, the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" etc. mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the described specific features, structures, materials or characteristics may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0073] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. A method for manufacturing a die forging, characterized in that: The following steps are involved: S1, select the blank; S2. Design a forging die according to the product shape, wherein the forging die includes a plurality of product cavities, a skin-jointing cavity and a flash cavity, wherein two adjacent product cavities are connected through the skin-jointing cavity, and the flash cavity is connected with a plurality of product cavities, wherein the product cavity is used to form a forged part, the skin-jointing cavity is used to accommodate the skin-jointing cavity, and the flash cavity is used to accommodate the flash; S3, forging the blank using the forging die to form a forging blank, wherein the forging blank comprises a plurality of forgings, a joint skin and a flash, wherein two adjacent ones of the plurality of forgings are connected by a joint skin, and the flash is connected to the edges of the plurality of forgings; S4. Removing the skin and flash on the forgings so as to separate the plurality of forgings.

2. The die forging manufacturing method according to claim 1, characterized in that: In step S1, The billet is at least one of a cast rod, an extruded rod, a profile and a plate; The blank is preformed, and the preforming step includes at least one of upsetting, roll forging, wedge cross rolling and bending.

3. The die forging manufacturing method according to claim 2, characterized in that: In step S1, When the blank is a bar, the bar is chamfered, and the radius of the chamfer is greater than or equal to 2 mm; The relationship between the diameter of the bar and the maximum cross-section of the forging satisfies the formula: Wherein, D is the diameter of the bar, S is the area of ​​the maximum cross section of the forging, and 0.8≤k≤1.

2.

4. The die forging manufacturing method according to claim 1, characterized in that: The forging die comprises at least one product cavity group, and each of the product cavity groups comprises two product cavities; The two product cavities of each product cavity group are point symmetrical so that the two forgings formed by the two product cavities of each product cavity group are point symmetrical on the forging blank; Alternatively, the two product cavities of each product cavity group are symmetrical so that the two forgings formed by the two product cavities of each product cavity group are symmetrical on the forging blank; Alternatively, the two product cavities of each product cavity group are translationally symmetrical so that the two forgings formed by the two product cavities of each product cavity group are translationally symmetrical on the forging blank; Alternatively, the axes of the two product cavities of each product cavity group are rotationally symmetric so that the two forgings formed by the two product cavities of each product cavity group are rotationally symmetric on the axes of the forging blank.

5. The die forging manufacturing method according to claim 1, characterized in that: In the step S2, the forging die includes a pre-forging die and a final forging die, and both the pre-forging die and the final forging die have the product cavity, the skin cavity and the flash cavity; In the step S3, the pre-forging die is used to pre-forge the blank to form a plurality of pre-forgings, wherein two adjacent pre-forgings are connected by a joint, and the final forging die is used to forge the pre-forgings to form a plurality of forgings.

6. The die forging manufacturing method according to claim 5, characterized in that: In step S3, The pre-forging die pre-forges the blank to form the pre-forging, and the final forging die forges the pre-forging to form the final forging, and the mass ratio of the pre-forging to the final forging is (1-1.4):1; The final forging die comprises a material storage cavity, and the material storage cavity is communicated with the skin connection cavity.

7. The die forging manufacturing method according to claim 1, characterized in that: The distance between two adjacent product cavities is greater than or equal to 10 mm so that the width of the skin between the two forgings on the forging blank is greater than or equal to 10 mm.

8. The die forging manufacturing method according to claim 7, characterized in that: In step S4, A first portion of the skin on the forged part is removed by a trimming and punching die, and then a second portion of the skin on the forged part is removed by machining, wherein the width of the first portion of the skin is greater than or equal to 20 mm, and the width of the second portion of the skin is greater than or equal to 10 mm.

9. The method for manufacturing a die forging according to any one of claims 1 to 8, characterized in that: The method further comprises step S5, in which the forged part is heat treated.

10. A forging die suitable for the die forging manufacturing method according to any one of claims 1 to 9, characterized in that: The forging die comprises a plurality of product cavities, a skin-jointing cavity and a flash cavity. Two adjacent product cavities are connected through the skin-jointing cavity. The flash cavity is connected with a plurality of product cavities. The product cavity is used to form a forged part. The skin-jointing cavity is used to accommodate the skin-jointing cavity. The flash cavity is used to accommodate the flash.

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