Aluminum alloy forging production device and production method thereof

Abstract

The application discloses an aluminum alloy forge production device and a production method thereof, which comprises a first die and a second die, the first die is used for extruding a cake blank into a blank body, and the second die is used for extruding the blank body into a required product; the first die comprises a first upper die and a first lower die, the surface of the first upper die is provided with a first positioning boss and a claw arm boss, the first lower die is provided with a first positioning groove and a claw groove, the cake blank is placed in the first positioning groove, in the process that the first positioning boss extrudes the cake blank, the sidewall of the cake blank flows to the claw groove through the first positioning groove, the claw arm boss is used for extruding and forming the cake blank in the claw groove, and the first positioning boss, the claw arm boss, the first positioning groove and the claw groove jointly extrude the blank body. Through precise die design and process optimization, the quality and production efficiency of the aluminum alloy forge are remarkably improved, and the production cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy forging production technology, specifically to an aluminum alloy forging production apparatus and its production method. Background Technology

[0002] Aluminum alloy forgings are widely used in transportation, aerospace, and machinery due to their low density, high strength, and corrosion resistance. With the increasing demands for lightweight and high-performance components in modern industry, the demand for aluminum alloy forgings continues to grow. The production of aluminum alloy forgings typically involves multiple steps, including smelting, forging, heat treatment, and machining, with forging being one of the key processes.

[0003] In the traditional aluminum alloy forging production process, the aluminum alloy is mainly extruded and formed by dies. However, the existing aluminum alloy forging extrusion process has some problems, especially when extruding forgings with complex shapes. Uneven metal flow often occurs, which is called "through flow". Through flow will cause uneven thickness of the forging, thus affecting its mechanical properties and appearance quality. This problem has greatly limited the improvement of the production efficiency and product quality of aluminum alloy forgings. Summary of the Invention

[0004] The purpose of this invention is to solve the above-mentioned technical problems, thereby providing an aluminum alloy forging production apparatus and a production method thereof;

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0006] One object of the present invention is to provide an apparatus for producing aluminum alloy forgings.

[0007] It includes a first mold and a second mold. The first mold is used to extrude the dough into a blank, and the second mold is used to extrude the blank into the desired product.

[0008] The first mold includes a first upper mold and a first lower mold. The surface of the first upper mold is provided with a first positioning boss and a claw arm boss. The claw arm boss is provided on the side wall of the first positioning boss. The first lower mold is provided with a first positioning groove and a claw groove. The claw groove is provided on the edge of the first positioning groove and is connected to the first positioning groove. The claw arm boss is adapted to the claw groove. The first positioning boss is adapted to the first positioning groove. The blank is placed in the first positioning groove. During the process of the first positioning boss extruding the blank, the side wall of the blank flows through the first positioning groove to the claw groove. The claw arm boss is used to extrude and shape the blank in the claw groove. The first positioning boss, the claw arm boss and the first positioning groove and the claw groove work together to extrude and form the blank. The blank includes a claw arm blank and a forging blank. The claw arm blank is distributed on the side wall of the forging blank. The first positioning boss is provided with a recessed part. The surface of the forging blank is formed with a protrusion corresponding to the recessed part.

[0009] Optionally, the second mold includes a second upper mold and a second lower mold. The second lower mold has a second positioning groove, a third positioning groove, and a first mounting groove. The second positioning groove and the third positioning groove are both located in the first mounting groove. The second positioning groove is located at the center of the second lower mold. The third positioning groove is located on the edge of the second positioning groove and is connected to the second positioning groove. The third positioning groove is adapted to the claw arm blank. The second positioning groove is adapted to the forging blank. The second positioning groove is provided with a first positioning protrusion and a second positioning protrusion. A first gap is formed between the first positioning protrusion and the second positioning protrusion. A second gap is formed between the second positioning protrusion and the side wall of the second positioning groove.

[0010] The second upper mold has a fourth positioning groove, a fifth positioning groove, and a second mounting groove. The fourth and fifth positioning grooves are both located within the second mounting groove. The fourth positioning groove is located at the center of the second upper mold. The first mounting groove overlaps with the second mounting groove. A first positioning protrusion is provided in the fourth positioning groove, and a second positioning protrusion is provided in the fifth positioning groove. The first positioning protrusion is used to compress the protrusion on the upper surface of the forging blank into a first positioning groove. The first positioning protrusion and the first gap are used to compress the lower surface of the forging blank into a first through groove. The second positioning protrusion and the second gap are used to compress the lower surface of the forging blank into a second through groove. Under their combined action, a forging is formed. The second positioning protrusion is used to compress the claw arm blank into a second positioning groove, thereby forming a claw arm. The claw arm and the forging together form the desired product.

[0011] Optionally, a blocking mechanism is provided on the first mounting groove, and the blocking mechanism is located on both sides of the third positioning groove. A fixing groove is provided on the second mounting groove, and the fixing groove is adapted to the blocking mechanism. When the second upper mold and the second lower mold are closed, the blocking mechanism is inserted into the fixing groove. The blocking mechanism is used to prevent flow through the claw arm blank during the compression process, which would result in uneven thickness.

[0012] Optionally, the surface shape of the blocking mechanism facing the third positioning groove is the same as the sidewall shape of the third positioning groove.

[0013] Optionally, the blocking mechanism is provided with guide slopes on both sides. The guide slopes facilitate the smooth insertion of the blocking mechanism into the fixing groove when the second upper mold and the second lower mold are closed. At the same time, when the mold is opened, the guide slopes can guide the blocking mechanism to smoothly disengage from the fixing groove, reducing friction and wear.

[0014] Optionally, a positioning and guiding structure is provided between the second upper mold and the second lower mold. The positioning and guiding structure includes a guide post, a first guide hole, and a second guide hole. The first guide hole is provided on the side wall of the second lower mold, and the second guide hole is provided on the side wall of the second upper mold. One end of the guide post is provided in the first guide hole. The guide post and the second guide hole are adapted to provide accurate positioning guidance when the molds are closed, so as to ensure precise alignment between the molds.

[0015] Optionally, the discharge end of the second mold is provided with an ejection mechanism, which includes an ejector rod and an ejection hole. The ejection hole is located at the bottom of the second lower mold. One end of the ejector rod is located in the ejection hole, and the other end is in contact with the forging. After the forging is formed, the forging is ejected from the mold by the upward movement of the ejector rod, which facilitates the removal of the forging and subsequent production operations.

[0016] Another object of the present invention is to provide a method for producing aluminum alloy forgings.

[0017] Includes the following steps:

[0018] S1: Provide a first mold and a second mold, wherein the first mold includes a first upper mold and a first lower mold for extruding the dough into a blank; the second mold includes a second upper mold and a second lower mold for extruding the blank into the desired product.

[0019] S2: The blank is placed in the first positioning groove of the first lower mold. The first positioning boss and claw arm boss of the first upper mold cooperate with the first positioning groove and claw groove of the first lower mold to form the blank into a blank by extrusion. The blank includes the claw arm blank and the forging blank.

[0020] S3: Transfer the blank to the second mold, wherein the second lower mold is provided with a second positioning groove and a third positioning groove, which are adapted to the forging blank and claw arm blank in the blank, and the second upper mold is provided with a fourth positioning groove and a fifth positioning groove, which are used to further compress the blank to form a forging.

[0021] S4: Close the second upper mold and the second lower mold. The first positioning protrusion and the second positioning protrusion of the second upper mold cooperate with the first positioning protrusion, the second positioning protrusion and the positioning groove of the second lower mold to extrude the blank and form a forging with a first positioning groove, a first through groove, a second through groove and a claw arm.

[0022] S5: During the extrusion process, a blocking mechanism set on the second die is used to prevent flow through the extruded claw arm blank, ensuring uniform thickness of the forging.

[0023] S6: After the forging is formed, the forging is ejected from the mold by the ejection mechanism of the second mold using the ejector rod, which facilitates the removal of the forging and subsequent production operations.

[0024] In summary, the present invention has the following beneficial effects:

[0025] The close fit between the first positioning boss and the claw arm boss and the first positioning groove and the claw groove in this application enables the blank to flow accurately to the predetermined position during the extrusion process, forming a blank with the required shape and size. The design of the second positioning groove, the third positioning groove and the first mounting groove in the second mold further ensures that the blank can maintain a stable shape and size during the extrusion process, ultimately forming a high-quality forging.

[0026] Furthermore, in the traditional aluminum alloy forging process, uneven pressure distribution during extrusion easily leads to flow penetration, resulting in uneven thickness of the forging and severely affecting its mechanical properties and service life. The blocking mechanism in this application effectively solves this problem. It is set on both sides of the third positioning groove. When the second upper die and the second lower die are closed, the blocking mechanism will be inserted into the fixed groove to prevent uneven metal flow during extrusion, thereby avoiding flow penetration. As a result, the thickness of the forging is more uniform, and its mechanical properties and service life are significantly improved. Attached Figure Description

[0027] Figure 1 This is a three-dimensional view of the forging product structure of the present invention.

[0028] Figure 2 This is a top view of the forging product structure of the present invention.

[0029] Figure 3 This is an axial view of the forging product of the present invention.

[0030] Figure 4 This is a bottom view of the forging product structure of the present invention.

[0031] Figure 5 This is a schematic diagram of the first mold structure of the present invention.

[0032] Figure 6 This is a schematic diagram of the first upper mold structure of the present invention.

[0033] Figure 7 This is a schematic diagram of the first lower mold structure of the present invention.

[0034] Figure 8 This is a schematic diagram of the forging blank structure of the present invention.

[0035] Figure 9 This is a schematic diagram of the second upper mold structure of the present invention.

[0036] Figure 10 This is a schematic diagram of the second lower mold structure of the present invention.

[0037] Figure 2.1 a) Front view of the part schematic diagram; b) Back view of the part schematic diagram.

[0038] Figure 2.2 Enlarged view of a partial cross-section for part delivery.

[0039] Figure 2.3 This is a schematic diagram of the U-shaped cross-section of the claw body (a) part drawing, b) forging delivery drawing.

[0040] Figure 2.4 This is a schematic diagram of a thin-walled circular structure and its cross-section.

[0041] Figure 2.5 This is a cross-section and partial dimensions of the thin-walled section around the circumference.

[0042] Figure 2.6 This is a schematic diagram of the forging and part at the maximum cross-section.

[0043] Figure 2.7 This is a complete 3D model of the forging.

[0044] Explanation of reference numerals in the attached drawings: 1-First upper mold, 2-First lower mold, 3-First positioning boss, 4-Claw arm boss, 5-First positioning groove, 6-Claw groove, 7-Blank body, 8-Claw arm blank body, 9-Forging blank body, 10-Recessed part, 11-Protruding part, 12-Second upper mold, 13-Second lower mold, 14-Second positioning groove, 15-Third positioning groove, 16-First mounting groove, 17-First positioning protrusion, 18-Second positioning protrusion, 19-Fourth positioning groove, 20-Fifth positioning groove, 21-Second mounting groove, 22-First positioning protrusion, 23-Second positioning protrusion, 24-First positioning groove, 25-First through groove, 26-Second through groove, 27-Second positioning groove, 28-Blocking mechanism, 29-Fixing groove, 30-Guide inclined surface, 31-First guide hole, 32-Second guide hole, 33-Ejection hole, 34-Forging, 35-Claw arm. Detailed Implementation

[0045] The technical solutions of this novel system embodiment will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0046] Example:

[0047] like Figures 1-10 As shown, one object of the present invention is to provide an aluminum alloy forging production apparatus.

[0048] It includes a first mold and a second mold. The first mold is used to extrude the dough into a blank, and the second mold is used to extrude the blank into the desired product.

[0049] The first mold includes a first upper mold 1 and a first lower mold 2. The surface of the first upper mold 1 is provided with a first positioning boss 3 and a claw arm boss 4. The claw arm boss 4 is disposed on the side wall of the first positioning boss 3. The first lower mold 2 is provided with a first positioning groove 5 and a claw groove 6. The claw groove 6 is disposed on the edge of the first positioning groove 5 and is connected to the first positioning groove 5. The claw arm boss 4 is adapted to the claw groove 6. The first positioning boss 3 is adapted to the first positioning groove 5. The blank is placed in the first positioning groove 5. During the process of pressing the blank by platform 3, the side wall of the blank flows through the first positioning groove 5 into the claw groove 6. The claw arm boss 4 is used to press and shape the blank in the claw groove 6. The first positioning boss 3, the claw arm boss 4 and the first positioning groove 5 and the claw groove 6 work together to press and shape the blank body 7. The blank body 7 includes the claw arm blank body 8 and the forging blank body 9. The claw arm blank body 8 is distributed on the side wall of the forging blank body 9. The first positioning boss 3 is provided with a recessed part 10. The surface of the forging blank body 9 is formed with a protrusion 11 corresponding to the recessed part 10.

[0050] Through the above design, this application realizes a complete forging process from basic blank to the final desired product by cooperating with the first mold and the second mold.

[0051] First, the design of the first mold ensures that the blank can be placed accurately in the first positioning groove 5, guaranteeing the stability and accuracy of the blank during the forging process. Once the blank is in place, it can be further processed by the first mold to form the required shape.

[0052] Next, the first mold applies a precise extrusion action to the blank through the design of the first positioning boss 3 and the claw arm boss 4. This extrusion action not only changes the shape of the blank, but also makes it form a complex-shaped blank 7 with a claw arm blank 8 and a forging blank 9. This step is the most critical link in the forging process because it directly determines the shape and structure of the final forging.

[0053] The second mold includes a second upper mold 12 and a second lower mold 13. The second lower mold 13 has a second positioning groove 14, a third positioning groove 15, and a first mounting groove 16. The second positioning groove 14 and the third positioning groove 15 are both located in the first mounting groove 16. The second positioning groove 14 is located at the center of the second lower mold 13. The third positioning groove 15 is located on the edge of the second positioning groove 14 and is connected to the second positioning groove 14. The third positioning groove 15 is adapted to the claw arm blank 8. The second positioning groove 14 is adapted to the forging blank 9. The second positioning groove 14 is provided with a first positioning protrusion ring 17 and a second positioning protrusion ring 18. A first gap is formed between the first positioning protrusion ring 17 and the second positioning protrusion ring 18. A second gap is formed between the second positioning protrusion ring 18 and the side wall of the second positioning groove 14.

[0054] The second upper mold 12 is provided with a fourth positioning groove 19, a fifth positioning groove 20, and a second mounting groove 21. The fourth positioning groove 19 and the fifth positioning groove 20 are both located in the second mounting groove 21. The fourth positioning groove 19 is located at the center of the second upper mold 12. The first mounting groove 16 overlaps with the second mounting groove 21. A first positioning protrusion 22 is provided in the fourth positioning groove 19, and a second positioning protrusion 23 is provided in the fifth positioning groove. The first positioning protrusion 22 is used to compress the protrusion 11 on the upper surface of the forging blank 9 into a first positioning groove 24. The first positioning protrusion ring and the first gap are used to compress the lower surface of the forging blank 9 into a first through groove 25. The second positioning protrusion ring and the second gap are used to compress the lower surface of the forging blank 9 into a second through groove 26. Under their combined action, a forging is formed. The second positioning protrusion 23 is used to compress the claw arm blank 8 into a second positioning groove 27, thereby forming a claw arm. The claw arm and the forging together form the desired product.

[0055] The design of the second mold plays a crucial role in the aluminum alloy forging production equipment. It further enables the fine forging of the blank 7, ensuring the accuracy of forging and the consistency of shape. The second positioning groove 14 and the third positioning groove 15 on the second mold are precisely matched with the blank 7. This design ensures that the blank 7 can be stably placed in the mold during the forging process without displacement or deformation. Through this matching design, the second mold can accurately control the shape and size of the forging, thereby ensuring the consistency and accuracy of the forging.

[0056] The first positioning protrusion 17 and the second positioning protrusion 18 on the second positioning groove 14 interact with the forging blank 9 during the forging process to form the first through groove 25 and the second through groove 26. The design of these two through grooves not only increases the structural complexity of the forging, but also gives it more functionality. For example, the through grooves can be used as positioning points during assembly or to fix other components.

[0057] The fourth positioning groove 19 and the fifth positioning groove 20 are respectively provided with a first positioning protrusion 22 and a second positioning protrusion 23. During the forging process, these protrusions interact with the blank 7, so that positioning grooves can be formed on the forging and the claw arm. These positioning grooves further meet the shape and functional requirements of the product. For example, they can be used as docking points during assembly or to increase the gripping force of the forging.

[0058] In summary, the design of the second mold, through precise positioning grooves, convex rings, and protrusions, enables the fine forging of the blank 7. This design not only ensures the accuracy of forging and the consistency of shape, but also increases the structural complexity and functionality of the forging. These features enable the produced aluminum alloy forgings to meet higher application requirements and a wider range of application scenarios.

[0059] In the aluminum alloy forging production equipment, the first positioning protrusion 22 compresses the protrusion 11 on the upper surface of the forging blank 9 into the first positioning groove 24. This design has multiple effects, and the following is a detailed description of the effects of the protrusion 11:

[0060] Increase structural complexity:

[0061] The design of the protrusion 11 increases the structural complexity of the upper surface of the forging blank 9, giving the final forging product more functions and uses.

[0062] Improve forging precision:

[0063] As part of the forging blank 9, the protrusion 11 plays a positioning role in the forging process. Its interaction with the first positioning protrusion 22 ensures the accurate positioning of the forging during the extrusion process, thereby improving the precision and consistency of forging.

[0064] Enhance the properties of forgings:

[0065] After the protrusion 11 is extruded into the first positioning groove 24, it can form a specific geometric shape or texture. These shapes or textures can enhance certain properties of the forging, such as grip, wear resistance or aesthetics. By precisely controlling the shape and size of the protrusion 11, the performance of the forging can be further optimized.

[0066] Facilitates subsequent processing and assembly:

[0067] After the protrusion 11 is squeezed into the first positioning groove 24, it can facilitate subsequent processing and assembly. For example, the groove can serve as a positioning point or fixing point during assembly, ensuring accurate alignment and firm connection between the forging and other components.

[0068] In summary, the protrusion 11 plays an important role in the aluminum alloy forging production equipment. It not only increases the structural complexity and functional diversity of the forging, but also improves the forging precision and consistency and enhances the performance of the forging. At the same time, the design of the protrusion 11 also brings convenience to subsequent processing and assembly.

[0069] A blocking mechanism 28 is provided on the first mounting groove 16. The blocking mechanism 28 is located on both sides of the third positioning groove 15. A fixing groove 29 is provided on the second mounting groove 21. The fixing groove 29 is adapted to the blocking mechanism 28. When the second upper mold 12 and the second lower mold 13 are closed, the blocking mechanism 28 is inserted into the fixing groove 29. The blocking mechanism 28 is used to prevent flow through the claw arm blank 8 during the compression process, which would result in uneven thickness.

[0070] The main function of the blocking mechanism 28 is to effectively prevent flow through the extrusion process of the extrusion claw arm blank 8. Flow through the extrusion process refers to the material flowing out of the mold gaps due to uneven pressure or improper mold design, forming irregular shapes or sizes. By setting the blocking mechanism 28, the material can be ensured to flow along the predetermined path and shape during the extrusion process, thereby avoiding the occurrence of flow through the extrusion process.

[0071] Solving the problem of uneven thickness in forgings:

[0072] The flow-through phenomenon is one of the main reasons for uneven thickness of forgings. The setting of the blocking mechanism 28 effectively solves this problem, enabling the forging to maintain a uniform thickness during the extrusion process. The uniform thickness not only improves the appearance of the forging, but more importantly, ensures its mechanical properties and service life.

[0073] Improve forging quality and production efficiency:

[0074] The design of the blocking mechanism 28 makes the forging more stable during the extrusion process, reducing the scrap rate caused by uneven material flow or improper die design. At the same time, due to the presence of the blocking mechanism 28, the number of adjustments during the production process is reduced, and production efficiency is improved.

[0075] Reduce scrap rate:

[0076] The reduction in scrap rate is one of the direct benefits of the blocking mechanism 28. By reducing scrap caused by uneven thickness or other shape problems, production costs can be significantly reduced and overall economic efficiency can be improved. In addition, the reduction in scrap rate also helps to reduce resource waste and environmental pollution, which is in line with the requirements of sustainable development.

[0077] In summary, the blocking mechanism 28 set on the first mounting groove 16 plays an important role in the production process of aluminum alloy forgings. It not only effectively prevents the occurrence of flow through and solves the problem of uneven thickness of forgings, but also improves the quality and production efficiency of forgings and reduces the scrap rate.

[0078] The surface shape of the blocking mechanism 28 facing the third positioning groove 15 is the same as the side wall shape of the third positioning groove 15.

[0079] During the forging process, the flow of metal is strictly controlled by the shape and size of the die. One of the main functions of the blocking mechanism 28 is to prevent the metal from flowing in an unwanted direction. The same surface shape design ensures a tight fit between the blocking mechanism 28 and the third positioning groove 15, enabling the blocking mechanism 28 to effectively block the flow of metal and ensure the accuracy of the forging shape and the stability of the dimensions.

[0080] The blocking mechanism 28 is provided with guide slopes 30 on both sides. The guide slopes 30 facilitate the blocking mechanism 28 to be smoothly inserted into the fixing groove 29 when the second upper mold 12 and the second lower mold 13 are closed. At the same time, when the mold is opened, the guide slopes 30 can guide the blocking mechanism 28 to be smoothly disengaged from the fixing groove 29, reducing friction and wear.

[0081] When the second upper mold 12 and the second lower mold 13 are closed, the blocking mechanism 28 needs to be accurately inserted into the fixed groove 29. The design of the guide slope 30 allows the blocking mechanism 28 to gradually align with the side wall of the fixed groove 29 during the insertion process, reducing the resistance and friction during insertion. This design ensures that the blocking mechanism 28 can be smoothly and accurately inserted into the fixed groove 29, providing stable support and blocking for the subsequent forging process.

[0082] Successfully disengaged from the fixing slot 29:

[0083] When the mold opens, the blocking mechanism 28 needs to disengage from the fixed groove 29 in order to proceed with the next forging process. The design of the guide slope 30 also plays a key role. It allows the blocking mechanism 28 to gradually separate from the side wall of the fixed groove 29 during the disengagement process, reducing resistance and friction during disengagement. This design ensures that the blocking mechanism 28 can disengage from the fixed groove 29 smoothly and quickly, improving production efficiency and reducing mold wear caused by friction and resistance.

[0084] Reduce friction and wear:

[0085] The design of the guide slope 30 reduces the contact area and friction between the blocking mechanism 28 and the mold when it is inserted into and removed from the fixing groove 29. This friction-reducing design not only reduces the wear rate of the mold but also extends its service life. At the same time, reducing friction also means reducing energy consumption and heat generation, which helps maintain the stability and precision of the mold.

[0086] Improve production efficiency and forging quality:

[0087] The design of the guide ramp 30 makes the insertion and removal process of the blocking mechanism 28 smoother and faster, improving production efficiency. At the same time, due to the reduction of friction and wear, the precision and stability of the mold are better maintained, which helps to improve the quality of the forgings.

[0088] In summary, the design of having guide ramps 30 on both sides of the blocking mechanism 28 not only allows the blocking mechanism 28 to smoothly insert into and disengage from the fixing groove 29, but also reduces friction and wear, extends the service life of the mold, and improves production efficiency and forging quality.

[0089] A positioning and guiding structure is provided between the second upper mold 12 and the second lower mold 13. The positioning and guiding structure includes a guide post, a first guide hole 31, and a second guide hole 32. The first guide hole 31 is provided on the side wall of the second lower mold 13, and the second guide hole 32 is provided on the side wall of the second upper mold 12. One end of the guide post is provided in the first guide hole 31. The guide post and the second guide hole 32 are adapted to provide accurate positioning guidance when the molds are closed, so as to ensure precise alignment between the molds.

[0090] The second mold is provided with an ejection mechanism at the discharge end. The ejection mechanism includes an ejector rod and an ejection hole 33. The ejection hole 33 is located at the bottom of the second lower mold 13. One end of the ejector rod is located in the ejection hole 33, and the other end is in contact with the forging. It is used to eject the forging from the mold by the upward movement of the ejector rod after the forging is formed, so as to facilitate the removal of the forging and subsequent production operations.

[0091] In summary:

[0092] This application achieves precise control over the shape and size of forgings during the extrusion process through the design of the first and second molds, particularly the matching design of the first positioning boss 3, the claw arm boss 4 with the first positioning groove 5 and the claw groove 6, and the design of structures such as the second positioning groove 14, the third positioning groove 15, and the first mounting groove 16 in the second mold. This precise control not only ensures that the forgings can be formed according to the predetermined shape and size, but also greatly reduces the scrap caused by inaccurate shape and size, thereby significantly improving the quality and precision of the forgings.

[0093] Specifically, the close cooperation between the first positioning boss 3 and the claw arm boss 4 and the first positioning groove 5 and the claw groove 6 enables the blank to flow accurately to the predetermined position during the extrusion process, forming a blank 7 with the required shape and size. The design of the second positioning groove 14, the third positioning groove 15 and the first mounting groove 16 in the second mold further ensures that the blank 7 can maintain a stable shape and size during the extrusion process, ultimately forming a high-quality forging.

[0094] Furthermore, in the traditional aluminum alloy forging process, uneven pressure distribution during extrusion can easily lead to flow penetration, resulting in uneven thickness of the forging and severely affecting its mechanical properties and service life. The blocking mechanism 28 in this application effectively solves this problem. It is set on both sides of the third positioning groove 15. When the second upper die 12 and the second lower die 13 are closed, the blocking mechanism 28 will be inserted into the fixed groove 29 to prevent uneven metal flow during extrusion, thereby avoiding flow penetration. As a result, the thickness of the forging is more uniform, and its mechanical properties and service life are significantly improved.

[0095] Due to the precision of mold design and the optimization of processes, the amount of waste generated during production is greatly reduced. This means less waste of raw materials and also reduces the additional processing costs caused by waste, such as waste recycling and reprocessing. The reduction in the scrap rate directly leads to a decrease in production costs, bringing economic benefits to the enterprise.

[0096] On the other hand, improved production efficiency is also an important factor in reducing costs. The rational layout of the mold and the design of the positioning and guiding structure, as well as the ingenious application of the ejection mechanism, make the production process smoother, reduce production interruptions and time waste. Improved production efficiency means that more forgings can be produced in the same amount of time, thereby spreading fixed costs such as equipment depreciation and labor costs, and further reducing the cost per unit product.

[0097] Furthermore, the optimized design of the blocking mechanism 28 also plays an important role in reducing mold wear. In the traditional aluminum alloy forging process, the mold often bears greater pressure and friction due to uneven metal flow, resulting in severe mold wear and shortened service life. The blocking mechanism 28 in this application effectively solves this problem. It prevents flow through the extrusion process, making the metal flow more uniform and reducing mold wear. As a result, the service life of the mold is extended, reducing the frequency of mold replacement and maintenance, thereby reducing related costs.

[0098] For example:

[0099] like Figure 2.1 The diagram shows a schematic of a stationary ring, which mainly consists of a claw body, a connecting arm, and an intermediate ring. Its shape is complex, requiring a fully fiber-reinforced metal fabrication process, and coarse grains are not permitted. Dimensional accuracy is HB 6077 E grade, with allowable misalignment ≤1.0mm and warpage ≤1.2mm. It exhibits various forms of difficult-to-form structures, including high ribs, thin webs, and multiple non-machined surfaces.

[0100] Three of the four claws of the part have a groove structure, such as Figure 2.1 As shown, the cross-section is U-shaped, with a maximum height of 61.8 mm, a width of 22.4 mm, and a web thickness of 12 mm. It is very easy for quality problems such as flow through and reinforcement through the web and reinforcement to occur.

[0101] Because the claw-shaped area of ​​the forging in this application is a non-machined surface, if a rib-top parting die is used, the rib ejection margin will increase by 3mm, and it will also cause uneven margins on the upper and lower parts of the rib. Therefore, an intermediate parting die is adopted. Furthermore, based on field production experience, the minimum draft angle for LC9 series aluminum alloys formed using standard forging is 3° inward and 6° outward. Therefore, the forging of the claw-shaped area is designed with an intermediate parting die, with a draft angle of 3° inward and 6° outward. (See the forming cross-sectional diagram of the claw body.) Figure 2.3 .

[0102] The delivered part has a circular thin-walled structure in the middle, and its cross-sectional view is as follows. Figure 2.4 As shown. The outermost thin-walled section has dimensions of 117.5 mm in height and 20 mm in thickness, forming a ring structure. It connects to the web with a minimum thickness of 7 mm, and the web contains periodic holes. The central section is hollow, resulting in low resistance to deformation. The four claws are arranged in a 90° array, making them susceptible to deformation under their own stress or external forces during forging, heat treatment, and other hot working processes. The thin-walled sections are primarily affected by bending forces. The formula for calculating the bending deformation strength of aluminum alloy is as follows:

[0103] σ=Mc / I

[0104] Where σ is the stress of the material, and the unit is Pa;

[0105] M is the bending moment applied to the material, with units of N·m;

[0106] c is the maximum distance across the cross section, in meters (m).

[0107] I is the moment of inertia of the cross section, in m^4.

[0108] Depend on Figure 2.1 The part schematic diagram shows that the outer and bottom surfaces of the part are machined surfaces. This can be achieved by adding machining allowance, but increasing the allowance would significantly increase the machining cycle and the production cost of forging materials. For this research object, based on the forging structure, the web connection dimension is designed to be 12mm to ensure the strength requirements during production. The draft angle is based on minimum die forging, with a minimum draft angle of 3° inwards and 6° outwards. The cross-sectional shape of the part to the forging is shown in [reference needed]. Figure 2.5 .

[0109] like Figure 2.1 As shown, the maximum outer contour of the entire part is φ877×148, with the claws extending outwards by 70mm. There are numerous through holes, and the cross-section varies significantly. To meet the requirements of the fully streamlined four-claw structure, solid filler is used at the transition points, and a rounded design is employed at large cross-sections to reduce metal flow resistance during forging. The maximum cross-sectional view of the forging is shown below. Figure 2.6 .

[0110] In summary, based on the characteristics and usage requirements of the stationary ring structure, the connection parts of the three claw bodies are filled and compensated; the wall thickness of the connecting arm is increased to reduce the deformation during forging and subsequent cooling; and the hollow design of the intermediate ring forging is retained. Figure 2.7 This is a schematic diagram of the forging's external shape design.

[0111] like Figure 2.1 As shown, the maximum outer contour of the entire part is φ877×148, with the claws extending outwards by 70mm. There are numerous through holes, and the cross-section varies significantly. To meet the requirements of the fully streamlined four-claw structure, solid filler is used at the transition points, and a rounded design is employed at large cross-sections to reduce metal flow resistance during forging. The maximum cross-sectional view of the forging is shown below. Figure 2.6 .

[0112] Another object of the present invention is to provide a method for producing aluminum alloy forgings.

[0113] Includes the following steps:

[0114] S1: Provide a first mold and a second mold, wherein the first mold includes a first upper mold 1 and a first lower mold 2 for extruding the dough into a blank 7; the second mold includes a second upper mold 12 and a second lower mold 13 for extruding the blank 7 into the desired product.

[0115] S2: The blank is placed in the first positioning groove 5 of the first lower mold 2. The first positioning boss 3 and claw arm boss 4 of the first upper mold 1 cooperate with the first positioning groove 5 and claw groove 6 of the first lower mold 2 to form the blank into a blank body 7 by extrusion. The blank body 7 includes a claw arm blank body 8 and a forging blank body 9.

[0116] S3: Transfer the blank 7 to the second mold, wherein the second lower mold 13 is provided with a second positioning groove 14 and a third positioning groove 15, which are adapted to the forging blank 9 and claw arm blank 8 in the blank 7, and the second upper mold 12 is provided with a fourth positioning groove 19 and a fifth positioning groove 20, which are used to further compress the blank 7 to form a forging.

[0117] S4: Close the second upper mold 12 and the second lower mold 13. The first positioning protrusion 22 and the second positioning protrusion 23 of the second upper mold 12 cooperate with the first positioning protrusion 17, the second positioning protrusion 18 and the positioning groove of the second lower mold 13 to extrude the blank 7 and form a forging with the first positioning groove 24, the first through groove 25, the second through groove 26 and the claw arm.

[0118] S5: During the extrusion process, the blocking mechanism 28 set on the second mold is used to prevent flow through the extruded claw arm blank 8, ensuring uniform thickness of the forging.

[0119] S6: After the forging is formed, the forging is ejected from the mold by the ejection mechanism of the second mold using the ejector rod, which facilitates the removal of the forging and subsequent production operations.

[0120] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An aluminum alloy forging production apparatus, characterized in that, It includes a first mold and a second mold. The first mold is used to extrude the dough into a blank, and the second mold is used to extrude the blank into the desired product. The first mold includes a first upper mold and a first lower mold. The surface of the first upper mold is provided with a first positioning boss and a claw arm boss. The claw arm boss is provided on the side wall of the first positioning boss. The first lower mold is provided with a first positioning groove and a claw groove. The claw groove is provided on the edge of the first positioning groove and is connected to the first positioning groove. The claw arm boss is adapted to the claw groove. The first positioning boss is adapted to the first positioning groove. The blank is placed in the first positioning groove. During the process of the first positioning boss extruding the blank, the side wall of the blank flows through the first positioning groove to the claw groove. The claw arm boss is used to extrude and shape the blank in the claw groove. The first positioning boss, the claw arm boss and the first positioning groove and the claw groove work together to extrude and form the blank. The blank includes a claw arm blank and a forging blank. The claw arm blank is distributed on the side wall of the forging blank. The first positioning boss is provided with a recess. The surface of the forging blank is formed with a protrusion corresponding to the recess. The second mold includes a second upper mold and a second lower mold. The second lower mold has a second positioning groove, a third positioning groove, and a first mounting groove. The second positioning groove and the third positioning groove are both located in the first mounting groove. The second positioning groove is located at the center of the second lower mold. The third positioning groove is located on the edge of the second positioning groove and is connected to the second positioning groove. The third positioning groove is adapted to the claw arm blank. The second positioning groove is adapted to the forging blank. The second positioning groove is provided with a first positioning protrusion and a second positioning protrusion. A first gap is formed between the first positioning protrusion and the second positioning protrusion. A second gap is formed between the second positioning protrusion and the side wall of the second positioning groove. The second upper mold has a fourth positioning groove, a fifth positioning groove, and a second mounting groove. The fourth and fifth positioning grooves are both located within the second mounting groove. The fourth positioning groove is located at the center of the second upper mold. The first mounting groove overlaps with the second mounting groove. A first positioning protrusion is provided in the fourth positioning groove, and a second positioning protrusion is provided in the fifth positioning groove. The first positioning protrusion is used to compress the protrusion on the upper surface of the forging blank into a first positioning groove. The first positioning protrusion and the first gap are used to compress the lower surface of the forging blank into a first through groove. The second positioning protrusion and the second gap are used to compress the lower surface of the forging blank into a second through groove. Under their combined action, a forging is formed. The second positioning protrusion is used to compress the claw arm blank into a second positioning groove, thereby forming a claw arm. The claw arm and the forging together form the desired product.

2. The aluminum alloy forging production apparatus according to claim 1, characterized in that, The first mounting groove is provided with a blocking mechanism, which is located on both sides of the third positioning groove. The second mounting groove is provided with a fixing groove, which is adapted to the blocking mechanism. When the second upper mold and the second lower mold are closed, the blocking mechanism is inserted into the fixing groove. The blocking mechanism is used to prevent flow through the claw arm blank during the compression process, which would result in uneven thickness.

3. The aluminum alloy forging production apparatus according to claim 2, characterized in that, The surface shape of the blocking mechanism facing the third positioning groove is the same as the sidewall shape of the third positioning groove.

4. The aluminum alloy forging production apparatus according to claim 2, characterized in that, The blocking mechanism is provided with guide slopes on both sides. The guide slopes facilitate the blocking mechanism to be smoothly inserted into the fixed groove when the second upper mold and the second lower mold are closed. At the same time, when the mold is opened, the guide slopes can guide the blocking mechanism to be smoothly disengaged from the fixed groove, reducing friction and wear.

5. The aluminum alloy forging production apparatus according to claim 4, characterized in that, A positioning and guiding structure is provided between the second upper mold and the second lower mold. The positioning and guiding structure includes a guide post, a first guide hole, and a second guide hole. The first guide hole is provided on the side wall of the second lower mold, and the second guide hole is provided on the side wall of the second upper mold. One end of the guide post is provided in the first guide hole. The guide post and the second guide hole are adapted to provide accurate positioning guidance when the molds are closed, so as to ensure precise alignment between the molds.

6. The aluminum alloy forging production apparatus according to claim 2, characterized in that, The second mold is provided with an ejection mechanism at the discharge end. The ejection mechanism includes an ejector rod and an ejection hole. The ejection hole is located at the bottom of the second lower mold. One end of the ejector rod is located in the ejection hole, and the other end is in contact with the forging. After the forging is formed, the forging is ejected from the mold by the upward movement of the ejector rod, which facilitates the removal of the forging and subsequent production operations.

7. A method for producing aluminum alloy forgings according to claim 6, Its features are, Includes the following steps: S1: Provide a first mold and a second mold, wherein the first mold includes a first upper mold and a first lower mold for extruding the dough into a blank; the second mold includes a second upper mold and a second lower mold for extruding the blank into the desired product; S2: Place the blank in the first positioning groove of the first lower mold, and use the first positioning boss and claw arm boss of the first upper mold to cooperate with the first positioning groove and claw groove of the first lower mold to form the blank into a blank by extrusion. The blank includes the claw arm blank and the forging blank. S3: Transfer the blank to the second mold, wherein the second lower mold is provided with a second positioning groove and a third positioning groove, which are adapted to the forging blank and claw arm blank in the blank, and the second upper mold is provided with a fourth positioning groove and a fifth positioning groove, which are used to further compress the blank to form a forging; S4: Close the second upper mold and the second lower mold, and use the first positioning protrusion and the second positioning protrusion of the second upper mold to cooperate with the first positioning protrusion, the second positioning protrusion and the positioning groove of the second lower mold to extrude the blank and form a forging with the first positioning groove, the first through groove, the second through groove and the claw arm; S5: During the extrusion process, a blocking mechanism set on the second die is used to prevent flow through the extruded claw arm blank, ensuring uniform thickness of the forging; S6: After the forging is formed, the forging is ejected from the mold by the ejection mechanism of the second mold using the ejector rod, which facilitates the removal of the forging and subsequent production operations.

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