A Die Design Method for Improving the Local Fluidity of Large Components

Abstract

The present invention relates to the field of forging technology, specifically a die design method for improving the local fluidity of large components. The method includes the following steps: S1: Set an upper die and a lower die according to the forging; there is a first chamber on the upper die, and a first area for forming a high bulge and a second area for forming an earpiece are provided in the first chamber, and there is a second chamber on the lower die; S2: Measure the maximum distance H1 from the first area to the lower surface of the upper die and the maximum distance H2 from the second area to the lower surface of the upper die; S3: First bosses are arranged on both sides of the first area, and second bosses are arranged outside the second chamber; third bosses are arranged on both sides of the second area, and fourth bosses are arranged outside the second chamber; a first bridge portion is formed between the first boss and the second boss, and a second bridge portion is formed between the third boss and the fourth boss; in the present invention, according to the height requirements of different areas of the forging, bridge portions with different heights are set to improve the filling effect inside the cavity.

Description

Technical Field

[0001] The present invention relates to the technical field of forging, and specifically provides a die design method for improving the local fluidity of large components. Background Art

[0002] Die forgings are widely used in the fields of aviation and aerospace. The bridge and cavity structure designed around the die forging, the main function of the bridge part is to prevent metal from flowing out, forcing the metal to fill the die cavity, and the function of the cavity part is to accommodate the excess metal.

[0003] Chinese Utility Model Patent CN206356511U discloses a flash structure for ordinary die forging, including the orifice of the forging die cavity, the bridge part, and the cavity part. The cavity part includes a support surface and an arc surface, the support surface is tangent to the arc surface, and the support surface and the orifice of the forging die cavity of the same die form a triangular support structure.

[0004] The above patent can complete the forging of ordinary forgings, but there will be some problems when forging complex forgings. Figure 1 Shown is an aircraft landing gear, including a rod part, a high package 1 connected to the rod part, and a lug 2 connected to the rod part. The heights of the high package 1 and the lug 2 are significantly higher than the position of the rod part. During the forging process, a large forming force is required to fill the high package and the lug positions. If the bridge and cavity designs of the above patent are adopted, it is easy to have the situation that the high package and the lug positions are not filled, resulting in the formed forging not meeting the design requirements. In this regard, only the volume of the rough blank can be increased so that the volume of the rough blank is equal to the sum of the volume of the forging, the volume of the bridge part, and the volume of the cavity part, so as to ensure that the high package and the lug after forming meet the design requirements. Subsequently, the bridge and cavity parts of the formed forging still need to be removed, but this design will lead to low material utilization rate, causing a large amount of material waste and high cost. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a die design method for improving the local fluidity of large components, which is used to improve the forming efficiency of forgings.

[0006] The technical solution adopted by the present invention to solve its technical problems is a die design method for improving the local fluidity of large components, including the following steps,

[0007] S1: Set the upper die and the lower die according to the shape of the forging; a first chamber is provided on the upper die, and a first area for forming a high package and a second area for forming a lug are provided in the first chamber. A second chamber is provided on the lower die, and the first chamber and the second chamber form a cavity for forming the forging;

[0008] S2: Measure the maximum distance H1 from the first area to the lower surface of the upper die and the maximum distance H2 from the second area to the lower surface of the upper die, and compare the magnitudes of H1 and H2.

[0009] S3: First bosses are provided on both sides of the first area, the first bosses are located outside the first chamber, and second bosses for cooperating with the first bosses are provided outside the second chamber; third bosses are provided on both sides of the second area, the third bosses are located outside the first chamber, and fourth bosses for cooperating with the third bosses are provided outside the second chamber; fifth bosses are provided on the remaining part outside the first chamber, and sixth bosses for cooperating with the fifth bosses are provided outside the second chamber;

[0010] A first groove is provided on the outside of the first boss, a second groove for cooperating with the first groove is provided on the outside of the second boss, a third groove is provided on the outside of the third boss, a fourth groove for cooperating with the third groove is provided on the outside of the fourth boss, a fifth groove is provided on the outside of the fifth boss, a sixth groove for cooperating with the fifth groove is provided on the outside of the sixth boss, a first bridge part is formed between the first boss and the second boss, a second bridge part is formed between the third boss and the fourth boss, a third bridge part is formed between the fifth boss and the sixth boss, a storage part is formed between the first groove and the second groove, a storage part is formed between the third groove and the fourth groove, and a storage part is formed between the fifth groove and the sixth groove;

[0011] When H1 is greater than H2, the height of the first bridge part is less than the height of the second bridge part, and the height of the second bridge part is less than the height of the third bridge part;

[0012] When H1 is less than H2, the height of the second bridge part is less than the height of the first bridge part, and the height of the first bridge part is less than the height of the third bridge part.

[0013] Furthermore, a smooth transition is provided between the first boss and the third boss, and between the third boss and the fifth boss; a smooth transition is provided between the second boss and the fourth boss, and between the fourth boss and the sixth boss.

[0014] Furthermore, a first fillet transition is provided between the first boss and the first chamber, a second fillet transition is provided between the third boss and the first chamber, and a third fillet transition is provided between the fifth boss and the first chamber;

[0015] When H1 is greater than H2, the first fillet is less than the second fillet, and the second fillet is less than the third fillet;

[0016] When H1 is less than H2, the second fillet is less than the first fillet, and the first fillet is less than the third fillet.

[0017] Further, when H1 is greater than H2, the width of the first boss is greater than the width of the third boss, and the width of the third boss is greater than the width of the fifth boss;

[0018] When H1 is less than H2, the width of the third boss is greater than the width of the first boss, and the width of the first boss is greater than the width of the fifth boss.

[0019] The beneficial effects of the present invention are as follows: According to the height requirements of different regions of the forging, bridge parts with different heights are set. When the height requirement of the high boss area (the first area) is greater than that of the lug area (the second area), the height of the first bridge part is set to be less than the heights of the second bridge part and the third bridge part, so as to increase the resistance of the metal inside the cavity flowing towards the first bridge part, forcing more metal to flow towards the high boss area and improving its filling effect. Description of the Drawings

[0020] Figure 1 is a schematic structural view of the landing gear forging of the present invention;

[0021] Figure 2 is a schematic view of the upper die;

[0022] Figure 3 is a schematic view of the lower die;

[0023] Figure 4 is a schematic view of the first bridge part when H1 is greater than H2;

[0024] Figure 5 is a schematic view of the second bridge part when H1 is greater than H2;

[0025] Figure 6 is a schematic view of the third bridge part when H1 is greater than H2;

[0026] Figure 7 is a schematic view of the first bridge part when H1 is less than H2;

[0027] Figure 8 is a schematic view of the second bridge part when H1 is less than H2;

[0028] Figure 9 is a schematic view of the third bridge part when H1 is less than H2;

[0029] Figure 10 [[ID=?]]is a filling effect diagram of the high boss position in Embodiment 1.

[0030] It should be noted that there seems to be a small error in the original text where the tag for the description of the filling effect diagram of the high boss position in Embodiment 1 is not clearly defined as a unique ID. Here, I've used "?" to represent it in the translation for consistency with the original text structure. You may want to check and correct this in the original content if possible.Reference numerals: 1 - upper die; 2 - lower die; 3 - first chamber; 4 - first region; 5 - second region; 6 - second chamber; 7 - first boss; 8 - second boss; 9 - third boss; 10 - fourth boss; 11 - fifth boss; 12 - sixth boss; 13 - first groove; 14 - second groove; 15 - third groove; 16 - fourth groove; 17 - fifth groove; 18 - sixth groove; 19 - first bridge; 20 - second bridge; 21 - third bridge; 22 - first bin; 23 - second bin; 24 - third bin; 25 - first fillet; 26 - second fillet; 27 - third fillet. Detailed implementation

[0031] The embodiments of the present invention will be described in detail below. The examples of the embodiments are shown in the accompanying drawings, where the same or similar reference numerals denote the same or similar elements or elements with the same or similar functions throughout. The embodiments described below by referring to the accompanying drawings are exemplary and are only used to explain the present invention and should not be construed as a limitation of the present invention.

[0032] As Figures 1-9 shown, a mold design method for improving the local fluidity of large components according to the present invention includes the following steps:

[0033] S1: Set the upper die 1 and the lower die 2 according to the shape of the forging; a first chamber 3 is provided on the upper die 1, and a first region 4 for forming a high package and a second region 5 for forming an ear are provided in the first chamber 3. A second chamber 6 is provided on the lower die 2, and the first chamber 3 and the second chamber 6 form a cavity for molding the forging.

[0034] S2: Measure the maximum distance H1 from the first region 4 to the lower surface of the upper die 1 and the maximum distance H2 from the second region 5 to the lower surface of the upper die 1, and compare the magnitudes of H1 and H2. Here, H1 and H2 can be measured by a laser rangefinder.

[0035] S3: First bosses 7 are arranged on both sides of the first region 4. The first bosses 7 are located outside the first chamber 3, and second bosses 8 for cooperating with the first bosses 7 are arranged outside the second chamber 6. Third bosses 9 are arranged on both sides of the second region 5. The third bosses 9 are located outside the first chamber 3, and fourth bosses 10 for cooperating with the third bosses 9 are arranged outside the second chamber 6. The remaining part outside the first chamber 3 is provided with fifth bosses 11, and sixth bosses 12 for cooperating with the fifth bosses 11 are arranged outside the second chamber 6. Among them, the first bosses 7, the third bosses 9, and the fifth bosses 11 are made of the same material as the upper die 1 and are connected in an integrally formed manner. The first bosses 7, the third bosses 9, and the fifth bosses 11 form an annular structure that matches the outer contour of the forging. The length of the first boss 7 is the same as the width of the first region 4, and the length of the third boss 9 is the same as the width of the second region 5. The second bosses 8, the fourth bosses 10, and the sixth bosses 12 are made of the same material as the lower die 2 and are connected in an integrally formed manner. The second bosses 8, the fourth bosses 10, and the sixth bosses 12 form an annular structure that matches the outer contour of the forging. The length of the second boss 8 is the same as the length of the first boss 7, and the length of the fourth boss 10 is the same as the length of the second boss 8. The first boss 7 and the second boss 8 have the same height, the third boss 9 and the fourth boss 10 have the same height, and the fifth boss 11 and the sixth boss 12 have the same height.

[0036] A first groove 13 is arranged outside the first boss 7, and a second groove 14 for cooperating with the first groove 13 is arranged outside the second boss 8. A third groove 15 is arranged outside the third boss 9, and a fourth groove 16 for cooperating with the third groove 15 is arranged outside the fourth boss 10. A fifth groove 17 is arranged outside the fifth boss 11, and a sixth groove 18 for cooperating with the fifth groove 17 is arranged outside the sixth boss 12. A first bridge portion 19 is formed between the first boss 7 and the second boss 8, a second bridge portion 20 is formed between the third boss 9 and the fourth boss 10, and a third bridge portion 21 is formed between the fifth boss 11 and the sixth boss 12. A first storage portion 22 is formed between the first groove 13 and the second groove 14, a second storage portion 23 is formed between the third groove 15 and the fourth groove 16, and a third storage portion 24 is formed between the fifth groove 17 and the sixth groove 18. Among them, the center lines of the first bridge portion 19, the second bridge portion 20, and the third bridge portion 21 are on the same horizontal plane as the center line of the rod portion of the forging after forming. The first bridge portion 19, the second bridge portion 20, and the third bridge portion 21 all provide resistance to limit the flow of metal inside the cavity to the outside. The first storage portion 22 is used to store the metal flowing out from the first bridge portion 19, the second storage portion 23 is used to store the metal flowing out from the second bridge portion 20, and the remaining metal flowing out from the third bridge portion 21 is stored by the third bridge portion 21.

[0037] When H1 is greater than H2, the height of the first bridge part 19 is less than the height of the second bridge part 20, and the height of the second bridge part 20 is less than the height of the third bridge part 21; this indicates that the height of the high package position is greater than the height of the lug position, that is, the difficulty for the metal to flow to the deepest part of the first area 4 is greater than the difficulty for the metal to flow to the deepest part of the second area 5. The height of the first bridge part 19 is less than the height of the second bridge part 20, making the resistance for the metal to flow out from the first bridge part 19 greater than the resistance for the metal to flow out from the second bridge part 20, thereby forcing more metal to flow to the high package area; the area corresponding to the third bridge part 21 is relatively flat, the distance from these areas to the lower surface of the upper die 1 is small, and the forming difficulty is low. The height of the second bridge part 20 is less than the height of the third bridge part 21, making the resistance for the metal to flow out from the second bridge part 20 greater than the resistance for the metal to flow out from the third bridge part 21, thereby forcing more metal to flow to the lug area.

[0038] When H1 is less than H2, the height of the second bridge part 20 is less than the height of the first bridge part 19, and the height of the first bridge part 19 is less than the height of the third bridge part 21. This indicates that the height of the high package position is less than the height of the lug position, that is, the difficulty for the metal to flow to the deepest part of the second area 5 is greater than the difficulty for the metal to flow to the deepest part of the first area 4. The height of the second bridge part 20 is less than the height of the first bridge part 19, making the resistance for the metal to flow out from the second bridge part 20 greater than the resistance for the metal to flow out from the first bridge part 19, thereby forcing more metal to flow to the lug area; the area corresponding to the third bridge part 21 is relatively flat, the distance from these areas to the lower surface of the upper die 1 is small, and the forming difficulty is low. The height of the first bridge part 19 is less than the height of the third bridge part 21, making the resistance for the metal to flow out from the first bridge part 19 greater than the resistance for the metal to flow out from the third bridge part 21, thereby forcing more metal to flow to the high package area.

[0039] For better processing and forming, further, a smooth transition is provided between the first boss 7 and the third boss 9, and between the third boss 9 and the fifth boss 11; a smooth transition is provided between the second boss 8 and the fourth boss 10, and between the fourth boss 10 and the sixth boss 12.

[0040] In order to avoid stress concentration at the transition positions between the metal in the first chamber 3 and the first boss 7, the second boss 8, and the third boss 9 during the forming process, further, the transition between the first boss 7 and the first chamber 3 is achieved through a first rounded corner 25, the transition between the third boss 9 and the first chamber 3 is achieved through a second rounded corner 26, and the transition between the fifth boss 11 and the first chamber 3 is achieved through a third rounded corner 27; when H1 is greater than H2, it indicates that the height of the high package position is greater than the height of the lug position, that is, the difficulty of the metal flowing to the deepest part of the first region 4 is greater than the difficulty of the metal flowing to the deepest part of the second region 5. The first rounded corner 25 is smaller than the second rounded corner 26, and the second rounded corner 26 is smaller than the third rounded corner 27. This can increase the resistance of the metal flowing out from the first bridge portion 19. When H1 is less than H2, the height of the high package position is less than the height of the lug position, that is, the difficulty of the metal flowing to the deepest part of the second region 5 is greater than the difficulty of the metal flowing to the deepest part of the first region 4. The second rounded corner 26 is smaller than the first rounded corner 25, and the first rounded corner 25 is smaller than the third rounded corner 27. This can increase the resistance of the metal flowing out from the second bridge portion 20.

[0041] In order to further increase the resistance of the metal flowing out from the first bridge portion 19 or the resistance of the metal flowing out from the second bridge portion 20, further, when H1 is greater than H2, the width of the first boss 7 is greater than the width of the third boss 9, and the width of the third boss 9 is greater than the width of the fifth boss 11; when H1 is less than H2, the width of the third boss 9 is greater than the width of the first boss 7, and the width of the first boss 7 is greater than the width of the fifth boss 11.

[0042] Finally, it should also be noted that there is also a case where H1 and H2 are equal. In this case, the shapes and sizes of the first bridge portion 19 and the second bridge portion 20 are the same, and the first rounded corner 25 and the second rounded corner 26 are also the same. No further elaboration will be made here.

[0043] Of course, the two first bridge portions 19 can also be designed differently. When the deepest part of the first region 4 is not located in the middle of the two first bridge portions 19, the height of the first bridge portion 19 closer to the deepest part of the first region 4 can be less than the height of the first bridge portion 19 farther from the deepest part of the first region 4. Similarly, the two second bridge portions 20 can also be designed differently. When the deepest part of the second region 5 is not located in the middle of the two second bridge portions 20, the height of the second bridge portion 20 closer to the deepest part of the second region 5 is less than the height of the second bridge portion 20 farther from the deepest part of the second region 5.

[0044] Embodiment 1

[0045] Using the designed die, the depth of the first region 4 is greater than that of the second region 5. The height of the first bridge portion 19 is 10 mm, and the width of the first bridge portion 19 is 48 mm (i.e., the width of the first boss 7). The height of the second bridge portion 20 is 13 mm, and the width of the second bridge portion 20 is 45 mm (i.e., the width of the third boss 9). The height of the third bridge portion 21 is 16 mm, and the width of the third bridge portion 21 is 40 mm (i.e., the width of the fifth boss 11). The radius of the first fillet 25 is 12 mm, the radius of the second fillet 26 is 15 mm, and the radius of the third fillet 27 is 20 mm. Place a rough blank made of 300M steel with dimensions of 1600×300×280 mm in the second chamber 6 of the lower die 2. The forging temperature is 1135°C. Move the upper die 1 downward to forge the rough blank until the upper die 1 and the lower die 2 are closed to form the rough blank. After removing the flash formed by the bridge portion and the cavity portion, a landing gear forging is formed. Through measurement, the height at the lug position is 220 mm, meeting the design height. The height at the high package position is 300 mm, meeting the design height, and it is determined to be qualified. The volume of the formed landing gear forging is 0.110 m 3 , and the material utilization rate is 80%.

[0046] Comparative Example 1

[0047] Using the original die, the height of the bridge portion formed between the upper die and the lower die is 16 mm, the width of the bridge portion is 40 mm, and the fillet between the bridge portion and the cavity is 20 mm. Place a rough blank made of 300M steel with dimensions of 1600×300×280 mm in the cavity of the lower die. The forging temperature is 1135°C. Move the upper die downward to forge the rough blank until the upper die and the lower die are closed to form the rough blank. After removing the flash formed by the bridge portion and the cavity portion, a landing gear forging is formed. Through measurement, the height at the lug position is 220 mm, meeting the design height. The height at the high package position is 280 mm, less than the design height, and it is determined to be unqualified.

[0048] Comparative Example 2

[0049] Using the original die, the height of the bridge portion formed between the upper die and the lower die is 16 mm, the width of the bridge portion is 40 mm, and the fillet between the bridge portion and the cavity is 20 mm. Place a rough blank made of 300M steel with dimensions of 1600×300×300 mm in the cavity of the lower die. The forging temperature is 1135°C. Move the upper die downward to forge the rough blank until the upper die and the lower die are closed to form the rough blank. After removing the flash formed by the bridge portion and the cavity portion, a landing gear forging is formed. Through measurement, the height at the lug position is 220 mm, meeting the design height. The height at the high package position is 300 mm, meeting the design height, and it is determined to be qualified. The volume of the formed landing gear forging is 0.110 m 3 , and the material utilization rate is 76%.

[0050] The embodiments of this specific implementation manner are all preferred embodiments of the present invention, and do not limit the protection scope of the present invention accordingly. Therefore, all equivalent changes made according to the structure, shape, and principle of the present invention shall be covered within the protection scope of the present invention.

Claims

1. A die design method for improving the local fluidity of large components, characterized in that: It includes the following steps, S1: Set the upper die (1) and the lower die (2) according to the shape of the forging; a first chamber (3) is provided on the upper die (1), and a first region (4) for forming a high package and a second region (5) for forming lugs are provided in the first chamber (3), a second chamber (6) is provided on the lower die (2), and the first chamber (3) and the second chamber (6) form a cavity for forming the forging; S2: Measure the maximum distance H1 from the first region (4) to the lower surface of the upper die (1) and the maximum distance H2 from the second region (5) to the lower surface of the upper die (1), and compare the magnitudes of H1 and H2; S3: First bosses (7) are provided on both sides of the first region (4), the first bosses (7) are located outside the first chamber (3), and second bosses (8) for cooperating with the first bosses (7) are provided outside the second chamber (6); third bosses (9) are provided on both sides of the second region (5), the third bosses (9) are located outside the first chamber (3), and fourth bosses (10) for cooperating with the third bosses (9) are provided outside the second chamber (6); the remaining part outside the first chamber (3) is provided with fifth bosses (11), and sixth bosses (12) for cooperating with the fifth bosses (11) are provided outside the second chamber (6); A first groove (13) is provided on the outside of the first boss (7), a second groove (14) for cooperating with the first groove (13) is provided on the outside of the second boss (8), a third groove (15) is provided on the outside of the third boss (9), a fourth groove (16) for cooperating with the third groove (15) is provided on the outside of the fourth boss (10), a fifth groove (17) is provided on the outside of the fifth boss (11), a sixth groove (18) for cooperating with the fifth groove (17) is provided on the outside of the sixth boss (12), a first bridge portion (19) is formed between the first boss (7) and the second boss (8), a second bridge portion (20) is formed between the third boss (9) and the fourth boss (10), a third bridge portion (21) is formed between the fifth boss (11) and the sixth boss (12), a first storage portion (22) is formed between the first groove (13) and the second groove (14), a second storage portion (23) is formed between the third groove (15) and the fourth groove (16), and a third storage portion (24) is formed between the fifth groove (17) and the sixth groove (18); When H1 is greater than H2, the height of the first bridge portion (19) is less than the height of the second bridge portion (20), and the height of the second bridge portion (20) is less than the height of the third bridge portion (21); When H1 is less than H2, the height of the second bridge portion (20) is less than the height of the first bridge portion (19), and the height of the first bridge portion (19) is less than the height of the third bridge portion (21).

2. The mold design method for improving the local fluidity of large components according to claim 1, characterized in that: The first boss (7) and the third boss (9), and the third boss (9) and the fifth boss (11) are in smooth transition; the second boss (8) and the fourth boss (10), and the fourth boss (10) and the sixth boss (12) are in smooth transition.

3. A mold design method for improving the local fluidity of large components as described in claim 1, characterized in that: The first boss (7) and the first chamber (3) are in transition through a first rounded corner (25), the third boss (9) and the first chamber (3) are in transition through a second rounded corner (26), and the fifth boss (11) and the first chamber (3) are in transition through a third rounded corner (27); When H1 is greater than H2, the first rounded corner (25) is smaller than the second rounded corner (26), and the second rounded corner (26) is smaller than the third rounded corner (27); When H1 is less than H2, the second rounded corner (26) is smaller than the first rounded corner (25), and the first rounded corner (25) is smaller than the third rounded corner (27).

4. A mold design method for improving the local fluidity of large components as described in claim 1, characterized in that: When H1 is greater than H2, the width of the first boss (7) is greater than the width of the third boss (9), and the width of the third boss (9) is greater than the width of the fifth boss (11); When H1 is less than H2, the width of the third boss (9) is greater than the width of the first boss (7), and the width of the first boss (7) is greater than the width of the fifth boss (11).

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