Forming method for special-shaped annular forge piece with upper end face and lower end face unequal in diameter size

Abstract

The invention relates to the technical field of metal material forming, discloses a forming method for a special-shaped annular forge piece with the upper end face and the lower end face unequal in diameter size, and achieves forming of the special-shaped annular forge piece by designing an inner tool and an outer tool. The inner tool has a non-equivalent outer diameter and controls the inner diameter shape of the forge piece; the outer tool has a non-equivalent outer diameter and controls the outer diameter shape of the forge piece. A simple tool is adopted to replace a traditional special rolling tool, the production cost is reduced, the manufacturing period is shortened, production of the complex special-shaped annular forge piece can be completed through conventional forging equipment, meanwhile, it is guaranteed that the internal structure meets the requirement by controlling forging parameters, and the problems that a traditional method is high in cost, high in equipment requirement and the like are effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of metal material forming, and particularly to a forming method for a special-shaped ring forging with unequal diameters of upper and lower end faces. Background Art

[0002] GH4098 alloy is a nickel-based age-hardening superalloy containing strengthening elements such as tungsten, molybdenum, aluminum, and titanium, with a total content reaching 14%. This alloy is mainly used to manufacture high-temperature components in the fields of aerospace gas turbines, energy, chemical engineering, and steam turbines, such as turbine blades, turbine disks, and combustion chamber liners. It can work in a high-temperature environment below 950 degrees Celsius and has excellent comprehensive properties.

[0003] For special-shaped ring forgings with unequal diameters of upper and lower end faces, in the prior art, forging is usually carried out on a ring rolling forging machine using special tooling. This method requires designing and manufacturing special rolling rolls and rolling wheels according to the shape and size of the forging, resulting in high production costs, long production cycles, and poor adaptability. In addition, the design of special tooling also needs to consider the structural characteristics of different ring forging machines. For example, horizontal ring forging machines and vertical ring forging machines have different control capabilities for the height of the forging. It is difficult to accurately control the height of the forging with a vertical non-rolling ring device, while for horizontal ring forging machines, due to the limitation of the equipment's holding rolls in assembly, it is impossible to normally control the coaxiality of the forging for ring parts with a height exceeding 350 mm, leading to production difficulties.

[0004] These problems seriously restrict the production efficiency and quality stability of special-shaped ring forgings. Especially for high-temperature alloy materials such as GH4098, due to their high deformation resistance and low plasticity, problems such as uneven deformation and unstable internal structure are more likely to occur during forging. Therefore, on the premise of ensuring the dimensional accuracy and internal structure requirements of the forging, how to simplify the tooling design, reduce production costs, and shorten the production cycle has become an urgent technical problem in this field. Summary of the Invention

[0005] The purpose of the present invention is to provide a forming method for a special-shaped ring forging with unequal diameters of upper and lower end faces to solve the problems of high production costs, long tooling production cycle, and high equipment requirements for special-shaped ring forgings in the prior art.

[0006] To achieve the above technical purpose, the present invention provides a forming method for a special-shaped ring forging with unequal diameters of upper and lower end faces, including:

[0007] Providing an inner tooling and an outer tooling, the inner tooling having non-equal outer diameters for controlling the shape of the non-equal inner diameters of the special-shaped ring forging; the outer tooling having non-equal outer diameters for controlling the shape of the non-equal outer diameters of the special-shaped ring forging;

[0008] Forging the preformed blank with the inner tooling and the outer tooling.

[0009] Optionally, the method for determining the parameters of the inner tooling is as follows:

[0010] The maximum outer diameter A of the inner tooling 外max = B 内max - △ 余量 ;

[0011] The minimum outer diameter A of the inner tooling 外min = B 内min - △ 余量 ;

[0012] The equal inner diameter A of the inner tooling 内径等值 = B 内min - δ;

[0013] The tooling height H1 of the inner tooling = h + ε;

[0014] Wherein, B 内min is the minimum inner diameter of the special-shaped ring forging, B 内max is the maximum inner diameter of the special-shaped ring forging, △ 余量 is the allowance, δ is the strength value of the inner tooling, h is the height of the special-shaped ring forging, and ε is the deviation value.

[0015] Optionally, the method for determining the parameters of the outer tooling is as follows:

[0016] The maximum inner diameter C of the outer tooling 内max = B 外max + △ 余量 ;

[0017] The minimum inner diameter C of the outer tooling 内min = B 外min + △ 余量 ;

[0018] The equal outer diameter C of the outer tooling 外径等值 = B 外max + δ';

[0019] The tooling height H2 of the outer tooling = h + ε;

[0020] Wherein, B 外min is the minimum outer diameter of the special-shaped ring forging, B 外max is the maximum outer diameter of the special-shaped ring forging, △ 余量 is the allowance, δ' is the strength value of the outer tooling, h is the height of the special-shaped ring forging, and ε is the deviation value.

[0021] Optionally, the allowance is selected according to the maximum outer diameter dimension of the special-shaped ring forging:

[0022] When the maximum outer diameter dimension of the special-shaped ring forging is not greater than 200 mm, the allowance is 2.5 mm;

[0023] When the maximum outer diameter dimension of the special-shaped ring forging is greater than 200 mm and not greater than 499 mm, the allowance is 3.0 mm;

[0024] When the maximum outer diameter dimension of the special-shaped ring forging is greater than 500 mm and not greater than 800 mm, the allowance is 3.5 mm;

[0025] When the maximum outer diameter dimension of the special-shaped ring forging is greater than 801 mm and not greater than 999 mm, the allowance is 4.0 mm;

[0026] When the maximum outer diameter dimension of the special-shaped ring forging is greater than 1000 mm, the allowance is 5.0 mm.

[0027] Optionally, the strength value of the inner tooling and the strength value of the outer tooling are selected according to the weight of the special-shaped ring forging:

[0028] When the weight of the special-shaped ring forging is not greater than 100 kg, the strength value is not less than 50 mm;

[0029] When the weight of the special-shaped ring forging is greater than 100 kg and not greater than 300 kg, the strength value is not less than 60 mm;

[0030] When the weight of the special-shaped ring forging is greater than 300 kg and not greater than 600 kg, the strength value is not less than 80 mm;

[0031] When the weight of the special-shaped ring forging is greater than 600 kg and not greater than 900 kg, the strength value is not less than 100 mm;

[0032] When the weight of the special-shaped ring forging is greater than 900 kg, the strength value is not less than 120 mm.

[0033] Optionally, the deviation value ε is selected according to the height of the special-shaped ring forging:

[0034] When the height of the special-shaped ring forging is not greater than 100 mm, the deviation value is 3 mm;

[0035] When the height of the special-shaped ring forging is greater than 100 mm and not greater than 200 mm, the deviation value is 4 mm;

[0036] When the height of the special-shaped ring forging is greater than 200 mm and not greater than 300 mm, the deviation value is 5 mm;

[0037] When the height of the special-shaped ring forging is greater than 300 mm, the deviation value is 6 mm.

[0038] Optionally, the height H3 of the preform blank is h×(1 + x%);

[0039] where h is the height of the special-shaped annular forging, and x is the deformation amount.

[0040] Optionally, the process of forging the preform blank with the inner tooling and the outer tooling includes:

[0041] Heating the raw material to the working temperature and performing the first heat preservation, and performing preform forging to form the preform blank;

[0042] Reheating the preform blank to the working temperature and performing the second heat preservation, and performing final forming forging with the inner tooling and the outer tooling;

[0043] Performing sand blasting and grinding inspection after forging;

[0044] Performing heat treatment.

[0045] Optionally, the working temperature is 1080 - 1150°C, the first heat preservation time is 120 - 200 minutes, and the second heat preservation time is 60 - 100 minutes.

[0046] Optionally, the special-shaped annular forging includes a forging made of GH4098 alloy material.

[0047] Compared with the prior art, the present invention has at least the following beneficial effects:

[0048] The method for forming a special-shaped annular forging with unequal diameters of the upper and lower end faces provided by the present invention can forge a preform blank with inner tooling and outer tooling having non-equal outer diameters, which can replace complex special molds with simple tooling, effectively reduce the production cost, shorten the tooling production cycle, and can complete the production of complex special-shaped annular forgings with conventional forging equipment, avoiding the dependence on special equipment.

[0049] The forming method provided by the present invention accurately calculates various parameters such as the outer diameter, inner diameter, and height, selects corresponding allowance, strength value, and deviation value according to the characteristics of the forging such as the outer diameter, weight, and height, and combines reasonable control of the heating temperature and heat preservation time, which not only ensures the dimensional accuracy of the forging, but also ensures that the internal structure and mechanical properties of the product meet the requirements, improving the production efficiency and product quality. Description of the Drawings

[0050] Figure 1 It is a step flow chart of a method for forming a special-shaped annular forging with unequal diameters of the upper and lower end faces in an embodiment of the present invention;

[0051] Figure 2Schematic diagram of the external tooling, forging, and internal tooling structures in the embodiments of the present invention;

[0052] Figure 3 Schematic diagram of the external tooling structure in the embodiments of the present invention. Detailed implementation manners

[0053] The following will describe in more detail a method for forming a special-shaped annular forging with unequal diameters of the upper and lower end faces in conjunction with the accompanying drawings, in which the preferred embodiments of the present invention are shown. It should be understood that those skilled in the art can modify the present invention described herein while still achieving the advantageous effects of the present invention. Therefore, the following description should be understood as broad knowledge for those skilled in the art and not as a limitation to the present invention.

[0054] Based on the revelation of this specification and without generating technical contradictions, those skilled in the art can form new technical solutions through cross-combination of different embodiments, and such variations should be regarded as falling within the protection scope of the present invention.

[0055] In the following paragraphs, the present invention will be described more specifically by way of example with reference to the accompanying drawings. According to the following description, the advantages and features of the present invention will be clearer. It should be noted that the accompanying drawings are all in very simplified forms and use non-precise scales, only for conveniently and clearly assisting in explaining the purpose of the embodiments of the present invention.

[0056] Embodiment 1

[0057] In this embodiment, a method for forming a special-shaped annular forging with unequal diameters of the upper and lower end faces is provided. Please refer to Figure 1 - Figure 3 , including the following steps:

[0058] S11: Provide an internal tooling and an external tooling. The internal tooling has non-equal outer diameters and is used to control the non-equal inner diameter shape of the special-shaped annular forging; the external tooling has non-equal outer diameters and is used to control the non-equal outer diameter shape of the special-shaped annular forging;

[0059] S12: Forge the preformed blank using the internal tooling and the external tooling.

[0060] Furthermore, the method for determining the parameters of the internal tooling A is as follows:

[0061] The maximum outer diameter A of the internal tooling A 外max = B 内max - △ 余量 ;

[0062] The minimum outer diameter A of the internal tooling A 外min = B 内min - △ 余量 ;

[0063] The inner diameter equivalent value A of the inner tooling A 内径等值 = B 内min - δ;

[0064] The tooling height H1 of the inner tooling A = h + ε;

[0065] Wherein, B 内min is the minimum inner diameter of the special-shaped ring forging, and B 内max is the maximum inner diameter of the special-shaped ring forging, △ 余量 is the allowance, δ is the strength value of the inner tooling, h is the height of the special-shaped ring forging, and ε is the deviation value.

[0066] Furthermore, the method for determining the parameters of the outer tooling C is as follows:

[0067] The maximum inner diameter C of the outer tooling 内max = B 外max + △ 余量 ;

[0068] The minimum inner diameter C of the outer tooling 内min = B 外min + △ 余量 ;

[0069] The outer diameter equivalent value C of the outer tooling C 外径等值 = B 外max + δ';

[0070] The tooling height H2 of the outer tooling C = h + ε;

[0071] Wherein, B 外min is the minimum outer diameter of the special-shaped ring forging, and B 外max is the maximum outer diameter of the special-shaped ring forging, △ 余量 is the allowance, δ' is the strength value of the outer tooling, h is the height of the special-shaped ring forging, and ε is the deviation value.

[0072] In a specific example, the allowance is selected according to the maximum outer diameter dimension B of the special-shaped ring forging B 外max :

[0073] When the outer diameter dimension of the special-shaped ring forging is not greater than 200 mm, the allowance is 2.5 mm; when the maximum outer diameter dimension of the special-shaped ring forging is greater than 200 mm and not greater than 499 mm, the allowance is 3.0 mm; when the maximum outer diameter dimension of the special-shaped ring forging is greater than 500 mm and not greater than 800 mm, the allowance is 3.5 mm; when the maximum outer diameter dimension of the special-shaped ring forging is greater than 801 mm and not greater than 999 mm, the allowance is 4.0 mm; when the maximum outer diameter dimension of the special-shaped ring forging is greater than 1000 mm, the allowance is 5.0 mm.

[0074] The strength value δ of the inner tooling and the strength value δ' of the outer tooling are selected according to the weight of the special-shaped ring forging:

[0075] When the weight of the special-shaped ring forging is not greater than 100 kg, the strength value is not less than 50 mm; when the weight of the special-shaped ring forging is greater than 100 kg and not greater than 300 kg, the strength value is not less than 60 mm; when the weight of the special-shaped ring forging is greater than 300 kg and not greater than 600 kg, the strength value is not less than 80 mm; when the weight of the special-shaped ring forging is greater than 600 kg and not greater than 900 kg, the strength value is not less than 100 mm; when the weight of the special-shaped ring forging is greater than 900 kg, the strength value is not less than 120 mm.

[0076] The deviation value ε is selected according to the height of the special-shaped ring forging:

[0077] When the height of the special-shaped ring forging is not greater than 100 mm, the deviation value is 3 mm; when the height of the special-shaped ring forging is greater than 100 mm and not greater than 200 mm, the deviation value is 4 mm; when the height of the special-shaped ring forging is greater than 200 mm and not greater than 300 mm, the deviation value is 5 mm; when the height of the special-shaped ring forging is greater than 300 mm, the deviation value is 6 mm.

[0078] In a preferred embodiment, the preformed blank adopts the principle of equal volume and the dimensional allowance is considered according to the thermal shrinkage rate; where:

[0079] The height H3 of the preformed blank = h×(1 + x%);

[0080] Wherein, h is the height of the special-shaped ring forging and x is the deformation amount.

[0081] In a specific example, the deformation amount x can be adjusted according to different material properties and forging temperatures. For GH4098 alloy, the generally selected deformation amount is 15%-25% to ensure sufficient deformation effect and metal fluidity.

[0082] The process of forging the preformed blank with the inner tooling and the outer tooling specifically includes the following steps:

[0083] S121. Heat the raw material to the working temperature and conduct the first heat preservation, and perform preforming forging to form the preformed blank;

[0084] S122. Reheat the preformed blank to the working temperature and conduct the second heat preservation, and perform final forming forging with the inner tooling and the outer tooling;

[0085] S123. Conduct sandblasting and grinding inspection after forging;

[0086] S124. Conduct heat treatment;

[0087] Further, it further includes step S125. After physical and chemical inspection, final inspection and warehousing.

[0088] Among them, the working temperature is 1080 - 1150 °C, the first heat preservation time is 120 - 200 minutes, and the second heat preservation time is 60 - 100 minutes.

[0089] In a preferred embodiment of the present invention, the working temperature can be maintained at 1120 °C, the first heat preservation time is 160 minutes, and the second heat preservation time is 80 minutes. Such process parameters can ensure that the GH4098 alloy obtains good tissue state and deformation effect.

[0090] The special-shaped ring forging includes a forging made of GH4098 alloy material.

[0091] In a specific example, the GH4098 alloy, as a nickel-based age-hardening superalloy, is mainly used to manufacture load-bearing parts below 950 degrees Celsius and has excellent comprehensive properties. It is mainly applied to high-temperature parts such as aerospace gas turbines, energy, chemical engineering, and steam turbines.

[0092] In a specific example, the technical solution of the present invention is specifically as follows:

[0093] Material: GH4098; blanking specification: Φ200mm×255mm; weight: 67.5kg; category: II Name: fulcrum housing cover plate.

[0094] The dimensional specifications of the special-shaped ring forging B are:

[0095] Outer diameter: Φ285±3mm to Φ300±3mm; inner diameter: Φ220±3mm to Φ240±3mm; height: 145±3mm.

[0096] The specific steps are as follows:

[0097] Step S21: According to the forging size requirements, design the inner tooling A and the outer tooling C. According to the above parameter calculation method, it is calculated that:

[0098] The maximum outer diameter of the inner tooling A: A 外max = 240 - 3 = 237mm; the minimum outer diameter of the inner tooling A: A 外min = 220 - 3 = 217mm; the inner diameter of the inner tooling A is equal to 220 - 100 = 120mm; the tooling height of the inner tooling A: H1 = 145 + 3 = 148mm.

[0099] The maximum inner diameter of the outer tooling C: C 内max= 300 + 3 = 303 mm; The minimum inner diameter of the outer tooling C: C 内min = 285 + 3 = 288 mm; The equivalent outer diameter of the outer tooling C is: 300 + 100 = 400 mm; The tooling height of the outer tooling C: H2 = 145 + 3 = 148 mm.

[0100] Step S22: Design the size of the preform blank;

[0101] The height of the preform blank: H3 = 145 × (1 + 20%) = 174 mm (rounded to 175 mm); The size of the preform blank is: Φ320 × Φ230 × 175 mm.

[0102] Step S23: Heat the raw material to 1120 °C, keep it warm for 160 minutes, and perform preform forging to form the preform blank;

[0103] Step S24: Reheat the preform blank to 1120 °C, keep it warm for 80 minutes, and perform final forming forging using the inner tooling A and the outer tooling C;

[0104] Step S25: Perform sandblasting and grinding inspection after forging;

[0105] Step S26: Perform heat treatment;

[0106] Step S27: Conduct physical and chemical tests and then final inspection and warehousing.

[0107] In summary, a forming method for a special-shaped annular forging with unequal diameters of the upper and lower end faces provided by the present invention solves the problem of forming a special-shaped annular forging with unequal diameters of the upper and lower end faces by designing inner and outer toolings with non-equivalent outer diameters, and avoids the complex toolings of special rolling rollers and rolling wheels in the traditional process. The provided parameter calculation method for the inner and outer toolings is simple and feasible. By considering factors such as the size and weight of the forging, the allowances, strength values, and deviation values are reasonably selected to ensure the applicability and reliability of the tooling design. This method can complete the forming of the special-shaped annular forging using conventional forging equipment, greatly reducing the production cost, shortening the tooling production cycle, and improving the production efficiency. This method is particularly suitable for the forming of special-shaped annular forgings made of high-temperature alloy materials such as GH4098, and has important practical value for the manufacturing of high-temperature components in the fields of aerospace, energy, etc.

[0108] Obviously, those skilled in the art can make various modifications and variations to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention is also intended to include these modifications and variations.

Claims

1. A forming method for a special-shaped annular forging with unequal diameters of the upper and lower end faces, characterized in that, Including: Providing an inner tooling and an outer tooling, where the inner tooling has a non-uniform outer diameter for controlling the shape of the non-uniform inner diameter of the special-shaped ring forging; the outer tooling has a non-uniform outer diameter for controlling the shape of the non-uniform outer diameter of the special-shaped ring forging; Forging a preformed blank using the inner tooling and the outer tooling.

2. The forming method of the special-shaped annular forging according to claim 1, characterized in that, The method for determining the parameters of the inner tooling is: The maximum outer diameter A of the inner tooling 外max =B 内max -△ 余量 ; The minimum outer diameter A of the inner tooling 外min = B 内min - △ 余量 ; The inner diameter equivalent value A of the inner tooling 内径等值 = B 内min - δ; The tooling height H1 of the inner tooling = h + ε; Among them, B 内min is the minimum inner diameter of the special-shaped ring forging, B 内max is the maximum inner diameter of the special-shaped ring forging, △ 余量 is the allowance, δ is the strength value of the inner tooling, h is the height of the special-shaped ring forging, and ε is the deviation value.

3. The method for forming a special-shaped annular forging according to claim 1, wherein, The method for determining the parameters of the outer tooling is: The maximum inner diameter C of the external tooling 内max = B 外max + △ 余量 ; The minimum inner diameter C of the external tooling 内min = B 外min + △ 余量 ; The outer diameter value C of the external tooling 外径等值 = B 外max + δ'; The tooling height H2 of the outer tooling = h + ε; Among them, B 外min is the minimum value of the outer diameter of the special-shaped ring forging, B 外max is the maximum value of the outer diameter of the special-shaped ring forging, △ 余量 is the allowance, δ' is the strength value of the outer tooling, h is the height of the special-shaped ring forging, and ε is the deviation value.

4. The forming method of the special-shaped annular forging according to claim 2 or 3, characterized in that, The allowance is selected according to the maximum outer diameter dimension of the special-shaped ring forging: When the maximum outer diameter dimension of the special-shaped ring forging is not greater than 200 mm, the allowance is 2.5 mm; When the maximum outer diameter dimension of the special-shaped ring forging is greater than 200 mm and not greater than 499 mm, the allowance is 3.0 mm; When the maximum outer diameter dimension of the special-shaped ring forging is greater than 500 mm and not greater than 800 mm, the allowance is 3.5 mm; When the maximum outer diameter dimension of the special-shaped ring forging is greater than 801 mm and not greater than 999 mm, the allowance is 4.0 mm; When the maximum outer diameter dimension of the special-shaped ring forging is greater than 1000 mm, the allowance is 5.0 mm.

5. The method for forming a special-shaped annular forging according to claim 2 or 3, characterized in that, The strength value of the inner tooling and the strength value of the outer tooling are selected according to the weight of the special-shaped ring forging: When the weight of the special-shaped ring forging is not greater than 100 kg, the strength value is not less than 50 mm; When the weight of the special-shaped ring forging is greater than 100 kg and not greater than 300 kg, the strength value is not less than 60 mm; When the weight of the special-shaped ring forging is greater than 300 kg and not greater than 600 kg, the strength value is not less than 80 mm; When the weight of the special-shaped ring forging is greater than 600 kg and not greater than 900 kg, the strength value is not less than 100 mm; When the weight of the special-shaped ring forging is greater than 900 kg, the strength value is not less than 120 mm.

6. The forming method of the special-shaped annular forging according to claim 2 or 3, characterized in that The deviation value ε is selected according to the height of the special-shaped ring forging: When the height of the special-shaped ring forging is not greater than 100 mm, the deviation value is 3 mm; When the height of the special-shaped ring forging is greater than 100 mm and not greater than 200 mm, the deviation value is 4 mm; When the height of the special-shaped ring forging is greater than 200 mm and not greater than 300 mm, the deviation value is 5 mm; When the height of the special-shaped ring forging is greater than 300 mm, the deviation value is 6 mm.

7. The forming method of the special-shaped annular forging according to claim 1, wherein, The height H3 of the preformed blank = h × (1 + x%); Where h is the height of the special-shaped ring forging and x is the deformation amount.

8. The forming method of the special-shaped annular forging according to claim 7, characterized in that The process of forging the preformed blank using the inner tooling and the outer tooling includes: Heating the raw material to the working temperature and performing the first heat preservation, and performing preforming forging to form the preformed blank; Reheating the preformed blank to the working temperature and performing the second heat preservation, and performing final forming forging using the inner tooling and the outer tooling; Performing sand blasting and grinding inspection after forging; Performing heat treatment.

9. The method for forming a special-shaped annular forging according to claim 8, characterized in that, The working temperature is 1080 - 1150 °C, the first heat preservation time is 120 - 200 minutes, and the second heat preservation time is 60 - 100 minutes.

10. The forming method of the special-shaped ring forging according to claim 1, characterized in that, The special-shaped ring forging includes a forging made of GH4098 alloy material.

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