Self-adaptive positioning and upsetting tool system and method for die forging of alloy wheel disc difficult to deform

Abstract

The invention relates to the technical field of alloy material forging, in particular to a self-adaptive positioning upsetting tool system and method for die forging of a difficult-to-deform alloy wheel disc, and the tool system comprises a first tool, a second tool and a third tool; the step type side face (alpha / beta / gamma angle gradual change) of the first tool ensures automatic centering of the bar; circumferential deformation is limited through the delta angle of the second tool, stress concentration is reduced, and metal flowing uniformity is improved; according to the design of the characteristic bodies of the second tool and the third tool, the next procedure positioning reference is directly formed during upsetting, and the second tool and the third tool are automatically matched after being overturned by 180 degrees; the requirements of different wheel disc forgings are met by adjusting tool parameters (angles and characteristic bodies); high-precision, high-efficiency and high-quality production of the difficult-to-deform alloy upsetting process is achieved, meanwhile, the operation difficulty and cost are reduced, and the method is suitable for manufacturing of high-performance wheel disc forgings in the fields of aviation, energy and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of alloy material forging, and particularly to an adaptive positioning upsetting tooling system and method for die forging of difficult-to-deform alloy discs. Background Art

[0002] As a core component between the combustion chamber and the nozzle of an aeroengine, the performance of the turbine disc plays a crucial role in the thrust-to-weight ratio, thermal efficiency, and service life of the aeroengine. With the rapid development of the aerospace industry, the thrust-to-weight ratio of aircraft has increased, and the working temperature of engine components has been continuously rising, which has promoted the research and application of wrought superalloys for turbine discs. To meet the working conditions requirements of aeroengines, the temperature-bearing capacity of wrought superalloys for turbine discs has risen to over 700 °C. In order to improve the service performance of the alloy and meet the high-temperature strength requirements, a large amount of solid solution strengthening elements (W, Mo), γ'-phase forming elements (Al, Ti, Nb), and stacking fault energy reducing elements (Co, Ta) are added to the wrought superalloys for high-performance turbine discs. However, the high degree of alloying not only increases the preparation cost of the alloy but also increases the difficulty of hot deformation and microstructure property control of the alloy. Although powder metallurgy is a way to solve the difficult machining problem in the preparation of advanced turbine discs, considering production efficiency and cost control, the casting and forging process still has outstanding advantages; the upsetting process in the manufacturing of alloy disc die forgings is a key step in forming. Wrought superalloys usually have the characteristics of high alloying, low plasticity, and narrow deformable temperature range. Problems such as upsetting skew, uneven circumferential deformation, and low positioning accuracy between processes are prone to occur in the traditional upsetting process. Summary of the Invention

[0003] The purpose of the present invention is to provide an adaptive positioning upsetting tooling system and method for die forging of difficult-to-deform alloy discs, which realize uniform deformation and automatic positioning between processes through the cooperation of multiple toolings.

[0004] To achieve the above purpose, the present invention adopts the following technical solutions:

[0005] An adaptive positioning upsetting tooling system for die forging of difficult-to-deform alloy discs includes a first tooling, a second tooling, and a third tooling; The first tooling includes a first die holder and a lower cavity opened on the first die holder with an upward opening, which is used for initial positioning and upsetting guidance; the lower cavity includes a bottom surface, and a first toroidal surface, a second toroidal surface, a third toroidal surface and a fourth toroidal surface that are smoothly connected; the diameter of the bottom surface is the initial diameter of the bar stock, and a chamfer is provided between the first toroidal surface and the bottom surface, and the chamfer is the chamfer between the end surface of the bar stock and the toroidal surface; the diameter of the first toroidal surface is equal to the diameter of the bar stock, and the height of the first toroidal surface is 15 - 30 mm; the second toroidal surface, the third toroidal surface and the fourth toroidal surface are all toroidal surfaces inclined outward, the inclination angle α of the second toroidal surface is 1° - 3°, the height of the second toroidal surface is 10 - 20 mm, which stabilizes the deformation in the middle stage of upsetting; the inclination angle β of the third toroidal surface is 3° - 5°, the height of the third toroidal surface is 60 - 90 mm; the inclination angle γ of the fourth toroidal surface is greater than 20°, and the height of the fourth toroidal surface is set according to the disk forging. The second tooling includes a second die holder and an upper cavity opened on the second die holder with a downward opening, which is used for forming the characteristic body and circumferential constraint; the top surface diameter of the upper cavity is 1.1 - 1.2 times the initial diameter of the bar stock, and a characteristic body for providing a positioning reference for the next process is provided in the middle of the top surface; the toroidal surface and the top surface of the upper cavity are smoothly transitioned, and its toroidal surface is an inclined surface inclined outward, and the inclination angle δ is 10° - 15°. The third tooling is a cavity tooling for the disk forging, and a characteristic body identical to that of the second tooling is arranged in its cavity.

[0006] Further, the characteristic body is one of a frustum, a hemisphere, and a trapezoidal cavity.

[0007] The present invention also provides an adaptive positioning upsetting method for a difficult-to-deform alloy disk forging, which includes the following steps: Step 1: Install the first tooling and the second tooling described in claim 1 on the forging equipment, and preheat the forging equipment. Step 2: Heat the alloy bar stock, place the heated bar stock vertically in the first tooling, and then control the second tooling to move towards the first tooling to achieve initial upsetting. Step 3: Rotate the billet after initial upsetting by 180° and place it in the third tooling for the next process.

[0008] Further, the preheating temperature of the forging equipment is the same as the heating temperature of the alloy bar stock, and both are 30 - 50 °C below the β-phase transformation temperature of the alloy.

[0009] The present invention has the following beneficial effects:

[0010] (1) Improve the stability of upsetting process; The stepped side surface (gradual change of α / β / γ angles) of the first tooling ensures automatic centering of the bar stock, avoiding the problem of upsetting skew. The δ angle (10° - 15°) of the second tooling restricts circumferential deformation, reduces stress concentration, and improves the uniformity of metal flow; The tooling guides the forming process, reduces human error, and improves the dimensional consistency of forgings.

[0011] (2) Enhance the efficiency of process connection; The design of the feature bodies of the second tooling and the third tooling (such as hemispherical protrusions, frustum of a cone) directly form the positioning reference for the next process during upsetting. After flipping 180°, it automatically matches with the third tooling, reducing the manual adjustment time.

[0012] (3) Design guide posts / guide holes in the die bases of the first tooling, the second tooling, and the third tooling; Ensure the assembly accuracy of the tooling and improve the process consistency.

[0013] (4) Reduce production costs; Avoid material waste caused by upsetting skew and uneven deformation; Automated positioning reduces the adjustment time between processes and improves the overall efficiency.

[0014] (5) Adapt to a variety of difficult-to-deform alloys (such as In718 superalloy, etc.). By adjusting the tooling parameters (angles, feature bodies), it can meet the requirements of different disk forgings; Achieve high-precision, high-efficiency, and high-quality production of the upsetting process for difficult-to-deform alloys. At the same time, it reduces the operation difficulty and cost, and is applicable to the manufacture of high-performance disk forgings in the fields of aviation, energy, etc. Brief Description of the Drawings

[0015] Figure 1 It is a schematic structural diagram of the first tooling of the present invention.

[0016] Figure 2 It is a schematic structural diagram of the second tooling of the present invention.

[0017] Figure 3 It is a schematic structural diagram of the third tooling of the present invention. Detailed Description of the Invention

[0018] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments.

[0019] Embodiment 1

[0020] An adaptive positioning upsetting tooling system for the die forging of a difficult-to-deform alloy disk disclosed in this embodiment aims to solve problems such as easy upsetting skew, uneven circumferential deformation, and low positioning accuracy between processes in the traditional upsetting process of the prior art.

[0021] Such as Figures 1 to 3As shown in the figure, an adaptive positioning upsetting tooling system for die forging of a difficult-to-deform alloy wheel disc includes a first tooling, a second tooling, and a third tooling.

[0022] As Figure 1 shown, the first tooling includes a first die holder 11 and a lower cavity 12 formed on the first die holder 11 with an upward opening, which is used for initial positioning and upsetting guidance. The lower cavity 12 includes a bottom surface 13, and a first toroidal surface 14, a second toroidal surface 15, a third toroidal surface 16, and a fourth toroidal surface 17 that are smoothly connected; the diameter of the bottom surface 13 is the initial diameter D0 of the bar stock, and there is a chamfer between the first toroidal surface 14 and the bottom surface 13, and the chamfer R is the chamfer between the end face of the bar stock and the toroidal surface. The diameter of the first toroidal surface 13 is equal to the diameter of the bar stock, and the height H1 of the first toroidal surface 13 is 15 - 30 mm. By means of the first toroidal surface 14, the bottom surface 13, and the matching bar stock chamfer R, it is ensured that the bar stock can be placed vertically and plays a role in circumferentially fixing the bar stock, realizing adaptive positioning. The second toroidal surface 15, the third toroidal surface 16, and the fourth toroidal surface 17 are all toroidal surfaces inclined outward. The inclination angle α of the second toroidal surface 15 is 1° - 3°, and the height H2 of the second toroidal surface 15 is 10 - 20 mm, which stabilizes the deformation in the middle stage of upsetting; the inclination angle β of the third toroidal surface 16 is 3° - 5°, and the height H3 of the third toroidal surface 16 is 60 - 90 mm; the inclination angle γ of the fourth toroidal surface 17 is greater than 20°, and the height H4 of the fourth toroidal surface 17 is determined according to the bar stock that needs to be forged and upset actually, and the height H4 is adjusted as required, preferably 100 - 150 mm, which promotes uniform deformation. The inclination angles increase gradually (α = 1° - 3° → β = 3° - 5° → γ > 20°), and the metal flow is controlled in stages.

[0023] As Figure 2 shown, the second tooling includes a second die holder 21 and an upper cavity 22 formed on the second die holder 21 with a downward opening, which is used for forming the feature body and circumferential constraint. The diameter DSO of the top surface 23 of the upper cavity 22 is 1.1 - 1.2 times the initial diameter of the bar stock, which accommodates the radial expansion after upsetting; a feature body 24 is provided in the middle of the top surface 23. The feature body 24 is a frustum of a cone, a hemisphere, a trapezoidal pit, or various other feature bodies convenient for positioning, providing a positioning reference for the next process. The toroidal surface 25 of the upper cavity 22 is smoothly transitioned with the top surface 23 part, and its toroidal surface 25 is an inclined surface inclined outward, and the inclination angle δ is 10° - 15°; restricting the circumferential deformation in the later stage of upsetting.

[0024] The third tooling is the cavity tooling for the wheel disc forging. In this embodiment, the cavity tooling of the existing wheel disc forging is improved by providing a feature body 31 on its bottom surface that is the same as the one on the second tooling, realizing adaptive positioning after flipping. Other feature shapes are designed according to the product features.

[0025] The die bases of the first tooling, the second tooling, and the third tooling are all provided with guide holes and guide columns that facilitate positioning and installation on the forging press, enabling precise positioning and installation, ensuring the centering during the upsetting of the bar stock and the consistency of the manufacturing process.

[0026] By changing different design parameters in the first tooling and the second tooling and the feature bodies in the second tooling, billets with various shapes are obtained. After the billet is rotated 180 degrees up and down, it is self-adaptively positioned with the third tooling. The overall forming process is ensured by the tooling, reducing the operation difficulty, having good control over production consistency, improving the production efficiency of the disk, and reducing the production cost.

[0027] Example 2

[0028] An adaptive positioning upsetting method for die forging of a difficult-to-deform alloy disk disclosed in this example is realized by using the tooling system provided in Example 1, and specifically includes the following steps: Step 1: Assemble the first tooling and the second tooling on the upper and lower anvil surfaces of the isothermal forging equipment through the guide columns and guide holes; Step 2: Design the upsetting temperature according to the alloy bar stock, and then preheat it to the forging equipment by setting the isothermal forging equipment. At the same time, the first tooling and the second tooling are heated to the same temperature; at the same time, the bar stock is also heated to the upsetting temperature.

[0029] The upsetting temperature is heated to 30 - 50° below the β-phase transformation temperature of the alloy material.

[0030] Step 3: Place the heated bar stock in the lower cavity 12 of the first tooling, and then the isothermal forging equipment controls the second tooling to move towards the first tooling for primary upsetting to obtain an initial billet; Step 4: Rotate the billet 180 degrees up and down and place it in the third tooling. The billet and the third tooling are self-adaptively positioned through the feature body 31, and disk die forgings with various shapes are obtained under the action of different toolings or dies.

[0031] Example 3

[0032] Taking a certain In718 superalloy disk die forging as an example for a specific embodiment.

[0033] The parameters of the first tooling are D0 = 420mm, R = 20mm, α = 1°, β = 3°, γ = 35°, H1 = 20mm, H2 = 10mm, H3 = 70mm, H4 = 130, and the adjacent surfaces are smoothly transitioned with R50.

[0034] The parameters of the second tooling are DS0 = 500mm, δ = 15°, HS1 = 350mm, and the feature body 24 is a convex hemisphere with a radius of 150mm, and the center of the circle overlaps with the DS0 surface.

[0035] The third tooling is internally designed with a feature body 31 having the same parameters as the second tooling.

[0036] Heat an In718 bar stock with dimensions of φ400×1300 mm to 1000 - 1020 °C; transfer the heated bar stock into the lower cavity of the first tooling within 160 seconds, place it vertically, and stop when the second tooling moves towards the first tooling under the action of a forging equipment until the height between the upper and lower planes of the blank reaches 650 mm to obtain a upset blank.

[0037] Place the upset blank in subsequent toolings for pre-forging and finish-forging to finally obtain a final form disk forging.

[0038] As described above, it is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, makes equivalent substitutions or changes, and should be covered within the protection scope of the present invention.

Claims

1. An adaptive positioning upsetting tooling system for die forging of a difficult-to-deform alloy wheel disc, characterized in that, It includes a first tooling, a second tooling, and a third tooling; The first tooling includes a first die base and a lower cavity opened on the first die base with an upward opening, which is used for initial positioning and upsetting guidance; the lower cavity includes a bottom surface, and a first annular surface, a second annular surface, a third annular surface, and a fourth annular surface that are smoothly connected; the diameter of the bottom surface is the initial diameter of the bar stock, and a chamfer is provided between the first annular surface and the bottom surface, and the chamfer is the chamfer between the end surface of the bar stock and the annular surface; the diameter of the first annular surface is equal to the diameter of the bar stock, and the height of the first annular surface is 15 - 30 mm; the second annular surface, the third annular surface, and the fourth annular surface are all annular surfaces inclined outward, the inclination angle α of the second annular surface is 1° - 3°, the height of the second annular surface is 10 - 20 mm, to stabilize the middle-stage deformation of upsetting; the inclination angle β of the third annular surface is 3° - 5°, the height of the third annular surface is 60 - 90 mm; the inclination angle γ of the fourth annular surface is greater than 20°, and the height of the fourth annular surface is set according to the disk forging; The second tooling includes a second die base and an upper cavity opened on the second die base with a downward opening, which is used for forming the feature shape and circumferential constraint; the top surface diameter of the upper cavity is 1.1 - 1.2 times the initial diameter of the bar stock, and a feature body for providing a positioning reference for the next process is provided in the middle of the top surface; the annular surface and the top surface of the upper cavity are smoothly transitioned, and its annular surface is an inclined surface inclined outward, and the inclination angle δ is 10° - 15°; The third tooling is a cavity tooling for the disk forging, and a feature body identical to that of the second tooling is provided in its cavity.

2. The self-adaptive positioning upsetting tooling system for die forging of a difficult-to-deform alloy wheel disc according to claim 1, wherein The feature body is one of a frustum, a hemisphere, and a trapezoidal cavity.

3. The self-adaptive positioning upsetting tooling system for die forging of a difficult-to-deform alloy wheel disc according to claim 1, wherein Guide holes and guide posts for facilitating positioning and installation on the forging press are provided on the die bases of the first tooling, the second tooling, and the third tooling.

4. An adaptive positioning upsetting method for die forging of a difficult-to-deform alloy disk, characterized in that, It includes the following steps: Step 1: Install the first tooling and the second tooling described in claim 1 on the forging equipment, and preheat the forging equipment; Step 2: Heat the alloy bar stock, place the heated bar stock vertically in the first tooling, and then control the second tooling to move towards the first tooling to achieve initial upsetting; Step 3: Rotate the initially upset blank by 180° and place it in the third tooling for the next process.

5. An adaptive positioning upsetting method for die forging of a difficult-to-deform alloy wheel disc according to claim 4, characterized in that The preheating temperature of the forging equipment is the same as the heating temperature of the alloy bar stock, both of which are 30 - 50 °C below the β-phase transformation temperature of the alloy.

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