A die design method capable of regulating strain and filling of high package forgings

Abstract

This invention relates to a die design method for controlling the strain and filling of high-lumen forgings, belonging to the field of forging die design technology. The method includes: using full-process numerical simulation technology to simulate and analyze the forging process, determining the height and diameter of the blank (L1 and h1); designing the lower die and its cavity based on the forging contour (h2); designing the upper die and its deep cavity based on the high-lumen forging (H, α, R, and L2 < L1); obtaining the upper die's downward pressure t during forging, where t = h1 - h2; comparing the relationship between H and 0.68t to obtain the comparison result; and determining the values ​​of α and R based on the comparison result. This method controls the strain of the high-lumen forging during forging by adjusting the height of the blank, ensuring complete filling of the deep cavity.

Description

Technical Field

[0001] This invention belongs to the field of forging die design technology, and specifically relates to a die design method that can control the strain and filling of high-end forgings. Background Technology

[0002] The filling performance of forgings is influenced by both the material and the design limitations. For high-waisted and high-rib forgings, material filling is more difficult, and local areas of the forging are prone to missing material during the forging process. Therefore, to ensure the dimensional requirements of the forgings, it is particularly important to design a reasonable forging shape. By selecting a reasonable forging morphology and billet height, the optimal filling conditions can be obtained. In addition, the amount of deformation must be taken into account, while also adhering to the principle of material saving, reducing the design allowance of the forging, and improving the material utilization rate.

[0003] Currently, to ensure proper filling of difficult-to-fill areas, the method used is to increase the allowance in these areas to guarantee filling. However, when the allowance size does not match the filling method, uneven strain occurs, leading to mixed grains or obvious demarcation in the microstructure of the forging, severely affecting its mechanical properties. Existing technology lacks mold design methods that can control the strain and filling of high-end forgings. Instead, different design parameters must be continuously verified using numerical simulation software in the early stages of forging design, significantly impacting design efficiency. Incorrect design directions result in undesirable forging morphologies, necessitating more complex forming methods to mitigate or eliminate difficult-to-fill areas, further increasing the demands on forging equipment.

[0004] Therefore, a mold design method that can ensure full filling of high-grade forgings while also ensuring more uniform strain during the forging process is urgently needed. Summary of the Invention

[0005] This invention provides a mold design method that can control the strain and filling of high-laden forgings, which solves the technical problems that current mold design methods for high-laden forgings cannot simultaneously take into account the principles of material saving, the fullness of the high-laden filling of the forging, and the uniformity of strain during forging.

[0006] This invention is achieved through the following technical solution: a mold design method capable of controlling the strain and filling of high-bundle forgings, comprising:

[0007] The forging process is simulated and analyzed using full-process numerical simulation technology to determine the height and diameter of the blank, wherein the diameter of the blank is L1 and the height of the blank is h1.

[0008] The lower die and its cavity are designed according to the forging profile, and the depth of the cavity is h2;

[0009] The upper die and the deep cavity of the upper die are designed according to the high ladle design on the forging. The depth of the deep cavity is H, the draft angle of the deep cavity is α, the fillet radius at the opening of the deep cavity is R, and the opening diameter of the deep cavity is L2, where L2 < L1.

[0010] Obtain the amount of downward pressure t of the upper die during the forging process, where t = h1 - h2;

[0011] Compare the magnitudes of H and 0.68t to obtain the comparison results;

[0012] The values ​​of α and R are determined based on the comparison results.

[0013] Furthermore, to better implement the present invention, determining the range of values ​​for α and R based on the comparison results includes:

[0014] When the depth H of the deep cavity is equal to 0.68t, the draft angle α of the deep cavity is greater than or equal to 5° and less than or equal to 20°, and the fillet radius R at the opening of the deep cavity is greater than or equal to 30mm and less than or equal to 80mm.

[0015] Furthermore, in order to better realize the present invention, when the depth H of the deep cavity is equal to 0.68t, the draft angle α of the deep cavity is 5°, and the fillet radius R at the opening of the deep cavity is 30mm.

[0016] Furthermore, to better implement the present invention, determining the range of values ​​for α and R based on the comparison results includes:

[0017] When the depth H of the deep cavity is greater than 0.68t, the draft angle α of the deep cavity is greater than or equal to 8° and less than or equal to 25°, and the fillet radius R at the opening of the deep cavity is greater than or equal to 45mm and less than or equal to 90mm.

[0018] Furthermore, in order to better realize the present invention, when the depth H of the deep cavity is greater than 0.68t, the draft angle α of the deep cavity is 8°, and the fillet radius R at the opening of the deep cavity is 45mm.

[0019] Furthermore, to better implement the present invention, determining the range of values ​​for α and R based on the comparison results includes:

[0020] When the depth H of the deep cavity is less than 0.68t, the draft angle α of the deep cavity is greater than or equal to 3° and less than or equal to 15°, and the fillet radius R at the opening of the deep cavity is greater than or equal to 25mm and less than or equal to 70mm.

[0021] Furthermore, in order to better realize the present invention, when the depth of the deep cavity is less than 0.68t, the draft angle α of the deep cavity is 3°, and the fillet radius R at the opening of the deep cavity is 25mm.

[0022] Compared with the prior art, the present invention has the following advantages:

[0023] The mold design method provided by this invention, which can regulate the strain and filling of high-end forgings, compares the deep cavity H of the upper mold with 0.68 times the downward pressure t of the upper mold during forging. Based on the comparison result, the draft angle α of the deep cavity of the upper mold and the radius R of the fillet at the opening of the deep cavity are determined. The deep cavity of the upper mold designed in this way can ensure that the forging material is completely filled in the deep cavity during forging. When H=0.68t, the strain distribution in different regions of the forging is more uniform during forging. If the high-end structure of the forging is complex and requires a large strain, then H>0.68t; if the high-end structure of the forging requires a small strain, then H<0.68t.

[0024] The above design method allows for the control of strain in the ladle during forging by adjusting the height of the blank. It also ensures complete material filling within the deep cavity of the upper die, thereby improving material utilization and saving material. This significantly reduces the likelihood of incomplete filling and material loss. Furthermore, this method provides deep cavity design guidelines for high-ladle forgings, reducing the complexity of die design for such forgings. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure during forging;

[0027] Figure 2 This is a flowchart of a mold design method for controlling the strain and filling of high-strength forgings provided in an embodiment of the present invention.

[0028] In the picture:

[0029] 100 - Dough blank, 200 - Lower mold, 300 - Upper mold, 310 - Deep cavity. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0031] Example:

[0032] This embodiment provides a mold design method that can control the strain and filling of high-strength forgings, such as... Figure 1 and Figure 2 As shown, it includes the following steps:

[0033] Step 1: Using full-process numerical simulation technology, the forging process is simulated and analyzed to determine the height and diameter of the blank 100, wherein the diameter of the blank 100 is L1 and the height of the blank 100 is h1.

[0034] Step 2: Design the lower die 200 and its cavity according to the forging contour, wherein the depth of the cavity is h2;

[0035] Step 3: Based on the high-profile design of the forging, design the upper die 300 and its deep cavity 310. The depth of the deep cavity 310 is H, the draft angle of the deep cavity 310 is α, the fillet radius at the opening of the deep cavity 310 is R, and the opening diameter of the deep cavity 310 is L2, where L2 < L1. The opening diameter L2 of the deep cavity 310 is smaller than the diameter L1 of the blank 100, which ensures that the forging material flows into the deep cavity 310 through reverse extrusion, significantly reducing the deformation dead zone.

[0036] Step 4: Obtain the upper die pressing amount t during the forging process, where t = h1 - h2. It should be noted that the upper die pressing amount refers to the stroke of the upper die 300 during the forging process, from pressing down to fitting against the blank 100 to closing with the lower die 200. Specifically, as shown below... Figure 1 As shown.

[0037] Step 5: Compare the magnitudes of H and 0.68t to obtain the comparison results;

[0038] Step 6: Determine the values ​​of α and R based on the comparison results.

[0039] Step 6 above specifically refers to:

[0040] When the depth H of the deep cavity 310 is equal to 0.68t, the draft angle α of the deep cavity 310 ranges from greater than or equal to 5° to less than or equal to 20°, and the fillet radius R at the opening of the deep cavity 310 ranges from greater than or equal to 30mm to less than or equal to 80mm. That is, when H = 0.68t, 5° ≤ α ≤ 20°, 30mm ≤ R ≤ 80mm. Ideally, when H = 0.68t, the draft angle α of the deep cavity 310 is 5°, and the fillet radius R at the opening of the deep cavity 310 is 30mm; in this case, material utilization is considered. Of course, when H = 0.68t, the draft angle α of the deep cavity 310 can also be 10° or 20°, and the fillet radius R at the opening of the deep cavity 310 can also be 50mm or 80mm.

[0041] When the depth H of the deep cavity 310 is greater than 0.68t, the draft angle α of the deep cavity 310 ranges from greater than or equal to 8° to less than or equal to 25°, and the fillet radius R at the opening of the deep cavity 310 ranges from greater than or equal to 45mm to less than or equal to 90mm. That is, when H > 0.68t, the difficulty of material filling into the deep cavity 310 is extremely high. Therefore, the values ​​of α and R are designed to be larger, specifically, 8° ≤ α ≤ 25°, and 45mm ≤ R ≤ 90mm. Ideally, when H > 0.68t, the draft angle α of the deep cavity 310 is 8°, and the fillet radius R at the opening of the deep cavity 310 is 45mm. In this case, material utilization is considered. Of course, when H > 0.68t, the draft angle α of the deep cavity 310 can also be 15° or 25°, and the fillet radius R at the opening of the deep cavity 310 can also be 75mm or 90mm.

[0042] When the depth H of the deep cavity 310 is less than 0.68t, the draft angle α of the deep cavity 310 ranges from 3° to 15°, and the fillet radius R at the opening of the deep cavity 310 ranges from 25mm to 70mm. That is, when H < 0.68t, the material is easier to fill into the deep cavity 310. Therefore, the values ​​of α and R are designed to be smaller, specifically 3° ≤ α ≤ 15° and 25mm ≤ R ≤ 70mm. Ideally, when H < 0.68t, the draft angle α of the deep cavity 310 is 3°, and the fillet radius R at the opening of the deep cavity 310 is 25mm. In this case, material utilization is considered. Of course, when H < 0.68t, the draft angle α of the deep cavity 310 can also be 8° or 15°, and the fillet radius R at the opening of the deep cavity 310 can also be 35mm or 70mm.

[0043] In addition, during the forging process, it is necessary to ensure that the forging has good lubrication conditions. If the forging does not have good lubrication conditions during the forging process, the values ​​of α and R should be designed to be larger in the corresponding case to reduce the probability that the material cannot be fully filled in the deep cavity 310.

[0044] The above design method allows for the control of strain on the ladle during forging by adjusting the height of the blank 100. It also ensures that the material can be fully filled into the cavity of the upper die 300 during forging, thereby improving material utilization and saving material. This significantly reduces the likelihood of material shortages due to incomplete filling. Furthermore, this design method provides a deep cavity design guideline (310) for ladle-type forgings, reducing the difficulty of mold design for such forgings.

[0045] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope described in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A mold design method for controlling the strain and filling of high-strength forgings, characterized in that, include: The forging process is simulated and analyzed using full-process numerical simulation technology to determine the height and diameter of the blank (100), wherein the diameter of the blank (100) is L1 and the height of the blank (100) is h1. The lower die (200) and its cavity are designed according to the forging profile, and the depth of the cavity is h2; Based on the high-profile design of the forging, the upper die (300) and the deep cavity (310) of the upper die (300) are designed. The depth of the deep cavity (310) is H, the draft angle of the deep cavity (310) is α, the fillet radius at the opening of the deep cavity (310) is R, and the opening diameter of the deep cavity (310) is L2, where L2 < L1; Obtain the amount of downward pressure t of the upper die during the forging process, where t = h1 - h2; Compare the magnitudes of H and 0.68t to obtain the comparison results; When H=0.68t, 5°≤α≤20°, 30mm≤R≤80mm; When H > 0.68t, 8° ≤ α ≤ 25°, 45mm ≤ R ≤ 90mm; When H < 0.68t, 3° ≤ α ≤ 15°, 25mm ≤ R ≤ 70mm.

2. The mold design method for controlling the strain and filling of high-strength forgings according to claim 1, characterized in that: When the depth H of the deep cavity (310) is equal to 0.68t, the draft angle α of the deep cavity (310) is 5°, and the fillet radius R at the opening of the deep cavity (310) is 30mm.

3. The mold design method for controlling the strain and filling of high-strength forgings according to claim 1, characterized in that: When the depth H of the deep cavity (310) is greater than 0.68t, the draft angle α of the deep cavity (310) is 8°, and the fillet radius R at the opening of the deep cavity (310) is 45mm.

4. The mold design method for controlling the strain and filling of high-strength forgings according to claim 1, characterized in that: When the depth of the deep cavity (310) is less than 0.68t, the draft angle α of the deep cavity (310) is 3°, and the fillet radius R at the opening of the deep cavity (310) is 25mm.

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