Bulging tool, bulging device and bulging method for oversized ring forgings

Abstract

The invention relates to the technical field of forming of ring forgings, and discloses a bulging tool, a bulging device and a bulging method for oversized ring forgings. The bulging tool comprises a plurality of fan-shaped dies, each fan-shaped die comprises an arc-shaped inner die block, a supporting rod and an arc-shaped outer die block, the side face of each arc-shaped inner die block is provided with a first inner diameter face and a first outer diameter face which are opposite, and the side face of each arc-shaped outer die block is provided with a second inner diameter face and a second outer diameter face which are opposite. The supporting rod is connected between the first outer diameter surface and the second inner diameter surface, and the second outer diameter surface is matched with the inner diameter surface of the ring forging; during use, a plurality of fan-shaped molds are combined in the circumferential direction to form an annular structure. By the adoption of the bulging tool, the forming size range can be effectively widened, the original maximum forming size of bulging machine equipment is broken through, the problem that an existing bulging machine cannot meet the forming requirement of the oversized ring forgings can be solved, the universality of the bulging machine to the oversized ring forgings is greatly improved, and the bulging tool is large in forming size range, high in adaptability and high in production efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ring forging forming, in particular to a bulging tool, a bulging device and a bulging method for super-large ring forgings. BACKGROUND

[0002] Large ring forgings are mainly used in important fields such as aerospace, wind power and nuclear power industry. Ring forgings are manufactured through upsetting, punching and ring rolling processes. Due to the large diameter and thin wall of the ring forgings, defects such as ovality, size difference, and uneven wall thickness may occur during the forming process, which makes it necessary to increase the design allowance of the ring forgings during actual production, reduces the material utilization rate, and increases the machining allowance and difficulty. Therefore, a sizing process such as bulging is often required after forming.

[0003] The existing bulging method for ring forgings is to use a bulging machine to bulge the ring forgings. The bulging machine usually adopts two kinds of bulging die structures: one is a whole pyramid bulging die which directly contacts with the inner diameter of the ring forging to achieve bulging; the other is a split bulging die composed of multiple sector blocks. However, these methods have the following disadvantages: (1) High die cost and long customization cycle: whether it is a whole die or a split die, it needs to be specially designed and manufactured according to the size and shape of the ring forging, resulting in high die cost and long production preparation cycle, which is difficult to meet the needs of multi-specification and small-batch production.

[0004] (2) Limited forming capacity of equipment: the forming range of the existing bulging machine is limited by the structure and tonnage of the equipment, especially for super-large diameter ring forgings such as those with a diameter greater than 3000mm. The existing split bulging die cannot provide sufficient radial expansion force or uniform deformation control, which may lead to insufficient forming precision or equipment overload.

[0005] (3) Poor process flexibility: a single die structure cannot meet the processing needs of different specifications of ring forgings. When changing products, the die needs to be redesigned, further increasing the production cost and management complexity.

[0006] For the bulging of super-large size ring forgings, special dies need to be customized, which is costly and has a long production cycle. The existing bulging machine is limited by the forming range of the equipment and cannot meet the forming needs of super-large size ring forgings. Therefore, it is urgent to develop a bulging process and device with high adaptability for super-large size ring forgings. SUMMARY

[0007] The present application aims to solve the problem that the existing bulging machine is limited by the forming range of the equipment and cannot meet the forming needs of super-large size ring forgings, and provides a bulging tool, a bulging device and a bulging method for super-large size ring forgings.

[0008] In a first aspect, the present invention provides a forming fixture for ultra-large ring forgings, the forming fixture comprising multiple fan-shaped molds, each fan-shaped mold comprising an arc-shaped inner module, a support rod, and an arc-shaped outer module. The arc-shaped inner module has opposing first inner diameter surfaces and first outer diameter surfaces on its side surface, and the arc-shaped outer module has opposing second inner diameter surfaces and second outer diameter surfaces on its side surface. The support rod connects the first outer diameter surface and the second inner diameter surface, the second outer diameter surface matching the inner diameter surface of the ring forging. In use, the multiple fan-shaped molds are combined along the circumferential direction to form a ring structure.

[0009] In the above technical solution, the forming fixture consists of multiple fan-shaped molds. Each fan-shaped mold includes an arc-shaped inner module, a support rod, and an arc-shaped outer module. The first inner diameter surface is matched and connected with the existing forming machine, and the second outer diameter surface is matched with the inner diameter surface of the ring forging for fitting the inner diameter of the ring forging. By combining multiple fan-shaped molds to form a ring structure, the forming fixture is set on the existing forming machine. The formed ring structure can move towards / away from the ring forging simultaneously under the drive of the existing forming machine to form the ring forging, breaking through the forming size limitation of the existing forming machine and being able to process ultra-large ring forgings with a diameter of φ4000mm or more.

[0010] Through the above technical solution, compared with the traditional integral mold, the bulging tooling of the present invention is composed of multiple fan-shaped molds. The segmented design reduces the amount of material used and the mold manufacturing cost. Moreover, when the fan-shaped molds are used in general bulging, they save more mold costs than the fan-shaped blocks of traditional bulging molds. By using the bulging tooling of the present invention, the forming size range can be effectively improved, breaking through the original maximum forming size of the bulging machine equipment. It can solve the problem that the existing bulging machine cannot meet the forming requirements of ultra-large ring forgings, greatly improving the versatility of the bulging machine for ultra-large ring forgings. It has the advantages of a large forming size range, strong adaptability, high production efficiency and reduced costs.

[0011] Preferably, the multiple fan-shaped molds can be the same or different.

[0012] Preferably, the inner arc-shaped module, the support rod, and the outer arc-shaped module are an integral structure, and the connection between the support rod and the inner arc-shaped module or the outer arc-shaped module is a welded connection. In the above technical solution, the inner arc-shaped module, the support rod, and the outer arc-shaped module are integrated into a single structure through welding, which enhances the overall rigidity of the fan-shaped mold, reduces assembly steps, lowers processing complexity, and is suitable for high-load conditions, such as high-temperature expansion forming.

[0013] Preferably, the support rod is detachably connected to the arc-shaped inner module and / or the arc-shaped outer module. When the support rod is detachably connected to the arc-shaped inner module, a first placement groove is provided on the first outer diameter surface, and the end of the support rod away from the arc-shaped outer module is located in the first placement groove. When the support rod is detachably connected to the arc-shaped inner module, a second placement groove is provided on the second inner diameter surface, and the end of the support rod away from the arc-shaped inner module is located in the second placement groove. For the detachable connection between the support rod and the arc-shaped inner module or the arc-shaped outer module, the arc-shaped inner module and the support rod are general-purpose tooling, while the arc-shaped outer module is a special tooling designed according to the size and shape of the ring forging. For ring forgings of different sizes and cross-sections, the arc-shaped outer module can be replaced, making it more versatile. Only a partial module needs to be replaced instead of the entire mold, further reducing costs.

[0014] Preferably, the radial dimension of the first placement groove is D + (5~8) mm, and the radial dimension of the second placement groove is D + (5~8) mm, where D is the radial dimension of the support rod in mm. By limiting these parameters, an assembly clearance is provided to prevent jamming.

[0015] Preferably, the effective depth of the first placement groove is 15~45mm, and the effective depth of the second placement groove is 15~45mm.

[0016] Preferably, the outline of the first inner diameter surface in the cross-section parallel to the radial direction of the ring forging is a first arc, and the outline of the first outer diameter surface in the cross-section parallel to the radial direction of the ring forging is a second arc. The central angle corresponding to the second arc is θ, and the diameter range of the support rod is 0.3 Asin. ~ 0.8Asin , where A is the diameter of the second arc.

[0017] Preferably, the length of the support rod is 2D to 8D, where D is the radial dimension of the support rod in mm.

[0018] Preferably, the number of sector-shaped molds is 12 to 18. Balancing roundness accuracy and assembly efficiency, the bulging fixture consists of 12 to 18 sector-shaped molds, evenly distributed along the circumference to form a ring structure, which can distribute the bulging force evenly and extend the equipment's lifespan.

[0019] Preferably, the gap between the fan-shaped molds is 2~5mm.

[0020] Preferably, the support rod is a hydraulically retractable support rod. The length of the hydraulic support rod is adjusted in real time according to the inner diameter of the ring forging, achieving "one mold for multiple uses" and reducing the frequency of mold replacement.

[0021] Preferably, the fan-shaped mold is made of forged alloy steel.

[0022] In a second aspect, the present invention provides an bulging device for ultra-large size ring forgings, the bulging device comprising the aforementioned bulging fixture for ultra-large size ring forgings.

[0023] Preferably, the forming device further includes a worktable, a forming pyramid, a drive mechanism, and multiple forming sliders; The workbench is provided with clearance holes, the bulging pyramid is vertically arranged above the workbench, the drive mechanism is arranged below the workbench, the bulging pyramid is connected to the drive mechanism, and the upper surface of the workbench is provided with multiple slide rails in the radial direction, and the bulging slider is slidably connected to the slide rails. The outer side of the bulging pyramid is fitted with a plurality of bulging sliders, and the outer side of the bulging sliders is fitted with the bulging tooling. The fan-shaped mold is slidably mounted on the slide rail.

[0024] Preferably, the number of the bulging sliders is equal to the number of the inclined surfaces of the bulging pyramid, and the inclined surface of each bulging slider is in contact with one inclined surface of the bulging pyramid. The number of the fan-shaped molds is the same as the number of the bulging sliders, and each bulging slider is equipped with one fan-shaped mold. Each fan-shaped mold is set on a single slide rail in the radial direction.

[0025] In a third aspect, the present invention provides a bulging method for ultra-large size ring forgings, using the aforementioned bulging apparatus for ultra-large size ring forgings, comprising the following steps: S1: The ring forging to be expanded is placed on the outside of the fan-shaped mold. When the driving mechanism drives the expanding pyramid to move downward, it pushes the expanding slider to move outward through its inclined surface, thereby pushing the fan-shaped mold to move outward, applying an expanding force to the inner wall of the ring forging to be expanded, and realizing the expansion of the ring forging. S2: After the bulging is completed, the driving mechanism drives the bulging pyramid to move upward, the thrust of the bulging pyramid on the bulging slider disappears, the fan-shaped mold moves towards the center of the worktable, and the bulged ring forging is taken out.

[0026] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention provides a forming fixture for ultra-large ring forgings. The forming fixture consists of multiple fan-shaped molds. Each fan-shaped mold includes an arc-shaped inner module, a support rod, and an arc-shaped outer module. The first inner diameter surface is matched and connected to an existing forming machine, and the second outer diameter surface is matched to the inner diameter surface of the ring forging. By combining multiple fan-shaped molds to form a ring structure, the forming fixture is set on an existing forming machine. The formed ring structure can synchronously approach / move away from the ring forging under the drive of the existing forming machine to form the ring forging. The forming fixture of this invention breaks through the forming size limitation of existing forming machines and can handle ultra-large ring forgings with a diameter of φ4000mm or more.

[0027] 2. This invention provides a forming fixture for ultra-large ring forgings, solving the problem that existing forming machines cannot meet the processing requirements of ultra-large ring forgings, improving the versatility of forming machines for ring forgings of different sizes, and featuring a wide range of forming sizes, strong adaptability, high production efficiency, and reduced costs. Compared with traditional integral molds, the forming fixture of this invention is composed of multiple fan-shaped molds. The segmented design reduces material usage and mold manufacturing costs. Furthermore, the fan-shaped molds are more cost-effective than the fan-shaped blocks of traditional forming molds when applied to general forming.

[0028] 3. This invention provides a forming device for ultra-large ring forgings. The forming fixture can effectively increase the forming size range, break through the original maximum forming size of the forming machine, and solve the problem that the existing forming machine cannot meet the forming requirements of ultra-large ring forgings, thus greatly improving the versatility of the forming machine for ultra-large ring forgings.

[0029] 4. This invention provides a method for bulging ultra-large ring forgings. The method uses a bulging device to bulge the ring forging. The material is transferred horizontally to the ring forging through a fan-shaped mold, thereby achieving the effect of bulging the ring forging. The resulting ring forging has uniform wall thickness, good roundness of inner and outer diameters, and flat end face. This invention can be used for bulging processing of ultra-large ring forgings. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of a structural tooling for forming ultra-large ring forgings according to the present invention; Figure 2 This is a three-dimensional assembly diagram of the fan-shaped mold in this invention; Figure 3 This is a three-dimensional structural diagram of the fan-shaped mold in this invention; Figure 4 This is a schematic diagram of the dimensions of the fan-shaped mold in this invention; Figure 5 This is a schematic diagram of a structural device for forming ultra-large ring forgings according to the present invention. Figure 6 This is a schematic diagram of the ring forging structure in Example 3; Figure 7 This is a schematic diagram of the bulging shape in Example 3; Marked in the image: 1-Ring forging, 2-Fan-shaped mold, 21-Arc-shaped inner module, 211-First inner diameter surface, 212-First outer diameter surface, 213-First placement groove, 22-Support rod, 23-Arc-shaped outer module, 231-Second inner diameter surface, 232-Second outer diameter surface, 233-Second placement groove, 3-Workbench, 4-Expanded pyramid, 5-Expanded slider, 6-Slide rail. Detailed Implementation

[0031] The present invention will now be described in further detail with reference to specific embodiments. However, this should not be construed as limiting the scope of the present invention to the following embodiments; all technologies implemented based on the content of the present invention fall within the scope of the present invention.

[0032] Unless otherwise specified, the use of terms such as "upper," "lower," "left," "right," "center," "inner," and "outer" to indicate orientation or positional relationships in the description of specific embodiments of the present invention is based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationship in which the product / equipment / device is typically placed during use. These terms are merely for the purpose of facilitating the description of the present invention or simplifying the description in specific embodiments, enabling those skilled in the art to quickly understand the solution, and do not indicate or imply that a particular device / component / element must have a specific orientation, or be constructed and operated in a specific positional relationship. Therefore, they should not be construed as limitations on the present invention.

[0033] Furthermore, the use of terms such as "horizontal," "vertical," "suspended," "parallel," and "coaxial" does not imply that the corresponding device / component / element must be absolutely horizontal, vertical, suspended, parallel, or coaxial. Slight tilt or deviation is permissible, as long as it does not affect the normal function of the relevant component. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," not that the structure must be perfectly horizontal; a slight tilt is acceptable. "Coaxial" means that two components are set as coaxially as possible, allowing them to move coaxially or approximately coaxially when their relative positions change. Alternatively, it can be simplified to mean that the corresponding device / component / element, when set in a "horizontal," "vertical," "suspended," "parallel," or "coaxial" direction, can have an error / deviation of ±10% relative to the corresponding direction, more preferably within ±8%, more preferably within ±6%, more preferably within ±5%, and more preferably within ±4%. For example, the deviation in the "coaxial" direction is controlled within 0.2-1mm, preferably within 0.2-0.5mm. As long as the corresponding device / component / element is within the error / deviation range, it can still achieve its function in the solution of the present invention.

[0034] Furthermore, the use of terms such as "first," "second," and "third" in terminology is merely for distinguishing descriptions of identical or similar components and should not be interpreted as emphasizing or implying the relative importance of a particular component.

[0035] Furthermore, in the description of the embodiments of the present invention, "several", "more than", and "a number of" represent at least two. The number can be any number, such as 2, 3, 4, 5, 6, 7, 8, or 9, and can even exceed nine.

[0036] Furthermore, in the description of the technical solution of this invention, unless otherwise explicitly specified / limited / restricted, the terms "set up," "install," "connect," "link," "provided with," "laid out," and "arranged" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to common connection methods in the art, such as welding, riveting, bolting, and threaded connections. Such connections can be mechanical, electrical, or communication connections; they can be direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components.

[0037] Example 1 like Figure 1 As shown, this embodiment provides a forming fixture for ultra-large ring forgings. The forming fixture includes multiple fan-shaped molds 2. Each fan-shaped mold 2 includes an arc-shaped inner module 21, a support rod 22, and an arc-shaped outer module 23. The side of the arc-shaped inner module 21 is provided with a first inner diameter surface 211 and a first outer diameter surface 212, and the side of the arc-shaped outer module 23 is provided with a second inner diameter surface 231 and a second outer diameter surface 232, respectively. The support rod 22 connects the first outer diameter surface 212 and the second inner diameter surface 231, and the second outer diameter surface 232 matches the inner diameter surface of the ring forging 1. In use, multiple fan-shaped molds 2 are combined along the circumferential direction to form a ring structure.

[0038] In some embodiments, multiple sector molds 2 are identical, and the arc-shaped inner module 21, support rod 22, and arc-shaped outer module 23 of each sector mold 2 are integral structures. The connection between the support rod 22 and the arc-shaped inner module 21 or arc-shaped outer module 23 is a welded connection. In the above technical solution, the arc-shaped inner module 21, support rod 22, and arc-shaped outer module 23 are integrally structured by welding, which enhances the overall rigidity of the sector mold 2, reduces the assembly steps of the bulging tooling before bulging, reduces the complexity of the bulging tooling processing, and is suitable for high-load conditions, such as high-temperature bulging.

[0039] In other embodiments, the support rod 22 is detachably connected to the arc-shaped inner module 21 and / or the arc-shaped outer module 23; when the support rod 22 is detachably connected to the arc-shaped inner module 21, a first placement groove 213 is provided on the first outer diameter surface 212, and the end of the support rod 22 away from the arc-shaped outer module 23 is located in the first placement groove 213; when the support rod 22 is detachably connected to the arc-shaped inner module 21, a second placement groove 233 is provided on the second inner diameter surface 231, and the end of the support rod 22 away from the arc-shaped inner module 21 is located in the second placement groove 233. In this embodiment, as... Figure 2 , Figure 3 As shown, the support rod 22 and the arc-shaped inner module 21, and the support rod 22 and the arc-shaped outer module 23 are all detachably connected. The support rod 22 and the arc-shaped inner module 21 or the arc-shaped outer module 23 are detachably connected. The arc-shaped inner module 21 and the support rod 22 are general-purpose tooling, while the arc-shaped outer module 23 is a special tooling designed according to the size and shape of the ring forging 1. For ring forgings 1 of different sizes and cross-sections, the arc-shaped outer module 23 can be replaced, which makes it more applicable. Only a part of the module is replaced instead of the whole mold, which further reduces the cost.

[0040] The radial dimension of the first placement groove 213 is D + (5~8) mm, and the radial dimension of the second placement groove 233 is D + (5~8) mm, where D is the radial dimension of the support rod 22 in mm. These parameters provide assembly clearance and prevent jamming. When the support rod 22 is a cylinder, the first placement groove 213 and the second placement groove 233 are both circular grooves, and the radial dimension of the support rod 22 refers to the diameter of the cylinder.

[0041] The effective depth of the first placement groove 213 is 15~45mm, and the effective depth of the second placement groove 233 is 15~45mm. The effective depth refers to the actual depth used to place the support rod.

[0042] In some embodiments, the profile of the first inner diameter surface 211 in the cross-section parallel to the radial direction of the ring forging is a first circular arc, and the first inner diameter surface matches the outer surface of the bulging slider of an existing bulging machine. The first outer diameter surface 212 is either a circular arc surface or a vertical surface. Preferably, the first outer diameter surface 212 is a circular arc surface, and the profile of the first outer diameter surface 212 in the cross-section parallel to the radial direction of the ring forging is a second circular arc. The central angle corresponding to the second circular arc is θ, and the radial dimension of the support rod 22 is in the range of 0.3 Asin. ~ 0.8Asin Where A is the diameter of the second arc in the first outer diameter surface 212, in mm, as shown below. Figure 4As shown. During bulging, the radial direction of the ring forging refers to the horizontal plane direction, where the central angles corresponding to the first and second arcs are the same. When the support rod 22 is a cylinder, its radial dimension refers to the cylinder diameter. If the diameter of the support rod 22 is too small, it will cause bending deformation during bulging, affecting the forming accuracy; if the diameter is too large, it will increase the mold weight and reduce economic efficiency. Therefore, the diameter of the support rod 22 is limited to 0.3 Asin. ~ 0.8Asin For example, A=Φ1200mm, θ=22°, the radial dimension range of the support rod 22 is calculated according to the above formula, and then the radial dimension of the support rod 22 is determined according to the design requirements.

[0043] In some embodiments, the length L of the support rod 22 is 2D to 8D, where D is the radial dimension of the support rod 22 in mm.

[0044] In some embodiments, there are 12 to 18 fan-shaped dies 2. The fan-shaped dies 2 are evenly distributed along the circumference to form a ring structure. The number of fan-shaped dies 2 affects the accuracy of bulging. If the number of fan-shaped dies 2 is too small (e.g., <12), it will cause discontinuous local deformation of the ring forging 1 after bulging, resulting in poor roundness. If the number of fan-shaped dies 2 is too large (e.g., >18), it will increase the assembly complexity and reduce production efficiency. To balance roundness accuracy and assembly efficiency, the bulging fixture consists of 12 to 18 fan-shaped dies 2, which are evenly distributed along the circumference to form a ring structure, thus distributing the bulging force and extending the equipment life.

[0045] The bulging force is evenly distributed across multiple sector-shaped dies 2, ensuring uniform force transfer to the ring forging 1, avoiding localized stress concentration, and extending die life. The 3500T bulging machine distributes the force evenly across 16 sector-shaped dies 2, with each die bearing approximately 218.75T, meeting the strength requirements of the support rod 22. In the bulging of the φ4000mm ring forging 1, using 16 sector-shaped dies 2, the roundness error can be controlled within ±2mm.

[0046] In some embodiments, the forming tooling can employ multi-stage hydraulic partitioning pressurization, dividing the arc-shaped outer module 23 into multiple hydraulic chambers, or it can uniformly and smoothly transmit the forming force to the ring forging 1.

[0047] In some embodiments, the gap between the fan-shaped molds 2 is 2~5mm. A dynamically adjustable gap of 2~5mm is provided between the fan-shaped molds 2.

[0048] In some embodiments, the support rod 22 is a hydraulically retractable support rod. The length of the hydraulic support rod is adjusted in real time according to the inner diameter of the ring forging 1, achieving "one mold for multiple uses" and reducing the frequency of mold replacement. The hydraulically retractable support rod adopts an existing structure; hydraulic telescopic rods are commercially available. Generally, a hydraulically retractable support rod includes a cylinder, a piston rod, and a displacement sensor, with a stroke adjustment accuracy ≤0.05mm.

[0049] The fan-shaped mold 2 is made of forged alloy steel, which has excellent high-temperature strength, wear resistance and fatigue resistance, such as 5CrNiMo, 4Cr5MoSiV1, 42CrMo, Cr12Mo1V1, 5Cr3SiMnMoV, etc.

[0050] In the above technical solution, the forming fixture consists of multiple fan-shaped molds 2. Each fan-shaped mold 2 includes an arc-shaped inner module 21, a support rod 22, and an arc-shaped outer module 23. The first inner diameter surface 211 is matched and connected with the existing forming machine, and the second outer diameter surface 232 is matched with the inner diameter surface of the ring forging 1. By combining multiple fan-shaped molds 2 to form a ring structure, the above forming fixture is set on the existing forming machine. The formed ring structure can synchronously approach / move away from the ring forging under the drive of the existing forming machine to form the ring forging. This breaks through the forming size limitation of the existing forming machine and can handle ultra-large ring forgings with a diameter of φ4000mm or more.

[0051] The existing 3500T bulging machine has a maximum forming inner diameter ≤ φ3450mm. Through the above technical solution, the bulging fixture of this invention consists of multiple fan-shaped molds 2. The segmented design reduces material usage and mold manufacturing costs. Furthermore, when applied to general bulging, the fan-shaped molds 2 are more cost-effective than traditional bulging mold fan-shaped blocks. Using the bulging fixture of this invention effectively increases the forming size range, breaking through the original maximum forming size of the bulging machine. It solves the problem that existing bulging machines cannot meet the forming requirements of ultra-large ring forgings. Hot or cold ultra-large ring forgings can be placed on the bulging fixture, and the bulging machine expands the diameter to achieve the required forming size. Ultra-large ring forgings are those with an inner diameter ≥ φ4000mm. Compared to traditional integral molds, this greatly improves the versatility of the bulging machine for ultra-large ring forgings, offering a wide forming size range, strong adaptability, high production efficiency, and reduced costs.

[0052] Example 2 This embodiment provides a forming device for ultra-large ring forgings. The forming device includes the forming fixture for ultra-large ring forgings described above, and the forming fixture adopts the forming fixture shown in Embodiment 1. The forming device further includes a worktable 3, a forming pyramid 4, a driving mechanism, and multiple forming sliders 5. The worktable 3 has clearance holes. The forming pyramid 4 is vertically positioned above the worktable 3. The driving mechanism is positioned below the worktable 3 and connected to the driving mechanism. Multiple slide rails 6 are provided radially on the upper surface of the worktable 3, and the forming sliders 5 are slidably connected to the slide rails 6. Multiple forming sliders 5 are sleeved on the outer side of the forming pyramid 4, and the forming fixture is sleeved on the outer side of the forming sliders 5. A fan-shaped mold 2 is slidably mounted on the slide rails 6. Figure 5 .

[0053] The structure of the workbench 3 is an existing structure, such as the workbench 3 including a fixed beam and a support platform, the support platform being set on the upper surface of the fixed beam, and a number of bulging sliders 5 being set on the upper surface of the support platform.

[0054] The bulging pyramid 4 is vertically positioned above the worktable 3, with the small end of the bulging pyramid 4 positioned close to the worktable 3 and the large end of the bulging pyramid 4 positioned away from the worktable 3. The small end of the bulging pyramid 4 can pass through the clearance hole when descending.

[0055] Several bulging sliders 5 are disposed on the upper surface of the worktable 3 and are evenly distributed around the outer periphery of the bulging pyramid 4 along the circumferential direction of the ring forging 1 to be bulged. The bulging sliders 5 can slide and connect on the upper surface of the worktable 3. The end of each bulging slider 5 near the bulging pyramid 4 is set as an inclined surface parallel to the side wall of the bulging pyramid 4 to form an inclined surface contact pair with the side wall of the bulging pyramid 4. The end of each bulging slider 5 away from the bulging pyramid 4 is provided with multiple pushing surfaces, which are arranged in a multi-layered stepped manner from top to bottom along the axial direction of the bulging pyramid 4.

[0056] The number of bulging sliders 5 is equal to the number of inclined surfaces of the bulging pyramid 4. The inclined surface of each bulging slider 5 is in contact with one inclined surface of the bulging pyramid 4. The number of fan-shaped molds 2 is the same as the number of bulging sliders 5. Each bulging slider 5 is equipped with one fan-shaped mold 2. Each fan-shaped mold 2 is set on a single slide rail 6 in the radial direction.

[0057] The drive mechanism is located below the worktable 3 and connected to the expanding pyramid 4. It pulls the expanding pyramid 4 down and simultaneously pushes several expanding sliders 5 outward along the radial direction of the ring forging 1. As the expanding pyramid 4 descends, the force perpendicularly downward along the direction of gravity is transmitted to the upper surface of the worktable 3 through the hole formed by the several expanding sliders 5. This causes the expanding sliders 5 to open outward along the slide rail 6, driving the expanding fixture to expand its diameter outward. The horizontal force is then transmitted to the ring forging 1, enabling the oversized ring forging to reach the required forming size.

[0058] In some embodiments, the contact surfaces of the bulging slider 5 and the bulging pyramid 4, and the bulging slider 5 and the fan-shaped mold 2 are all inlaid with wear-resistant guide plates. The wear-resistant guide plates are made of materials such as W6Mo5Cr4V2 and ZCuAl10Fe4Ni2, which have high hardness, wear resistance, and long service life.

[0059] In some embodiments, a plurality of rotating mechanisms are also provided for driving the ring forging 1 to be expanded to rotate around the expanded pyramid 4.

[0060] In some embodiments, a reset cylinder is also provided to drive the bulging tool to move radially inward and reset along the ring forging 1 to be bulged, which can ensure that after the ring forging 1 is bulged, the bulging slider 5 is driven to move radially inward and wait for the next bulging.

[0061] Example 3 This embodiment provides a bulging method for ultra-large ring forgings, using a bulging device for ultra-large ring forgings from Embodiment 2, including the following steps: S1: Place the ring forging 1 to be expanded on the outside of the fan-shaped mold 2. When the driving mechanism drives the expanding pyramid 4 to move downward, it pushes the expanding slider 5 to move outward through its inclined surface, thereby pushing the fan-shaped mold 2 to move outward, applying an expanding force to the inner wall of the ring forging 1 to achieve the expansion of the ring forging 1. S2: After the bulging is completed, the drive mechanism drives the bulging pyramid 4 to move upward. The thrust of the bulging pyramid 4 on the bulging slider 5 disappears, and the fan-shaped mold 2 moves towards the center of the worktable 3 to remove the bulging ring forging 1.

[0062] Before bulging, multiple sector-shaped dies 2 are combined along the circumference of the ring forging 1 to form a ring structure according to the size of the ring forging 1, and connected to the bulging slider 5 and the slide rail 6, as shown. Figure 6 , Figure 7 After the bulging process is completed, the bulging pyramid 4 moves upward, causing the bulging slider 5 to contract. The bulging fixture contracts slightly, and the overhead crane removes the ring forging 1. The fan-shaped mold 2 can be easily unloaded. The resulting ring part has uniform wall thickness, good roundness of inner and outer diameters, and a flat end face. The bulging method of this invention can be used for bulging ultra-large ring forgings.

[0063] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A tooling for forming ultra-large ring forgings, characterized in that, The forming fixture includes multiple fan-shaped molds (2). Each fan-shaped mold (2) includes an arc-shaped inner module (21), a support rod (22), and an arc-shaped outer module (23). The arc-shaped inner module (21) has a first inner diameter surface (211) and a first outer diameter surface (212) on its side. The arc-shaped outer module (23) has a second inner diameter surface (231) and a second outer diameter surface (232) on its side. The support rod (22) is connected between the first outer diameter surface (212) and the second inner diameter surface (231). The second outer diameter surface (232) matches the inner diameter surface of the ring forging (1). In use, multiple fan-shaped molds (2) are combined along the circumferential direction to form a ring structure.

2. The tooling for forming ultra-large ring forgings according to claim 1, characterized in that, The arc-shaped inner module (21), the support rod (22), and the arc-shaped outer module (23) are an integral structure.

3. The tooling for forming ultra-large ring forgings according to claim 1, characterized in that, The support rod (22) is detachably connected to the inner arc-shaped module (21) and / or the outer arc-shaped module (23); When the support rod (22) is detachably connected to the arc-shaped inner module (21), a first placement groove (213) is provided on the first outer diameter surface (212), and the end of the support rod (22) away from the arc-shaped outer module (23) is located in the first placement groove (213); When the support rod (22) is detachably connected to the arc-shaped inner module (21), a second placement groove (233) is provided on the second inner diameter surface (231), and one end of the support rod (22) away from the arc-shaped inner module (21) is located in the second placement groove (233).

4. The tooling for forming ultra-large ring forgings according to claim 3, characterized in that, The radial dimension of the first placement groove (213) is D+5~8mm, and the radial dimension of the second placement groove (233) is D+5~8mm, where D is the radial dimension of the support rod; The effective depth of the first placement groove (213) is 15~45mm, and the effective depth of the second placement groove (233) is 15~45mm.

5. The tooling for forming ultra-large ring forgings according to claim 1, characterized in that, The outline of the first inner diameter surface (211) in the cross-section parallel to the radial direction of the ring forging is a first circular arc, and the outline of the first outer diameter surface (212) in the cross-section parallel to the radial direction of the ring forging is a second circular arc. The central angle corresponding to the second circular arc is θ, and the diameter range of the support rod (22) is 0.3 Asin. ~ 0.8Asin , where A is the diameter of the second arc; The length of the support rod (22) is 2D~8D, where D is the radial dimension of the support rod.

6. The tooling for forming ultra-large ring forgings according to claim 1, characterized in that, The number of fan-shaped molds (2) is 12 to 18.

7. The tooling for forming ultra-large ring forgings according to claim 1, characterized in that, The support rod (22) is a hydraulically retractable support rod.

8. A device for bulging ultra-large ring forgings, characterized in that, The forming device includes the forming fixture for ultra-large size ring forgings as described in any one of claims 1-7.

9. The device for forming ultra-large size ring forgings according to claim 8, characterized in that, The bulging device also includes a worktable (3), a bulging pyramid (4), a drive mechanism, and multiple bulging sliders (5). The workbench (3) is provided with clearance holes, the bulging pyramid (4) is vertically arranged above the workbench (3), the driving mechanism is arranged below the workbench (3), the bulging pyramid (4) is connected to the driving mechanism, the upper surface of the workbench (3) is provided with multiple slide rails (6) in the radial direction, and the bulging slider (5) is slidably connected to the slide rails (6); The outer side of the bulging pyramid (4) is fitted with a plurality of bulging sliders (5), the outer side of the bulging sliders (5) is fitted with the bulging tooling, and the fan-shaped mold (2) is slidably mounted on the slide rail (6).

10. A method for bulging ultra-large ring forgings, characterized in that, Using the bulging apparatus for ultra-large size ring forgings as described in claim 8 or 9 includes the following steps: S1: Place the ring forging to be expanded on the outside of the fan-shaped mold (2). When the driving mechanism drives the expanding pyramid (4) to move downward, it pushes the expanding slider (5) outward through its inclined surface, thereby pushing the fan-shaped mold (2) outward to apply the expanding force to the inner wall of the ring forging to be expanded, so as to realize the expansion of the ring forging. S2: After the bulging is completed, the driving mechanism drives the bulging pyramid (4) to move upward. The thrust of the bulging pyramid (4) on the bulging slider (5) disappears. The fan-shaped mold (2) moves towards the center of the worktable (3) and the bulging ring forging (1) is taken out.

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