A method and system for controlling the press forming of a nickel-based superalloy

Abstract

The application provides a nickel-based superalloy stamping forming control method and system, which is used for stamping forming of a nickel-based superalloy plate and comprises the following steps: constructing a condition parameter prediction model based on plate base material parameters, and calculating and obtaining the condition parameters of optimal forming of the plate through the model; then, according to the condition parameters, the plate is subjected to overall preheating and local supplementary heating to form a gradient temperature field suitable for forming requirements; then, the plate is subjected to stamping action in the gradient temperature field environment to ensure uniform and stable deformation; finally, the plate after stamping forming is subjected to partition cooling based on the condition parameters, and the plate is quickly ejected after the temperature of the plate decreases to a preset cooling temperature, and the whole precise stamping forming process is completed. The application can solve the core pain points of difficult deformation, easy cracking, high springback and uncontrolled dynamic recrystallization of the nickel-based superalloy plate, and improve the processing efficiency and processing stability of the nickel-based superalloy plate in the stamping forming process.

Description

Technical Field

[0001] This application relates to the field of special metal material processing technology, and in particular to a method and system for controlling the stamping and forming of nickel-based high-temperature alloys. Background Technology

[0002] Nickel-based superalloys are mainly composed of elements such as nickel, chromium, molybdenum, and tungsten. They possess high strength, high hardness, good wear resistance, corrosion resistance, and thermal stability, and can maintain their performance unchanged in high-temperature environments. Nickel-based superalloys (such as 718, 625, and 690) are core materials for aerospace engine hot-end components, nuclear reactor cooling systems, and chemical reactors due to their excellent strength, oxidation resistance, and corrosion resistance in extreme environments (-253 to 700°C).

[0003] However, existing nickel-based superalloys still have some significant problems in controlled forming processes, which seriously affect the processing efficiency and stability of controlled forming. For example, there are problems such as a narrow dynamic recrystallization window and a significant work hardening effect, which limits the effective plastic deformation range and easily leads to cracking or insufficient deformation of the sheet; or, they exhibit nonlinear thermal expansion characteristics at high temperatures, with springback after forming reaching 3-5 times that of conventional steel, making it difficult for traditional mold designs to guarantee the dimensional accuracy of parts; or, when the temperature exceeds 700℃, an oxide layer is easily formed on the surface of the sheet, causing severe adhesion to the mold, resulting in a low demolding success rate, which affects both production efficiency and damages the surface quality of the parts; or, the uniform heat conduction design of existing molds cannot match the alloy's requirement for a precise temperature field, further exacerbating the above forming defects.

[0004] Therefore, how to provide a method and system for controlling the stamping of nickel-based superalloys, which can improve the processing efficiency and stability of nickel-based superalloy sheets during the stamping process, has become one of the technical problems that urgently need to be solved by those in the field. Summary of the Invention

[0005] This application aims to at least partially address one of the technical problems in the related art.

[0006] Therefore, the first objective of this application is to propose a method and system for controlling the stamping process of nickel-based superalloys.

[0007] To achieve the above objectives, the first aspect of this application proposes a method for controlling the stamping forming of nickel-based superalloys, used for stamping forming of nickel-based superalloy sheets, comprising:

[0008] Based on the basic material parameters of the plate, a conditional parameter prediction model is constructed, and the optimal conditional parameters for forming the plate are obtained using the parameter prediction model.

[0009] Based on the aforementioned condition parameters, the board material is preheated as a whole and partially heated locally, and the temperature of the board material is dynamically adjusted according to the real-time temperature monitoring results to form a gradient temperature field.

[0010] Based on the aforementioned condition parameters, the sheet metal under the gradient temperature field is stamped, and the distribution of the blank holder force of the sheet metal is monitored and adjusted in real time during the stamping process.

[0011] Based on the aforementioned condition parameters, the stamped sheet is subjected to zoned cooling, and the sheet is rapidly ejected after reaching the preset cooling temperature.

[0012] Optionally, the condition parameter prediction model includes at least a dynamic recrystallization critical model, a hot deformation constitutive relation model, a plastic deformation window prediction model, a gradient temperature field control model, and a gradient cooling residual stress model; wherein,

[0013] The heat deformation constitutive model is used to obtain the mechanical response parameters of the plate under different process conditions;

[0014] The dynamic recrystallization critical model is used to obtain the boundary control parameters for the dynamic recrystallization of the plate.

[0015] The deformation window prediction model is used to obtain the stamping control parameters when the sheet metal undergoes plastic deformation;

[0016] The gradient temperature field control model is used to obtain heating control parameters for different structural regions of the plate after molding.

[0017] The gradient cooling residual stress model is used to obtain cooling control parameters for different structural zones of the plate after molding.

[0018] Optionally, the step of constructing a conditional parameter prediction model based on the basic material parameters of the sheet material, and using the parameter prediction model to obtain the optimal conditional parameters for forming the sheet material, includes:

[0019] Based on the basic material parameters of the plate, combined with the thermal deformation constitutive equation, the thermal deformation constitutive relationship model is constructed, and the mechanical response parameters of the plate under different process conditions are obtained using the thermal deformation constitutive relationship model.

[0020] Based on the mechanical response parameters and basic material parameters of the plate, combined with the Zener-Hollomon parametric equation and critical strain equation, the dynamic recrystallization critical model is constructed, and the boundary control parameters for the plate to undergo dynamic recrystallization are obtained using the dynamic recrystallization critical model.

[0021] Based on the boundary control parameters, mechanical response parameters, and basic material parameters of the sheet metal, and combined with the power dissipation efficiency equation, the deformation window prediction model is constructed. The deformation window prediction model is then used to predict whether the sheet metal can undergo stable plastic deformation under different stamping control parameters, and outputs the boundaries of the safe forming range and the unstable region.

[0022] Based on the basic material parameters and stamping control parameters for stable plastic deformation of the plate, combined with the structure to be formed and transient heat transfer equation of the plate, the gradient temperature field control model is constructed, and the heating control parameters of different structural regions of the plate are obtained using the gradient temperature field control model.

[0023] Based on the basic material parameters of the plate and the heating control parameters of different structural regions, combined with the thermoelastic stress equation, the gradient cooling residual stress model is constructed, and the residual stress distribution of the plate after molding and the corresponding cooling control parameters are predicted using the gradient cooling residual stress model.

[0024] Optionally, the step of preheating the plate material as a whole and supplementing heat locally based on the condition parameters includes:

[0025] Based on the heating control parameters of different structural zones of the plate, the plate is preheated as a whole and locally supplemented with heat.

[0026] The heating control parameters for different structural zones of the board material include at least the target control temperature for each structural zone.

[0027] Optionally, the step of performing stamping on the sheet metal under the gradient temperature field based on the condition parameters includes:

[0028] Based on the stamping control parameters that cause plastic deformation of the sheet metal, stamping is performed on the sheet metal under the gradient temperature field;

[0029] The stamping control parameters for plastic deformation of the sheet metal include at least the strain rate of the sheet metal.

[0030] Optionally, the step of performing stamping on the sheet metal under the gradient temperature field, and monitoring and adjusting the blank holder force distribution of the sheet metal in real time during the stamping process, includes:

[0031] The sheet metal under the gradient temperature field is stamped using a split mold assembly, and the distribution of the blank holder force on the sheet metal during the stamping process is monitored and dynamically compensated and adjusted in real time using a dynamic compensation assembly.

[0032] Optionally, before the step of stamping the sheet metal under the gradient temperature field using a split mold structure, the method further includes:

[0033] A high-temperature resistant and wear-resistant coating is applied to the surface of the mold in the split mold structure. The coating is used to reduce the adhesion between the sheet metal and the mold.

[0034] Optionally, the step of performing zoned cooling on the stamped sheet based on the condition parameters includes:

[0035] Based on the residual stress distribution of the sheet metal and the corresponding cooling control parameters, the stamped sheet metal is subjected to zoned cooling.

[0036] The cooling control parameters for the stamped sheet include at least the cooling rate of the sheet.

[0037] To achieve the above objectives, a second aspect of this application provides a nickel-based superalloy stamping control system for stamping nickel-based superalloy sheets, comprising:

[0038] A multi-level temperature field control module includes a calculation unit and a thermal control unit. The calculation unit is used to construct a condition parameter prediction model based on the basic material parameters of the sheet metal, and to use the parameter prediction model to obtain the optimal forming condition parameters of the sheet metal. The thermal control unit is used to dynamically adjust the temperature of the sheet metal during the stamping process and to collect the temperature data of the sheet metal.

[0039] The stamping module includes a split mold assembly and a dynamic compensation assembly. The split mold assembly is used to perform stamping on the sheet metal, and the dynamic compensation assembly is used to monitor and dynamically compensate the distribution of the blank holder force of the sheet metal in real time.

[0040] The dynamic control module is used to control the thermal control unit to dynamically regulate the temperature of the sheet during the stamping process based on the optimal forming condition parameters of the sheet, the structure of the sheet to be formed, and the temperature data collected and output by the thermal control unit; and the dynamic control module is also used to control the dynamic compensation component to adjust the edge pressure force distribution of the sheet.

[0041] Optionally, the computing unit includes:

[0042] The first calculation unit is used to construct a thermal deformation constitutive relationship model based on the basic material parameters of the plate and the thermal deformation constitutive equation, and to use the thermal deformation constitutive relationship model to obtain the mechanical response parameters of the plate under different process conditions.

[0043] The second calculation unit is used to construct a dynamic recrystallization critical model based on the mechanical response parameters and basic material parameters of the plate, combined with the Zener-Hollomon parametric equation and critical strain equation, and to use the dynamic recrystallization critical model to obtain the boundary control parameters for the plate to undergo dynamic recrystallization.

[0044] The third calculation unit is used to construct a deformation window prediction model based on the boundary control parameters, mechanical response parameters and basic material parameters of the sheet metal, combined with the power dissipation efficiency equation, and to use the deformation window prediction model to predict whether the sheet metal can undergo stable plastic deformation under different stamping control parameters, and output the boundary between the safe forming range and the unstable zone.

[0045] The fourth calculation unit is used to construct a gradient temperature field control model based on the basic material parameters and stamping control parameters for stable plastic deformation of the plate, combined with the structure to be formed and the transient heat transfer equation of the plate, and to use the gradient temperature field control model to obtain the heating control parameters of different structural regions of the plate.

[0046] The fifth calculation unit is used to construct a gradient cooling residual stress model based on the basic material parameters of the plate and the heating control parameters of different structural zones, combined with the thermoelastic stress equation, and to use the gradient cooling residual stress model to predict the residual stress distribution of the plate after molding, as well as the corresponding cooling control parameters.

[0047] The nickel-based superalloy stamping control method and system provided in this application have at least the following beneficial effects:

[0048] The nickel-based superalloy stamping control method and system provided in this application address the core pain points of nickel-based superalloy sheets, such as difficulty in deformation, easy cracking, high springback, and uncontrolled dynamic recrystallization. Through multi-model driving, it predicts process condition parameters at different stages, enabling the sheet to achieve stable plastic deformation within a safe range during the stamping process based on the predicted condition parameters. Simultaneously, it achieves grain refinement through DRX control, while suppressing residual stress and springback. This application can improve the processing efficiency and stability of nickel-based superalloy sheets during stamping, providing technical support for the efficient and high-quality forming of key hot-end components (such as turbine disks and steam generator heat transfer tubes) in the aerospace and nuclear power fields, filling the technological gap in refined stamping control of nickel-based superalloys.

[0049] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0050] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein:

[0051] Figure 1 This is a schematic flowchart illustrating a nickel-based superalloy stamping control method according to an embodiment of this application.

[0052] Figure 2 This is a schematic diagram illustrating the workflow of a conditional parameter prediction model according to an embodiment of this application.

[0053] Figure 3 This is a schematic diagram of a nickel-based high-temperature alloy stamping control system according to an embodiment of this application.

[0054] 10. Sheet metal; 20. Multi-level temperature field control module; 30. Stamping and forming module; 31. Split mold assembly; 32. Dynamic compensation assembly. Detailed Implementation

[0055] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0056] According to the first aspect of this application, a method for controlling the stamping forming of nickel-based superalloys is provided for stamping nickel-based superalloy sheets, thereby improving the processing efficiency and stability of the nickel-based superalloy sheets during the stamping process. Please see [link to relevant documentation]. Figure 1 , Figure 1 This is a flowchart illustrating a method for controlling the stamping and forming of nickel-based superalloys, as provided in an embodiment of this application. Figure 1 As shown, the method includes the following steps:

[0057] S1. Construct a parameter prediction model based on the basic material parameters of the sheet material, and use the conditional parameter prediction model to obtain the conditional parameters for the optimal forming of the sheet material.

[0058] It is understood that "sheet material" refers to nickel-based high-temperature alloy sheets to be stamped and formed, including but not limited to Inconel 718, Inconel 625, Inconel 690, etc. in the high-temperature alloy series.

[0059] The fundamental material parameters of sheet metal refer to the key performance parameters inherent to the material or measured experimentally, which are quantitatively calculated by the support condition parameter prediction model. These fundamental material parameters determine the material's thermal deformation behavior, microstructure evolution, thermophysical properties, and mechanical response. As an example, the fundamental material parameters of sheet metal include thermal deformation behavior parameters, thermophysical parameters, mechanical property parameters, and microstructure-related parameters.

[0060] A parametric prediction model refers to a model that can output the optimal stamping parameters of a sheet metal based on its basic material.

[0061] In some embodiments, the condition parameter prediction model includes at least a dynamic recrystallization critical model, a hot deformation constitutive model, a plastic deformation window prediction model, a gradient temperature field control model, and a gradient cooling residual stress model. The hot deformation constitutive model is used to obtain the mechanical response parameters of the sheet metal under different process conditions; the dynamic recrystallization critical model is used to obtain the boundary control parameters for dynamic recrystallization of the sheet metal; the deformation window prediction model is used to obtain the stamping control parameters when the sheet metal undergoes plastic deformation; the gradient temperature field control model is used to obtain the heating control parameters for different structural regions of the sheet metal after forming; and the gradient cooling residual stress model is used to obtain the cooling control parameters for different structural regions of the sheet metal after forming.

[0062] Therefore, please see Figure 2 , Figure 2 This is a schematic diagram illustrating the workflow of a conditional parameter prediction model provided in an embodiment of this application. Step S2 may specifically include the following steps:

[0063] S11. Based on the basic material parameters of the sheet metal and combined with the thermal deformation constitutive equation, a thermal deformation constitutive relation model is constructed, and the mechanical response parameters of the sheet metal under different process conditions are obtained using the thermal deformation constitutive relation model.

[0064] It is understandable that the mechanical response parameter of a sheet material can be its strain rate. The constitutive equation for thermal deformation is used to describe the rheological stress σ of a sheet metal in relation to temperature T and strain rate. The relationship, using the modified Arrhenius hyperbolic sine model, satisfies the following relationship:

[0065]

[0066] in, σ is the stamping strain rate; A, α, and n are plate constants describing the relationship between stress, temperature, and strain rate; σ is the peak flow stress, MPa; Q is the activation energy of hot deformation, kJ / mol; and R is the gas constant, with R = 8.314 J / mol·K; T is the absolute temperature, K.

[0067] For example, the heat distortion activation energy Q of the Inconel 690 sheet is 417.6 kJ / mol, and n is 7.51.

[0068] S12. Based on the mechanical response parameters and basic material parameters of the plate, combined with the Zener-Hollomon parametric equation and critical strain equation, a dynamic recrystallization (DRX) critical model is constructed, and the boundary control parameters for dynamic recrystallization of the plate are obtained using the dynamic recrystallization critical model.

[0069] Understandably, the boundary control parameters for dynamic recrystallization of sheet metal refer to key quantitative indicators calculated using the DRX critical condition model that can accurately determine whether DRX is initiated, the extent of DRX progression, and whether DRX is harmful. For example, the critical strain ε of the sheet metal... c Critical strain ε c It directly determines whether DRX can achieve the beneficial effect of grain refinement during the stamping of nickel-based superalloys, or whether uncontrolled DRX will lead to harmful effects such as grain coarsening and cracking.

[0070] The Zener-Hollomon parametric equation reflects the degree to which hot deformation conditions inhibit or promote DRX (Dry Grain Reduction), while the critical strain equation reflects the minimum deformation required to initiate DRX and the process boundary to avoid grain coarsening or insufficient recrystallization, providing a basis for judging microstructure evolution. Since dynamic recrystallization is the core mechanism of grain evolution in the hot forming of nickel-based superalloys, its triggering condition is determined by the critical strain, which is directly related to the Zener-Hollomon (Z) parameter. Therefore, the critical strain equation and the Z-parameter equation satisfy the following relationship:

[0071]

[0072] ε c =a+b ln z,

[0073] Where Z is the Zener-Hollomon parameter, ε c Let Z be the critical strain, and a and b be constants describing the relationship between the Z parameter and the critical strain.

[0074] As an example, for Inconel 617 type sheets, ε c The value increases with increasing Z parameter, and at high temperatures ranging from 1075℃ to 1175℃, the low strain rate (ε) increases. c <0.01s -1 It can inhibit harmful effects such as grain coarsening and cracking caused by DRX.

[0075] S13, based on the boundary control parameters, mechanical response parameters and basic material parameters of the sheet metal, combined with the power dissipation efficiency equation, constructs a deformation window prediction model, and uses the deformation window prediction model to predict whether the sheet metal can undergo stable plastic deformation under different stamping control parameters, and outputs the safe forming range and the boundary of the unstable region.

[0076] It is understandable that stamping control parameters can be combinations of different heating temperatures and strain rates of sheet metal. In the stamping process of nickel-based superalloy sheet metal, stamping control parameters can directly affect the forming quality and microstructure evolution of the sheet metal, thereby ensuring that the sheet metal undergoes stable plastic deformation within the plastic deformation window, suppressing cracking, wrinkling and springback, and achieving grain refinement by regulating dynamic recrystallization (DRX) behavior.

[0077] Since the core function of power dissipation efficiency is to quantify the stability of material deformation and the evolution trend of microstructure, when the power dissipation efficiency is greater than a preset threshold, it can macroscopically determine that the sheet material is in a safe forming zone. This means that the sheet material in the corresponding range can achieve stable plastic deformation, thus avoiding cracking and instability. Microscopically, it can also determine whether dynamic recrystallization can fully occur and achieve grain refinement, ensuring mechanical properties. The power dissipation efficiency equation satisfies the following relationship:

[0078]

[0079] As an example, the sheet material region corresponding to η > 30% can be designated as the safe forming zone (safe zone), and the sheet material region corresponding to η < 30% can be designated as the unstable zone. For example, Inconel 617 type sheet material at 1075–1175°C... When η reaches its maximum value, it exhibits the best plastic deformation capacity.

[0080] S14. Based on the basic material parameters of the sheet metal and the stamping control parameters for stable plastic deformation, combined with the sheet metal structure to be formed and the transient heat transfer equation, a gradient temperature field control model is constructed, and the heating control parameters of different structural regions of the sheet metal are obtained using the gradient temperature field control model.

[0081] It is understandable that the heating control parameters for different structural regions of the sheet metal refer to key quantitative temperature control indicators calculated through a gradient temperature field control model. These parameters are designed to accurately adapt to the forming requirements of different structures (such as corners, thin-walled areas, and planar areas) of the sheet metal, ensuring that each region is within a safe forming range. For example, heating temperature or heating rate. This parameter directly determines whether different structural regions can simultaneously achieve stable plastic deformation and reasonable dynamic recrystallization during the stamping of nickel-based superalloys, or whether improper local temperatures can lead to harmful effects such as cracking and grain coarsening.

[0082] The heating control parameters can be obtained by solving the structural characteristics (coordinate position) of the sheet material to be formed and the transient heat transfer equation, and satisfy the following relationship:

[0083]

[0084] Where ρ is the density of the board, in g / cm³ 3 c p is the specific heat capacity of the plate, J / g·K; k is the thermal conductivity of the plate, W / m·K; This represents the power density of the heat source.

[0085] As an example, based on the target temperature of different structural areas of the sheet metal, for corner areas with large deformation that are prone to cracking, the target temperature should be set to 1155℃~1175℃ (upper limit of the safe forming range) to improve local plasticity, promote the full occurrence of DRX, and dissolve the Laves phase; for planar areas with small deformation and requiring prevention of grain coarsening, the target temperature should be set to 1055℃~1075℃ (lower limit of the safe forming range) to suppress excessive DRX; for example, the heating rate of the sheet metal in different zones should be controlled at 10~12℃ / s (slower rate) in thin-walled areas to avoid instability caused by thermal stress due to excessive heating, while it can be set at 13~15℃ / s (faster rate) in thick-walled areas to ensure a consistent overall forming rhythm; and for example, the local heating power should be adjusted to 20~25kW for edge areas where the temperature drops quickly during stamping to maintain the target temperature and prevent DRX interruption and work hardening cracking due to the temperature falling below the safe range.

[0086] S15. Based on the basic material parameters of the sheet and the heating control parameters of different structural zones, combined with the thermoelastic stress equation, a gradient cooling residual stress model is constructed. The gradient cooling residual stress model is then used to predict the residual stress distribution of the sheet after molding, as well as the corresponding cooling control parameters.

[0087] Understandably, cooling control parameters refer to key quantitative parameters, such as cooling rate, calculated using a gradient cooling residual stress model. These parameters are crucial for precisely controlling the temperature drop of the sheet metal after forming, balancing differences in thermal shrinkage across regions to suppress residual stress and springback. This parameter directly determines whether, after stamping, nickel-based superalloys can avoid stress concentration, dimensional deviations, or microstructural degradation caused by uneven cooling, or whether improper cooling strategies lead to excessive springback or cracking.

[0088] According to the thermoelastic stress equation, the residual stress of the sheet metal after stamping should satisfy the following relationship:

[0089] σ res =E·α T ·ΔT·f(κ),

[0090] Where, σres Let E be the residual stress of the sheet material, E be the elastic modulus of the sheet material, and α be the residual stress of the sheet material. T κ is the coefficient of thermal expansion of the sheet material, and κ is the coefficient of cooling unevenness.

[0091] As an example, for corner areas where the temperature is high after molding, the amount of thermal shrinkage is large, and stress concentration is easily generated, the cooling rate can be controlled at 40-45℃ / s. By cooling faster, the stress accumulation caused by excessive thermal shrinkage is suppressed, recrystallization is induced, and the γ-reinforcing phase is refined. For planar areas with lower temperature and less thermal shrinkage, the cooling rate is set at 30-35℃ / s to avoid excessive shrinkage difference between the corner area and the temperature after cooling too fast.

[0092] S2, based on condition parameters, preheats the board as a whole and supplements local heating, and dynamically adjusts the temperature of the board according to the real-time temperature monitoring results to form a gradient temperature field.

[0093] It is understandable that the conditional parameters here refer to the heating control parameters output by the gradient temperature field control model. These include, for example, the preheating temperature of the entire sheet, the target control temperature of different structural zones, the heating rate, and the local supplementary heating power, so that the temperature of each structural zone of the sheet can be accurately adapted to its own molding requirements, while ensuring that the whole is within a safe molding range.

[0094] As an example, firstly, during the preheating stage of the sheet metal blank, the sheet metal can be preheated as a whole; for example, the overall temperature of the sheet metal can be raised to 300℃±10℃, providing a basis for subsequent localized heating and stamping deformation. Secondly, for areas with special deformation requirements, such as corners and thin walls, the temperature can be controlled according to the target temperature of the same structural area. For example, the corner area can be locally heated to 1075~1175℃, and the temperature of different structural areas can be matched with their own plasticity requirements through differentiated heating.

[0095] Meanwhile, by using equipment such as infrared thermal imagers to monitor the temperature of each area of ​​the sheet in real time, the temperature control accuracy is controlled within ±5. To address the core pain points of nickel-based high-temperature alloy sheets, such as difficulty in deformation, easy cracking, high springback, and easy loss of control over dynamic recrystallization, multi-model driving is used to predict the process condition parameters at different stages in sequence. This allows the sheet to achieve stable plastic deformation within a safe range during the stamping process based on the predicted condition parameters, while also achieving grain refinement through DRX control, and suppressing residual stress and springback. This application can improve the processing efficiency and stability of nickel-based superalloy sheets during the stamping process, providing technical support for the efficient and high-quality forming of key hot-end components (such as turbine disks and steam generator heat transfer tubes) in the aerospace and nuclear power fields. It fills the technical gap in the fine stamping control of nickel-based superalloys. If local temperature deviations from the target value are found, such as the edge temperature falling below 1050°C due to heat loss, it addresses the core pain points of nickel-based superalloy sheets, such as difficulty in deformation, easy cracking, high springback, and easy loss of control in dynamic recrystallization. Through multi-model driving, the process condition parameters at different stages are predicted sequentially. Based on the predicted condition parameters, the sheet can achieve stable plastic deformation within a safe range during the stamping process, and grain refinement can be achieved through DRX control. At the same time, residual stress and springback are suppressed. This application can improve the processing efficiency and stability of nickel-based superalloy sheets during the stamping process, providing technical support for the efficient and high-quality forming of key hot-end components (such as turbine disks and steam generator heat transfer tubes) in the aerospace and nuclear power fields. It fills the technical gap in the fine stamping control of nickel-based superalloys. By adjusting the supplementary heating power or heating time in real time through PLC, the temperature deviation is dynamically corrected, and finally a gradient temperature field is formed on the sheet with high temperature in the corner area, low temperature in the plane area, and the temperature of each area within the safe range. This provides a suitable temperature environment for subsequent stable stamping and reasonable dynamic recrystallization (DRX).

[0096] S3, based on condition parameters, performs stamping action on the sheet metal under gradient temperature field, and monitors and adjusts the distribution of blank holder force in real time during the stamping process.

[0097] It is understandable that the conditional parameters here refer to the safety stamping control parameters output by the plastic deformation window prediction model, such as stamping strain rate, initial blank holder force distribution, etc., as well as the temperature parameters determined by the gradient temperature field control model, such as the target control temperature of each structural zone, etc., which are comprehensive process parameters. On the basis of the sheet material reaching temperature adaptation, the stamping process and blank holder force are precisely controlled to ensure uniform deformation of the sheet material and avoid wrinkling and cracking.

[0098] As an example, given that a gradient temperature field has been formed in the sheet metal, the stamping action is initiated based on the stamping strain rate in the condition parameters. At this time, each structural area has the corresponding plasticity due to temperature adaptation, and can flow uniformly with the mold cavity, avoiding stress concentration cracking caused by insufficient local plasticity. Exemplarily, the stamping action is performed using a split mold assembly. Replacing the traditional integral rigid mold with a split mold assembly can effectively address the high springback characteristics (up to 3-5 times that of conventional steel) and high-temperature adhesion problems of nickel-based superalloys, significantly improving dimensional accuracy and demolding success rate. Among them, the upper mold in the split mold assembly can use an S7 tool steel base and be coated with a high-temperature wear-resistant coating, such as a CrAlN coating, to enhance the wear resistance and anti-high-temperature adhesion of the upper mold.

[0099] Simultaneously, during the stamping process, the dynamic compensation component is used to monitor and dynamically compensate the distribution of blank holder force on the sheet metal in real time. For example, the blank holder force in the dynamic compensation component can be set according to the initial zone blank holder force in the condition parameters. Material flow is constrained by differentiated blank holder forces; for instance, a lower blank holder force is used in thin-walled areas to prevent over-constraint leading to cracking, while a higher blank holder force is used in thick-walled areas to ensure sufficient material filling of the mold cavity. Furthermore, pressure sensors in the dynamic compensation component monitor changes in blank holder force in each area in real time. For example, a sudden drop in blank holder force in thin-walled areas due to material flow, or a sudden increase in blank holder force in thick-walled areas due to increased deformation resistance. Once the blank holder force deviates from the set range, for example, if the deviation exceeds ±50kN, the blank holder force in the corresponding area is immediately adjusted through the dynamic compensation component to achieve stable, defect-free forming of the sheet metal.

[0100] S4, based on condition parameters, performs zoned cooling on the stamped sheet, and quickly ejects the sheet after reaching the preset cooling temperature.

[0101] It can be understood that the condition parameters here refer to the cooling control parameters output by the gradient cooling residual stress model, such as the zoned cooling rate, cooling sequence, preset cooling temperature, etc., in order to reduce residual stress and springback by precisely controlling the cooling process after molding, while ensuring that the sheet material can quickly leave the mold and avoid dimensional deviations.

[0102] As an example, for areas with high residual stress and large thermal shrinkage after molding, such as corner areas and edge areas, cooling devices, such as local water channels and airflow cooling, are preferentially activated at a cooling rate of 40-45℃ / s to quickly balance the thermal stress in the area; for planar areas with low stress and small thermal shrinkage, cooling is carried out at a slower rate of 30-35℃ / s to avoid new stress concentration caused by excessive differences in cooling rates between areas.

[0103] Secondly, during the cooling process, the overall temperature of the sheet metal needs to be monitored in real time using a temperature sensor. When the temperature in the core area of ​​the sheet metal drops to the preset cooling temperature set by the condition parameters, a rapid ejection operation should be immediately performed to avoid the sheet metal sticking due to prolonged residence in the mold. This further ensures the dimensional accuracy and surface quality of the parts, ultimately completing the entire stamping process. A high-speed pneumatic ejection device configured at the bottom of the split mold assembly can be used to perform the rapid ejection operation.

[0104] According to a second aspect embodiment of this application, a nickel-based superalloy stamping control system is also provided, such as... Figure 3 As shown, it includes a multi-level temperature field control module 20, a stamping and forming module 30, and a dynamic control module.

[0105] The multi-level temperature field control module 20 includes a calculation unit and a thermal control unit. The calculation unit is used to construct a condition parameter prediction model based on the basic material parameters of the sheet material, and to obtain the optimal forming condition parameters of the sheet material using the parameter prediction model. The thermal control unit is used to dynamically adjust the temperature of the sheet material during the stamping process, and to collect the temperature data of the sheet material.

[0106] The thermal control module includes a thermal control component and a temperature acquisition component. The thermal control component is used to dynamically adjust the temperature of the sheet metal during the stamping process, and the temperature acquisition component is used to collect the temperature data of the sheet metal.

[0107] The stamping module 30 includes a split mold assembly 31 and a dynamic compensation assembly 32. The split mold assembly 31 is used to perform stamping operations on the sheet metal, and the dynamic compensation assembly 32 is used to monitor and dynamically compensate the distribution of the blank holder force of the sheet metal in real time.

[0108] The dynamic control module is used to control the thermal control unit to dynamically regulate the temperature parameters of the sheet during the stamping process based on the optimal forming conditions and the structure of the sheet to be formed, as well as the temperature data collected and output by the thermal control unit. In addition, the dynamic control module is also used to control the dynamic compensation component 32 to adjust the distribution of the blank holder force of the sheet.

[0109] In some embodiments, the computing unit includes a first computing unit, a second computing unit, a third computing unit, a fourth computing unit, and a fifth computing unit.

[0110] The first calculation unit is used to construct a thermal deformation constitutive relation model based on the basic material parameters of the plate and the thermal deformation constitutive equation, and to obtain the mechanical response parameters of the plate under different process conditions using the thermal deformation constitutive relation model.

[0111] The second calculation unit is used to construct a dynamic recrystallization critical model based on the mechanical response parameters and basic material parameters of the plate, combined with the Zener-Hollomon parametric equation and critical strain equation, and to obtain the boundary control parameters for the plate to undergo dynamic recrystallization using the dynamic recrystallization critical model.

[0112] The third calculation unit is used to construct a deformation window prediction model based on the boundary control parameters, mechanical response parameters, and basic material parameters of the sheet metal, combined with the power dissipation efficiency equation. The deformation window prediction model is then used to predict whether the sheet metal can undergo stable plastic deformation under different stamping control parameters, and output the boundaries of the safe forming range and the unstable zone.

[0113] The fourth calculation unit is used to construct a gradient temperature field control model based on the basic material parameters of the sheet and the stamping control parameters for stable plastic deformation, combined with the sheet's structure to be formed and the transient heat transfer equation, and to obtain the heating control parameters for different structural zones of the sheet using the gradient temperature field control model.

[0114] The fifth calculation unit is used to construct a gradient cooling residual stress model based on the basic material parameters of the plate and the heating control parameters of different structural zones, combined with the thermoelastic stress equation, and to use the gradient cooling residual stress model to predict the residual stress distribution of the plate after molding, as well as the corresponding cooling control parameters.

[0115] It should be noted that for details not described in the nickel-based superalloy stamping control system, the above explanation of the nickel-based superalloy stamping control method also applies to the nickel-based superalloy stamping control system of this embodiment, and will not be repeated here.

[0116] In summary, the nickel-based superalloy stamping control method and system provided in this application address the core pain points of nickel-based superalloy sheets, such as difficulty in deformation, easy cracking, high springback, and uncontrolled dynamic recrystallization. Through multi-model driving, it predicts process condition parameters at different stages, enabling the sheet to achieve stable plastic deformation within a safe range during the stamping process based on the predicted condition parameters. Furthermore, it achieves grain refinement through DRX control, while simultaneously suppressing residual stress and springback. This application can improve the processing efficiency and stability of nickel-based superalloy sheets during stamping, providing technical support for the efficient and high-quality forming of key hot-end components (such as turbine disks and steam generator heat transfer tubes) in the aerospace and nuclear power fields, filling the technological gap in refined stamping control of nickel-based superalloys.

[0117] In the foregoing descriptions of the embodiments, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0118] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

Claims

1. A method for controlling the stamping forming of nickel-based superalloys, used for stamping forming of nickel-based superalloy sheets, characterized in that, include: Based on the basic material parameters of the plate, a conditional parameter prediction model is constructed, and the conditional parameters for the optimal forming of the plate are obtained using the parameter prediction model. Based on the aforementioned condition parameters, the board material is preheated as a whole and partially heated locally, and the temperature of the board material is dynamically adjusted according to the real-time temperature monitoring results to form a gradient temperature field. Based on the aforementioned condition parameters, a stamping action is performed on the sheet metal under the gradient temperature field, and the distribution of the blank holder force of the sheet metal is monitored and adjusted in real time during the stamping process. Based on the aforementioned condition parameters, the stamped sheet is subjected to zoned cooling, and the sheet is rapidly ejected after reaching the preset cooling temperature. The conditional parameter prediction model includes at least a dynamic recrystallization critical model, a hot deformation constitutive relation model, a plastic deformation window prediction model, a gradient temperature field control model, and a gradient cooling residual stress model; wherein... The heat deformation constitutive model is used to obtain the mechanical response parameters of the plate under different process conditions; The dynamic recrystallization critical model is used to obtain the boundary control parameters for the dynamic recrystallization of the plate. The deformation window prediction model is used to obtain the stamping control parameters when the sheet metal undergoes plastic deformation; The gradient temperature field control model is used to obtain heating control parameters for different structural regions of the plate after forming. The gradient cooling residual stress model is used to obtain cooling control parameters for different structural regions of the plate after forming. The step of constructing a conditional parameter prediction model based on the basic material parameters of the sheet metal, and using the parameter prediction model to obtain the optimal conditional parameters for forming the sheet metal, includes: Based on the basic material parameters of the plate, combined with the thermal deformation constitutive equation, the thermal deformation constitutive relationship model is constructed, and the mechanical response parameters of the plate under different process conditions are obtained using the thermal deformation constitutive relationship model. Based on the mechanical response parameters and basic material parameters of the plate, combined with the Zener-Hollomon parametric equation and critical strain equation, the dynamic recrystallization critical model is constructed, and the boundary control parameters for the plate to undergo dynamic recrystallization are obtained using the dynamic recrystallization critical model. Based on the boundary control parameters, mechanical response parameters, and basic material parameters of the sheet metal, and combined with the power dissipation efficiency equation, the deformation window prediction model is constructed. The deformation window prediction model is then used to predict whether the sheet metal can undergo stable plastic deformation under different stamping control parameters, and outputs the boundaries of the safe forming range and the unstable region. Based on the basic material parameters and stamping control parameters for stable plastic deformation of the plate, combined with the structure to be formed and transient heat transfer equation of the plate, the gradient temperature field control model is constructed, and the heating control parameters of different structural regions of the plate are obtained using the gradient temperature field control model. Based on the basic material parameters of the plate and the heating control parameters of different structural regions, combined with the thermoelastic stress equation, the gradient cooling residual stress model is constructed, and the residual stress distribution of the plate after molding and the corresponding cooling control parameters are predicted using the gradient cooling residual stress model.

2. The method according to claim 1, characterized in that, The step of preheating the board material as a whole and supplementing heat locally based on the condition parameters includes: Based on the heating control parameters of different structural zones of the plate, the plate is preheated as a whole and locally supplemented with heat. The heating control parameters for different structural zones of the board material include at least the target control temperature for each structural zone.

3. The method according to claim 1, characterized in that, The step of performing a stamping action on the sheet metal under the gradient temperature field based on the condition parameters includes: Based on the stamping control parameters that cause plastic deformation of the sheet metal, a stamping action is performed on the sheet metal under the gradient temperature field; The stamping control parameters for plastic deformation of the sheet metal include at least the stamping strain rate.

4. The method according to claim 1, characterized in that, The step of performing a stamping operation on the sheet metal under the gradient temperature field, and monitoring and adjusting the blank holder force distribution of the sheet metal in real time during the stamping process, includes: The sheet metal under the gradient temperature field is stamped using a split mold assembly, and the distribution of the blank holder force on the sheet metal during the stamping process is monitored and dynamically compensated and adjusted in real time using a dynamic compensation assembly.

5. The method according to claim 4, characterized in that, Before the step of performing a stamping action on the sheet metal under the gradient temperature field using a split mold structure, the method further includes: A high-temperature resistant and wear-resistant coating is applied to the surface of the mold in the split mold structure. The coating is used to reduce the adhesion between the sheet metal and the mold.

6. The method according to claim 1, characterized in that, The step of performing zoned cooling on the stamped sheet metal based on the aforementioned condition parameters includes: Based on the residual stress distribution of the sheet metal and the corresponding cooling control parameters, the stamped sheet metal is subjected to zoned cooling. The cooling control parameters for the stamped sheet include at least the cooling rate of the sheet.

7. A stamping control system for nickel-based superalloys, used for stamping nickel-based superalloy sheets, characterized in that, include: A multi-level temperature field control module includes a calculation unit and a thermal control unit. The calculation unit is used to construct a condition parameter prediction model based on the basic material parameters of the sheet metal, and to use the parameter prediction model to obtain the optimal forming condition parameters of the sheet metal. The thermal control unit is used to dynamically adjust the temperature of the sheet metal during the stamping process and to collect the temperature data of the sheet metal. The stamping module includes a split mold assembly and a dynamic compensation assembly. The split mold assembly is used to perform stamping on the sheet metal, and the dynamic compensation assembly is used to monitor and dynamically compensate the distribution of the blank holder force of the sheet metal in real time. The dynamic control module is used to control the thermal control unit to dynamically regulate the temperature of the sheet metal during the stamping process based on the optimal forming condition parameters of the sheet metal, the structure of the sheet metal to be formed, and the temperature data collected and output by the thermal control unit; furthermore, the dynamic control module is also used to control the dynamic compensation component to adjust the distribution of the blank holder force of the sheet metal. The multi-level temperature field control module includes: The first calculation unit is used to construct a thermal deformation constitutive relationship model based on the basic material parameters of the plate and the thermal deformation constitutive equation, and to use the thermal deformation constitutive relationship model to obtain the mechanical response parameters of the plate under different process conditions. The second calculation unit is used to construct a dynamic recrystallization critical model based on the mechanical response parameters and basic material parameters of the plate, combined with the Zener-Hollomon parametric equation and critical strain equation, and to use the dynamic recrystallization critical model to obtain the boundary control parameters for the plate to undergo dynamic recrystallization. The third calculation unit is used to construct a deformation window prediction model based on the boundary control parameters, mechanical response parameters and basic material parameters of the sheet metal, combined with the power dissipation efficiency equation, and to use the deformation window prediction model to predict whether the sheet metal can undergo stable plastic deformation under different stamping control parameters, and output the boundary between the safe forming range and the unstable zone. The fourth calculation unit is used to construct a gradient temperature field control model based on the basic material parameters and stamping control parameters for stable plastic deformation of the plate, combined with the structure to be formed and the transient heat transfer equation of the plate, and to use the gradient temperature field control model to obtain the heating control parameters of different structural regions of the plate. The fifth calculation unit is used to construct a gradient cooling residual stress model based on the basic material parameters of the plate and the heating control parameters of different structural zones, combined with the thermoelastic stress equation, and to use the gradient cooling residual stress model to predict the residual stress distribution of the plate after molding, as well as the corresponding cooling control parameters.

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