Forge piece blanking method based on simulation technology and control device

Abstract

The invention belongs to the technical field of metal forgings, and particularly relates to a forge piece blanking method based on a simulation technology and a control device. The method comprises the steps that firstly, the machining allowance is designed on the basis of the outline of a part finished product, the total material volume needed for producing a forge piece and the corresponding bar size are determined based on the machining allowance, and then the whole part forging process is simulated according to the bar size based on machining equipment needed for producing the forge piece and physical and thermodynamic data of the bar, if the forge piece obtained after simulation has the forging defect, optimizing and adjusting the total volume of the material according to the forging defect, and simulating the whole forging process of the part again according to the bar size corresponding to the optimized and adjusted total volume of the material; and the forged piece obtained after simulation is analyzed again, if forging defects still exist, the material total volume and simulation analysis are repeatedly optimized till the forged piece obtained after simulation meets the requirement, the optimal blanking size is determined based on the corresponding bar size during final simulation, and the material utilization rate is increased.

Description

Technical Field

[0001] This invention belongs to the field of metal forging technology, specifically relating to a forging blanking method and control device based on simulation technology. Background Technology

[0002] Forging is a complex process involving metal flow and heat exchange, solid-state phase transformation, and friction and wear between the billet and the die cavity. Forgings are parts obtained by forging and deforming metal billets. Problems such as deformation temperature rise, forging burrs, forging defects, forging chamfers, die cavity wear, and low turning efficiency are all related to the blanking weight (or volume). Chinese patent application CN115365441A discloses a method for calculating the blanking weight of forgings. Based on the forging manufacturing requirements, it records the dimensions of each part of the forging and sets allowances. The blanking weight is calculated based on these dimensions and allowances. When the forging is a ring, the allowance is set according to the range of the ring's outer diameter, height, and the difference between the outer and inner diameters. When the forging is a disc, the allowance is set according to the range of the disc's outer diameter. This method is only applicable to the calculation of blank weight for forging rings and forging discs, and its scope of application is relatively small. Furthermore, the forging processes of different materials and the forging processes of the same material in different forging equipment are not completely consistent. Using a fixed allowance value is not accurate, and the blank weight is prone to being too large or too small. When the blank weight is too large, the forgings obtained need to be rough turned before entering the CNC precision turning to unify the dimensions. When the blank weight is too small, it is easy to produce unqualified forgings such as missing pieces. Both of these situations will cause material waste during processing, resulting in low material utilization.

[0003] For bearing parts, the current design of bearing forging blanks often uses CAD or other graphic software to design a certain machining allowance based on the finished product outline and empirical values. Based on the principle of constant volume, the required bar dimensions (diameter and length) for forging are calculated using formulas. The blank is then cut according to these calculated parameters before forging. This method relies on human experience to design the machining allowance, which is often inaccurate. It frequently involves roughening the forging outline, leading to uneven machining allowances throughout the bearing part. For example... Figure 1 As shown, when the blank weight is too large, forging defects such as large burrs are easily generated. The ratio of the weight of the forged part to the weight of the finished bearing part is too high. Forgings with large allowances need to be rough turned before entering CNC precision turning to unify the dimensions, which affects the processing efficiency, the material utilization rate is low, and the wear of the mold is more prominent.

[0004] With the development of near-net-shape forming technology, the demand for lightweight bearing forgings is receiving increasing attention. Small and medium-sized bearing parts are generally mass-produced, and improving material utilization is crucial for enterprises to enhance operational quality and reduce costs. Therefore, there is an urgent need for a method to accurately design the weight of forging blanks to improve material utilization, increase processing efficiency, and reduce production costs in the forging process. Summary of the Invention

[0005] The purpose of this invention is to provide a forging blanking method and control device based on simulation technology, so as to solve the problem of low material utilization caused by inaccurate blanking dimensions of forgings designed by existing methods.

[0006] To solve the above-mentioned technical problems, this invention provides a forging blanking method based on simulation technology, comprising the following steps:

[0007] 1) Design the machining allowance based on the finished part outline, and determine the total material volume required to produce the forging and the corresponding bar stock size based on the machining allowance;

[0008] 2) Based on the physical and thermodynamic data of the processing equipment and bars required for producing forgings, and according to the bar dimensions, the entire forging process of the parts is simulated;

[0009] 3) If the forging obtained after simulation has forging defects, the total material volume is optimized and adjusted according to the forging defects. The entire forging process of the part is simulated again according to the bar size corresponding to the optimized total material volume. The forging obtained after simulation is analyzed again. If forging defects still exist, the total material volume is optimized and the simulation analysis is repeated until the forging obtained after simulation meets the requirements.

[0010] 4) Determine the optimal cutting size based on the bar stock size corresponding to the final simulation.

[0011] Furthermore, the forging defects include excessively large forging burrs, which refers to burrs exceeding the standard value for forging burr size; when the forging burrs obtained after simulation are excessively large, the optimization adjustment refers to reducing the total volume of the material.

[0012] Furthermore, the forging defects also include filling defects. When the forging obtained after simulation has filling defects, the optimization adjustment refers to redetermining the total material volume required to produce the forging after increasing the machining allowance at the filling defect.

[0013] Further, the total material volume in step 1) is the sum of the machining allowance volume, the finished part volume, and the flash volume corresponding to the flash size; the flash size includes the flash width and the flash thickness.

[0014] Furthermore, the forging defect includes excessive flash, which means that the width of the flash in the forging exceeds the designed flash width; when the flash width of the forging is excessive after simulation, the optimization adjustment refers to reducing the total volume of the material.

[0015] Further, the total material volume in step 1) is the sum of the machining allowance volume, the finished part volume, and the core volume corresponding to the core size; the core size includes the core thickness.

[0016] Furthermore, the forging defects also include core thickness, which refers to the designed core thickness; when the core thickness of the forging obtained after simulation is too thick, the optimization adjustment refers to reducing the total volume of the material.

[0017] Furthermore, the method also includes: when simulating the entire forging process of the part according to the bar stock size, the temperature field during the forging process is also analyzed, and when overheating occurs during the simulation, the total volume of the material is reduced.

[0018] Furthermore, the optimal blanking size in step 4) is obtained by correcting the bar size corresponding to the final simulation using the weight loss from heating.

[0019] The beneficial effects of the above technical solution are as follows: This invention is an improved invention. First, a machining allowance is designed on the finished part contour. Based on the designed machining allowance, the total material volume required for the forging is determined. After converting the total material volume into bar stock dimensions, the entire forging process is simulated in simulation software based on the corresponding processing equipment and the physical and thermodynamic data of the bar stock material during forging production. The total material volume is adjusted based on the simulation results. Under the premise of ensuring quality, the optimal solution for blanking is obtained. Simulation technology provides a solution for precise blanking, avoiding the problems of low material utilization, need for rough machining, large forging defects, and rapid die damage caused by excessive or insufficient blanking weight (or volume). This improves the material utilization rate and part processing efficiency of forging processing and reduces enterprise costs.

[0020] To address the aforementioned technical problems, this invention also provides a forging blanking control device based on simulation technology. This device controls the blanking process according to the optimal blanking dimensions determined by a forging blanking method based on simulation technology. The method includes the following steps:

[0021] 1) Design the machining allowance based on the finished part outline, and determine the total material volume required to produce the forging and the corresponding bar stock size based on the machining allowance;

[0022] 2) Based on the physical and thermodynamic data of the processing equipment and bars required for producing forgings, and according to the bar dimensions, the entire forging process of the parts is simulated;

[0023] 3) If the forging obtained after simulation has forging defects, the total material volume is optimized and adjusted according to the forging defects. The entire forging process of the part is simulated again according to the bar size corresponding to the optimized total material volume. The forging obtained after simulation is analyzed again. If forging defects still exist, the total material volume is optimized and the simulation analysis is repeated until the forging obtained after simulation meets the requirements.

[0024] 4) Determine the optimal cutting size based on the bar stock size corresponding to the final simulation.

[0025] Furthermore, the forging defects include excessively large forging burrs, which refers to burrs exceeding the standard value for forging burr size; when the forging burrs obtained after simulation are excessively large, the optimization adjustment refers to reducing the total volume of the material.

[0026] Furthermore, the forging defects also include filling defects. When the forging obtained after simulation has filling defects, the optimization adjustment refers to redetermining the total material volume required to produce the forging after increasing the machining allowance at the filling defect.

[0027] Further, the total material volume in step 1) is the sum of the machining allowance volume, the finished part volume, and the flash volume corresponding to the flash size; the flash size includes the flash width and the flash thickness.

[0028] Furthermore, the forging defect includes excessive flash, which means that the width of the flash in the forging exceeds the designed flash width; when the flash width of the forging is excessive after simulation, the optimization adjustment refers to reducing the total volume of the material.

[0029] Further, the total material volume in step 1) is the sum of the machining allowance volume, the finished part volume, and the core volume corresponding to the core size; the core size includes the core thickness.

[0030] Furthermore, the forging defects also include core thickness, which refers to the designed core thickness; when the core thickness of the forging obtained after simulation is too thick, the optimization adjustment refers to reducing the total volume of the material.

[0031] Furthermore, the method also includes: when simulating the entire forging process of the part according to the bar stock size, the temperature field during the forging process is also analyzed, and when overheating occurs during the simulation, the total volume of the material is reduced.

[0032] Furthermore, the optimal blanking size in step 4) is obtained by correcting the bar size corresponding to the final simulation using the weight loss from heating.

[0033] The beneficial effects of the above technical solution are as follows: This invention is an improved invention that designs the bar stock size used in forging blanking. First, a machining allowance is designed on the finished part contour. Based on the designed machining allowance, the total material volume required for the forging is determined. After converting the total material volume into bar stock size, the entire forging process is simulated in simulation software based on the corresponding processing equipment and the physical and thermodynamic data of the bar stock material during forging production. The total material volume is adjusted based on the simulation results. Under the premise of ensuring quality, the optimal blanking solution is obtained. Simulation technology provides a solution for precise blanking, avoiding the problems of low material utilization, need for rough machining, large forging defects, and rapid die damage caused by excessive or insufficient blanking weight (or volume). This improves the material utilization rate and part processing efficiency of forging processing and reduces enterprise costs. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the outline of a forging in the prior art;

[0035] Figure 2 This is a schematic diagram of the steel ball forging design of the present invention;

[0036] Figure 3 This is the simulated equivalent stress diagram of the initial state of the steel ball forging according to the present invention;

[0037] Figure 4 This is a simulated temperature field diagram of the steel ball forging process according to the present invention;

[0038] Figure 5 This is an equivalent stress diagram of the simulated steel ball forging process of the present invention;

[0039] Figure 6 This is a simulation of the equivalent deformation diagram of a steel ball forging during the forging process of the present invention;

[0040] Figure 7 This is a simulated temperature field diagram of the steel ball forging after mold closing, based on the present invention.

[0041] Figure 8 This is a simulation of the forming effect of the steel ball forging after mold closing, based on the present invention.

[0042] Figure 9 This is a simulation of the forming effect of the steel ball forging after mold closing, after adjusting the total volume of the material according to the present invention.

[0043] Figure 10 This is a schematic diagram of the bearing ring forging design of the present invention;

[0044] Figure 11 This is a three-dimensional solid schematic diagram of the bearing ring forging section obtained by rotating the cross section of the present invention;

[0045] Figure 12 This is a simulated temperature field diagram of the bearing ring forging in its initial state according to the present invention.

[0046] Figure 13 This is a simulated temperature field diagram of the initial state of the pre-forming bearing ring forging according to the present invention.

[0047] Figure 14 This is a simulated temperature field diagram of the bearing ring forging completed state according to the present invention.

[0048] Figure 15 This is a simulated temperature field diagram of the bearing ring forging completed punching state according to the present invention;

[0049] Figure 16 This is a temperature field diagram of the completed punching state after the overall material volume is adjusted according to the present invention.

[0050] Figure 17 This is a flowchart of the forging blanking process based on simulation technology of the present invention. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of the present invention clearer, the specific embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0052] After designing the machining allowance for the finished part contour, this invention simulates the forging process of the part based on the total material volume and bar size required for the set machining allowance. The simulation results are used to adjust the total material volume to obtain the optimal blanking parameters.

[0053] Method Implementation

[0054] This invention provides a forging blanking method based on simulation technology, which can produce forgings that meet quality requirements with minimal material consumption while ensuring forging quality. This method is particularly suitable for the precise design of the blanking volume (or weight) of forgings for mass production of bearing parts using precision die forging. Figure 17 As shown, it includes the following steps:

[0055] 1. Design machining allowance on the finished part outline.

[0056] Image drawing software is used to design transition fillets and appropriate machining allowances on the finished part contour.

[0057] CAD software can be used for image drawing. The machining allowance design should fully consider the rigidity of the forging, taking the minimum value that simultaneously satisfies the requirements of heating oxidation and decarburization performance, forging form and position tolerances, and die cavity forming performance. The shape design should fully consider the feasibility of forming the forging blank; the forging contour should fit the dimensions of the workpiece during subsequent finishing, ensuring uniform allowance, and using smooth transitions at contour corners.

[0058] 2. Determine the total volume of material required for producing forgings and the corresponding bar stock dimensions based on the machining allowance.

[0059] Specifically, select the processing equipment required for producing forgings, design the forging process, and determine whether it is necessary to increase the volume of flash or core material based on the characteristics of the parts and the mold structure, and determine the total volume of material required for producing die forgings.

[0060] If no additional flash or core volume is required, the total material volume required to produce the forging is the sum of the machining allowance volume and the finished part volume.

[0061] If the part is a bearing roller, steel ball, or the mold structure is complex, the flash size needs to be designed. The total material volume is the sum of the machining allowance volume, the finished part volume, and the flash volume corresponding to the flash size. The flash size includes the flash width and flash thickness.

[0062] If the part has a perforated structure, such as a bearing ring, then the core size needs to be designed. The total material volume is the sum of the machining allowance volume, the finished part volume, and the core volume corresponding to the core size; the core size includes the core thickness.

[0063] The bar stock dimensions are determined based on the total material volume, which includes the bar diameter and bar length, thereby converting the total material volume into a bar stock with a suitable length-to-diameter ratio. The preferred length-to-diameter ratio range is 1.3-1.8.

[0064] To improve the accuracy of the total material volume, when the parts are bearing rings, rollers, and retainers, which have rotationally symmetric cross-sections, 3D modeling is used to calculate the total material volume. The specific steps are as follows:

[0065] 1) Draw the two-dimensional cross-sectional outline of the forging at a 1:1 scale in CAD graphics software and create a "region";

[0066] 2) Draw the center line of rotation;

[0067] 3) Use the "Solid-3D Modeling-Rotation" function in the graphics software to generate a 3D solid graphic;

[0068] 4) Select the entity and use the "Calculate Volume" command to obtain the precise volume value.

[0069] The software-based calculation of the total volume of forging material is more accurate and has less error compared to the calculation using formulas. It can accurately calculate the material volume at fine structures such as fillets in forgings.

[0070] 3. Based on the physical and thermodynamic data of the processing equipment and bar stock required for producing forgings, and according to the bar stock dimensions, the entire forging process of the parts is simulated.

[0071] Simulation software is used to simulate the entire forging process of bearing parts. Based on the simulation results, the total volume (or weight) of the material is adjusted to obtain the optimal material cutting solution while ensuring quality. Simulation software such as Deform can be used.

[0072] Specifically, the basic physical and thermodynamic data of the bearing component material (i.e., bar stock) required for simulation are obtained, the coefficient of thermal expansion of the bar stock at the hot forming temperature during forging is determined, and the corresponding bar stock length and diameter are calculated for simulation. In the simulation software, the bar stock is modeled and meshed according to the calculated bar stock length and diameter, and the simulation is performed according to the corresponding process of the entire forging process, executing process calculations.

[0073] 4. Simulation analysis and optimization.

[0074] In the post-processing window of the simulation software, observe and analyze the forging defects, material distribution, and flash groove flow pattern after simulation to obtain the optimization strategy. Repeat the above steps according to the optimization strategy until the optimal solution for blanking size is obtained.

[0075] Specifically, if the forging obtained after simulation has forging defects, the total material volume is optimized and adjusted according to the forging defects. The entire forging process is then simulated again based on the bar size corresponding to the optimized total material volume. The forging obtained after simulation is analyzed again. If forging defects still exist, the optimization of the total material volume and simulation analysis are repeated until the forging obtained after simulation meets the requirements. Material allocation refers to the filling situation of the material in the mold cavity. For example, if there is insufficient filling of metal material near the runner, flash is added; if the flash size is too large or the temperature rise is abnormal, flash is reduced; if the equipment load exceeds the limit, the core volume is increased; if the core is too thick, the core volume is reduced. The total material volume required for producing the die forging is determined based on the optimization results.

[0076] Specifically, forging defects include:

[0077] 1) Excessive burrs on forgings. Excessive burrs on forgings refer to burrs exceeding the standard value for forging burrs. When the burrs on the forgings obtained after simulation are too large, the total volume of the material should be reduced.

[0078] 2) Filling defects. When the forging obtained after simulation has filling defects, the total material volume required to produce the forging is re-determined after increasing the machining allowance at the filling defect location.

[0079] 3) Excessive flash. Excessive flash refers to the flash width of the forging exceeding the designed flash width. When the flash width of the bearing roller forging obtained after simulation is excessive, the total material volume should be reduced. For example, when the part is a bearing roller, the reduction in total material volume is calculated using the following formula:

[0080]

[0081] in, This refers to the reduction in the total material volume when the flash is wide. The bearing roller diameter obtained after simulation. This is the flash diameter obtained after simulation. The thickness of the flash is obtained after simulation.

[0082] 4) Core thickness is too high. Core thickness refers to the designed core thickness. When the core of the bearing roller forging obtained after simulation is too thick, the overall material volume should be reduced.

[0083] 5) Folding defects.

[0084] When the forging obtained after simulation has folding defects, the mold structure is optimized and the blanking volume is reduced.

[0085] When simulating the entire forging process of a part according to the bar stock size, the temperature field during the forging process is also analyzed. When overheating occurs during the simulation, the total volume of the material is reduced.

[0086] When simulating the entire forging process of a part according to the bar stock size, the stress and strain field during the forging process is also analyzed to observe whether the stress at various points of the forging is appropriate and whether the deformation is uniform. Based on the observation results, it is determined whether the mold structure needs to be adjusted.

[0087] Preferably, considering that bearing parts are mostly axisymmetric geometry, when the part is a bearing part, 2D mode is used for simulation, which makes the calculation and solution faster and significantly improves efficiency.

[0088] 5. Determine the optimal cutting size based on the bar stock size corresponding to the final simulation.

[0089] In one embodiment, the bar stock size corresponding to the final simulation is used as the optimal cutting size.

[0090] In a preferred embodiment, heating weight loss is also considered. The bar stock dimensions corresponding to the final simulation are corrected using the heating weight loss, and the corrected bar stock dimensions are used as the optimal blanking dimensions. The optimal blanking dimensions include the optimal blanking diameter and the optimal blanking length. Precise blanking control is performed based on the optimal blanking dimensions of each part.

[0091] The correction method is as follows: multiply the bar stock cutting length corresponding to the final simulation by the heat loss coefficient to obtain the optimal cutting length, and take the bar stock diameter corresponding to the final simulation as the optimal cutting diameter.

[0092] Device Implementation

[0093] This invention discloses a forging blanking control device based on simulation technology. This device controls the blanking process according to the optimal blanking dimensions determined by a forging blanking method based on simulation technology. The method includes:

[0094] S1. Design machining allowance on the finished part outline.

[0095] Image drawing software is used to design transition fillets and appropriate machining allowances on the finished part contour.

[0096] The machining allowance design should fully consider the rigidity of the forging, taking the minimum value that simultaneously satisfies the requirements of heating oxidation and decarburization performance, forging form and position tolerances, and die cavity forming performance. The shape design should fully consider the feasibility of forming the forging blank, and the forging contour should fit the dimensions of the workpiece during subsequent finishing, ensuring uniform allowance and smooth transitions at contour corners.

[0097] S2. Determine the total material volume required for producing forgings and the corresponding bar dimensions based on the machining allowance.

[0098] Specifically, select the processing equipment required for producing forgings, design the forging process, and determine whether it is necessary to increase the volume of flash or core material based on the characteristics of the parts and the mold structure, and determine the total volume of material required for producing die forgings.

[0099] If no additional flash or core volume is required, the total material volume required to produce the forging is the sum of the machining allowance volume and the finished part volume.

[0100] If the part is a bearing roller, steel ball, or the mold structure is complex, the flash size needs to be designed. The total material volume is the sum of the machining allowance volume, the finished part volume, and the flash volume corresponding to the flash size. The flash size includes the flash width and flash thickness.

[0101] If the part has a perforated structure, such as a bearing ring, then the core size needs to be designed. The total material volume is the sum of the machining allowance volume, the finished part volume, and the core volume corresponding to the core size; the core size includes the core thickness.

[0102] The bar stock dimensions are determined based on the total material volume, which includes the bar diameter and bar length, thereby converting the total material volume into a bar stock with a suitable length-to-diameter ratio. The preferred length-to-diameter ratio range is 1.3-1.8.

[0103] To improve the accuracy of the total material volume, when the parts are bearing rings, rollers, and retainers, which have rotationally symmetric cross-sections, 3D modeling is used to calculate the total material volume. The specific steps are as follows:

[0104] 1) Draw the two-dimensional cross-sectional outline of the forging at a 1:1 scale in CAD graphics software and create a "region";

[0105] 2) Draw the center line of rotation;

[0106] 3) Use the "Solid-3D Modeling-Rotation" function in the graphics software to generate a 3D solid graphic;

[0107] 4) Select the entity and use the "Calculate Volume" command to obtain the precise volume value.

[0108] S3. Based on the physical and thermodynamic data of the processing equipment and bar stock required for producing forgings, and according to the bar stock dimensions, the entire forging process of the parts is simulated.

[0109] Simulation software is used to simulate the entire forging process of bearing parts. The total volume (or weight) of the material is adjusted based on the simulation results to obtain the optimal material cutting solution while ensuring quality.

[0110] Specifically, the basic physical and thermodynamic data of the bearing component material (i.e., bar stock) required for simulation are obtained, the coefficient of thermal expansion of the bar stock at the hot forming temperature during forging is determined, and the corresponding bar stock length and diameter for simulation are calculated. In the simulation software, the bar stock is modeled and meshed according to the calculated bar stock length and diameter, and the simulation is performed according to the corresponding process of the entire forging process, executing process calculations.

[0111] S4. Simulation Analysis and Optimization.

[0112] In the post-processing window of the simulation software, observe and analyze the forging defects, material distribution, and flash groove flow pattern after simulation to obtain the optimization strategy. Repeat the above steps according to the optimization strategy until the optimal solution for blanking size is obtained.

[0113] Specifically, if the forging obtained after simulation has forging defects, the total material volume is optimized and adjusted according to the forging defects. The entire forging process is then simulated again based on the bar size corresponding to the optimized total material volume. The forging obtained after simulation is analyzed again. If forging defects still exist, the optimization of the total material volume and simulation analysis are repeated until the forging obtained after simulation meets the requirements. Material allocation refers to the filling situation of the material in the mold cavity. For example, if there is insufficient filling of metal material near the runner, flash is added; if the flash size is too large or the temperature rise is abnormal, flash is reduced; if the equipment load exceeds the limit, the core volume is increased; if the core is too thick, the core volume is reduced. The total material volume required for producing the die forging is determined based on the optimization results.

[0114] Specifically, forging defects include:

[0115] 1) Excessive burrs on forgings. Excessive burrs on forgings refer to burrs exceeding the standard value for forging burrs. When the burrs on the forgings obtained after simulation are too large, the total volume of the material should be reduced.

[0116] 2) Filling defects. When the forging obtained after simulation has filling defects, the total material volume required to produce the forging is re-determined after increasing the machining allowance at the filling defect location.

[0117] 3) Excessive flash. Excessive flash refers to the flash width of the forging exceeding the designed flash width. When the flash width of the bearing roller forging obtained after simulation is excessive, the total material volume should be reduced. For example, when the part is a bearing roller, the reduction in total material volume is calculated using the following formula:

[0118]

[0119] in, This refers to the reduction in the total material volume when the flash is wide. The bearing roller diameter obtained after simulation. This is the flash diameter obtained after simulation. The thickness of the flash is obtained after simulation.

[0120] 4) Core thickness is too high. Core thickness refers to the designed core thickness. When the core of the bearing roller forging obtained after simulation is too thick, the overall material volume should be reduced.

[0121] 5) Folding defects.

[0122] When the forging obtained after simulation has folding defects, the mold structure is optimized and the blanking volume is reduced.

[0123] When simulating the entire forging process of a part according to the bar stock size, the temperature field during the forging process is also analyzed. When overheating occurs during the simulation, the total volume of the material is reduced.

[0124] When simulating the entire forging process of a part according to the bar stock size, the stress and strain field during the forging process is also analyzed to observe whether the stress at various points of the forging is appropriate and whether the deformation is uniform. Based on the observation results, it is determined whether the mold structure needs to be adjusted.

[0125] Preferably, considering that bearing parts are mostly axisymmetric geometry, when the part is a bearing part, 2D mode is used for simulation, which makes the calculation and solution faster and significantly improves efficiency.

[0126] 5. Determine the optimal cutting size based on the bar stock size corresponding to the final simulation.

[0127] In one embodiment, the bar stock size corresponding to the final simulation is used as the optimal cutting size.

[0128] In a preferred embodiment, heating weight loss is also considered. The bar stock dimensions corresponding to the final simulation are corrected using the heating weight loss, and the corrected bar stock dimensions are used as the optimal blanking dimensions. The optimal blanking dimensions include the optimal blanking diameter and the optimal blanking length. Precise blanking control is performed based on the optimal blanking dimensions of each part.

[0129] The correction method is as follows: multiply the bar stock cutting length corresponding to the final simulation by the heat loss coefficient to obtain the optimal cutting length, and take the bar stock diameter corresponding to the final simulation as the optimal cutting diameter.

[0130] The present invention will now be described using bearing steel balls and bearing rings as examples.

[0131] Bearing steel ball embodiment

[0132] The finished size of the bearing steel ball is Φ60.325mm, the material is GCr15SiMn, and the chemical composition is shown in Table 1. The unit of measurement for each chemical component in Table 1 is mass percentage (wt%).

[0133] Table 1

[0134]

[0135] 1. Design the process for the Φ60.325mm steel ball forging.

[0136] The machining allowance for the finished part is set at 1.5 + 0.3 mm, meaning the diameter of the forged ball at room temperature is Φ63.3 + 0.6 mm, the flash groove thickness is designed to be 1.5 mm, and the flash width is 3 mm. The steel ball forging design is as follows: Figure 2 As shown.

[0137] 2. Calculate the total volume of the materials.

[0138] Based on the dimensions of the steel ball, a 315T mechanical press billet was selected, and the forging process was "heating-forming-cooling". The raw material was GCr15SiMn bar stock, according to... Using the formula R = (63.3 + 0.6) / 2, the cold-state volume of the steel ball forging is calculated to be 136547 mm². 3 .according to Using the formula, taking D as (63.3 + 0.6 + 6), d as (63.3 + 0.6), and h as 1.5, the flash volume is found to be 945 mm². 3 The actual cold volume required for forming is the sum of the two, 137492 mm². 3 .

[0139] 3. Calculate the cutting dimensions.

[0140] The calculated suitable effective blanking size is Φ42×99.3mm.

[0141] 4. Simulation.

[0142] The coefficient of thermal expansion of the bar stock at a forging temperature of 1040℃ is 1.013. Multiplying the blank size calculated in step 3 by 1.013 yields a blank size of Φ42.5×100.6mm for simulation. This Φ42.5×100.6mm blank is then imported into Deform software for forging process simulation, and the temperature field, stress-strain field, and forging defects are observed during deformation. The simulation results of the forging process are as follows: Figure 3-8 As shown.

[0143] 5. Optimization.

[0144] Depend on Figure 8 It can be seen that when the crank slider of the 315T press reaches the bottom dead center of the mold, the temperature rise at the junction of the flash and the steel ball is about 60℃, and the actual width of the flash reaches 17.7mm, with no filling defects. The reference hot ball diameter is 63.3 × 1.013 = 64mm. The compressible material volume is [(64 + 17.7 × 2)]. 2 -64 2 ] / 4×3.14×1.5=6811mm 3 The equivalent length of the cold-state bar stock is 4.8mm, meaning the cutting size is adjusted to Φ42×94.5mm.

[0145] The simulation was re-performed based on the adjusted blanking dimensions, and the simulation results are as follows: Figure 9 As shown, the temperature rise at the junction of the flash and the steel ball is about 20°C, and the flash width is 2mm, which is smaller than the preset flash width. There are no filling defects, achieving the optimization effect.

[0146] 6. Determine the optimal cutting dimensions.

[0147] The simulated and optimized blanking size Φ42×94.5mm was corrected. Considering the weight heat loss coefficient of 1.005, the optimal blanking size is Φ42×95mm.

[0148] Bearing ring embodiment

[0149] The bearing ring is made of G20Cr2Ni4, and its chemical composition is shown in Table 2. The unit of measurement for each chemical component in Table 2 is mass percentage (wt%).

[0150] Table 2

[0151]

[0152] 1. Design the process for this bearing ring forging, setting the machining allowance to the finished product as (2~3) mm. For example... Figure 10 As shown, the blue outline represents the finished contour of the bearing ring.

[0153] 2. Based on the dimensions of the forging, a 1T die forging hammer is selected for billet preparation. The processing flow is "heating pre-forming - forming - piercing - cooling". A 3D solid model is created using CAD software, such as... Figure 11 As shown.

[0154] 3. The calculated cold volume of the forging is 137182.6 mm². 3 The core thickness is 8mm, and the core volume is calculated as follows: The calculation yields 12158mm. 3 The actual cold volume required for forming is the sum of the two, 149341 mm². 3 .

[0155] 4. The corresponding effective blanking size is calculated to be Φ50×76mm.

[0156] 5. Multiply the result calculated in step 4 by the corresponding coefficient of thermal expansion of 1.013 at 1150℃ to obtain the blank size required for simulation as Φ50.7×77mm. Import the blank into Deform software according to Φ50.7×77mm for simulation and observe the temperature field, stress-strain field and forging defects during deformation.

[0157] 6. Simulation analysis and optimization.

[0158] Simulation results of the forging process are as follows Figure 12-15 As shown. When the forging hammer completes the blanking, the highest temperature of the forging rises to approximately 60°C. A folding defect appears at the rounded corner of the flange. Software measurement shows a fold depth of 0.5mm, with a corresponding machining allowance of 3mm. This can be removed during subsequent machining without adding any allowance. The core thickness of 8mm is too thick and can be optimized to 5mm, which would reduce the material volume to 4560mm². 3 The equivalent length of the cold-state bar stock is 2.3mm, meaning the blanking dimensions are adjusted to Φ50×73.7mm.

[0159] The simulation was repeated according to the adjusted blanking dimensions, and the results are as follows: Figure 16 As shown, the obtained core thickness is 5mm, with no filling defects, and the maximum temperature rise is 70℃. The evaluation is within the safe range of forging temperature. Slight burrs are extruded at the bottom of the forging at the die gap, which does not affect the final product quality and achieves the optimization effect.

[0160] 7. Determine the optimal cutting dimensions.

[0161] The simulated and optimized blanking size Φ50×73.7mm was corrected. Considering the weight heat loss coefficient of 1.005, the appropriate blanking size is Φ50×74mm.

[0162] It should be noted that although the present invention has been described through the above embodiments, the present invention may have many other embodiments. Without departing from the spirit and scope of the present invention, those skilled in the art can obviously make various corresponding changes and modifications to the present invention, but all such changes and modifications should fall within the scope of protection of the appended claims and their equivalents.

[0163] This invention first uses drawing software to set appropriate machining allowances, then calculates the total material volume based on flash or core volume to determine the corresponding blanking dimensions. Next, simulation software is used to simulate the entire forging process of bearing parts. The blanking volume is adjusted based on the simulation results to obtain the optimal blanking solution while ensuring quality. Furthermore, heat loss is calculated to arrive at the final blanking dimensions, thus providing a solution for precise blanking. This effectively solves many problems caused by relying on experience-based calculations of blanking weight, such as high material loss, poor forging quality, low processing efficiency, and premature die damage. It significantly improves material utilization and reduces material and energy waste. Since small and medium-sized bearing parts are generally produced in batches, improved material utilization is crucial for improving operational quality and reducing costs for enterprises. It also has practical value for precise blanking control in the development of precision forging processes for new products and equipment.

Claims

1. A forging blanking method based on simulation technology, characterized in that, Includes the following steps: 1) Design the machining allowance based on the finished part outline, and determine the total material volume required to produce the forging and the corresponding bar stock size based on the machining allowance; 2) Based on the physical and thermodynamic data of the processing equipment and bars required for producing forgings, and according to the bar dimensions, the entire forging process of the parts is simulated; 3) If the forging obtained after simulation has forging defects, the total material volume is optimized and adjusted according to the forging defects. The entire forging process of the part is simulated again according to the bar size corresponding to the optimized total material volume. The forging obtained after simulation is analyzed again. If forging defects still exist, the total material volume is optimized and the simulation analysis is repeated until the forging obtained after simulation meets the requirements. 4) Determine the optimal cutting size based on the bar stock size corresponding to the final simulation.

2. The forging blanking method based on simulation technology according to claim 1, characterized in that, The forging defects include excessively large forging burrs, which refers to burrs exceeding the standard value for forging burr size; when the simulation results show excessively large forging burrs, the optimization adjustment refers to reducing the total volume of the material.

3. The forging blanking method based on simulation technology according to claim 2, characterized in that, The forging defects also include filling defects. When the forging obtained after simulation has filling defects, the optimization adjustment refers to redetermining the total material volume required to produce the forging after increasing the machining allowance at the filling defect.

4. The forging blanking method based on simulation technology according to any one of claims 1-3, characterized in that, The total material volume in step 1) is the sum of the machining allowance volume, the finished part volume, and the flash volume corresponding to the flash size; the flash size includes the flash width and flash thickness.

5. The forging blanking method based on simulation technology according to claim 4, characterized in that, The forging defects include excessive flash, which means that the width of the flash in the forging exceeds the designed flash width; when the flash width of the forging is excessive after simulation, the optimization adjustment refers to reducing the total volume of the material.

6. The forging blanking method based on simulation technology according to any one of claims 1-3, characterized in that, The total material volume in step 1) is the sum of the machining allowance volume, the finished part volume, and the core volume corresponding to the core size; the core size includes the core thickness.

7. The forging blanking method based on simulation technology according to claim 6, characterized in that, The forging defects also include core thickness, which refers to the designed core thickness; when the core thickness of the forging obtained after simulation is too thick, the optimization adjustment refers to reducing the total volume of the material.

8. The forging blanking method based on simulation technology according to claim 1, characterized in that, The method also includes: when simulating the entire forging process of the part according to the bar stock size, the temperature field during the forging process is also analyzed, and when overheating occurs during the simulation, the total volume of the material is reduced.

9. The forging blanking method based on simulation technology according to claim 1, characterized in that, The optimal blanking size in step 4) is obtained by correcting the bar size corresponding to the final simulation using the weight loss from heating.

10. A forging blanking control device based on simulation technology, characterized in that, The device controls the blanking according to the optimal blanking size determined by the simulation-based forging blanking method as described in any one of claims 1-9.

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