Forging method of disc forging cake blank

Abstract

The invention relates to a forging method of a disc forging cake blank, which belongs to the technical field of forging, and comprises the following steps: designing to obtain a cake blank with a positioning hole according to a disc forging and die forging positioning requirements of the disc forging; an upper swage with a punch is designed and manufactured according to the cake blank, the punch is matched with the positioning hole, then a needed bar is obtained according to the material of the cake blank, the bar is forged and pressed through an upper flat anvil, the bar is upset to the specified height, the upper swage replaces the upper flat anvil, the bar with the specified height is continuously forged and pressed, and the bar is continuously upset to form the cake blank; and in the continuous upsetting process, the punch presses a positioning hole in the upper end face of the cake blank. According to the method, in the process of upsetting the bar to form the cake blank, the positioning hole is formed in the end face of the cake blank, so that the cake blank obtained through the method does not need additional machining to machine the positioning hole, time and labor are saved, materials needed during blanking of the bar are fewer, the material utilization rate can be increased by adopting the method, and the production cost is reduced. And the cost of disc forgings is reduced.

Description

Technical Field

[0001] This invention belongs to the field of forging technology, and specifically relates to a forging method for disc-shaped forging blanks. Background Technology

[0002] Disc-shaped forgings generally employ a process of upsetting and die forging. Heated bar stock is upset into a disc shape, and after cooling, a blind hole is machined at the center of the disc's end face as a locating hole. During die forging, the disc is positioned precisely in the center of the die by matching the locating hole with the die ejector pin, preventing displacement and ensuring uniform forming of the forging. Currently, machining the locating hole at the center of the disc's end face is done by machine, which is time-consuming and labor-intensive. Furthermore, the scrap generated during machining is usually discarded, resulting in material waste.

[0003] For example, a high-temperature alloy disc forging weighs 961 kg and has dimensions of φ350×960 mm. After upsetting, the blank height is 260 mm. A φ200 mm, 35 mm deep positioning hole needs to be machined to meet the positioning requirements during die forging. The material loss due to machining this positioning hole is approximately 13.5 kg, accounting for 1.4% of the blank weight, with a material loss of approximately 4700 yuan per piece. Statistics show that for other disc forgings, the material loss due to machining the positioning hole accounts for 1.1%-1.8% of the blank weight, and the wasted time due to blank cooling, transfer, and machining processes is approximately 3-5 days. Summary of the Invention

[0004] This invention provides a forging method for disc-shaped forging blanks. During the process of forming the blank from bar stock through forging and upsetting, the aforementioned positioning holes can be forged on the end face of the blank. This eliminates the need for additional machining after the blank is forged to create the positioning holes, saving time and effort, shortening the production cycle of disc-shaped forgings, and preventing the generation of waste material due to machining the positioning holes. Therefore, less material is required when cutting the bar stock. Thus, this method can also improve material utilization and reduce the cost of disc-shaped forgings.

[0005] This invention is achieved through the following technical solution: a forging method for disc-shaped forging blanks, comprising:

[0006] Step 1: Based on the disc forging and its die forging positioning requirements, design a blank with positioning holes;

[0007] Step 2: Design and manufacture an upper anvil with a punch according to the blank, wherein the punch is adapted to the positioning hole, and then obtain the required bar stock according to the blank material;

[0008] Step 3: Use an upper flat anvil to forge the bar stock, so that the bar stock is upset to the specified height;

[0009] Step 4: Use the upper anvil instead of the upper flat anvil to continue forging the bar stock to a specified height, so that the bar stock continues to be upset to form the blank. During the continued upsetting process, the punch presses out the positioning hole on the upper end surface of the blank.

[0010] Furthermore, to better realize the present invention, the following is also included between step 3 and step 4:

[0011] Step 3.5: When the bar stock is upset to the specified height, the upper flat anvil of the forging bar stock is replaced with the upper shaped anvil using the quick anvil change function of the press.

[0012] Furthermore, in order to better realize the present invention, steps 3 and 4 are completed in the same firing cycle when the bar stock is in the same firing cycle.

[0013] Furthermore, to better implement the present invention, the following is further included between step 3.5 and step 4:

[0014] Step 3.6: Using the centering and positioning function of the press, reposition the bar stock to a suitable position on the press, so that the center area of ​​the top end face of the bar stock is aligned with the punch of the upper anvil.

[0015] Furthermore, in order to better realize the present invention, when the bar stock is upset to the specified height, the top diameter of the bar stock is d, d≥2D, where D is the bottom diameter of the positioning hole;

[0016] The specified height is a, where a ≥ 3H + h, and H is the depth of the positioning hole and h is the height of the dough.

[0017] Furthermore, in order to better realize the present invention, the bottom diameter of the positioning hole is 150-250mm, and the depth of the positioning hole is 15-40mm.

[0018] Furthermore, in order to better realize the present invention, in step 3, the upsetting speed of the bar stock is b;

[0019] In step 4, the upsetting speed of the bar stock is v, where v < b.

[0020] Furthermore, in order to better realize the present invention, in step 3, the upsetting speed of the bar stock is 10-15 mm / s;

[0021] In step 4, the upsetting speed of the bar stock is 8-10 mm / s.

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

[0023] The forging method for disc-shaped forging blanks provided by this invention first involves designing a blank with positioning holes based on the disc-shaped forging and its die forging positioning requirements; then, an upper anvil with a punch is designed and manufactured based on the blank, the punch being adapted to the positioning holes, and the required bar stock is obtained according to the blank material; then, the bar stock is forged using an upper flat anvil to upset it to a specified height; finally, the upper anvil is used instead of the upper flat anvil to continue forging the bar stock to a specified height, so that the bar stock continues to upset to form a blank. During the continued upset process, the punch presses positioning holes on the upper end face of the blank.

[0024] The blank obtained by the above method can form positioning holes on the blank during the upsetting process. These positioning holes are used to position the blank in the mold during the subsequent die forging of the blank into a disc forging. Therefore, the blank obtained by this method does not require additional machining to process the positioning holes, saving time and effort, shortening the production cycle of disc forgings, and avoiding the waste generated by machining the positioning holes. Therefore, less material is required when cutting the bar stock. Thus, this method can also improve material utilization and reduce the cost of disc forgings. Attached Figure Description

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

[0026] Figure 1 This is a flowchart of the forging method for disc-shaped forging blanks provided in the embodiments of the present invention;

[0027] Figure 2 This is a schematic diagram of the final shaped cake obtained in an embodiment of the present invention;

[0028] Figure 3 This is a schematic diagram of the upper anvil structure in an embodiment of the present invention;

[0029] Figure 4 This is a schematic diagram of the structure when upsetting bar stock using an upper flat anvil in an embodiment of the present invention;

[0030] Figure 5 This is a schematic diagram of the structure of a bar stock upsetting to a specified height using an upper flat anvil in an embodiment of the present invention.

[0031] Figure 6 This is a schematic diagram of the structure when upsetting a bar stock to a specified height using an upper anvil in an embodiment of the present invention;

[0032] Figure 7 This is a schematic diagram of the structure of obtaining a blank using an upper anvil upsetting bar stock in an embodiment of the present invention.

[0033] In the picture:

[0034] 10-cake base, 11-positioning hole, 20-upper flat anvil, 30-upper anvil, 31-punch, 40-bar. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0036] Example 1:

[0037] like Figures 1-7 As shown, this embodiment provides a forging method for disc-shaped forging blanks, including the following steps:

[0038] Step 1: Based on the disc forging and its die forging positioning requirements, a blank 10 with positioning holes 11 is designed. This step is actually a reverse design based on the final product (i.e., the disc forging) to obtain the blank 10, and the end face of the blank 10 also has positioning holes 11. The positioning holes 11 are used to position the blank 10 in the mold during the subsequent die forging of the disc forging, and the blank 10 is the billet in the above-mentioned die forging process. The aforementioned positioning hole 11 has the following characteristics: the bottom diameter D of the positioning hole 11 ranges from 150 to 250 mm; the depth H of the positioning hole 11 ranges from 15 to 40 mm; the positioning hole 11 is an open hole and the transition angle S of the positioning hole 11 ranges from 30 to 60°; the fillet radius R1 of the edge of the positioning hole 11 ranges from 10 to 25 mm; and the transition fillet radius R2 between the hole wall and the bottom of the positioning hole 11 ranges from 10 to 25 mm.

[0039] In practice, the bottom diameter of the positioning hole 11 can be 150mm, 200mm or 250mm, the depth of the positioning hole 11 can be 15mm, 20mm, 30mm or 40mm, the transition angle of the positioning hole 11 can be 30°, 45° or 60°, the radius of the rounded corner of the edge of the positioning hole 11 can be 10mm, 15mm, 20mm or 25mm, and the radius of the transition rounded corner between the hole wall and the bottom of the positioning hole 11 can be 10mm, 15mm, 20mm or 25mm.

[0040] Step 2: Based on the blank 10, an upper anvil 30 with a punch 31 is designed and manufactured. The punch 31 is adapted to the positioning hole 11. Specifically, the punch 31 and the positioning hole 11 on the blank 10 are the same in outline shape and size. In fact, the difference between the upper anvil 30 and the upper flat anvil 20 is that the punch 31 is added to the forging surface of the upper flat anvil 20. Subsequently, the required bar stock 40 is obtained according to the material of the blank 10. It is easy to understand that the bar stock 40 will be upset to form the blank 10 after forging.

[0041] Step 3: Forging the bar stock 40 using the upper flat anvil 20, so that the bar stock 40 is upset to the specified height. This step of forging the bar stock 40 using the upper flat anvil 20 actually involves installing the upper flat anvil 20 on the press, placing the bar stock 40 inside the press, and using the press to drive the upper flat anvil 20 downwards to forge the bar stock 40. Naturally, when the bar stock 40 is upset to the specified height, its diameter is thicker than the original bar stock 40.

[0042] Step 4: Using the upper anvil 30 instead of the upper flat anvil 20, continue forging the bar stock 40 to a specified height, so that the bar stock 40 continues to be upset to form a blank 10. During the continued upsetting process, the punch 31 presses out positioning holes 11 on the upper end face of the blank 10. When performing this step, the press used can be the same as the press used in step 3, or it can be different; moreover, when performing this step, the tempering process of the bar stock 40 can be the same as that in step 3, or it can be different.

[0043] In the preferred embodiment, the press used in steps 3 and 4 is the same, that is, the following is included between steps 3 and 4:

[0044] Step 3.5: When the bar stock 40 is upset to the specified height, the upper flat anvil 20 of the forging bar stock 40 is replaced with the upper shaped anvil 30 using the press's quick anvil change function. It is worth noting that most presses currently manufactured by enterprises have a quick anvil change function. In this embodiment, the technical means used to replace the upper flat anvil 20 with the upper shaped anvil 30 is the same as existing technology, so it will not be described in detail here.

[0045] Furthermore, during steps 3 and 4, the bar stock 40 is subjected to the same heating cycle, meaning it is within one heating period. This significantly shortens the forging cycle.

[0046] Because the bar stock 40 may shift under forging pressure during the forging process using the upper flat anvil 20, after replacing the upper flat anvil 20 with the aforementioned upper die anvil 30, it is necessary to move the bar stock 40 to change its position in the press. This allows the bar stock 40 to be repositioned and aligned with the appropriate position on the press, ensuring that the center area of ​​the top end face of the bar stock 40 is aligned with the punch 31 of the upper die anvil 30. Therefore, step 3.6 is included between steps 3.5 and 4.

[0047] Using the centering and positioning function of the press, the bar stock 40 is repositioned to the appropriate position on the press, so that the center area of ​​the top end face of the bar stock 40 is aligned with the punch 31 of the upper anvil 30. This ensures that the positioning hole 11 punched by the punch 31 on the blank 10 is located at the center of the upper end face of the blank 10.

[0048] It is worth noting that most presses used by enterprises now have automatic centering and positioning functions. The re-centering and positioning of the bar stock 40 to the appropriate position of the press, as described in this embodiment, is accomplished by the automatic centering and positioning function of the press. Since this is existing technology, it will not be described in detail here.

[0049] Optionally, the specified height mentioned above corresponds to the height of the bar stock 40 when the upper flat anvil 20 is replaced with the upper shaped anvil 30. This specified height is defined as a, a≥3H+h, where H is the depth of the positioning hole 11 and h is the height of the blank 10 (i.e., the total height of the final formed blank 10). When the bar stock 40 is upset to the specified height, the top diameter of the bar stock 40 is defined as d, d≥2D, where D is the bottom diameter of the positioning hole 11. It is worth noting that the depth of the positioning hole 11 is the same as the height of the punch 31 of the upper shaped anvil 30, and the bottom diameter of the positioning hole 11 is the same as the outer diameter of the head end of the upper shaped anvil 30.

[0050] This not only ensures the stability of the bar stock 40 when the upper anvil 30 forges it, but also ensures that the positioning hole 11 can be fully formed.

[0051] Optionally, the upsetting speed of the bar stock 40 in step 3 above is b, and the upsetting speed of the bar stock 40 in step 4 above is v, where v < b. That is, the upsetting speed of the bar stock 40 using the upper anvil 30 is less than the upsetting speed using the upper flat anvil 20. This can also be understood as the pressing speed of the press decreasing after changing the upper anvil. Specifically, the value of b is in the range of 10-15 mm / s, for example, b = 10 mm / s, b = 12 mm / s, or b = 15 mm / s, and the value of v is in the range of 8-10 mm / s, for example, v = 8 mm / s, v = 9 mm / s, or v = 10 mm / s, but v < b must be satisfied. In this way, upsetting can be performed at a faster speed when using the upper flat anvil 20, resulting in higher overall upsetting efficiency and shorter time.

[0052] To more accurately forge and upset the bar stock 40 into the blank 10 with positioning holes 11 using the upper flat anvil 20 and the upper die anvil 30, the forming process can be precisely simulated using DEFORM numerical simulation software (i.e., finite element numerical simulation) before performing steps 3 and 4 to determine the optimal pressing speed and bar stock 40 temperature, etc. Furthermore, when forging the blank 10 into a disc-shaped forging in the mold, the blank 10 needs to be inverted in the mold cavity, so that the positioning holes 11 on the blank 10 face downwards.

[0053] Example 2:

[0054] This embodiment is a specific implementation of Embodiment 1. In this embodiment:

[0055] The blank weight of the disc forging is 961kg, and the blank size is φ350×960mm. The final height of the upsetting blank 10 is 260mm. The blank 10 is designed with positioning holes 11. The diameter of the positioning hole 11 of the blank 10 is 200mm, the depth of the positioning hole 11 is 35mm, the transition angle is 40°, the radius of the fillet of the hole edge of the positioning hole 11 is 20mm, and the radius of the transition fillet between the hole wall and the bottom of the hole is also 20mm.

[0056] Based on the blank 10 and the positioning hole 11 thereon, an upper anvil 30 with a punch 31 is designed. The diameter of the punch 31 of the upper anvil 30 is 200mm, the height of the punch 31 is 35mm, the transition angle is 40°, the transition radius between the side wall of the punch 31 and the forging surface of the upper anvil 30 is 20mm, and the transition radius between the side wall of the punch 31 and its head end face is 20mm.

[0057] The upper anvil 20 is then mounted on the press, and the heated bar stock 40 is loaded into the press, positioning the bar stock 40 directly below the upper anvil 20. The press is controlled to drive the upper anvil 20 to upset the bar stock 40 at an upsetting speed of 10 mm / s, upsetting the bar stock 40 to a specified height. Specifically, at this specified height, the height 'a' of the bar stock 40 is greater than 365 mm, and the diameter of the upper end face of the bar stock 40 is greater than 400 mm. Based on calculations and measurements, it is determined that when the bar stock 40 is upset to a specified height of 500 mm using the upper anvil 20, the upper anvil 20 is replaced with the aforementioned upper die anvil 30, and the bar stock 40 continues to be upset until it reaches a blank 10 with a height of 260 mm. The upsetting speed when using the upper die anvil 30 for continued upsetting is 8 mm / s.

[0058] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope described in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A forging method for a disc-shaped forging blank, characterized in that, include: Step 1: Based on the disc forging and its die forging positioning requirements, design a blank (10) with positioning holes (11); Step 2: Design and manufacture an upper anvil (30) with a punch (31) based on the blank (10). The punch (31) is adapted to the positioning hole (11). Then, obtain the required bar stock (40) based on the material of the blank (10). Step 3: Use an upper flat anvil (20) to forge the bar stock (40) to upset the bar stock (40) to a specified height; Step 4: Use the upper anvil (30) instead of the upper flat anvil (20) to continue forging the bar stock (40) to a specified height, so that the bar stock (40) continues to be upset to form the blank (10). During the continued upsetting process, the punch (31) presses out the positioning hole (11) on the upper end surface of the blank (10).

2. The forging method for disc-shaped forging blanks according to claim 1, characterized in that, Between step 3 and step 4, the following is also included: Step 3.5: When the bar stock (40) is upset to the specified height, the upper flat anvil (20) of the forging bar stock (40) is replaced with the upper shaped anvil (30) using the quick anvil change function of the press.

3. The forging method for disc-shaped forging blanks according to claim 2, characterized in that: Steps 3 and 4 are completed within the same firing cycle of the bar stock (40).

4. The forging method for disc-shaped forging blanks according to claim 3, characterized in that, Between step 3.5 and step 4, the following is also included: Step 3.6: Using the centering and positioning function of the press, the bar stock (40) is repositioned to a suitable position on the press, so that the center area of ​​the top end face of the bar stock (40) is aligned with the punch (31) of the upper anvil (30).

5. The forging method for disc-shaped forging blanks according to any one of claims 1-4, characterized in that: When the bar stock (40) is upset to the specified height, the top diameter of the bar stock (40) is d, d≥2D, where D is the bottom diameter of the positioning hole (11); The specified height is a, a≥3H+h, where H is the depth of the positioning hole (11) and h is the height of the dough (10).

6. The forging method for disc-shaped forging blanks according to claim 5, characterized in that: The bottom diameter of the positioning hole (11) is 150-250mm, and the depth of the positioning hole (11) is 15-40mm.

7. The forging method for disc-shaped forging blanks according to claim 1, characterized in that: In step 3, the upsetting speed of the bar stock (40) is b; In step 4, the upsetting speed of the bar stock (40) is v, where v < b.

8. The forging method for disc-shaped forging blanks according to claim 7, characterized in that: In step 3, the upsetting speed of the bar stock (40) is 10-15 mm / s; In step 4, the upsetting speed of the bar stock (40) is 8-10 mm / s.

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