Hexagonal top press hinge beam single station die forging forming process and die
By using a six-sided top press for single-station die forging process for hinge beams, combined with upsetting, pressure holding, and die preheating, the internal structure problem of hinge beams was solved, achieving highly reliable direct forming and extending die life.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- TONGYU HEAVY IND
- Filing Date
- 2026-06-26
- Publication Date
- 2026-07-31
AI Technical Summary
Existing casting and die forging processes result in poor internal density and uniformity of the hinge beam, which cannot meet the high reliability requirements of the six-sided top press and also has defects such as shrinkage cavities, porosity and grain boundary segregation.
The single-station die forging process using a six-sided top press hinge beam includes upsetting and drawing pretreatment, one-time filling of the concave die cavity and pressure holding forming, combined with high-temperature glass powder lubrication and die preheating to ensure continuous distribution of metal flow lines and dense structure.
This method enables the direct forming of hinge beams, improves the internal density and uniformity of the structure, reduces the amount of subsequent machining, and enhances the mechanical properties of the forgings and the life of the mold.
Smart Images
Figure CN122480207A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of forging technology, and in particular to a single-station die forging process and mold for a hinge beam of a six-sided top press. Background Technology
[0002] The statements herein provide only background information in relation to this invention and do not necessarily constitute prior art.
[0003] As a component of a six-sided top press that bears heavy loads and impacts, the manufacturing process of the hinge beam determines the lifespan and reliability of the equipment. Currently, the industry mainly uses two processes for manufacturing hinge beams: casting and die forging. Die forging initially improves the coarse structure of the cast state through plastic deformation, but it is essentially a transitional process, and the final shape of the forging still depends on subsequent machining. In the casting process, when the liquid metal solidifies in the mold, defects such as shrinkage cavities, porosity, and grain boundary segregation inevitably occur, resulting in poor density and uniformity of the internal structure of the casting. Consequently, when subjected to high loads and impacts, its toughness and fatigue life cannot meet the requirements for high reliability. Summary of the Invention
[0004] The purpose of this invention is to provide a single-station die forging process and mold for a six-sided top press hinge beam, which can at least solve one of the above-mentioned technical problems.
[0005] To achieve the above objectives, one embodiment of the present invention provides a single-station die forging process for a hinge beam of a six-sided top press, comprising the following steps: The billet is heated and kept at the initial forging temperature range, and then transported to the forging press for upsetting and drawing. The billet is upset by hammering it a set number of times. The upset billet is then laid down and repeatedly forged along the billet axis by an anvil. The billet is drawn out by hammering it a set number of times. The heated billet is placed in the cavity of the die. The forging press drives the punch to apply downward pressure, so that the billet is fully filled in the cavity of the die. At this time, the working surface of the punch is in complete contact with the billet. The punch continues to press down until the distance between the bottom surface of the punch and the bottom surface of the die is the size of the required hinge beam forging. After the punch is pressed down to the specified position, it is held under pressure for a preset time to form a hinge beam with a set lug depth. Then the punch is removed.
[0006] Furthermore, after removing the punch, the ejector rod pushes out the forged hinge beam forging and transports it to the heat treatment workshop for heat treatment.
[0007] Furthermore, the billet is returned to the furnace and heated to the initial forging temperature. After exiting the furnace, a high-pressure water gun is used to remove the surface oxide scale, and high-temperature glass powder is sprayed for lubrication and heat insulation.
[0008] Furthermore, the concave mold cavity and the convex mold are preheated.
[0009] Furthermore, the diameter of the blank is equal to the diameter of the bottom surface of the die.
[0010] Another embodiment of the present invention provides a single-station die forging forming mold for a hinge beam of a six-sided top press, including a die cavity and a punch. The inner side of the die cavity is provided with a lug, and the bottom surface of the die cavity is provided with a through hole for the ejector rod of the forging press to pass through and eject the forging. The punch includes a punch head and a punch up surface, and the punch up surface contacts the top surface of the lug.
[0011] Furthermore, a chamfer is provided at the connection between the punch and the rough surface of the punch holder.
[0012] Furthermore, the distance between the bottoms of the two sides of the lugs is equal to the bottom diameter of the concave mold cavity.
[0013] Furthermore, the top of the punch is provided with a connecting hole that mates with the forging press.
[0014] Furthermore, the bottom surface of the die is provided with a through hole through which the ejector rod of the top press passes to eject the forging.
[0015] The beneficial effects of the embodiments of the present invention are as follows: This invention effectively improves the problems of shrinkage cavities, porosity defects, and reliance on subsequent cutting processes in casting by using upsetting and drawing pretreatment, one-time filling in the concave mold cavity, and pressure holding forming. The upsetting and drawing process causes the billet to undergo sufficient plastic deformation, breaks up the casting structure and refines the grains. Combined with the pressure holding process, it ensures that the metal flow lines are continuously distributed along the force direction of the hinge beam, improves the density and uniformity of the internal structure of the forging, and thus realizes direct forming from billet to finished product in a single station, as well as one-time forging of the lug depth. Attached Figure Description
[0016] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.
[0017] Figure 1 This is a schematic diagram of the initial state of the blank placed into the die according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the punch according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the concave mold according to an embodiment of the present invention.
[0018] In the diagram: 1. Punch; 2. Blank; 3. Die; 4. Ejector pin; 5. Punch head; 6. Punch punch; 7. Lug. Detailed Implementation
[0019] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.
[0020] Example 1 like Figures 1-3 As shown in the embodiment of the present invention, a single-station die forging process for a hinge beam of a six-sided top press is described. This process is used to forge the hinge beam, which is a component of the six-sided top press that bears heavy loads and impacts.
[0021] Specifically, the following steps are included: First, through 3D modeling, the losses generated during forging and heat treatment are calculated in advance. Then, the blanking weight of billet 2 is determined so that the final forging conforms to the standard. In this embodiment, existing 3D modeling software such as UG and SOLIDWORKS is used. First, a finishing drawing is drawn, then a roughing drawing is drawn with the corresponding heat treatment allowance. Then, a matching forging allowance is added on the roughing drawing to obtain the weight of the forging. Based on the ingot shape, the proportion of water risers and the heat loss, the blanking weight of the steel ingot is deduced. Then, the raw material steel ingot of billet 2 of the required specifications is cast through LF refining furnace, VD vacuum degassing, and atmospheric casting.
[0022] After the raw material steel ingot of billet 2 solidifies, it is transferred to the forging workshop in a hot state. The steel ingot is heated and kept at the initial forging temperature range. By increasing the initial forging temperature, the entire forging process can be kept in a state that is easy to deform. Before the billet 2 is formally forged, it needs to be hoisted from the pre-forging heating furnace to the cavity of the die 3. Especially in winter when the temperature is low, the surface temperature of billet 2 drops quickly. Therefore, in this embodiment, the temperature of billet 2 needs to be heated to the initial forging temperature of 1220-1250℃.
[0023] In this embodiment, the holding time is related to the effective size required for the billet 2. The recommended holding time for the billet 2 in this embodiment is 12-18 hours. During this time period, the internal temperature of the billet 2 can be evenly distributed, and the grains can be sufficiently refined and homogenized, avoiding defects such as cracks and folds in the subsequent forging process due to insufficient or overheating in some areas.
[0024] Meanwhile, the heat preservation time ensures that the surface temperature of the raw material steel ingot 2 can still be maintained within the initial forging temperature range during the process of transferring it from the heating furnace to the cavity of the die 3. It will not affect the forging deformation performance due to a sudden drop in temperature, thus providing a stable thermal state guarantee for the smooth progress of subsequent forging processes, thereby improving the forming accuracy and mechanical properties of the forging.
[0025] The billet 2 is then transported to the forging press for upsetting. The height of the billet 2 is reduced and the diameter is increased by the forging hammer. The upset billet 2 is then laid down and repeatedly forged along the axial direction of the billet 2 by the anvil, so that the length of the billet 2 is increased and the cross-section is reduced, so as to ensure uniform deformation along the entire length of the billet 2. By performing the upsetting process on the billet 2, the original coarse grains are effectively broken and refined, and the internal structure uniformity and density of the billet 2 are improved. At this time, the billet 2 is the billet 2 to be forged by the upsetting process of the steel ingot.
[0026] Then, the heated blank 2 is placed in the cavity of the die 3. The forging press drives the punch 1 to apply downward pressure, so that the blank 2 is fully filled in the cavity of the die 3. At this time, the working surface of the punch 1 is in complete contact with the blank 2. The punch 1 continues to press down until the distance between the bottom surface of the punch 1 and the bottom surface of the die 3 is the required size of the hinge beam forging. Through single-station die forging, the blank 2 is fully plastically flowed and filled in the cavity of the die 3, the size of the forging is controlled, and the allowance of subsequent cutting is greatly reduced.
[0027] Furthermore, in this embodiment, after the punch 1 is pressed down to the specified position, it needs to be held under pressure for a preset time. After holding the pressure, a hinge beam with a certain depth of lug 7 is formed. Then, the punch 1 is removed. After removing the punch 1, the ejector rod 4 ejects the forged hinge beam forging and transports it to the heat treatment workshop for heat treatment.
[0028] Specifically, the ejected forgings are transported to the heat treatment workshop for heat treatment. This process can adjust the internal stress and unstable internal structure generated during the forging process, eliminate residual internal stress, optimize the internal structure of the forgings, and improve the comprehensive mechanical properties of the forgings. This enables the hinge beam to meet the requirements of the six-sided top press to withstand heavy loads and impacts for a long time.
[0029] In this embodiment, the billet 2 is reheated to the initial forging temperature in the furnace. After exiting the furnace, a high-pressure water gun is used to remove the surface oxide scale, which effectively avoids the damage to the surface quality of the forging and the wear of the mold during the die forging process. This ensures the forming quality of the forging and extends the service life of the mold. Subsequently, high-temperature glass powder is sprayed. The lubricating effect of the high-temperature glass powder reduces the friction between the billet 2 and the mold, allowing the billet 2 to flow and fill smoothly in the cavity of the die 3, which facilitates the subsequent demolding and ejection of the billet 2.
[0030] Meanwhile, the heat insulation effect of the high-temperature glass powder effectively slows down the heat loss of the billet 2 before die forging, maintains the forging temperature of the billet 2, ensures its good plasticity, and avoids forming difficulties caused by insufficient temperature. In addition, the heat insulation layer also blocks the large amount of high temperature of the billet 2 from being transferred to the mold, effectively reducing the working temperature of the mold and preventing the mold from reducing its structural strength due to prolonged exposure to high temperature.
[0031] The cavity of the die 3 and the punch 1 are preheated. In this embodiment, the preheating temperature is 300℃. By preheating the cavity of the die 3 and the punch 1, the problems of excessive thermal stress, shortened die life, uneven temperature, reduced plasticity, and poor filling fluidity of the die 2 when the die components come into contact with the high-temperature blank 2 during the die forging process are solved. At the same time, the preheated cavity of the die 3 and the punch 1 can reduce the temperature difference between them and the high-temperature blank 2, thereby reducing the thermal stress generated by the die components due to sudden heating, effectively avoiding cracking and deformation of the die, and extending the service life of the die.
[0032] Furthermore, the preheated mold components can better maintain the temperature uniformity of the blank 2 in the cavity, prevent the surface of the blank 2 from cooling down rapidly, and ensure that the blank 2 maintains good plasticity throughout the forming process. This promotes the blank 2 to fully fill the cavity, which is beneficial to obtaining hinge beam forgings with uniform structure and qualified dimensions.
[0033] like Figure 1 As shown in the figure, the diameter of the blank 2 is equal to the diameter of the bottom surface of the die 3, i.e., a=b as shown in the figure. Here, a represents the diameter of the blank 2 and b represents the diameter of the bottom surface of the die 3.
[0034] Specifically, by setting the diameter of the billet 2 to be equal to the diameter of the bottom surface of the die 3, the billet 2 can be smoothly and unobstructedly placed into the die 3, effectively avoiding the problem of jamming or inability to place due to the billet 2 being too large, thus ensuring the smooth progress of the production process. At the same time, since the initial diameter of the billet 2 matches the bottom size of the cavity, the billet 2 can fill the cavity without excessive radial deformation during the subsequent forging process, thereby reducing the risk of insufficient cavity filling and lowering the requirements for the forging pressure.
[0035] Furthermore, the depth of the lugs 7 around the forming cavity 3 in this application is c. This depth can be increased or decreased according to the shape and size of the hinge beam itself and the tonnage of the press, but should satisfy the following relationship: c≤1 / 2 the maximum groove depth of the hinge beam lugs 7.
[0036] In actual manufacturing processes, the depth *c* can be appropriately increased or decreased depending on specific forming requirements and equipment conditions. However, the depth *c* must strictly satisfy the following relationship: the depth *c* must not exceed half the maximum groove depth of the hinge beam lug 7, i.e., *c* ≤ 1 / 2 the maximum groove depth of the hinge beam lug 7. This prevents excessive material stretching, stress concentration, or structural failure during the forming process, thereby ensuring the mechanical properties and forming accuracy of the hinge beam.
[0037] Example 2 like Figure 2 and Figure 3As shown, another embodiment of the present invention provides a single-station die forging forming mold for a hinge beam using a six-sided top press, including a die 3 and a punch 1. The inner side of the die 3 is provided with a lug 7, and the bottom surface of the die 3 is provided with a through hole for the ejector rod 4 of the forging press to pass through and eject the forging. The punch 1 includes a punch 6 and a punch up surface 5, which contacts the top surface of the lug 7. By designing the lug 7 on the inner side of the die 3 and the punch up surface 5 to contact the top surface of the lug 7, a limiting effect is achieved. Simultaneously, a through hole is provided on the bottom surface of the die 3 for the ejector rod 4 to pass through. The mold mentioned in this embodiment directly forms the hinge beam lug 7 structure during the single-station die forging process and ensures that the blank 2 fully fills the cavity. Therefore, the resulting hinge beam forging has a dense and uniform internal structure.
[0038] A chamfer is provided at the connection between the punch 6 and the rough surface 5 of the punch holder, transforming the originally sharp right-angle transition area into a smooth inclined or arc surface. During the forging process, when the blank 2 is squeezed by the punch 1, the stress is no longer concentrated in a narrow sharp-angle area, but is dispersed to the larger surface formed by the chamfer. This effectively avoids cracking and damage to the die due to stress concentration at the connection, extending the service life of the die. At the same time, the chamfer ensures that the formed hinge beam forging forms a smooth transition structure at the corresponding position, eliminating stress concentration points inside the forging and avoiding subsequent additional processing (such as deburring and chamfering) to eliminate sharp-angle stress concentration, simplifying the overall processing flow.
[0039] The distance between the bottom of the two opposing lugs 7 is equal to the bottom diameter of the cavity of the die 3, which can avoid insufficient filling or dimensional deviation of the blank 2 due to unreasonable position of lug 7. In the lug 7 area, the defects of insufficient material filling or excessive residue are avoided, ensuring that the dimensions of the formed hinge beam forging meet the design requirements.
[0040] The top of the punch 1 is provided with a connection hole that mates with the forging press. At this time, the connection structure of the forging press can be directly connected and fixed with the connection hole on the top of the punch 1 to realize the installation and positioning of the punch 1. Then, when the forging press applies forging pressure, it can transmit the force through the punch 1 to the die 3, avoiding the reduction of force transmission efficiency or direction deviation caused by loose connection or misalignment.
[0041] In this embodiment, the punch 1 and die 3 are specifically designed for the structure of the hinge beam, which can be adapted to the processing flow of single-station die forging, ensuring that the structural dimensions of the formed hinge beam meet the processing requirements and reducing subsequent unnecessary cutting processes.
[0042] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.
Claims
1. A single station swage forming process for a hexagonal press hinge beam, characterized by, Includes the following steps: The billet is heated and kept at the initial forging temperature range, and then transported to the forging press for upsetting and drawing. The billet is upset by hammering it a set number of times. The upset billet is then laid down and repeatedly forged along the axial direction of the billet by an anvil. The billet is drawn out by hammering it a set number of times. The heated billet is placed in the cavity of the die. The forging press drives the punch to apply downward pressure, so that the billet is fully filled in the cavity of the die. At this time, the working surface of the punch is in complete contact with the billet. The punch continues to press down until the distance between the bottom surface of the punch and the bottom surface of the die is the size of the required hinge beam forging. After the punch is pressed down to the specified position, it is held under pressure for a preset time to form a hinge beam with a set lug depth. Then the punch is removed.
2. A single station die forming process for a hexagonal press hinge beam as claimed in claim 1, wherein, After removing the punch, the ejector rod pushes out the forged hinge beam forging and transports it to the heat treatment workshop for heat treatment.
3. The single-station die forging process for a hinge beam of a six-sided top press as described in claim 1, characterized in that, The billet is returned to the furnace and heated to the initial forging temperature. After exiting the furnace, a high-pressure water gun is used to remove the surface oxide scale, and high-temperature glass powder is sprayed for lubrication and heat insulation.
4. The single-station die forging process for a hinge beam of a six-sided top press as described in claim 1, characterized in that, The concave mold cavity and the convex mold are preheated.
5. The single-station die forging process for a hinge beam of a six-sided top press as described in claim 1, characterized in that, The diameter of the blank is equal to the diameter of the bottom surface of the die.
6. A single-station die forging forming mold for a hinge beam of a six-sided top press, characterized in that, It includes a die cavity and a punch. The inner side of the die cavity is provided with a lug. The punch includes a punch head and a punch block surface. The punch block surface contacts the top surface of the lug.
7. The single-station die forging forming mold for a six-sided top press hinge beam as described in claim 6, characterized in that, A chamfer is provided at the connection between the punch and the rough surface of the punch holder.
8. The single-station die forging forming mold for a six-sided top press hinge beam as described in claim 6, characterized in that, The distance between the bottoms of the two protruding ears is equal to the bottom diameter of the concave mold cavity.
9. A single-station die forging mold for a hinge beam of a six-sided top press as described in claim 6, characterized in that, The top of the punch is provided with a connection hole that mates with the forging press.
10. A single-station die forging mold for a hinge beam of a six-sided top press as described in claim 6, wherein the bottom surface of the die is provided with a through hole through which the ejector rod of the top press passes to eject the forging.