A method of forging a structural irregular triangle

Abstract

The application provides a forging forming method of an irregular triangular structural member, which comprises the following steps: step 1, a preform is designed based on a forging part; step 2, a blank is designed based on the preform and the forging part; step 3, a forging blank mold is designed according to the blank; step 4, the blank is designed, which comprises a first blank, a second blank and a third blank; step 5, the blank is manufactured; and step 6, the triangular structural member is pre-forged and finish-forged. Through the forging forming method, an irregular triangular blank can be produced, and the forming requirement of the irregular triangular structural member can be met. The designed blank mold can reduce the difficulty of free forging operation and improve the consistency of the forged blank.

Description

Technical Field

[0001] This invention belongs to the field of hot forging technology and relates to a forging method for irregular triangular structural parts. Background Technology

[0002] Irregular triangular structural components are used in aircraft manufacturing to securely connect various parts within the aircraft structure. Aerospace systems require high performance to ensure flight safety and a long service life. Good performance depends on a sound internal structure, which in turn requires a stable forging process. The overall shape of an irregular triangular structural component is an obtuse triangle, meaning the largest angle is greater than 90°, and the longest side is more than twice the length of the shortest side. Different degrees of bosses are present along the sides of the triangle, resulting in an irregularly curved outer contour. Furthermore, the triangle's thickness varies, and it contains various shapes of thin web structures within its interior.

[0003] The rough shape of a triangular structural component is generally also a triangle. Such regular triangular rough shapes can be forged directly one-to-one in free forging, but this is difficult to operate, and the resulting triangles have poor consistency and a large discrepancy with the required dimensions. Regular triangular rough shapes can also be made by first forging the blank into a regular quadrilateral blank (rectangular or parallelogram) and then dividing it in half. This method produces triangular rough shapes with a more regular shape, better consistency, and smaller deviation from the requirements, but requires an additional machining process. After machining, the edges need to be rounded, increasing the amount of grinding work. For irregular triangular structural components, because all the boss structures at the edges must be fully formed, the shape cannot be a regular triangle, and therefore cannot be forged using the above methods. If the boss structure of the forging is extensively covered to make the shape of the blank more regular, firstly, this results in excessive material usage in some areas, reducing material utilization; secondly, the blank cannot be fully placed into the mold cavity, with some parts "stuck" outside the cavity, potentially leading to unstable die forging, misalignment, and the risk of the forging being damaged and scrapped after forging. Furthermore, the thin web structure in the middle of the forging will have a relatively high truncated pyramid at the corresponding position in the mold cavity, which also poses some difficulties for blank placement.

[0004] For forging triangular structural parts, to achieve high material utilization and effective die forging positioning, the corresponding triangular blank must be completely placed into the die cavity without significant dimensional deviations. Otherwise, some sharp corners of the triangle will suffer severe material loss, making rework difficult, especially for metals with high deformation resistance and poor fluidity, such as TC18, TC32, and A-100. For forging irregular triangular structural parts, due to their more complex shapes, the requirements for consistency of the corresponding blank and the placement of materials during die forging are even higher. Summary of the Invention

[0005] This invention provides a forging method for irregular triangular structural parts. This method enables the hot-working portion of these parts to be manufactured with high production efficiency and material utilization. This invention is applicable to the forging production of irregular triangular structural parts made of various materials, ensuring high stability in each forging process and ultimately guaranteeing that the internal and external quality of the forging meets the required standards. This invention is particularly beneficial for forging irregular triangular structural parts with high material deformation resistance, large projected area, large cross-sectional changes, and larger maximum angles within the triangle. The technical solution is as follows: A forging method for an irregular triangular structural component includes: Step 1: Design pre-forgings based on forgings. Step 2: Design the rough shape based on the pre-forging and forging. Step 3: Design the forging mold based on the rough shape. Step 4: Design the blanks, including blank one, blank two, and blank three; Step 5: Create the rough shape; Step 6: Perform pre-forging and final forging on the triangular structural component.

[0006] In step 1, the lower half of the pre-forging is designed based on the lower half 11 of the forging. Compared with the depth dimension of the thin web 13 of the lower half of the forging, the thickness dimension of the thin web 12 of the lower half of the pre-forging is appropriately increased so that the depth d of the thin web of the lower half of the pre-forging is ≤15mm. All draft angles, transition radii and outer contour dimensions are consistent with the lower half of the forging. Furthermore, during the production of the pre-forging, the cavity dimension where the lower half of the pre-forging is located is used as the pre-forging lower die. The upper half 8 of the pre-forging part maintains the exact same dimensions as the upper half 10 of the forging part.

[0007] Specifically, step 2 involves: (1) Rotate the shape of the pre-forged part, rotate the longest side of the triangle to the horizontal plane and face upward, that is, place the largest angle of the triangle at the lowest end; (2) Design the three angles of the triangle shape of the rough die excluding the boss structure: The three angles of the triangle shape of the rough die excluding the boss structure and the three angles of the triangle outline of the pre-forged part excluding the boss structure satisfy the following: αmax=(0.99~1.01)Amax, αmid=(0.99~1.01)Amid, αmin=(0.99~1.01)Amin, Amax: The largest angle in the "triangular" profile of the pre-forged part, excluding the boss structure; Amid: The larger angle in the "triangular" profile of a pre-forged part, excluding boss structures; Amin: The smallest angle in the "triangular" profile of the pre-forged part, excluding the boss structure; αmax: The largest angle in the "triangle" shape of the rough shape, excluding the boss structure; αmid: The larger angle in the "triangle" shape of the rough shape, excluding the boss structure; αmin: The smallest angle in the "triangle" shape of the rough shape, excluding the boss structure; (3) Design the boss structure in the rough mold: Based on the shape of the boss structure in the pre-forged part, connect the boss structure in the rough mold with multiple straight line segments with a certain angle. The straight lines are transitioned with rounded corners. All the straight line segments maintain an angle of less than 85° with the horizontal line, and the straight line segments have a draft angle of more than 5°. (4) Design the gap between the outer contour of the rough die and the inner wall of the pre-forging die: An appropriate gap needs to be left between the outer contour of the rough die and the inner wall of the pre-forging die so that the rough die can be completely placed into the cavity of the pre-forging die. The gap should meet the following requirements: Smax≤20mm, Smin≥3mm Smax: The maximum gap between the outer contour of the rough shape and the inner wall of the pre-forging die; Smin: The minimum clearance between the outer contour of the roughing die and the inner wall of the pre-forging die; (5) After determining the outer contour dimensions of the rough mold, calculate the required height dimensions of the rough mold based on the volume ratio according to the cross-sectional dimensions of the forging, and ensure that the volume ratio of the rough mold to the forging is within the range of 1.16 to 1.28 to meet the final forming requirements and reduce material consumption.

[0008] In step 3, The mold is a single piece with a rectangular outer contour. The dimensions of the mold cavity in the depth direction are consistent with the outer contour dimensions of the rough mold, except that the total length should be appropriately increased along the side with the smallest angle of the triangle. The mold cavity is centered in width and located on the mold module. The width of the mold cavity is appropriately increased compared to the maximum height of the rough mold. The mold cavity should have a draft angle of more than 5°. The opening of the mold cavity is transitioned with an appropriate convex fillet.

[0009] The mold dimensions must meet the following requirements: L1 = L + (10~30) mm L: Overall length of the rough shape; L1: Overall length of the cavity section of the tire mold. B1 = Hmax + (20~60) mm, Hmax: Maximum thickness of the rough shape. B1: Width dimension of the cavity portion of the tire model. R≥R5, R: The convex rounded corner at the opening of the tire model cavity. Lmin>100mm, H1>150mm, B2= B1+2*(80~130)mm, Lmin: The minimum distance from the opening of the tire mold cavity to the edge of the tire mold along its length; H1: The minimum distance between the bottom of the tire mold cavity and the bottom of the tire mold; B2: Overall width dimension of the mold module.

[0010] Among them, blank 1 is a blank with a rectangular outer contour. The height dimension of blank 1 is consistent with the maximum height dimension of the blank shape. The width dimension of blank 1 is 5~30mm larger than the maximum width dimension of the blank shape. The volume ratio of blank 1 to the blank shape is between 1.05 and 1.20.

[0011] Among them, blank 2 is a blank with a parallelogram outer contour. The height and width dimensions of blank 2 are consistent with those of blank 1, and α1=αmid+(0°~10°), where α1 is the acute angle in the outer contour shape of blank 2.

[0012] Among them, billet 36 is obtained by drawing one end of billet 2. Its total width and maximum thickness are consistent with those of billet 2. Its overall shape is more than 60% similar to the rough shape and satisfies the following conditions: L2 = L - (30~60) mm, L2: Total length of the rough blank 3 B3 = Bmin + (10~30mm) B3: Minimum width dimension of blank three Bmin: Minimum width dimension of the rough shape.

[0013] In step 5, the bar stock is first forged into a blank 1 with a rectangular outer contour; then the blank 1 is pressed into a blank 2 with the same thickness and width as the blank 1 and a parallelogram outer contour; one end of the blank 2 is elongated so that its shape is as close as possible to the blank shape, and finally blank 3 is obtained; blank 3 is placed into the forging mold designed in step 3. When placing it in, the blank shape is rotated 90° along the length direction, with the longest side of the outer contour of the blank shape facing upwards, and the obtuse angle end of the blank shape is placed close to the obtuse angle end of the mold. After pressing and shaping, the required blank shape is obtained.

[0014] The beneficial effects of this invention are as follows: 1. This invention provides guidance for the forging of irregular triangular structural parts made of various metal materials; 2. The forging scheme proposed in this invention can produce an irregular triangular rough shape and meet the forming requirements of irregular triangular irregular structural parts.

[0015] 3. The mold designed in this invention can reduce the difficulty of free forging operations and improve the consistency of the rough shape after forging; 4. The pre-forging method designed by this invention eliminates the need for a milling process between pre-forging and final forging, thus improving production efficiency. 5. This invention provides a certain reference for the forging and forming production of irregular trapezoidal and irregularly shaped forgings. Attached Figure Description

[0016] 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. 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.

[0017] Figure 1 This is a schematic diagram of the molding process for an irregular triangular structural component. Figure 2 This is a schematic diagram of the forming process of an irregular triangular structural component. Figure 3 This is a schematic diagram of the pre-forged shape of an irregular triangular structural component. Figure 4 This is a schematic diagram of the shape of an irregular triangular structural component. Figure 5 This is a schematic diagram of the pre-forged shape after rotating the longest side to a horizontal position. Figure 6 This is a schematic diagram of the rough shape of an irregular triangular structural component. Figure 7This is a schematic diagram of the blank placement process in pre-forging. Figure 8 This is a schematic diagram of the shape of a die used for forging. Figure 9 This is a schematic diagram showing the outline and main dimensions of a triangular structural component. Figure 10 This is a schematic diagram showing the rough shape and main dimensions of a triangular structural component; Explanation of reference numerals in the attached figures: 1- Irregular triangular structural component rough shape, 2- Irregular triangular structural component pre-forging, 3- Irregular triangular structural component, 4- Rough blank one, 5- Rough blank two, 6- Rough blank three, 7- Die mold, 8- Upper half of pre-forging part, 9- Lower half of pre-forging part, 10- Upper half of forging part, 11- Lower half of forging part, 12- Thin web section of lower part of pre-forging part, 13- Thin web section of lower part of forging part. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] The features and illustrative embodiments of various aspects of the present invention will now be described in detail. Numerous specific details are set forth in the following detailed description to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of the invention by illustrating examples of the invention. The invention is by no means limited to any specific setups and methods set forth below, but covers any improvements, substitutions, and modifications to structures, methods, and devices without departing from the spirit of the invention. Well-known structures and techniques are not shown in the drawings and the following description to avoid unnecessarily obscuring the invention.

[0020] This invention employs a forming method involving round bar blanking → forging roughing → pre-forging → final forging (see...). Figure 1 Forging produces an irregular triangular structural component with guaranteed internal and external quality (see...). Figure 1 (3) The forging process involves a process of free forging of bar stock → forging into a square → pressing into a parallelogram → drawing one end → die shaping → and finally, free forging of the rough shape (see section 3). Figure 2 The production process involves forging the material using a specially designed pre-forging die.

[0021] This invention discloses a forging method for an irregular triangular structural component, comprising the following steps: Step 1: Design the pre-forging based on the forging, see... Figure 3 : In the lower half 11 of the forging (as shown) Figure 4 Based on the design shown), the lower half 9 of the pre-forged part is designed (as shown). Figure 3 As shown), compared to the thin web of the lower half of the forging at 13 (as shown) Figure 4 The depth dimension (as shown) is 12 (as shown) at the thin web of the lower half of the pre-forged part. Figure 3 The thickness of the pre-forging part (as shown) is appropriately increased so that the depth d at the thin web of the lower half of the pre-forging part is ≤15mm. All draft angles, transition radii and outer contour dimensions are consistent with the lower half of the forging part. Furthermore, during the production of the pre-forging part, the cavity dimensions where the lower half of the pre-forging part is located are used as the pre-forging lower die.

[0022] Thus, during the production of pre-forged parts, because there are no prominent frustum structures in the cavity of the lower die of the pre-forging part, it can be ensured that the blank is placed stably in it, and the pre-forging is well positioned.

[0023] Upper half of the pre-forged part 8 (e.g.) Figure 3 (As shown) Maintain with the upper half of the forging 10 (as shown) Figure 4 (as shown) are exactly the same size.

[0024] During the subsequent final forging process, the cavity dimensions where the upper part of the forging is located are used as the final forging die, and the lower part of the forging 11 (e.g.) Figure 4 The cavity dimensions shown are used as the upper die for final forging. Since the upper part of the pre-forged part is basically filled, the pre-forged part is rotated 90° to ensure that it is smoothly placed into the lower die cavity for final forging, thus achieving good positioning for final forging.

[0025] Step 2: Design the rough shape based on the pre-forging and forging: (1) Rotate the shape of the pre-forged part so that the longest side of the triangle is rotated to the horizontal plane and facing upwards, that is, place the largest angle of the triangle at the lowest end, such as Figure 5 As shown. The corresponding rough shape is designed according to this position of the pre-forged part.

[0026] (2) Design the three angles of the triangle shape of the rough die excluding the boss structure: The three angles of the triangle shape of the rough die excluding the boss structure and the three angles of the triangle outline of the pre-forged part excluding the boss structure satisfy the following: αmax=(0.99~1.01)Amax, αmid=(0.99~1.01)Amid, αmin=(0.99~1.01)Amin, Amax: The largest angle in the "triangular" profile of the pre-forged part, excluding the boss structure; Amid: The larger angle in the "triangular" profile of a pre-forged part, excluding boss structures; Amin: The smallest angle in the "triangular" profile of the pre-forged part, excluding the boss structure; αmax: The largest angle in the "triangle" shape of the rough shape, excluding the boss structure; αmid: The larger angle in the "triangle" shape of the rough shape, excluding the boss structure; αmin: The smallest angle in the "triangle" shape of the rough shape, excluding the boss structure; (3) Design of the boss structure in the rough die: The boss structure in the rough die is connected by multiple straight line segments with certain angles, based on the shape of the boss structure in the pre-forging. The straight lines are transitioned with rounded corners. All the straight lines should maintain an angle of less than 85° with the horizontal line. In this way, when designing the die later, there will be a draft angle of more than 5° at this point. The rough die shape of the irregular triangular structural part is shown in the figure. Figure 6 .

[0027] (4) An appropriate gap should be left between the outer contour of the rough shape and the inner wall of the pre-forging die: see Figure 7 An appropriate gap must be left between the outer contour of the rough die and the inner wall of the pre-forging die so that the rough die can be completely placed into the cavity of the pre-forging die. The gap must satisfy the following: Smax≤20mm, Smin≥3mm Smax: The maximum gap between the outer contour of the rough shape and the inner wall of the pre-forging die; Smin: The minimum clearance between the outer contour of the roughing die and the inner wall of the pre-forging die.

[0028] (5) After determining the outer contour dimensions of the rough mold, calculate the required height dimensions of the rough mold based on the volume ratio according to the cross-sectional dimensions of the forging, and ensure that the volume ratio of the rough mold to the forging is within the range of 1.16 to 1.28 to meet the final forming requirements and reduce material consumption.

[0029] Step 3: Design the forging die based on the rough shape, see... Figure 8 : The die mold is a single piece with a rectangular outer contour. The cavity dimensions in the depth direction of the die mold, except for the overall length which is slightly increased along the side with the smallest angle of the triangle, are consistent with the outer contour dimensions of the rough mold. The die mold cavity is centered on the die mold module in width, and the width of the die mold cavity is slightly larger than the maximum height of the rough mold. The die mold cavity should have a draft angle of at least 5°, and the cavity opening should be transitioned with appropriate convex rounded corners. This ensures that when using the die mold to shape the blank, the blank can be smoothly removed from the die mold, and the pressed rough mold achieves at least 90% conformity with the theoretical requirements.

[0030] L1 = L + (10~30) mm, L: Overall length of the rough shape; L1: Overall length of the cavity section of the tire mold. B1 = Hmax + (20~60) mm, Hmax: Maximum thickness of the rough shape. B1: Width dimension of the cavity portion of the tire model. R≥R5, R: The convex rounded corner at the opening of the tire model cavity. In addition, the mold needs to have a certain strength to ensure its service life.

[0031] Lmin>100mm, H1>150mm, B2= B1+2*(80~130)mm, Lmin: The minimum distance from the opening of the tire mold cavity to the edge of the tire mold along its length; H1: The minimum distance between the bottom of the tire mold cavity and the bottom of the tire mold; B2: Overall width dimension of the mold module.

[0032] Step 4: Design the rough blanks, including rough blank one, rough blank two, and rough blank three: Raw material 14 (see Figure 2 The blank is a rectangular blank. The height of the blank is consistent with the maximum height of the blank. The width of the blank is 5-30mm larger than the maximum width of the blank. The volume ratio of the blank to the blank is between 1.05 and 1.20.

[0033] Raw material 2.5 (see Figure 2 The first blank is a parallelogram-shaped blank, and its height and width dimensions are the same as those of the first blank.

[0034] α1 = αmid + (0°~10°) α1: The acute angle in the outer contour shape of the blank 2. Raw material 3, 6 (see Figure 2 The first type is obtained by elongating one end of the second rough blank. Its total width and maximum thickness are consistent with the second rough blank, and its overall shape is more than 60% similar to the rough blank.

[0035] L2 = L - (30~60) mm, L2: Total length of the rough blank 3 B3 = Bmin + (10~30mm) B3: Minimum width dimension of blank three Bmin: Minimum width dimension of the rough shape. Step 5: Create the rough shape: First, forge the bar stock into a blank 1 with a rectangular outer contour; then press the blank 1 into a blank 2 with the same thickness and width as the blank 1 and a parallelogram outer contour; lengthen one end of the blank 2 so that its shape is as close as possible to the blank shape, and finally obtain the blank 3; place the blank 3 into the forging mold designed in step 3. When placing it in, rotate the blank shape 90° along the length direction, with the longest side of the blank shape facing up, and place the obtuse angle end of the blank shape close to the obtuse angle end in the mold. After pressing and shaping, obtain the required blank shape.

[0036] Step 6: Perform pre-forging and final forging on the triangular structural component.

[0037] For example, a triangular structural component, material grade: TC6, forging weight: 34.50Kg, the forging shape and main dimensions are shown in the diagram. Figure 9 As shown, there are two boss structures on the shortest side, and the outer contour of the forging is irregularly curved. The thickness of the forging varies significantly, and there is also a thin web structure with a triangular shape and a depth of 26mm inside, which is a typical irregular triangular irregular structural part.

[0038] The pre-forging is designed based on the forging design. The upper half of the pre-forging has the same dimensions as the upper half of the forging. Except for the thin web area, all other draft angles, fillets, and outer contour dimensions of the lower half of the pre-forging are the same as the lower half of the forging. The cavity dimensions of the lower half of the pre-forging are used as the lower pre-forging die. After thickening the thin web area of ​​the lower pre-forging, the minimum frustum height within the lower pre-forging die cavity is 10mm.

[0039] Based on the pre-forging and forging design rough shape, such as Figure 10 As shown, the rough die can be completely placed into the pre-forging mold cavity, and the maximum gap between the outer contour of the rough die and the pre-forging mold is 14mm, the minimum gap between the outer contour of the rough die and the pre-forging mold is 5mm, and the volume ratio between the rough die and the forging is 1.19.

[0040] Design the forging mold based on the rough shape: The mold is a single piece, measuring 910 (length) × 400 (width) × 350 (height). The cavity dimensions in the depth direction are such that the total length is appropriately increased to 655 along the side of the triangle with the smallest angle, while the remaining dimensions remain consistent with the outer contour of the rough mold. The width of the cavity is 200. The minimum distance between the bottom of the cavity and the bottom of the mold is 160, the minimum draft angle within the cavity is 7°, and the cavity opening is smoothly rounded with an radius of 15 (R15).

[0041] Design the rough blank size based on the rough shape size: Blank 1: Dimensions are 275 (length) × 210 (width) × 170 (height). The volume ratio of blank 1 to the forging is 1.08.

[0042] Blank 2: A blank with a parallelogram outer contour and an acute angle of 60°. The width and height of blank 2 are 170 and 210, respectively.

[0043] Raw Block 3: The total width of Raw Block 3 is 210, the total length is 590, the maximum height is 170, and the minimum width is 60. Its overall shape is 70% similar to the raw block.

[0044] For example, the forging process of a triangular structural component is as follows: Step 1: Cut the material using a saw. The material size is Φ250×205.

[0045] Step 2: Chamfer using a lathe, chamfer size: R10~R15.

[0046] Step 3: Use a 3t free forging hammer to forge the material, heating it to 35℃ below the phase transformation point, and complete the process in 3 heats.

[0047] First heat: Forge the bar stock to produce billet one, then bevel billet one to produce billet two; Second heat: Lengthen one end of billet two to produce billet three; Third heat: Place billet three into a die, press and shape it to produce the finished billet.

[0048] Step 4: Pre-forging is performed using a 630KJ hammer at a heating temperature of 35℃ below the phase transformation point, completed in one heat cycle to produce a pre-forged part. During production, a trackless robotic arm is used to transfer the rough mold into the lower pre-forging mold cavity, align the material, and hammer it for pressing. After pressing, the trackless robotic arm is used to remove the pre-forged part for air cooling.

[0049] Step 5: Remove the oxide scale from the surface of the forging using a sandblasting machine.

[0050] Step 6: Use a pneumatic drill to grind the surface of the pre-forged part until it is smooth.

[0051] Step 7: Perform final forging with a 630KJ hammer at a heating temperature of 35°C below the phase transformation point, completing the process in one heat cycle to produce the forging. During production, a trackless robotic arm rotates the pre-forging part 90° and then transfers it into the lower mold cavity for final forging. The material is then aligned and hammered to press it down. The hammering stops when the forging is completely filled and formed. The trackless robotic arm removes the pre-forging part for air cooling.

[0052] Step 8: Remove the burrs from the forging by gas cutting until the remaining burrs are 15~20mm.

[0053] Step 9: Remove the oxide scale from the surface of the forging using a sandblasting machine.

[0054] Step 10: Use a pneumatic drill to grind the surface of the forging until it is smooth.

[0055] Step 11: Heat treatment using an electric furnace, heat treatment regime: double annealing.

[0056] Step 12: Remove the burrs from the forging using a milling machine until the remaining burrs are 0~2mm.

[0057] Step Thirteen: Conduct physical and chemical tests.

[0058] Ultimately, the triangular structural component was forged through three processes: rough forging, pre-forging, and final forging. The rough forging process was stable, with each step exhibiting good operability. The finished rough mold achieved 95% conformity with the theoretical design. During pre-forging, the rough mold could be completely placed into the lower pre-forging mold cavity and remained stable; during pre-forging pressing, the rough mold did not show any significant shifting. After pre-forging pressing, the upper pre-forging die was fully formed, and the lower pre-forging die was essentially formed. During final forging, the pre-forged part could be completely placed into the lower final forging mold cavity. After final forging pressing, the forging was completely filled. In conclusion, the rough mold, die, and pre-forging designs were reasonable and feasible.

[0059] Physicochemical testing showed that both the high-magnification and low-magnification microstructures of the forgings met the required levels according to the standards. Furthermore, the performance data of the forgings fully met the specified values ​​in the standards.

[0060] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention in any way. Any simple modifications, alterations, and equivalent changes made to the above embodiments based on the technical essence of the present invention should fall within the protection scope of the present invention.

Claims

1. A forging method for an irregular triangular structural component, characterized in that, include: Step 1: Design pre-forgings based on forgings; Step 2: Design the rough shape based on the pre-forging and forging; Step 3: Design the forging mold based on the rough shape; Step 4: Design the blanks, including blank one, blank two, and blank three; Step 5: Create the rough shape; Step 6: Perform pre-forging and final forging on the triangular structural component.

2. The method according to claim 1, characterized in that, In step 1, the lower half of the pre-forging is designed based on the lower half of the forging. Compared with the depth dimension of the thin web of the lower half of the forging, the thickness dimension of the thin web of the lower half of the pre-forging is increased, so that the depth d of the thin web of the lower half of the pre-forging is ≤15mm. All draft angles, transition radii and outer contour dimensions are consistent with the lower half of the forging. Furthermore, during the production of the pre-forging, the cavity dimensions where the lower half of the pre-forging is located are used as the pre-forging lower die. The upper part of the pre-forged part maintains the exact same dimensions as the upper part of the forging.

3. The method according to claim 1, characterized in that, Step 2 is as follows: (1) Rotate the shape of the pre-forged part, rotate the longest side of the triangle to the horizontal plane and face upward, that is, place the largest angle of the triangle at the lowest end; (2) Design the three angles of the triangle shape of the rough die excluding the boss structure: The three angles of the triangle shape of the rough die excluding the boss structure and the three angles of the triangle outline of the pre-forged part excluding the boss structure satisfy the following: αmax=(0.99~1.01)Amax, αmid=(0.99~1.01)Amid, αmin=(0.99~1.01)Amin, Amax: The largest angle in the "triangular" profile of the pre-forged part, excluding the boss structure; Amid: The larger angle in the "triangular" profile of a pre-forged part, excluding boss structures; Amin: The smallest angle in the "triangular" profile of a pre-forged part, excluding the boss structure; αmax: The largest angle in the "triangle" shape of the rough shape, excluding the boss structure; αmid: The larger angle in the "triangle" shape of the rough shape, excluding the boss structure; αmin: The smallest angle in the "triangle" shape of the rough shape, excluding the boss structure; (3) Design the boss structure in the rough mold: According to the shape of the boss structure in the pre-forging part, connect the boss structure in the rough mold with multiple straight line segments with angles. The straight lines are transitioned with rounded corners. All the straight line segments maintain an angle of less than 85° with the horizontal line, and the straight line segments have a draft angle of more than 5°. (4) Design the gap between the outer contour of the rough die and the inner wall of the pre-forging die: A gap is left between the outer contour of the rough die and the inner wall of the pre-forging die so that the rough die can be completely placed into the cavity of the pre-forging die. The gap satisfies: Smax≤20mm, Smin≥3mm Smax: The maximum gap between the outer contour of the rough shape and the inner wall of the pre-forging die; Smin: The minimum clearance between the outer contour of the roughing die and the inner wall of the pre-forging die; (5) After determining the outer contour dimensions of the rough mold, calculate the required height dimensions of the rough mold based on the volume ratio according to the cross-sectional dimensions of the forging, and ensure that the volume ratio of the rough mold to the forging is within the range of 1.16 to 1.

28.

4. The method according to claim 1, characterized in that, In step 3, the mold is a single piece with a rectangular outer contour. The dimensions of the mold cavity in the depth direction are consistent with the outer contour dimensions of the rough mold, except that the total length is increased along the side with the smallest angle of the triangle. The mold cavity is centered in width and located on the mold module. The width of the mold cavity is increased compared to the maximum height of the rough mold. The mold cavity has a draft angle of more than 5°. The opening of the mold cavity is transitioned with a convex rounded corner.

5. The method according to claim 4, characterized in that, The mold dimensions meet the following requirements: L1 = L + (10~30) mm, L: Overall length of the rough shape; L1: Overall length of the cavity section of the tire mold. B1 = Hmax + (20~60) mm, Hmax: Maximum thickness of the rough shape. B1: Width dimension of the cavity portion of the tire model. R≥R5, R: The convex rounded corner at the opening of the tire model cavity. Lmin>100mm, H1>150mm, B2=B1+2*(80~130)mm, Lmin: The minimum distance from the opening of the tire mold cavity to the edge of the tire mold along its length; H1: The minimum distance between the bottom of the tire mold cavity and the bottom of the tire mold; B2: Overall width dimension of the mold module.

6. The method according to claim 1, characterized in that, The first blank is a rectangular blank. The height of the first blank is consistent with the maximum height of the blank. The width of the first blank is 5 to 30 mm larger than the maximum width of the blank. The volume ratio of the first blank to the blank is between 1.05 and 1.

20.

7. The method according to claim 1, characterized in that, The second blank is a blank with a parallelogram outer contour. The height and width of the second blank are the same as those of the first blank, and α1 = αmid + (0°~10°), where α1 is the acute angle in the outer contour shape of the second blank.

8. The method according to claim 7, characterized in that, The third blank is obtained by drawing one end of the second blank. Its total width and maximum thickness are consistent with the second blank, and its overall shape is more than 60% similar to the blank shape, and it satisfies the following: L2 = L - (30~60) mm, L2: Total length of the rough blank 3 B3 = Bmin + (10~30mm) B3: Minimum width dimension of blank three Bmin: Minimum width dimension of the rough shape.

9. The method according to claim 1, characterized in that, In step 5, the bar stock is first forged into a blank 1 with a rectangular outer contour; then the blank 1 is pressed into a blank 2 with the same thickness and width as the blank 1 and a parallelogram outer contour; one end of the blank 2 is elongated so that its shape is as close as possible to the blank shape, and finally blank 3 is obtained; blank 3 is placed into the forging mold designed in step 3. When placing it in, the blank shape is rotated 90° along the length direction, with the longest side of the outer contour of the blank shape facing upwards, and the obtuse angle end of the blank shape is placed close to the obtuse angle end in the mold. After pressing and shaping, the required blank shape is obtained.

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