Material utilization simulation calculation system for ring forging manufacturing process

Abstract

The present application relates to the field of forging processing technology, in particular to a material utilization rate simulation calculation system for annular forging manufacturing process, which comprises a data acquisition module, a data inference module, a data calculation module and a parameter adjustment module; the finished product geometric parameters of the annular forging are obtained to calculate the estimated value of the outer diameter of the blank and the estimated value of the initial volume of the blank; the hole expanding ratio is calculated according to the estimated value of the outer diameter of the blank and the finished product outer diameter, combined with the wall thickness height ratio and the allowable cumulative logarithmic strain variable of single heating, the required heating times of the hole expanding process are inferred and the total heating times of the whole process chain are summarized; the mass corresponding to the estimated value of the initial volume of the blank is taken as the starting point to perform successive iteration calculation, the loss mass of each item is obtained and the total mass of the blank input is calculated by forward closed calculation; the material utilization rate is calculated, and the process parameter adjustment suggestion is triggered when it is lower than the preset target lower limit. The present application effectively eliminates the cumulative error of burning loss, and improves the accuracy of accounting.

Description

Technical Field

[0001] This invention relates to the field of forging technology, and more specifically to a simulation calculation system for material utilization in the manufacturing process of ring forgings. Background Technology

[0002] Ring forgings are core components of industrial equipment such as bearing rings, flanges, and gear rings. Their manufacturing process chain encompasses multiple steps, including blanking, heating, upsetting and punching, reaming, ring rolling, and heat treatment. Each step involves unavoidable material loss. Because ring forgings are highly non-standardized products, with finished outer diameters ranging from tens to thousands of millimeters and significant differences in the wall thickness to height ratio, the industry has long relied on fixed loss coefficients accumulated through engineering experience to calculate the material utilization rate across the entire process.

[0003] In existing technologies, companies typically pre-set a comprehensive loss coefficient in their accounting system, with a typical range of 12% to 25%. The amount of raw material input is obtained by directly multiplying this coefficient by the theoretical weight of the finished product, and the material utilization rate is calculated by reverse calculation. Some improvement schemes will set coefficient levels for different materials or introduce process categories to classify and correct the coefficient.

[0004] However, the core process parameters of ring rolling, namely the expansion ratio and the wall thickness-to-height ratio, jointly determine whether the ring can complete all plastic deformation within a single heating cycle during the rolling process. When the expansion ratio exceeds the critical value corresponding to the maximum allowable deformation of the material under single heating conditions, it indicates that the deformation demand of the ring is significantly limited beyond the allowable capacity of a single heating cycle. At this time, the process must introduce one or more intermediate heating cycles, and each heating cycle will generate a new round of oxidation loss on the surface of the forging. Since the fixed coefficient method is built on the implicit premise of single heating, it cannot perceive the actual heating cycle changes driven by geometric parameters. If this method is used directly, the estimation of oxidation loss will be continuously underestimated as the number of heating cycles increases, ultimately resulting in the calculated material utilization rate being systematically higher than the actual production consumption value. This deviation is particularly prominent in the case of thin-walled, large-diameter rings, directly leading to an underestimation of billet procurement and a distortion of production cost accounting. In order to eliminate the systematic deviation of the fixed coefficient method under multiple heating conditions, a new accounting scheme is urgently needed. Summary of the Invention

[0005] To eliminate the systematic bias of the fixed coefficient method under multiple heating conditions in the prior art, the present invention provides a material utilization simulation calculation system for the manufacturing process of ring forgings.

[0006] This invention provides a material utilization simulation calculation system for the manufacturing process of ring forgings, comprising: a data acquisition module for acquiring the finished geometric parameters of the ring forging, calculating the ratio of the theoretical mass to the wall thickness height based on the finished geometric parameters, and estimating the estimated outer diameter and initial volume of the billet; a data inference module for calculating the expansion ratio based on the estimated outer diameter of the billet and the finished outer diameter in the finished geometric parameters, combining the wall thickness height ratio and the allowable cumulative logarithmic strain of the single heating corresponding to the material, inferring the number of heating times required for the rolling expansion process, and summing up the total number of heating times for the entire process; a data calculation module for performing iterative calculations based on the mass corresponding to the estimated initial volume of the billet, according to the total number of heating times for the entire process, to obtain the total oxidation loss mass, forging flash loss mass, and cutting allowance loss mass, summing them up to obtain the total loss mass, and performing a forward closed-loop calculation to obtain the total mass of the billet input; and a parameter adjustment module for calculating the material utilization rate based on the theoretical mass of the finished product and the total mass of the billet input, and triggering process parameter adjustment suggestions for the process node corresponding to the total oxidation loss mass when the material utilization rate is lower than the preset target lower limit.

[0007] This invention establishes an automatic inference path from the geometric parameters of the ring forging to the actual number of heating cycles in the process path. It restores the total process loss, which is compressed into a single black box value in the traditional fixed coefficient method, into three independent sub-item accounting paths for three physical sources: oxidation loss, flash loss, and cutting allowance. This effectively improves the accuracy of billet procurement quantity estimation and production cost accounting.

[0008] Preferably, the estimation of the billet outer diameter and the billet initial volume includes: calculating the theoretical volume of the finished product based on the finished product geometric parameters; calculating the billet initial volume estimate based on the finished product theoretical volume and the pre-acquired estimated total loss rate; and calculating the billet outer diameter estimate from the billet initial volume estimate according to the preset height-to-diameter ratio constraint range.

[0009] Preferably, the step of inferring the number of heating cycles required for the rolling and expanding process by combining the wall thickness-to-height ratio with the allowable cumulative logarithmic strain for a single heating cycle corresponding to the material includes: obtaining the high-temperature thermal tensile shrinkage rate of the current material and calculating the theoretical limit logarithmic strain; introducing a process safety factor to correct the theoretical limit logarithmic strain downwards to obtain the allowable cumulative logarithmic strain for a single heating cycle; calculating the cumulative logarithmic strain required for the entire rolling and expanding process based on the hole expansion ratio; dividing the cumulative logarithmic strain required for the entire rolling and expanding process by the allowable cumulative logarithmic strain for a single heating cycle and rounding up, and making a correction judgment based on the deformation difficulty indicator of the wall thickness-to-height ratio, and finally inferring the number of heating cycles required for the rolling and expanding process.

[0010] By directly combining the hole expansion ratio and the allowable deformation of the material, the actual number of heating cycles can be inferred, providing an accurate input for subsequent sequential calculation of the burn-off of each component.

[0011] Preferably, the step of performing iterative calculations based on the total number of heating cycles in the entire process to obtain the total oxidation loss mass includes: obtaining the material oxidation rate coefficient and the holding time for each heating cycle; calculating the increase in oxide scale mass per unit area for each heating cycle; multiplying the increase in oxide scale mass per unit area by the actual surface area of ​​the ring billet before each heating cycle to obtain the single-cycle loss mass; performing a pure subtraction iterative update by deducting the single-cycle loss mass from the current billet mass in real time; and after completing the iterative calculations for the total number of heating cycles in the entire process, calculating the difference between the initial input billet mass and the remaining mass after all heating cycles to obtain the total oxidation loss mass.

[0012] Preferably, the forward closed-loop calculation of the total mass of the billet input includes: accumulating the total oxidation loss mass, the forging flash loss mass, the cutting allowance loss mass, and the blanking end cutting loss mass to obtain the total loss mass; adding the theoretical mass of the finished product to the total loss mass to obtain the initial total mass of the billet input; calculating the difference between the initial total mass of the billet input and the mass corresponding to the initial estimated volume of the billet; in response to the difference exceeding a preset convergence threshold, updating the estimated outer diameter of the billet with the current total mass of the billet input and re-performing the loss calculation until the difference between two adjacent calculations meets the convergence condition, and finally calculating the total mass of the billet input in a forward closed loop.

[0013] By dynamically tracking the actual geometric state of the ring blank before each heating through successive iterations, and by using a method that reduces the total process loss to three independent sub-item accounting paths for each of the three physical sources—oxidation loss, flash loss, and cutting allowance—the loss of each sub-item has physical traceability that can be directly verified against the process records, effectively improving the accuracy of the accounting.

[0014] Preferably, when the material utilization rate is lower than the preset target lower limit, the step of triggering a process parameter adjustment suggestion for the process node corresponding to the total oxidation loss mass includes: comparing the material utilization rate with the preset target lower limit; when the material utilization rate is lower than the preset target lower limit, retrieving the lower limit of the heating temperature supported by the current material and the condition for shortening the single holding time; generating a suggested value for shortening the holding time while ensuring plasticity, and recalculating and verifying the trend of material utilization rate change after adjustment, and finally triggering the process parameter adjustment suggestion for the process node corresponding to the total oxidation loss mass.

[0015] Preferably, the process parameter adjustment suggestion triggered for the process node corresponding to the total oxidation loss mass further includes: determining whether the number of heating cycles required for the rolling process is greater than a preset number threshold; if it is greater than the preset number threshold, generating an adjustment suggestion to extend the holding time of the soaking section to increase the allowable cumulative logarithmic strain of a single heating cycle; based on the increased allowable cumulative logarithmic strain of a single heating cycle, compressing the number of heating cycles required for the rolling process downward, and calculating the resulting saved loss mass, which is output as the composite saving benefit of the process parameter adjustment suggestion.

[0016] By directly using the material utilization rate calculation results and the distribution of the proportion of sub-items of loss to output the results, and providing verifiable parameter adjustment suggestions for different loss sources and paths, the system makes evidence-based adjustments to the billet input and process parameters based on the actual geometric path and physical loss law, effectively avoiding reliance on fixed coefficient experience.

[0017] Preferably, the forging flash loss mass is obtained by: retrieving the corresponding flash coefficient based on the forging process category and the outer diameter of the finished product in the finished product geometric parameters, multiplying the current mass of the ring billet when entering the forging forming process by the flash coefficient, and obtaining the forging flash loss mass.

[0018] Preferably, the method for obtaining the cutting allowance loss mass is as follows: based on the machining accuracy grade of the finished product and the geometric parameters of the finished product, the single-sided allowance of each machined surface is retrieved, and the sum of the allowance volumes of each machined surface is calculated; the sum of the allowance volumes of each machined surface is multiplied by the material density to obtain the cutting allowance loss mass.

[0019] Preferably, the process of summarizing the total number of heating cycles for the entire process includes: setting the initial number of heating cycles before material feeding to a fixed value; retrieving the corresponding number of heating cycles for the heat treatment process based on the heat treatment process type; adding the initial number of heating cycles before material feeding, the number of heating cycles for the heat treatment process, and the number of heating cycles required for the rolling and expanding process, and finally summing them to obtain the total number of heating cycles for the entire process.

[0020] This invention takes the quality of the billet input as a positive starting point and eliminates the cumulative error of burn-off caused by multiple heating under thin-walled conditions with large hole expansion ratio by iteratively deducting each process. This method of itemized and step-by-step accounting makes the material utilization rate calculation results truly maintain a dynamic correspondence with the actual production geometric path, effectively improving the physical interpretability and data transparency of the accounting system.

[0021] Furthermore, the automatic inference pathway established by this invention restores traditional black-box values ​​to independent sub-item accounting paths, which not only effectively improves the accuracy of billet procurement estimation and production cost accounting, but also provides a clear direction for subsequent process optimization, enabling process personnel to intuitively identify process nodes with concentrated losses, thereby achieving refined production control. Attached Figure Description

[0022] The above and other objects, features, and advantages of exemplary embodiments of the present invention will become readily apparent upon reading the following detailed description with reference to the accompanying drawings. In the drawings, several embodiments of the invention are illustrated by way of example and not limitation, and like or corresponding reference numerals denote like or corresponding parts, wherein: Figure 1 This is a flowchart illustrating a material utilization simulation calculation system for a ring forging manufacturing process according to the present invention.

[0023] Figure 2 This is a comparison chart showing the trend of material utilization rate changing with the hole expansion ratio in the rolling and expanding process in the embodiments of the present invention. Detailed Implementation

[0024] 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, not all, of the embodiments of the present invention. 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.

[0025] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0026] This invention discloses a material utilization simulation calculation system for the manufacturing process of ring forgings, referring to... Figure 1 This includes data acquisition module 100 and parameter adjustment module 400: The data acquisition module 100 is used to acquire the finished geometric parameters of the ring forging, calculate the ratio of the theoretical mass to the wall thickness height of the finished product based on the finished geometric parameters, and estimate the outer diameter and initial volume of the billet.

[0027] In an optional embodiment, the geometric parameters of the finished ring forging, including the outer diameter of the finished product, are received from the user. Finished product inner diameter Finished product height In addition to the material category code, the theoretical volume of the finished product is calculated using the existing formula for the volume of a toroidal body, based on the finished product's geometric parameters. :

[0028] in , and All units are in millimeters. Units are ; obtain Then, the density of the corresponding material is retrieved from the material database. The unit is Calculate the theoretical quality of the finished product This serves as the benchmark anchor point for calculating the losses of each subsequent process.

[0029] Furthermore, two key geometric feature parameters are calculated simultaneously, including wall thickness. Ratio of wall thickness to height In this relation, This value represents the difficulty of geometric deformation of the ring blank during the rolling process. As an indicator of deformation difficulty, the smaller the value, the thinner the ring blank is, the greater the cumulative deformation required for rolling, and the more sensitive it is to the number of intermediate reheating cycles.

[0030] Furthermore, based on Based on the forging process category, calculate the minimum solid cylindrical volume required for the billet before punching, i.e., the estimated initial volume of the billet. Retrieve the industry's existing estimated total loss rate from the process database, categorized by forging process type. This value is the average of the engineering reference intervals corresponding to each process category, and is directly stored in the process database. The estimated initial volume of the billet is:

[0031] The height-to-diameter ratio of the blank cylinder The value is taken from the constraint range corresponding to the forging category in the process database. For example, the height-to-diameter ratio constraint range can be taken as follows: Take the median value Back-calculation of billet outer diameter estimate and height As input for calculating the dimensions of the blank cutting section, it ensures that the subsequent blank design has a geometric closure basis.

[0032] In this way, by converting the finished product's geometric parameters into estimated initial billet volume and simultaneously extracting geometric feature indicators such as wall thickness-to-height ratio, an accurate geometric input basis is established for subsequent process path determination.

[0033] The data inference module 200 is used to calculate the expansion ratio based on the estimated outer diameter of the billet and the outer diameter of the finished product in the geometric parameters of the finished product. It combines the wall thickness-to-height ratio with the allowable cumulative logarithmic strain of the material for a single heating cycle to infer the number of heating cycles required for the rolling expansion process and summarizes the total number of heating cycles for the entire process.

[0034] In an optional embodiment, the estimated outer diameter of the billet is calculated based on the previously back-calculated value. and finished product outer diameter Calculate the expansion ratio in the rolling and expanding process: ; in This is the estimated initial outer diameter of the ring billet before it enters the ring rolling mill after the bolt hole is enlarged. The relationship between the wall thickness distribution after punching and the calculation results in the following formula: The core parameter representing the number of heating cycles is: the larger the value, the greater the amount of plastic deformation the ring blank needs to undergo from its initial size to the finished outer diameter. Under the condition that the allowable deformation capacity of a single heating is limited, the number of intermediate heating cycles required is also greater.

[0035] Retrieve the high-temperature hot tensile reduction of area of ​​the current material within the forging temperature range from the material database. This value is a retrievable physical quantity found in material handbooks or standard material databases, and is directly determined by high-temperature tensile testing. The theoretical limiting logarithmic strain of this material is calculated using existing formulas in metal plasticity mechanics:

[0036] Due to the temperature drop during the furnace transfer process, the actual usable deformation of the billet upon arrival at the rolling mill is lower than the theoretical limit. Therefore, a process safety factor is introduced. By downward correction of the theoretical limit logarithmic strain, the allowable cumulative logarithmic strain for a single heating cycle is obtained. This is to allow for temperature drop during the furnace transfer process. The specific values ​​are determined based on actual process conditions such as furnace type and furnace discharge conveying distance. For example, 0.85 is acceptable:

[0037] Furthermore, the cumulative logarithmic strain required for the entire rolling process is calculated based on the existing definition of logarithmic strain:

[0038] The cumulative logarithmic dependent variable required for the entire rolling process Divide by the allowable cumulative logarithmic strain of a single heating cycle Round up to get the initial number of heating cycles. Then, combined with the wall thickness to height ratio Perform a corrective judgment: when When the value is below the preset thin-wall threshold, it indicates that the ring is in a thin-walled high-cylinder state, and the deformation resistance in the wall thickness direction increases significantly. Based on the preliminary calculation results, the number of heating cycles is increased by one. If the number of heating cycles is not lower than this threshold, the preliminary calculation result is used. For example, the thin-wall determination threshold can be 0.3. After the above calculation and correction based on the wall thickness-to-height ratio, the final number of heating cycles required for the rolling expansion process is obtained. .

[0039] The initial heating number before blanking is determined based on the billet condition and equipment conditions. For example, the initial heating number before blanking can be set to 1 time. The heating number for each heat treatment process is retrieved from the process database according to the pre-stored heating number correspondence for each heat treatment process type. For example, annealing can correspond to 1 heating cycle, tempering to 2 heating cycles, and normalizing, quenching, and tempering to 3 heating cycles. The total number of heating cycles for the entire process is obtained by adding the initial heating cycles before material preparation, the heating cycles for heat treatment, and the heating cycles required for rolling.

[0040] In this way, the actual number of heating cycles can be inferred by directly combining the hole expansion ratio and the allowable deformation of the material. An automatic mapping from the geometric parameters of the ring forging to the thermal history of the entire process link is established, providing accurate input for the successive calculation of the subsequent sub-item burn loss.

[0041] The data calculation module 300 is used to perform iterative calculations based on the mass corresponding to the initial volume estimate of the billet, according to the total number of heating times in the entire process link, to obtain the total oxidation loss mass, forging flash loss mass, and cutting allowance loss mass, and to accumulate the total loss mass, and to calculate the total mass of the billet input in a positive closed loop.

[0042] In an optional embodiment, the sources of material loss are broken down into three independent categories: oxidation loss, forging flash loss, and cutting allowance loss, and calculation paths are established for each category. The mass corresponding to the estimated initial volume of the billet (i.e., the mass of the billet input) is used. Starting with the total number of heating cycles in the entire process, iterative calculations are performed for each cycle, ultimately based on the finished product quality. The endpoint is used to ensure that the direction of loss calculation is consistent with the actual material flow direction.

[0043] For the oxidation loss component, an iterative approach is used to calculate the absolute loss mass for each heating cycle, with the calculation starting at the current mass of the billet. ,in The estimated mass of the obtained billet is deducted in real time after each heating. The material oxidation rate coefficient and the holding time for each heating cycle are obtained to calculate the increase in oxide scale mass per unit area for each heating cycle. ; in This is the oxidation rate coefficient of the material, retrieved from the material database by material code, in units of... The result was obtained by fitting the parabolic oxidation kinetics curve of the material at a standard heating temperature; The holding time for each heating cycle, in units of Multiply the increase in oxide scale mass per unit area by the actual surface area of ​​the ring billet before each heating. The mass of a single burn loss is obtained as follows: ; in Based on the current outer diameter, inner diameter, and height of the ring billet before each heating, the surface area is calculated using the existing annular surface area formula. This is dynamically updated as the outer diameter increases after each rolling expansion to ensure that the burn-off mass corresponds to the geometric state in real time. A pure subtraction iterative update is performed by deducting the single burn-off mass from the current billet mass in real time. ; Complete the total number of heating cycles for the entire process link After successive iterations, the difference between the initial input billet mass and the remaining mass after all heating processes is calculated to obtain the total oxidation loss mass: ;because As the rolling expansion process dynamically increases, the single burn-off mass corresponding to each subsequent reheating is generally higher than that of the initial heating. The fixed coefficient method cannot capture this geometrically driven burn-off amplification effect.

[0044] Specifically, based on the forging process type and the outer diameter of the finished product in the geometric parameters of the finished product. Retrieve the corresponding fly edge coefficient This coefficient is derived from the flash width ratio specification value corresponding to different die forging categories in the forging design manual or enterprise process specifications. Multiplying the current mass of the ring billet when entering the forging forming process by the flash coefficient yields the forging flash loss mass:

[0045] in The current quality of the ring billet when it enters the forging process, i.e., the quality after all rolling, expansion, and reheating are completed. This value is used to ensure that the loss benchmark is consistent with the actual material quality. Based on the machining accuracy grade and geometric parameters of the finished product, the single-sided allowance of each machined surface is retrieved, and the sum of the allowance volumes of each machined surface is calculated. ,Will Multiply by material density The cutting allowance loss quality is obtained. .

[0046] Furthermore, the total oxidation loss mass, forging flash loss mass, cutting allowance loss mass, and blanking end cutting loss mass are combined. By summing the results, we obtain the total loss mass:

[0047] in The cutting amount at the sawing end is obtained from a table in the process database. The initial total mass of the blank is obtained by adding the theoretical mass of the finished product to the total loss mass.

[0048] Calculate the mass corresponding to the initial total mass of the billet input and the estimated initial volume of the billet (i.e., the initial estimated mass). The difference between the values ​​is used to determine the estimated outer diameter of the billet. If the difference exceeds a preset convergence threshold, the estimated outer diameter of the billet is updated using the current total mass of the billet input. The loss calculation is then re-executed until the difference between the two adjacent calculations meets the convergence condition, and finally the total mass of the billet input is calculated in a positive closed loop.

[0049] In this way, by dynamically tracking the actual geometric state of the ring blank before each heating in an iterative manner, the total process loss is reduced to three independent sub-item accounting paths for three physical sources: oxidation loss, flash loss, and cutting allowance. Each sub-item loss has physical traceability that can be directly verified against the process records, effectively improving the accuracy of the accounting.

[0050] S4, parameter adjustment module 400, is used to calculate the material utilization rate based on the theoretical quality of the finished product and the total mass of the billet input. When the material utilization rate is lower than the preset target lower limit, it triggers process parameter adjustment suggestions for the process node corresponding to the total oxidation loss mass.

[0051] In an optional embodiment, the material utilization rate is calculated based on the theoretical mass of the finished product and the total mass of the billet input:

[0052] in For the theoretical quality of the finished product, To calculate the total mass of the billet used, It directly benchmarks against the enterprise's process material consumption ledger, facilitating comparison and verification with measured values. It simultaneously outputs the proportion of the three types of losses to the total loss, presenting the contribution weight of each process's losses in a visual chart format, enabling process engineers to intuitively identify process nodes with concentrated losses.

[0053] By comparing the material utilization rate with the preset target lower limit, when the material utilization rate is lower than the preset target lower limit, the processor will automatically trigger process parameter adjustment suggestions for the process node corresponding to the total oxidation loss mass, and provide adjustment directions according to the source and path of loss. For scenarios with large oxidation loss, the processor retrieves the lower limit of the heating temperature supported by the current material and the conditions for shortening the single holding time, generates suggested values ​​for shortening the holding time while ensuring plasticity, and recalculates and verifies the trend of material utilization rate change after adjustment. Finally, it triggers process parameter adjustment suggestions for the process node corresponding to the total oxidation loss mass. Due to and There is a positive correlation; shortening the heat preservation time has a greater effect on inhibiting burn-off. The effect is more pronounced when the value is larger, and the adjustment benefit increases with the increase of the initial heat preservation time. Therefore, while providing the suggested value, the difference in burn-off quality before and after the adjustment is also output for process personnel to evaluate the feasibility.

[0054] Furthermore, it is determined whether the number of heating cycles required for the rolling and expanding process exceeds a preset threshold, for example, this threshold can be 2 cycles; if it exceeds the preset threshold, an adjustment suggestion to extend the holding time of the heat spreader is generated to increase the allowable cumulative logarithmic strain per heating cycle. Based on the improved allowable cumulative logarithmic strain of a single heating cycle, The process is compressed downwards, and the resulting reduction in burn-off mass is calculated, outputting a composite savings benefit as a recommendation for process parameter adjustments. Each reduction in intermediate reheating not only directly reduces one round of surface oxidation but also keeps the surface area of ​​the ring billet relatively small before subsequent heatings. The actual savings in burn-off mass are typically greater than the simple sum of burn-off losses from a single heating cycle; therefore, this composite savings benefit is included in the output report. It should be noted that there are many other ways in the art to extend the soaking time in the soaking zone, and those skilled in the art can choose different adjustment schemes based on actual equipment conditions and furnace capacity and energy consumption constraints.

[0055] like Figure 2 As shown in the figure, the trend comparison of material utilization rate with the expansion ratio of the rolling process in the embodiment of the present invention can be seen. It can be seen that the existing fixed coefficient method shows a significant downward trend in material utilization rate under high expansion ratio conditions, while the trend line corresponding to the successive iteration method of the present invention has a gentler downward slope and lower data dispersion. This indicates that the present invention has more robust accounting characteristics under the condition of thin-walled high cylinder with large expansion ratio, and effectively suppresses the systematic deviation caused by the fixed coefficient method due to ignoring the superposition of multiple heating and burning losses.

[0056] In this way, by combining the material utilization rate calculation results with the distribution of the proportion of sub-items of loss, and providing verifiable parameter adjustment suggestions for different loss sources and paths, the billet input and process parameters can be adjusted in a way that is based on actual geometric paths and physical loss laws, effectively avoiding reliance on fixed coefficient experience.

Claims

1. A simulation calculation system for material utilization rate in the manufacturing process of ring forgings, characterized in that, include: The data acquisition module is used to acquire the finished geometric parameters of the ring forging, calculate the ratio of the theoretical mass to the wall thickness height based on the finished geometric parameters, and estimate the outer diameter and initial volume of the billet. The data inference module is used to calculate the expansion ratio based on the estimated outer diameter of the billet and the outer diameter of the finished product in the geometric parameters of the finished product. It combines the wall thickness-to-height ratio with the allowable cumulative logarithmic strain of the material for a single heating cycle to infer the number of heating cycles required for the rolling expansion process and summarizes the total number of heating cycles for the entire process. The data calculation module is used to perform iterative calculations based on the mass corresponding to the initial volume estimate of the billet, according to the total number of heating times in the entire process link, to obtain the total oxidation loss mass, forging flash loss mass, and cutting allowance loss mass, and to accumulate the total loss mass, and to calculate the total mass of the billet input in a positive closed loop. The parameter adjustment module is used to calculate the material utilization rate based on the theoretical quality of the finished product and the total mass of the billet input. When the material utilization rate is lower than the preset target lower limit, it triggers process parameter adjustment suggestions for the process node corresponding to the total oxidation loss mass.

2. The material utilization simulation calculation system for the manufacturing process of annular forgings according to claim 1, characterized in that, The estimated values ​​of the billet's outer diameter and initial volume include: Calculate the theoretical volume of the finished product based on the aforementioned geometric parameters; Based on the theoretical volume of the finished product and the pre-obtained estimated total loss rate, the estimated initial volume of the billet is calculated. According to the preset height-to-diameter ratio constraint range, the estimated outer diameter of the billet is calculated from the estimated initial volume of the billet.

3. The material utilization simulation calculation system for the manufacturing process of annular forgings according to claim 1, characterized in that, The method of inferring the number of heating cycles required for the rolling process by combining the wall thickness-to-height ratio with the allowable cumulative logarithmic strain of a single heating cycle corresponding to the material includes: Obtain the high-temperature thermal tensile reduction of area of ​​the current material and calculate the theoretical limit logarithmic strain; By introducing a process safety factor to correct the theoretical limit logarithmic strain downward, the allowable cumulative logarithmic strain for a single heating cycle is obtained. Calculate the cumulative logarithmic strain required for the entire rolling expansion process based on the aforementioned expansion ratio; The cumulative logarithmic strain required for the entire rolling process is divided by the allowable cumulative logarithmic strain for a single heating cycle and rounded up. This is then combined with the deformation difficulty indicator of the wall thickness-to-height ratio for correction and judgment, ultimately leading to the deduction of the number of heating cycles required for the rolling process.

4. The material utilization simulation calculation system for the manufacturing process of ring forgings according to claim 1, characterized in that, The step of performing iterative calculations based on the total number of heating cycles in the entire process chain to obtain the total oxidation loss mass includes: Obtain the material oxidation rate coefficient and the holding time for each heating cycle, and calculate the mass increment of oxide scale per unit area for each heating cycle; Multiply the mass increment of oxide scale per unit area by the actual surface area of ​​the ring blank before each heating to obtain the mass loss per heating cycle. The single burn loss mass is subtracted from the current billet mass in real time and the update is performed using a pure subtraction method. After completing the iterative total number of heating cycles in the entire process chain, the difference between the initial input billet mass and the remaining mass after all heating cycles is calculated to obtain the total oxidation loss mass.

5. The material utilization simulation calculation system for the manufacturing process of annular forgings according to claim 1, characterized in that, The forward closed-loop calculation yields the total mass of the billet input, including: The total loss mass is obtained by summing the total oxidation loss mass, the forging flash loss mass, the cutting allowance loss mass, and the blanking end cutting loss mass. The initial total mass of the blank is obtained by adding the theoretical mass of the finished product to the total mass of the loss. Calculate the difference between the initial total mass of the billet input and the mass corresponding to the estimated initial volume of the billet; In response to the difference exceeding the preset convergence threshold, the estimated outer diameter of the billet is updated with the current total mass of the billet input and the loss calculation is re-executed until the difference between the two adjacent calculations meets the convergence condition, and finally the total mass of the billet input is calculated in a positive closed loop.

6. The material utilization simulation calculation system for the manufacturing process of annular forgings according to claim 1, characterized in that, When the material utilization rate is lower than the preset target lower limit, the proposed adjustment of process parameters for the process node corresponding to the total oxidation loss mass includes: Compare the material utilization rate with the preset target lower limit; When the material utilization rate is lower than the preset target lower limit, retrieve the lower limit of the heating temperature supported by the current material and the condition for shortening the single heat preservation time; While ensuring plasticity, a suggested value for shortening the heat preservation time is generated, and the trend of material utilization rate after adjustment is recalculated and verified. Finally, the process parameter adjustment suggestion is triggered for the process node corresponding to the total oxidation loss mass.

7. The material utilization simulation calculation system for the manufacturing process of annular forgings according to claim 6, characterized in that, The proposed adjustments to the process parameters triggered at the corresponding process node for the total oxidation loss also include: Determine whether the number of heating cycles required for the rolling and expanding process is greater than a preset threshold number; If the number of times exceeds the preset threshold, an adjustment suggestion to extend the heat preservation time of the heat-equalizing section is generated to increase the allowable cumulative logarithmic strain of a single heating cycle. Based on the increased allowable cumulative logarithmic strain per heating cycle, the number of heating cycles required for the rolling process is reduced downwards, and the resulting reduction in burn-off mass is calculated and output as a composite saving benefit of the process parameter adjustment recommendations.

8. The material utilization simulation calculation system for the manufacturing process of annular forgings according to claim 1, characterized in that, The method for obtaining the forging flash loss quality is as follows: Based on the forging process category and the outer diameter of the finished product in the geometric parameters of the finished product, the corresponding flash coefficient is retrieved. The current mass of the ring billet when entering the forging forming process is multiplied by the flash coefficient to obtain the forging flash loss mass.

9. The material utilization simulation calculation system for the manufacturing process of annular forgings according to claim 1, characterized in that, The method for obtaining the cutting allowance loss quality is as follows: Based on the machining accuracy grade of the finished product and the geometric parameters of the finished product, retrieve the single-sided allowance of each machined surface and calculate the sum of the allowance volumes of each machined surface; Multiply the sum of the volumes of the machining allowances on each surface by the material density to obtain the mass of the cutting allowance loss.

10. The material utilization simulation calculation system for the manufacturing process of annular forgings according to claim 1, characterized in that, The summary yields the total number of heating cycles across the entire process, including: Set the initial heating count before material feeding to a fixed value; Search for the corresponding number of heating steps in the heat treatment process based on the heat treatment process type; The total number of heating cycles in the entire process is obtained by adding the initial heating cycles before material feeding, the heating cycles in the heat treatment process, and the heating cycles required for the rolling and expanding process.

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