Flange shaft forging forming tool
The combination of a split die assembly and a rotary platform press hammer anvil solves the problems of long production cycle and high cost in forging small batches of multi-specification flange shafts, achieves a fast and efficient forging process, and ensures forming quality and die durability.
Patent Information
- Application Number
- CN202422746257.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-11
- Publication Date
- 2025-09-23
- Estimated Expiration
- 2034-11-11
AI Technical Summary
When existing technologies are used to produce large flange shafts of various specifications in small batches, the mold production cycle is long, the cost is high, and the forming quality is uneven, making it difficult to quickly respond to market demand.
The split die, including the forming die and the sleeve die, is used to form forging forming dies of different heights through flexible combination. It is suitable for forging flange shafts of different tonnages and sizes. The use of the rotating platform and the press hammer anvil ensures the alignment of the die and uniform force.
It shortens the production cycle, reduces tooling costs, improves forming quality and mold service life, is suitable for small batch and multi-specification production, and can quickly respond to market demand.
Smart Images
Figure CN223368108U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of flange shaft forging, in particular to a flange shaft forging forming tool. Background Art
[0002] Currently, in power transmission fields such as wind power and propulsion systems, large drive shafts are generally flanged. Due to their harsh operating conditions and the torque loads they bear, they are typically produced using forging methods to ensure good overall performance.
[0003] The flange shaft is a large free forging, and the conventional forging method is free forging. After the material is divided, a special forming die is used (open rather than closed forging). This method requires the production of a corresponding forming die for a flange shaft of a certain specification. Generally, the production cycle of a large forming die is long and the cost investment is high. It is only suitable for large-scale forgings. It is not applicable to the production of small-batch production of multiple specifications of forgings, either in terms of cost or production cycle. Utility Model Content
[0004] The utility model aims to provide a flange shaft forging tooling, which can flexibly adjust the combination mode to form end face flange shaft forging dies of different heights. It is suitable for forging flange shafts of different tonnages and sizes, has high versatility, and effectively reduces tooling costs.
[0005] The basic solution provided by the utility model is: a flange shaft forging forming tool, which is used to form end face flange shaft forgings in the flange shaft free forging process;
[0006] The tooling includes a plurality of forming dies and a plurality of sleeve dies; the forming dies and the sleeve dies each have an upper end face and a lower end face, and at least one end face has an end face concave portion or an end face convex portion; the centers of the forming dies and the sleeve dies respectively pass through the upper end face and the lower end face to form a first inner hole and a second inner hole, wherein the first inner hole and the second inner hole have the same diameter, and the upper portion of the first inner hole further has a curved portion;
[0007] The several forming dies include a main forming die and at least one auxiliary forming die; the main forming die is used to be stacked up and down with different numbers of sleeve dies and / or auxiliary forming dies to form different forging forming dies, wherein the main forming die is located at the top when stacked; the auxiliary forming die is used to replace the main forming die for combination when the main forming die is unavailable, and is also used as a sleeve die, and is located between the main forming die and the sleeve die when stacked; when the forming die and the sleeve die are stacked up and down, they are connected by the end face concave part and the end face convex part, all upper end faces and lower end faces are aligned, the curved part of the first inner hole is away from the second inner hole, and the centers of the first inner hole and the second inner hole are aligned.
[0008] The working principle and advantages of the utility model are as follows: according to the size of the flange shaft to be forged, an appropriate forming die and a sleeve die are selected, the forming die and the sleeve die are superimposed up and down, snap-fitted and connected, the upper and lower end faces are aligned, the inner hole centers are aligned, and the corresponding forging forming die is formed; after the free forging flange end and the shaft end are separated, the original blank is loaded into the die, and then the die and the blank are placed on a rotating platform as a whole, and the press hammer anvil is used to press down so that the blank is evenly compressed, and finally the flange shaft blank is formed, completing the forming process of this tooling; subsequently, the formed flange shaft blank is taken out from the die, and the shaft end is correspondingly stretched to complete the final forming of the shaft end.
[0009] Compared with the existing technology, the advantages of this tooling are: this tooling adopts a split mold, which can be flexibly combined and matched to adapt to the processing of different flange shafts. When the mold combination can meet the production of new specifications of flange shafts, there is no need to make new tooling, and there is no need to wait for the production time of new tooling. Only the combination needs to be adjusted to quickly produce, which greatly shortens the production cycle, speeds up the market response speed, and saves a lot of tooling costs. Even if the existing mold combination cannot meet the production of new specifications of flange shafts, only a small number of split molds need to be remade, and the original mold combination can be quickly put into production. Compared with traditional large-scale forming molds, the production cycle and cost of the new split mold are also advantageous, which is especially suitable for the production of small batches of multi-specification flange shafts. At the same time, based on the split combination mold, this solution cleverly carries out structural design, maintains the overall consistency of the mold after combination, the alignment of the upper and lower end faces and the concentricity of the inner hole, ensures uniform force under the action of the press hammer anvil, long mold service life, and good forming quality. BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Figure 1 A schematic diagram of die assembly for a flange shaft forging tooling provided in the first embodiment of the present invention;
[0011] Figure 2 This is a schematic structural diagram of the concave portion and the convex portion of the end surface provided in Example 1 of the present utility model;
[0012] Figure 3 This is a flow chart of forging the end flange shaft provided in the first embodiment of the present invention;
[0013] Figure 4 This is a schematic structural diagram of a conical plate provided in Example 2 of the present utility model;
[0014] Figure 5 This is a schematic structural diagram of the forming die provided in the third embodiment of the present utility model. DETAILED DESCRIPTION
[0015] The following is a further detailed description through specific implementation methods:
[0016] The marks in the drawings of the specification include: forming die 1, main forming die 11, auxiliary forming die 12, first inner hole 13, bending part 14, core die 15, outer die 16, sleeve die 2, second inner hole 21, blank 3, flange end forming part 31, flange shaft forming part 32, end face concave part 4, end face convex part 5, and conical plate 6.
[0017] The embodiment is basically as shown in the attached Figure 1 The figure shows a flange shaft forging tooling, which is used to form end face flange shaft forgings in the flange shaft free forging process. The tooling includes a plurality of forming dies 1 and a plurality of sleeve dies 2.
[0018] The plurality of forming dies 1 include a main forming die 11 and at least one auxiliary forming die 12 .
[0019] The main forming die 11 is used to be stacked with different numbers of sleeve dies 2 and / or auxiliary forming dies 12 to form a forging forming die 1 of different heights, wherein the main forming die 11 is located at the top when stacked, for example, the main forming die 11, different numbers of sleeve dies 2, and different numbers of auxiliary forming dies 12 are combined, or the main forming die 11 and different numbers of sleeve dies 2 are combined, or the main forming die 11 and different numbers of auxiliary forming dies 12 are combined. The auxiliary forming die 12 is used to replace the main forming die 11 when the main forming die 11 is unavailable, and is also used as the sleeve die 2. When stacked, it is located between the main forming die and the sleeve die 2. The flange shaft blank is formed by stacking and combining the dies.
[0020] Along the stacking direction ( Figure 1 (as indicated by the arrows), the height of the auxiliary forming die 12 is the same as that of the main forming die. In particular, when there is only one auxiliary forming die 12, to ensure functional consistency during replacement, the consistency of the forming die and the auxiliary forming die is maintained, which helps to ensure continuous and uniform forming quality. The height of the multiple sleeve dies 2 is the same as, or higher than, the height of the auxiliary forming die 12 and the main forming die. The heights of the multiple sleeve dies 2 may vary. The height of the forming die 1 and sleeve dies 2 may be 600-800mm, which is compatible with the current specifications of conventional flange shaft ends. In actual use, sleeve dies 2 of various heights can be configured according to conventional flange shaft specifications to improve versatility and flexibility.
[0021] In this embodiment, there are two sleeve dies 2, both of which are of the same height and taller than the auxiliary forming die 12 and the main forming die; there is only one auxiliary forming die 12. According to the aforementioned stacking and combination method, in this embodiment, the combination method is shown in Table 1, and can be divided into six levels according to the weight of the shaft end (each level is roughly the same weight, 5 tons, 10 tons, 12 tons, 17 tons, 19 tons, and 25 tons).
[0022] Table 1 Different combinations of forming dies and sleeve dies
[0023] Serial number Different combinations Shaft end weight (tons) 1 Main forming die 5 2 Main forming die + auxiliary forming die 10 3 Main forming mold + 1 piece of film 12 4 Main forming mold + auxiliary forming mold + 1 piece of film 17 5 Main forming mold + 2-piece film set 19 6 Main forming mold + auxiliary forming mold + 2-piece film set 25
[0024] Different combinations of this tooling can form end flange shaft forgings with shaft end weights of 5-25 tons, demonstrating its high versatility. Conventional integral forming dies of the same size are only suitable for forming similar products with shaft end weights of approximately 25 tons. In special circumstances, existing materials of similar grade and weight can be used to quickly organize production. Excess material can be chopped off after forging, significantly reducing material waste compared to integral forming dies. Furthermore, when flange shaft specifications change, production can be quickly organized without the need for new dedicated tooling, significantly shortening the production cycle. For example, if the sleeve die height is insufficient, this solution only requires the addition of a sleeve die. Compared to new integral forming tooling, the sleeve die still offers advantages in cost and timeframe.
[0025] In order to achieve upper and lower superposition, the structures of the forming die and the sleeve die are as follows:
[0026] The forming die 1 and sleeve die 2 each have an upper end face and a lower end face. When stacked, all upper and lower end faces are aligned, maintaining overall consistency across the entire forming die 1, ensuring uniform force on each force-bearing surface. A first inner hole 13 and a second inner hole 21 are formed through the center of the forming die 1 and sleeve die 2, respectively, extending through the upper and lower end faces. The first inner hole 13 and the second inner hole 21 have the same diameter, and the upper portion of the first inner hole 13 also has a curved portion 14. When stacked, the curved portion 14 of the first inner hole 13 is spaced away from the second inner hole 21, and the centers of the first and second inner holes 13 and 21 are aligned. The inner holes are used to accommodate the blank 3. The forming die 1 and sleeve die 2 can have an outer diameter of 1800-2300 mm and an inner diameter of 1000-1250 mm, adapting to the current specifications and dimensions of conventional flange shaft flange ends.
[0027] like Figure 2As shown, at least one end face of the forming die 1 and the sleeve die 2 has an end face concave portion 4 or an end face convex portion 5. When the upper and lower surfaces are stacked, the forming die 1 and the sleeve die 2 are connected by the end face concave portion 4 and the end face convex portion 5 through the clamping and superposition. In this embodiment, the lower end face of the main forming die 11 has an end face concave portion 4, but the upper end face has no concave and convex portion. Because when the press anvil is processed, the upper part of the main forming die 11 contacts the press anvil, and the possible interference of the press anvil with the concave and convex portion on the upper end face is avoided as much as possible. Of course, it can also be set. As long as the upper and lower end face sizes are reasonable, it can be achieved that there is no interference with the press anvil. The auxiliary forming die 12 and the sleeve die 2 both have an end face convex portion 5 on the upper end face and an end face concave portion 4 on the lower end face, thereby being clamped and connected. The end face concave portion 4 and the end face convex portion 5 are arranged along the outer edge of the corresponding end face, and the end face concave portion 4 and the end face convex portion 5 have two contact surfaces respectively along the stacking direction and perpendicular to the stacking direction. The connection between the two contact surfaces has an arc structure with an arc radius of 10-20 mm; the contact surfaces of the end face concave portion 4 and the end face convex portion 5 along the stacking direction have a counterclockwise inclination angle of 2-5°; along the stacking direction, the height H of the end face concave portion 4 is greater than or equal to the height h of the end face convex portion 5; along the direction perpendicular to the stacking direction, the width L of the end face concave portion 4 is greater than or equal to the width l of the end face convex portion 5 ( Figure 2 (The figure is only used as a parameter illustration); according to the structural design of the concave and convex parts, when the forming die 1 and the sleeve die 2 are lowered by the clamp for engagement, there is no need for precise alignment. The die can be automatically positioned and tightened based on the specially set arc and tilt angle by relying on its own weight, so that the tooling is concentric.
[0028] like Figure 3As shown, in step 2, the present tool is used to form the flange end formed part 31 shown in step 3. Step 1 is to perform free forging and split the flange end and the shaft end according to the target flange shaft specifications to obtain the blank 3 for flange end forming of the present tool, wherein the diameter of the flange end blank should be larger than the diameter of the first inner hole 13 of the forming die 1 (i.e. the diameter of the second inner hole 21), and the diameter of the shaft end blank is slightly smaller than the diameter of the first inner hole 13 of the forming die 1 (i.e. the diameter of the second inner hole 21); Step 2 is a schematic diagram of the use of the present tool, and an appropriate number of forming dies 1 and sleeve dies 2 are selected according to the target flange shaft specifications, and the mold is superimposed as described above, and the blank 3 is loaded into the assembled mold, and the flange end blank is higher than the upper surface of the main forming die 11 The end face is then placed on a rotating platform as a whole. The press hammer anvil is located directly above the flange end blank to press down. After each pressing, the rotating platform rotates to make the blank evenly compressed, and the flange end and shaft end blanks 3 are formed. During this process, the press hammer anvil is always located directly above the blank, and the blank and the mold are only subjected to force in the vertical direction. Therefore, the split superimposed mold of this scheme is not subject to horizontal reverse interference during use, and the forming effect is good; step 3 is the flange end formed part 31 taken out from this tooling mold; step 4 is to perform corresponding stretching on the shaft end blank 3 to realize the forming of the shaft end, and finally form the end face flange shaft.
[0029] The present embodiment provides a flange shaft forging tooling, which can form flange shaft forging molds of different heights with split molds. The tooling is suitable for forging flange shafts of different tonnages and sizes. Compared with traditional forging tooling, the use of the present tooling can save the time of switching tooling for different products, greatly shorten the production cycle, and speed up the market response speed. The split molds of the present tooling can form molds for forging flange shafts of different specifications through different combinations, and there is no need to add matching tooling based on the corresponding flange shaft specifications, which can save a lot of costs.
[0030] Example 2
[0031] The difference from the first embodiment is that the tooling further includes a conical plate 6, such as Figure 4 As shown, the taper of the conical plate 6 is 15°, and the bottom surface of the conical plate 6 in contact with the blank 3 has an arc segment with a radius of 300 mm, which is compatible with the size of a conventional flange shaft end and maintains versatility.
[0032] Specific usage process: After the blank 3 is placed in the forging die 1, the conical plate 6 is placed on the blank 3 to achieve center compaction during the flange end forming process.
[0033] When using the combination of numbers 1, 3, and 5 in Table 1, the shaft end can be completely filled in the mold during the production of products with corresponding shaft end weights. Graphite emulsion is sprayed on the inner surface of the mold before use (for easy demoulding). The conical plate 6 is clamped by a manipulator and placed above the blank. The upsetting is performed and pressed down. Since the shaft end has completely filled the mold, the flange neck can be centrally compacted to obtain refined grains. This can solve the problem of flaw detection noise caused by coarse grains in the neck of such forgings and effectively improve the mechanical properties and fatigue resistance of this part. In the conventional method, the shaft end is in a free state during the die-mounted flange forming process (the shaft end cannot be completely filled, otherwise it will cause the non-aligned part of the mold cavity to be stuck, making it impossible to demould and causing the product to be scrapped). There is no central compaction effect. During the forming process, the free-state blank slides directly into the mold cavity without vertical deformation and poor forming quality.
[0034] Table 2 shows the flaw detection results of 30 pieces under the two forming methods of free end and full end. The general requirement is that the noise should be less than 50%. Heat treatment can improve the noise of 60%-80%, but the situation of noise ≥80% is more difficult to handle.
[0035] Table 2 Flaw detection results of 30 pieces each under two forming modes: free end and full end
[0036] Clutter height ≥80％ 60％-80％ 40％-60％ ≤40％ Flaw detection results (end free state) 33.3％ 40％ 20％ 6.7％ Detection results (end full state) 0 9％ 45.5％ 45.5％
[0037] As can be seen from the above table, 73.3% of the traditional free state are unqualified, while only 9% of the end-filled state of this solution is unqualified, and this part can be treated by heat treatment. This shows that the use of this tooling mold to achieve the end-filled state combined with the use of the tapered plate effectively solves the problem of coarse grains in the core.
[0038] Example 3
[0039] Different from the first and second embodiments, Figure 5 As shown, the forming mold 1 is a nested structure, including a core mold 15 and an outer mold 16, wherein the core mold 15 and the outer mold 16 are assembled using a shrink fit method, the core mold 15 is made of mold steel, and the outer mold 16 is made of ordinary alloy steel.
[0040] The surface of the forming die 1 contacts the blank 3 and is subjected to stress at high temperature. Therefore, the core of the forming die 1 is made of die steel (5CrNiMo, etc.), which can be used under stress at high temperature without deformation. The outer die 16 and the stress-bearing surface of the sleeve are not in contact with the blank 3 and are not subjected to high temperature. Ordinary alloy steel (42CrMoA, etc.) can be used, which can greatly reduce the material cost of the sleeve.
[0041] Traditional flange shaft forging uses a special forming die after material separation. The die is made of only a single material and cannot meet both economic efficiency and durability. The use of this die can not only ensure the durability of the tooling, but also allow the use of a large amount of ordinary materials, saving a lot of costs.
[0042] The above description is merely an embodiment of the present invention. Common knowledge such as the known specific structures and characteristics in the scheme is not described in detail here. A person of ordinary skill in the art is aware of all common technical knowledge in the technical field to which the utility model belongs before the application date or priority date, is able to obtain all existing technologies in the field, and has the ability to apply conventional experimental means before that date. A person of ordinary skill in the art can, under the guidance of this application, improve and implement the present scheme in combination with his or her own abilities. Some typical known structures or methods should not become an obstacle for a person of ordinary skill in the art to implement the present application. It should be pointed out that a person of ordinary skill in the art can make several variations and improvements without departing from the structure of the present invention. These should also be considered as the scope of protection of the present invention. These will not affect the effect of the implementation of the present invention and the practicality of the patent.
Claims
1. A flange shaft forging tool, characterized in that: Used to form end face flange shaft forgings in flange shaft free forging process; The tooling includes a plurality of forming dies and a plurality of sleeve dies; the forming dies and the sleeve dies each have an upper end face and a lower end face, and at least one end face has an end face concave portion or an end face convex portion; the centers of the forming dies and the sleeve dies respectively pass through the upper end face and the lower end face to form a first inner hole and a second inner hole, wherein the first inner hole and the second inner hole have the same diameter, and the upper portion of the first inner hole further has a curved portion; The several forming dies include a main forming die and at least one auxiliary forming die; the main forming die is used to be stacked up and down with different numbers of sleeve dies and / or auxiliary forming dies to form different forging forming dies, wherein the main forming die is located at the top when stacked; the auxiliary forming die is used to replace the main forming die for combination when the main forming die is unavailable, and is also used as a sleeve die, and is located between the main forming die and the sleeve die when stacked; when the forming die and the sleeve die are stacked up and down, they are connected by the end face concave part and the end face convex part, all upper end faces and lower end faces are aligned, the curved part of the first inner hole is away from the second inner hole, and the centers of the first inner hole and the second inner hole are aligned.
2. A flange shaft forging tool according to claim 1, characterized in that: Along the stacking direction, the height of the auxiliary forming mold is the same as the height of the main forming mold.
3. A flange shaft forging tool according to claim 2, characterized in that: The heights of the plurality of set molds are the same as or greater than the heights of the auxiliary forming mold and the main forming mold.
4. A flange shaft forging tool according to claim 2, characterized in that: There is one auxiliary forming mold, and the plurality of sleeve molds include two sleeve molds. The two sleeve molds have the same height and are greater than the height of the auxiliary forming mold and the main forming mold.
5. The flange shaft forging tool according to claim 1, characterized in that: The end surface concave portion and the end surface convex portion are arranged along the outer edge of the corresponding end surface.
6. A flange shaft forging tool according to claim 5, characterized in that: The end face concave portion and the end face convex portion have two contact surfaces along the superposition direction and perpendicular to the superposition direction respectively. The connection between the two contact surfaces has an arc structure with an arc radius of 10-20 mm. The contact surfaces of the end face concave portion and the end face convex portion along the superposition direction have an inclination angle of 2-5°.
7. The flange shaft forging tool according to claim 6, characterized in that: Along the stacking direction, the height of the end surface concave portion is greater than or equal to the height of the end surface convex portion; along the direction perpendicular to the stacking direction, the width of the end surface concave portion is greater than or equal to the width of the end surface convex portion.
8. The flange shaft forging tool according to claim 1, characterized in that: It also includes a tapered plate for placing the blank above the forging die after the blank is placed in the forging die to achieve center compaction during the flange end forming process.
9. The flange shaft forging tool according to claim 8, characterized in that: The conical plate has a taper of 15°, and the bottom surface of the conical plate in contact with the blank has an arc segment with a radius of 300 mm.
10. The flange shaft forging tool according to claim 1, characterized in that: The forming mold is a nested structure, including a core mold and an outer mold, wherein the core mold and the outer mold are assembled using a shrink fit method, the core mold is made of mold steel, and the outer mold is made of ordinary alloy steel.