METHOD FOR UPSETTING A METAL BLOCK AND ASSEMBLY FOR IMPLEMENTING THE METHOD
The method simplifies the forging process for aircraft turbomachine parts by using a single die configuration to form a cavity and deform the billet, reducing complexity and cost.
Patent Information
- Application Number
- FR2023007314
- Authority / Receiving Office
- FR · FR
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2023-07-07
- Publication Date
- 2025-07-18
- Estimated Expiration
- 2043-07-07
AI Technical Summary
The existing methods for manufacturing aircraft turbomachine parts, such as straightening arms, involve complex tooling and multiple forging operations, making them time-consuming and expensive.
A method and assembly for upsetting a metal billet using a single die with a specific configuration to form a cavity that allows the billet to be crushed and shaped into an upset part, utilizing a punch to deform the billet within the die, minimizing the number of operations and tooling complexity.
The method simplifies the forging process by reducing the number of operations and tooling complexity, thereby decreasing production time and cost.
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Abstract
Description
Title of the invention: METHOD FOR UPSETTING A METAL BLOCK AND ASSEMBLY FOR IMPLEMENTING THE METHOD Technical field
[0001] The invention relates to the field of forging metal parts of aircraft turbomachines. It relates in particular to a method of upsetting a metal billet and an assembly for implementing said method. Prior art
[0002] In a known manner, the manufacture of certain aircraft turbomachine parts, such as straightening arms, is carried out via a succession of forging operations applied to a metal billet.
[0003] In the particular case of forging a straightening arm, as illustrated in [Fig.l], a metal billet 101 (i.e. a metal cylinder) first undergoes upsetting to become an upset part 103, a pre-finishing step to become a pre-finished part 105 and a finishing step to become the straightening arm 107.
[0004] Among these operations, upsetting involves in particular the compression of the billet, in the direction of its length, to make it take the shape of a mold (called a matrix) in which it is placed.
[0005] Furthermore, in the known state of the art, the upsetting of a billet intended for the manufacture of a straightening arm comprises three distinct stages which each involve the use of a pair of different dies to successively form the three parts which make up said straightening arm, namely, its foot, its central part which is an aerodynamic blade and its upper part which is called ears because of its shape.
[0006] The upsetting of the state of the art is therefore an operation involving complex tooling and a series of equally complex manipulations. All of the operations necessary for the production of an upset part are therefore both time-consuming and expensive. Summary of the invention
[0007] The present invention provides a solution to these drawbacks.
[0008] Thus, one objective of the invention is to reduce the number and complexity of the operations required for upsetting a billet. Furthermore, the number, complexity and consequently the cost of all the forging operations required for manufacturing a part such as an aircraft turbomachine straightening arm are also reduced.
[0009] To this end, the invention according to a first aspect relates to a method for upsetting a metal billet, intended for the manufacture of an upset part, of the blank type of an aircraft turbomachine rectifier arm, comprising, from bottom to top along a longitudinal axis, a foot, an aerodynamic blade and ears, said upsetting method being characterized in that it comprises:
[0010] - positioning the billet in a die in the open position, said die comprising an upper part and a lower part forming, when said die is in the closed position, a cavity, having an opening at one end, and having substantially, in hollow, the shape of the upturned part;
[0011] - closing the die, so as to crush the billet between the upper part and the lower part of the die and to form a crushed part of which a portion protrudes from the die at the level of the opening of the cavity; and,
[0012] - the upsetting of the crushed part, in the die in the closed position, by a punch exerting a force on the distal end of the portion of said crushed part which protrudes from the die, so as to form the upset part.
[0013] The method according to the invention may comprise one or more of the following characteristics, taken in isolation from one another or in combination with one another:
[0014] - the matrix is configured so that, when it is closed, a vacuum exists between side edges of the crushed part and said die.
[0015] - the shape of the punch is adapted to prevent rotation of the crushed part during from the re-upsetting, in the matrix, of said crushed part.
[0016] - the dimensions and shape of the cavity of the matrix, in the part corresponding to the foot of the upturned part, are adapted to minimize the rise in temperature of the part during the upturning stage.
[0017] - the dimensions and shape of the die cavity, in the corresponding part to the ears of the upturned part, are adapted to optimize the filling of said part of the die cavity, during the upturning step.
[0018] - the volume of the die cavity is greater than the volume of the billet.
[0019] - when the die is in the closed position, the movement of the upper part of said matrix is blocked by force recovery.
[0020] - in the matrix, the joint plane between the lower part and the upper part is positioned so that once the upsetting process has been carried out, when the die is in the open position, the volume of the portion of the upset part contained in the cavity is less than the remainder of the volume of the upset part.
[0021] - the shape and dimensions of the die cavity, in the part corresponding to the aerodynamic blade of the upturned part, are adapted to allow the upturned part to be gripped by a clamp.
[0022] Furthermore, the invention according to a second aspect also relates to an assembly comprising a punch and a die for implementing a method according to any one of the preceding claims. Brief description of the drawings
[0023] The invention will be better understood with the aid of the following description, given solely by way of example and with reference to the appended drawings in which:
[0024] [Fig.l] is a schematic representation of the forging operations of a straightening arm of an aircraft turbomachine;
[0025] [Fig.2] is a schematic representation of an upturned part intended for the manufacture of a straightening arm of an aircraft turbomachine;
[0026] [Fig.3] is a step diagram of a refoulement method according to an embodiment of the invention;
[0027] [Fig.4] is a schematic representation, in a perspective view, of the upsetting of a metal billet according to an embodiment of the invention;
[0028] [Fig.5] is a schematic representation, according to different views, of a step of closing a die of a refoulement method according to an embodiment of the invention; and,
[0029] [Fig. 6] is a schematic representation, according to different views, of a step of upsetting a method of upsetting according to an embodiment of the invention. Description of the embodiments
[0030] [Fig.2] shows an embodiment of an upturned part 201, intended for the manufacture of a straightening arm of an aircraft turbomachine, as obtained at the end of the upturning process described later.
[0031] The upturned part 201 is of the rough type of an aircraft turbomachine straightener arm in the sense that it then allows, after other forging operations (i.e. pre-finishing and finishing operations), to obtain a finished straightener arm.
[0032] The upturned part 201 comprises, from bottom to top along a longitudinal axis X, a foot 201a (the lower part), an aerodynamic blade 201b (central part) and ears 201c (the upper part). The section of the upturned part therefore varies according to the extent of the axis X and is in particular larger at the foot and the ears compared to the aerodynamic blade.
[0033] Furthermore, in the example shown in [Fig.2], the upturned part comprises a leading edge 203 and a trailing edge 205 with reference to the direction of circulation of the air flow in the turbomachine in which the finished straightening arm (obtained from the upturned part) is intended to be mounted.
[0034] With reference to [Fig.3] and [Fig.4], we will now describe a mode of implementation of a refoulement method according to the invention.
[0035] The upsetting method 301 aims to produce an upset part such as the upset part 201 described with reference to [Fig.2] (and also visible in [Fig.4]), that is to say a blank of a straightening arm of an aircraft turbomachine.
[0036] Step 303 consists of positioning the billet 401 in a die 403 in an open position. The die 403 comprises an upper portion 403a and a lower portion 403b. The open position designates a position in which the two portions 403a and 403b are sufficiently spaced from each other to allow the billet 401 to be positioned between the two. Whereas the closed position designates a position in which the two portions are in contact.
[0037] Furthermore, the shape of each portion of the die 403 is designed to form a cavity 405 when the die 403 is closed and the cavity 405 has substantially, in hollow, the shape of the upturned part 201 so that the closing of the die 403 makes it possible to obtain a mold used to produce the upturned part 201.
[0038] Thus, in the example shown in [Fig.4], the billet 401 is positioned in the hollow (i.e. the part of the cavity) which is formed in the lower part 403b of the die 403 before said die 403 is closed to carry out the rest of the process.
[0039] Furthermore, the cavity 405 has an opening at one end through which a portion of the billet 401 protrudes when the billet is positioned in the die 403 (whether the latter is in the open or closed position).
[0040] Step 305 consists of closing the die 403, so as to crush the billet 401 between the upper part 403a and the lower part 403b of the die 403 and to form a crushed part 505 of which a portion 503 protrudes from the die 403 at the level of the opening of the cavity 405.
[0041] This step is seen in more detail in [Fig.5] where the upper 403a and lower 403b parts of the die 403 are shown in the open position 501a and in the closed position 501b in which the billet 401 is crushed to form the crushed part 505.
[0042] As can also be seen in [Fig. 5], the crushed part 505 does not fill the entire cavity 405 formed by the die 403 in the closed position. In addition, a portion 503 of the crushed part 505 protrudes from the die 403 through the opening in the cavity 405.
[0043] In particular, in the non-limiting example shown, the die 403 is configured so that, when it is closed, a vacuum exists between the lateral edges (i.e. the leading edge and the trailing edge) of the crushed part 505 and the die 403 (in particular the walls of the cavity 405).
[0044] Advantageously, this vacuum facilitates the flow into the cavity 405 of the material which constitutes the part, in particular during the continuation of the process. In addition, this vacuum can also make it possible to limit the rate of deformation undergone by the part during the upsetting step described later.
[0045] The next step of the method therefore has the purpose of moving the material (in the cavity 405) and, consequently, obtaining the expected shape of the upturned part 201. Thus, step 307 of the upsetting method 301 consists of upsetting the crushed part 505, in the die 403 in the closed position, by a punch 407 which exerts a force on the distal end 603 of the portion 503 of said crushed part 505 which protrudes from the die 403, so as to form the upset part 201.
[0046] In other words, the punch 407 exerts pressure on the crushed part 505 such that the latter deforms in the cavity 405, adopting the shape of said cavity 405.
[0047] In other words, the material which originally constitutes the billet (in this case a metal) moves in the cavity 405 under the effect of the pressure exerted on one end of the part by the punch 407.
[0048] In a particular embodiment of the method, the shape of the punch 407 is adapted to prevent the rotation of the crushed part 505 during the upsetting, in the die 403, of the crushed part 505. For example, the punch 407 may have one or more flat faces (this is referred to as a multi-face punch) whose orientation prevents the crushed part 505 from rotating on itself when the punch 407 compresses it.
[0049] [Fig.6] illustrates step 307 in more detail and shows in particular, in configuration 601a the crushed part 505 not having undergone the upsetting and, in configuration 601b the crushed part having undergone the upsetting to become the upsetting part 201.
[0050] In the example shown, the upturned part 201 does not fill the cavity 405 in its entirety (in particular at the level of an ear of the upturned part) but has taken the desired shape for the upturned part 201 in which the ears 201c, the aerodynamic blade 201b and the root 201a are visible.
[0051] Generally speaking, in the particular embodiment shown in [Fig.6], the volume of the cavity 405 of the die 403 is greater than the volume of the billet.
[0052] Advantageously, the flow of the material in the cavity under the effect of the upsetting is facilitated while ultimately making it possible to obtain the desired shape.
[0053] Similarly, in a particular embodiment of the method, the dimensions and shape of the cavity 405 of the die 403, in the part corresponding to the ears 201c of the upturned part 201, can be adapted to optimize the filling of this part of the cavity 405 of the die 403, during the upturning step 307.
[0054] For example, the inclination of the walls of the cavity 405 in this portion and the size of the portion corresponding to the ears generally may be designed to facilitate their filling. In addition, this inclination may correspond to drafts made during forging processes.
[0055] In yet another embodiment, the dimensions and shape of the die cavity, in the part corresponding to the foot of the upturned part, can be adapted to minimize the rise in temperature of the part (in this zone) during the upturning step.
[0056] Indeed, typically, the temperature of the part in the area located at the intersection between the central part and the foot can reach 1000°C and modifying the inclination of the walls (also called draft) of the cavity or increasing its radius in this area can make it possible to reduce this temperature (and the associated risks of deterioration).
[0057] In yet another embodiment, when the die is in the closed position, the movement of the upper part of said die is blocked by force absorption.
[0058] For example, means for fixing the upper part to the lower part of the die can be added to secure the two parts when the die is in the closed position.
[0059] Advantageously, this type of device makes it possible to avoid the displacement of the upper part of the die, under the effect of high pressure, when the part is pushed back into the die in the closed position.
[0060] In yet another embodiment, in the die, the joint plane between the lower part and the upper part is positioned so that once the process is carried out, when the die is in the open position, the volume of the upturned part contained in the cavity is less than the remainder of the volume of the upturned part.
[0061] In other words, when the upsetting process is finished and the die is in the open position with the upset part positioned only in the lower part of the die, the portion of the upset part which protrudes is sufficiently large to allow easy gripping of said upset part, for example by pliers.
[0062] For the same purpose, in yet another embodiment, the shape and dimensions of the die cavity, in the part corresponding to the aerodynamic blade of the upturned part, can be adapted to allow the upturned part to be gripped by a clamp. Alternatively, an improvement in the design of the part to improve its gripping can be made in the area of the foot of said part.
[0063] Thus, in all the embodiments described, the method simplifies the upsetting and reduces the time required for its completion. Indeed, on the one hand, the method only requires the use of a single die to obtain the finished part and, on the other hand, it involves only two movements, namely closing the die to crush the billet and moving the punch to compress the crushed part.
Claims
Claims
1. Method (301) for manufacturing an upturned part (201), of the blank type of an aircraft turbomachine rectifier arm, comprising, from bottom to top along a longitudinal axis (X), a foot (201a), an aerodynamic blade (201b) and ears (201c), said method (301) being characterized in that it comprises: - positioning (303) a metal billet (401) in a die (403) in the open position, said die comprising an upper part (403a) and a lower part (403b) forming, when said die (403) is in the closed position, a cavity (405), having an opening at one end, and having substantially, in hollow, the shape of the upturned part (201);- closing (305) the die (403), so as to crush the billet (401) between the upper part (403a) and the lower part (403b) of the die (403) and to form a crushed part (505) of which a portion (503) protrudes from the die (403) at the opening of the cavity (405); and, - upsetting (307) the crushed part (505), in the die (403) in the closed position, by a punch (407) exerting a force on the distal end (603) of the portion (503) of said crushed part (505) which protrudes from the die (403), so as to form the upset part (201).;
2. The method (301) of claim 1, wherein the die (403) is configured so that the volume of the cavity (405) of the die (403) is greater than the volume of the billet (401) so that, upon its closure, a vacuum exists between lateral edges of the crushed part (505) and said die (403).
3. Method (301) according to claim 1 or claim 2, in which the punch (407) has several planar faces whose orientation prevents the crushed part (505) from rotating on itself when the punch (407) compresses it.
4. Method (301) according to any one of the preceding claims, in which, in the part corresponding to the foot (201a) of the upturned part (201), the inclination of the walls of the cavity (405) is modified or its radius is increased in order to minimize the rise in temperature of the part during the upturning step (307).
5. Method (301) according to any one of the preceding claims, in which the dimensions and the shape of the cavity (405) of the die (403), in the part corresponding to the ears (201c) of the upturned part (201), are adapted to optimize the filling of said part of the cavity (405) of the die (403), during the upturning step (307).
6. A method (301) according to any preceding claim, wherein the volume of the cavity (405) of the die (403) is greater than the volume of the billet (401).
7. Method (301) according to any one of the preceding claims, wherein, when the die (403) is in the closed position, the movement of the upper part (403a) of said die (403) is blocked by force recovery.
8. A method (301) according to any preceding claim, wherein, in the die (403), the joint plane between the lower portion (403b) and the upper portion (403a) is positioned such that once the upsetting method (301) has been carried out, when the die (403) is in the open position, the volume of the portion of the upset part (201) contained in the cavity (405) is less than the remainder of the volume of the upset part (201).
9. Method (301) according to any one of the preceding claims, in which the shape and dimensions of the cavity (405) of the die (403), in the part corresponding to the aerodynamic blade (201b) of the upturned part (201), are adapted to allow the upturned part (201) to be gripped by a clamp.
10. An assembly comprising a punch (407) and a die (403), the die comprising an upper portion (403a) and a lower portion (403b) forming, when said die (403) is in the closed position, a cavity (405), having an opening at one end, and having substantially, in hollow, the shape of an upturned part (201), the upturned part (201) comprising, from bottom to top along a longitudinal axis (X), a foot (201a), an aerodynamic blade (201b) and ears (201c), the punch being configured to upturn a crushed part, into the die (403) in the closed position, by exerting a force on the distal end (603) of the portion (503) of said crushed part (505) which projects from the die (403), so as to form the upturned part (201), the die (403) and the punch (407) being configured for implementing a method according to any one of the preceding claims.