A multi-pass free
forging punching method for deep blind holes in an engine
cylinder block includes the following steps: jaw pressing, chamfering, pre-drawing, upsetting, wide anvil strong pressure drawing, rolling and drawing blanking, upsetting, step forming, pre-
punching the
blind hole in the
first pass with a variable
diameter punch, mechanically expanding the
blind hole in the second pass, rolling
forging and drawing, deep-drawing the
blind hole in the third pass with a long punch, rolling
forging and drawing, flattening the end face, and finishing the finished product. The blind hole forming process is controlled in multiple passes and stages, with the use of a variable
diameter punch for pre-
punching and mechanically expanding the blind hole, and a long punch for deep-drawing the blind hole. Furthermore, the forming effect is ensured by combining rolling forging and drawing and end face flattening processes. The multi-pass blind hole forming process can achieve staged
shape control in each process, facilitate precise
parameter control, suppress inner wall shrinkage, overcome the large inner wall shrinkage phenomenon of traditional punching methods, ensure
fiber streamline integrity and dimensional reliability, and avoid the bottom folding phenomenon that is easily generated during traditional blind hole drawing. This method improves forging efficiency and provides more stable quality.