Lightweight Alloy Forging Press Cooling With Shrinkage Compensation

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Solution Overview

Problem

Existing forging processes for lightweight alloys face challenges in achieving optimal material properties and process stability, particularly in maintaining contact during cooling and ensuring homogeneous temperature distribution, leading to potential distortion and inefficiencies.

Innovation Solution

The process involves cooling the forged component directly in the forging tool, with adjustable forging press parameters such as press force and ram position changed based on cooling shrinkage, and using a sensor-controlled cooling fluid to maintain contact and achieve rapid, direct cooling, thereby counteracting shrinkage and ensuring a homogeneous temperature distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the forged component is cooled in the forging tool, then the cooling efficiency is improved, but the contact between the forging tool and the forged component is lost due to shrinkage

Engineering Contradiction:

Improvecooling efficiencyVSAvoidcontact maintenance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The forging tool is designed with movable components that can dynamically adjust their position during the cooling process. The tool parts move together with the shrinkage of the forged component, maintaining continuous contact throughout cooling. This dynamic adaptation resolves the contradiction by allowing efficient cooling while preventing contact loss.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the positional parameter of the forging tool components during cooling to match the dimensional changes of the forged component. By adjusting the tool parameters (position, distance) in response to the component's shrinkage, the system maintains contact while achieving effective cooling.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the forged component is cooled rapidly, then the production time is reduced, but distortion occurs due to uneven cooling

Engineering Contradiction:

Improveproduction timeVSAvoiddistortion control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The forging tool applies different cooling conditions to different regions of the forged component. By creating local variations in cooling intensity and timing, the system achieves rapid overall cooling while preventing uneven thermal gradients that cause distortion. Each region of the component receives tailored cooling treatment.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cooling process is dynamically controlled with varying rates at different stages and locations. The system transitions from initial rapid cooling to controlled slower cooling, adapting the cooling rate to prevent distortion while maintaining high productivity. The dynamic cooling profile resolves the contradiction between speed and precision.

Inventive Principle:

Principle #15Dynamics

3Reliability

If the press force is increased to maintain contact, then the contact is maintained, but the process complexity increases

Engineering Contradiction:

Improvecontact maintenanceVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of applying continuously high press force, the system uses dynamic positioning where the tool components move with the component's shrinkage. This mechanical adaptation maintains contact through motion rather than force, significantly reducing process complexity while ensuring reliable contact throughout cooling.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system replaces the mechanical approach of using high press force with a kinematic approach where the tool structure itself adapts to the component's dimensional changes. This substitution of force-based contact maintenance with motion-based contact maintenance simplifies the overall process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach results in forged components with high strength, ductility, and reduced distortion, along with improved process stability and energy efficiency, allowing for the production of thin-walled components with enhanced mechanical properties.

Implementation Method 1

The forged component is cooled directly in the forging tool

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

using a sensor-controlled cooling fluid to maintain contact and achieve rapid, direct cooling

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

depending on a shrinkage characteristic of the forged component caused by cooling of the forged component

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentEP3655176B1Forging method, in particular lightweight construction alloy forging method, and forging press

Publication Date: 2021.08.04 LEIBER GROUP

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AI summary

The invention relates to forging methods, in particular lightweight construction alloy forging methods, wherein in at least one method step a forged component is cooled in a forging tool (14, 16, 18), in particular in a shaping, stamping and/or calibration tool. It is proposed that, in at least one method step, at least one forging press parameter, in particular a maximum press force and/or a press ram position, of a forging press (20, 22) is changed or is kept at a constant value, in particular according to a cooling of the forged component in the forging tool (14, 16, 18). The invention also relates to a forging press.