Large Annular Forging Process With Hourglass Blank Forming
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Solution Overview
Problem
The existing manufacturing processes for large annular forgings are costly and time-consuming, with assembly welding methods resulting in lower performance at weld joints, affecting the reliability of the final product.
Innovation Solution
A manufacturing process involving prefabricated blanks transformed into hourglass-shaped modules through upsetting deformation and heat preservation, followed by vacuum electron beam welding and high-temperature diffusion bonding, optimizing deformation and reducing material and processing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If assembly welding method is used for large annular forgings, then manufacturing cost and manufacturing cycle are reduced, but weld joint performance deteriorates and product reliability is affected
Solution Approach 1:
The large annular forging is divided into multiple smaller forgings that are manufactured separately and then assembled through welding. This segmentation allows each component to be optimized independently while maintaining overall structural integrity and reliability through proper welding techniques.
Solution Approach 2:
The patent applies parameter changes by optimizing welding parameters (temperature, pressure, time) and material parameters (composition, microstructure) to ensure that the weld joints achieve performance comparable to or exceeding the base metal, thereby resolving the contradiction between cost reduction and reliability maintenance.
2Productivity
If assembly welding method is used for large annular forgings, then manufacturing cost and manufacturing cycle are reduced, but the same applies to manufacturing complexity
Solution Approach 1:
The manufacturing process is segmented into distinct phases: forging individual components, preparing welding surfaces, assembling components, and performing post-weld treatments. This segmentation simplifies process management and reduces overall complexity while maintaining productivity.
Solution Approach 2:
Surface preparation, including machining and cleaning of welding surfaces, is performed as a preliminary action before assembly welding. This preliminary preparation reduces the complexity of the welding process itself and ensures efficient assembly operations.
3Loss of substance
If traditional forging process is used, then material usage is high and manufacturing cycle is long, but product strength and impact toughness are maintained
Solution Approach 1:
The patent applies parameter changes in the forging process, including optimized heating temperatures, pressure parameters, and deformation rates, to reduce material waste while maintaining the mechanical properties of the forged components. Advanced process parameters enable more efficient material utilization.
Solution Approach 2:
Traditional mechanical forging methods are supplemented or replaced with advanced techniques such as computer-controlled forging systems and automated process control, which optimize material flow and reduce waste while maintaining product strength through precise parameter control.
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 process reduces material usage by 30%, shortens the manufacturing cycle by 50%, and lowers costs by 15%, while enhancing the strength and impact toughness of the annular forge pieces, improving their safety and reliability.
Implementation Method 1
performing upsetting deformation along the height direction on the level I hourglass-shaped module after heating
Implementation Method 2
inter-forging heat preservation after heating the level I hourglass-shaped module
Implementation Method 3
vacuum electron beam welding is conducted to prepare the level I hourglass-shaped modules
Data Source
Figure 1
Figure 2(a)~2(h)
Figure 3(a)~3(i)
AI summary
The invention relates to a manufacturing process for large annular forgings. The process comprises the following steps: firstly, preparing a prefabricated blank; then preparing a blank from the prefabricated blank through upsetting deformation and inter-forming heat preservation process of a multi-level hourglass-shaped module; and finally, manufacturing and processing the blank into the annular forge piece.