Annular Material Manufacturing via Controlled Strain Forging
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Solution Overview
Problem
The existing methods for manufacturing annular materials for aircraft turbine disks face challenges in achieving uniformity and sufficient mechanical strength while reducing facility and manufacturing costs, particularly due to the high cost and rarity of large-sized hydraulic control forging presses and the complexity of processes like ring rolling and combined forging and ring rolling methods.
Innovation Solution
A method involving preform forging and ring rolling with controlled strain ratios, where hot forging achieves strain values greater than or equal to 0.3 in both the circumferential and height directions, and ring rolling with reduced strain ratios to ensure isotropy and uniformity, thereby simplifying the process and enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large-sized hydraulic control forging press is used to manufacture annular material, then mechanical strength and uniformity are improved, but facility cost and manufacturing cost increase significantly
Solution Approach 1:
The manufacturing process is divided into two independent stages: (1) forging process to create a discoid forged material with controlled strain, and (2) ring rolling process to form the annular intermediate. This segmentation allows each process to be optimized separately, avoiding the need for a single large-scale forging press while achieving the desired mechanical properties through cumulative deformation.
Solution Approach 2:
The forging process performs preliminary deformation on the alloy to create a discoid forged material with specific strain characteristics (|εθ1|≥0.3, |εh|≥0.3, 0.4≤|εh/εθ1|≤2.5) before the ring rolling process. This preliminary action prepares the material structure to receive further deformation during ring rolling, ensuring uniformity and mechanical strength without requiring excessive force in the final forming stage.
2Ease of manufacture
If ring rolling process is applied to annular material, then facility cost is reduced, but anisotropy of mechanical property increases
Solution Approach 1:
The forging process performs preliminary deformation on the alloy to create a discoid forged material with specific strain characteristics (|εθ1|≥0.3, |εh|≥0.3, 0.4≤|εh/εθ1|≤2.5) before the ring rolling process. This preliminary action prepares the material structure to receive further deformation during ring rolling, ensuring uniformity and mechanical strength without requiring excessive force in the final forming stage.
Solution Approach 2:
The invention controls the strain parameters during forging (|εθ1|≥0.3, |εh|≥0.3, 0.4≤|εh/εθ1|≤2.5) to optimize the material structure before ring rolling. By adjusting these strain parameters, the material achieves a balanced microstructure that reduces anisotropy development during the subsequent ring rolling process, maintaining mechanical property uniformity.
3Strength
If combined forging and ring rolling process is used, then mechanical strength is improved, but process complexity increases
Solution Approach 1:
The manufacturing process is divided into two independent stages: (1) forging process to create a discoid forged material with controlled strain, and (2) ring rolling process to form the annular intermediate. This segmentation allows each process to be optimized separately, avoiding the need for a single large-scale forging press while achieving the desired mechanical properties through cumulative deformation.
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 an annular material with improved isotropy and uniformity of mechanical properties, reducing facility and manufacturing costs while maintaining high mechanical strength, suitable for aircraft turbine disks.
Implementation Method 1
a forging process of making a discoid forged material by forging an alloy
Implementation Method 2
hot forging in which an absolute value |εθ1| of a strain εθ1 in a circumferential direction of the forged material is greater than or equal to 0.3, an absolute value |εh| of a strain in a height direction of the forged material that is greater than or equal to 0.3
Implementation Method 3
a ring rolling process of making an annular material by performing ring rolling on an annular intermediate
Implementation Method 4
ring rolling in which 0.5 or higher of an absolute value |εθ2| of a strain in a circumferential direction of the annular material is exerted
Data Source
AI summary
A method of manufacturing an annular material includes: a forging process of making a discoid forged material by forging an alloy material; and a ring rolling process of making an annular material by performing ring rolling on an annular intermediate made by forming a through-hole in the forged material. In the forging process, hot forging which achieves an absolute value εθ1 of a strain in a circumferential direction of the forged material that is greater than or equal to 0.3, an absolute value εh of a strain in a height direction of the forged material that is greater than or equal to 0.3, and a ratio εh/εθ1 between the absolute values of the strains that is in a range of 0.4 to 2.5 is performed at least two or more times.