Long Blade Material Hot Forging with Localized Twisting
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Solution Overview
Problem
Existing methods for manufacturing long blade materials, such as those used in steam turbines, face challenges including deformation during forging, accuracy issues, and the need for high-load press forging machines, which increase costs and equipment investment.
Innovation Solution
A method involving sequential hot-forging from the root to the blade tip, with localized twisting and mold changes, using a manipulator to grasp and rotate the material, allowing for hot-forging and twisting in a continuous process without requiring a large press forging machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large press forging machine is used to manufacture long blade materials, then the manufacturing capability and productivity are improved, but the equipment investment and manufacturing cost increase significantly
Solution Approach 1:
The patent divides the long blade material into multiple sections and forges them sequentially from the root side to the tip side. The material is grasped at the root side and restrained by the mold, with local forging applied to areas between the grasped portion and restrained portion, allowing the entire blade to be forged without requiring a single large-capacity press machine
Solution Approach 2:
The patent employs dynamic control of the material during forging by rotating the material around its longitudinal axis while applying localized forging forces. This dynamic approach allows the material to be progressively shaped and twisted into the final blade configuration using smaller, more manageable forging equipment
2Device complexity
If the area to be forged is divided into multiple areas and forged sequentially, then the equipment capacity requirement is reduced, but the previously forged area may be deformed due to stress from subsequent forging
Solution Approach 1:
The patent applies preliminary forging to the root side of the material first, establishing a stable base before proceeding to forge the remaining sections. By grasping the material at the root side and applying force from this end, the already-forged areas are protected from deformation caused by subsequent forging operations on distant sections
Solution Approach 2:
The patent applies localized forging forces to specific areas between the grasped portion and restrained portion, rather than applying uniform force across the entire material. This localized approach allows precise control over each section's deformation while maintaining the integrity of previously forged areas
3Shape
If twisting is applied to a long blade at normal temperature, then the blade shape can be formed, but the hardness may be locally reduced during subsequent annealing
Solution Approach 1:
The patent performs twisting operations while the material is in a hot state, maintaining elevated temperature during the forming process. This temperature parameter change allows the material to be twisted and shaped without causing localized hardness reduction that would occur if twisting were performed at normal temperature followed by annealing
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
Enables the precise formation of long blade materials without the need for large press forging machines, maintaining high workability and productivity while reducing distortion and hardness variations.
Implementation Method 1
a blade material is formed by sequentially hot-forging a material from a root side to a blade tip with a mold
Data Source
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AI summary
Provided are a manufacturing method for a blade material and a manufacturing device for a blade material, by which a long blade material can be manufactured without using a large-sized press forging machine. A manufacturing method for a blade material, in which hot forging is sequentially performed by molds from the root side to a blade (vane) tip, wherein when a root-side portion is grasped and a material to be forged is restrained by a mold, twisting is performed on a region between the grasped portion and the restrained portion. A manufacturing method for a blade material, in which hot forging and twisting are repeated, is preferable, and a manufacturing method for a blade material, in which hot forging is performed while molds are sequentially changed, is more preferable.