Hot Forging Die with Segmented Pressing Zones
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Solution Overview
Problem
Existing hot forging technologies face challenges in effectively swaging difficult-to-work materials like Ni-based heat-resistant superalloys and Ti alloys for turbine blades, particularly due to insufficient adjustment of volume and dimension in preforms, leading to defects such as overlap defects and the need for separate processing steps.
Innovation Solution
A hot forging die with a novel shape featuring a gradually increasing width of the pressing portion from the rough processing area to the finishing area, including a concave portion that divides the pressing surface into two or more areas, allowing for efficient swaging of rod-shaped materials using a radial forging machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a groove is formed by necking in a material having a round rod shape using a special jig in a press machine, then the preform becomes sufficiently thicker in a die face during closed die forging, but the processing is complex and requires separate forging machines
Solution Approach 1:
The patent combines the necking process and swaging process into a single integrated operation using one hot forging die with multiple pressing portions. The die includes a first pressing portion for necking and a second pressing portion for swaging, eliminating the need for separate jigs and multiple forging machines while achieving both preform thickening and shape formation in one step
2Manufacturing precision
If a groove formed by necking has a small width and is vertically deep, then the preform thickness is improved, but an overlap defect occurs during hot forging in which the forging material is swaged
Solution Approach 1:
The pressing portion of the hot forging die is segmented into multiple distinct zones: a first pressing portion for necking, a second pressing portion for swaging, and intermediate portions with gradually changing cross-sections. This segmentation allows each zone to perform its specific function optimally while preventing defect formation through controlled material flow transitions
Solution Approach 2:
The patent transitions from forming a vertically deep groove to creating a horizontally expanded preform shape through the swaging portion. The pressing portions are arranged to expand material in the radial direction rather than solely in the vertical direction, preventing overlap defects while achieving the desired preform geometry
3Manufacturing precision
If a pressing portion is formed smooth, then the surface finish is improved, but it is not suitable for forming a desired groove in a difficult-to-work material
Solution Approach 1:
Different regions of the pressing portion have different surface characteristics tailored to their specific functions. The necking region has a rougher surface to facilitate groove formation in difficult-to-work materials, while the swaging and finishing regions have smoother surfaces to produce the desired final surface finish, with each zone optimized for its particular task
4Manufacturing precision
If separate open die forging machine is used to form preform shape, then the preform shape can be adjusted, but the productivity is reduced and multiple reheating steps are required
Solution Approach 1:
The hot forging die is designed as a multi-functional tool that performs necking, swaging, and final shape formation in a single operation. The die includes multiple pressing portions that can create grooves, expand the preform radially, and achieve the final desired shape, eliminating the need for separate open die forging machines and multiple reheating steps while maintaining precise shape control
Solution Approach 2:
The patent implements a continuous forging process where the workpiece moves sequentially through different pressing portions of the die without interruption. The first pressing portion creates the groove, the intermediate portions gradually transition the shape, and the second pressing portion completes the swaging, all in one continuous operation without removing the workpiece for reheating
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 efficient swaging of difficult-to-work materials into predetermined preform shapes with reduced risk of defects, improving productivity and reducing the need for multiple reheating steps, thus enhancing the manufacturing of high-accuracy turbine blade preforms.
Implementation Method 1
a hot forging die for hot-forging a rod shaped forging material by radial forging
Implementation Method 2
hot-forging a rod shaped forging material
Data Source
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Figure 7(A)~9
AI summary
Provided are a hot forging die and a hot forging method which enables to perform even a difficult-to-work material used for a turbine blade can be easily swaged using a radial forging machine. The hot forging die for hot-forging a rod shaped forging material by radial forging includes a pair of halved pressing portions between which the forging material is interposed, each of the halved pressing portions having a smooth surface having a concave shape configured to surround the forging material, wherein the halved pressing portion includes a rough processing portion and a finishing portion, and a width of the finishing portion in a longitudinal direction of the forging material is wider than a width of the rough processing portion.